KBK-KBT Maintenance & Repair Manual 04/03/2023

Table of Contents
General Safety for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lifting the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Throw and Data Plate Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Other Ariel Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Website . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Technical and Service Schools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ariel Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ariel Separately Purchased Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ariel Separately Purchased Tool Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Digital No-Flow Timer (DNFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DNFT Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Programmable DNFTs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DNFT Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting DNFT’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Proximity Switch A-18255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Proximity Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Main Bearing Temperature Alarms and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Thermocouples - J (Iron-Constantan) or K (Chromel-Alumel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Resistance Temperature Devices (RTD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing RTD’s and Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
RTD Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Thermocouple Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Initial Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Recommended Maintenance Intervals for Continuous Duty Operation . . . . . . . . . . . . . . . . . . . . . . . 35
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Six-Month (4,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
One-Year (8,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Two-Year (16,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Four-Year (32,000-Hour) Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Six-Year (48,000-Hour) Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Frame Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Dry Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil System Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Frame Oil System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Pump & Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil Temperature Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Transfer Valve Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Compressor Pre-lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Flushing to Change to a PAG Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Recommended Flushing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Flushing the Force Feed Lubrication System - Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Flushing the Force Feed Lubrication System - Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cylinder and Packing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Force Feed Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pump Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Priming the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pump Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Auto-Relief Valve (ARV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ARV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Distribution Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Distribution Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Divider Valve Bypass Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Balance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Selecting Balance Valves and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Installing Balance Valves and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Adjustment of Balance Valves Fed by a Divider Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adjustment of Balance Valves Fed by Primary/Secondary Divider Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Subsequent Compressor Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Force Feed System Design, Operating Parameters, and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Common Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Independent Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Force Feed Lubrication Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Under/Over Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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Cylinder Lubrication Paper Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Coolant System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Relieving Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Depressurization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Positioning a Throw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Variable Volume Clearance Pocket (VVCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
VVCP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
VVCP Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
VVCP Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
VVCP Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
VVCP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Compressor Valves - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Required Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Valve Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . . . . . . . . . . . . . . 90
Removal of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Valve Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Installation of Valve Caps on Cast Iron Cylinders or High-Pressure Caps without Spring Energized Seals . . . 94
Installation of Valve Cap with Spring Energized Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Gas Containment Fastener Torque Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Piston and Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Piston Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Piston and Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Hydraulic Tensioner Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Hydraulic Tensioner Tool Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Piston & Rod Disassembly with Hydraulic Tensioner Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Piston & Rod Reassembly with Hydraulic Tensioner Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Piston and Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Piston Rod Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Seal-Joint Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Straight-Cut Chamfered Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
High-Pressure Face-Cut Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Three-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Five-Piece Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Wear Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Piston Rod Packing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Piston Rod Packing Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Reassembling and Testing Cooled Packing Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Long Two-Compartment Intermediate Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

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Types of Piston Rod Packing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

“P” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
“PB1” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
“UP” Pressure Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
“P1U” Pressure Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
“BD” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Double "WAT" Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
“AL” Double-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
“BTS” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
“BTUU” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
“CUU” Single-Acting Seal Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
“RS3” Single-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
“DS” Double-Acting Seal Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
“3RWS” Oil Wiper Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Crossheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Crosshead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Crosshead Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Connecting Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Connecting Rod Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Crank Pin Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Connecting Rod Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Connecting Rod Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Connecting Rod Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Connecting Rod Thrust (Side) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Crankshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Main Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Main Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Crankshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Main Bearing Vertical Jack Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Crankshaft Thrust (End) Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Chain Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Chain and Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Chain Idler Sprocket Replacement (Eccentric Adjustment Caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Lube Oil Pump Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Force Feed Lubricator Dual Chain Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Crankshaft Chain Sprocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Component Cleaning & Thread Lube for Non-Lube Compressor Cylinders . . . . . . . . . . . . . . . . . . . 146
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Warranty Notification - Installation List Data and Start Up Check Lists for Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Piston Rod Runout Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Ariel Fasteners and Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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Recommendations for Torque Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

KBK:T Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Measuring Head End Clearance for Forged Steel Tandem Cylinders with Concentric Valves . . . 169
Frame Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Opposed Throw - Reciprocating Weight Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Compressor Clearance, Oil, & Temperature Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Balance Valve Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Cleaning, Handling, and Assembly Lubricants for Non-Lubricated Compressor Cylinders. . . . . . . . . 180
Hold-down Bolting to Resist Shaking Forces and Couples in Reciprocating Compressors. . . . . . . . . 182
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore Alignment in Reciprocating
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Soft Foot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Top Plane Flatness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Attachment of Wiring, Tubing, or Pipe Clamps to Ariel Compressor Cylinders . . . . . . . . . . . . . . . . . . . 187
Alternate Attachment Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Recommended Maintenance Intervals for Intermittent Duty Operation. . . . . . . . . . . . . . . . . . . . . . . . . 188
400-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8,000-Hour or 22,000 Starts Maintenance (whichever occurs first) . . . . . . . . . . . . . . . . . . . . . . . . . . 190
16,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
32,000-Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Latest Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
04/03/2023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

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KBK-KBT Maintenance & Repair Manual 04/03/2023

General Safety for Reciprocating Compressors

WARNING CAUTION

To reduce risk of injury or death, only trained personnel Noise generated by reciprocating machinery may
who have read and thoroughly understand the damage hearing. See Packager information for specific
appropriate Ariel Technical Manual and Packager recommendations. Wear hearing protection during
information should attempt any maintenance. compressor operation.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera- CAUTION
tional procedures.
Where applicable, compressor installation must
• Never tighten or loosen any fastener while the unit is
conform to Zone 1 requirements. A Zone 1 environment
operating or pressurized.
requires installation of proper intrinsically safe or
• Verify neither driver nor compressor can turn during equivalent protection to fulfill electrical requirements.
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis- CAUTION
tance.
• Verify each compressor cylinder is relieved to atmo- Hot gas temperatures (especially the cylinder
spheric pressure. To relieve residual cylinder bore discharge), 190°F (88°C) oil, and high friction areas. Wear
pressure after blowdown, open the “Kiene” valves proper protection. Shut down unit and allow to cool
on the indicator ports, if so equipped. before maintaining these areas.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with CAUTION
the gas being compressed to avoid a potentially Suction or discharge valves installed in improper
explosive gas/air mixture in the system. A gas/air locations may result in severe personal injury and
mixture under pressure can explode and cause severe property damage.
injury or death.

CAUTION

If applicable, do not remove the pin from the crosshead

guide to compressor cylinder mounting face. It is there
When the symbol to the left appears
to prevent installation of misapplied cylinders and avoid
on a compressor or control panel, consult the personal injury.
appropriate Ariel Maintenance and Repair
Manual for specific information before
proceeding. The Maintenance and Repair Lifting the Compressor
Manual applies to current design and build; it
may not apply to equipment built prior to the CAUTION
date on the front cover and is subject to When lifting a compressor with lifting lugs, use only
change without notice. For questions of Ariel-supplied lugs. Verify lugs are fastened with correct
grade cap screws, and properly tightened. Lifting cable
compressor safety, operation, maintenance,
spreaders are required perpendicular to the crankshaft
or repair, contact your packager or Ariel. axis and the lift point. Verify crane capacity is adequate.

• Determine compressor weight before lifting.

See the Ariel Performance Program for frame

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KBK-KBT Maintenance & Repair Manual – General Safety for Reciprocating Compressors 04/03/2023

and cylinder weights. Also account for any • Use spreader bars or lifting beams for a
extra weight such as external and internal vertical pull on eyebolts or lifting lugs. Chains
flywheels, etc. or straps attached to eyebolts or lifting lugs
• Each compressor ships with an attached should be within 5 degrees of vertical. For
Compressor Lifting Information packet. Refer eyebolt load capacity rating or if pulling on an
to the Compressor Lifting Information docu- eyebolt in a direction other than along the
ment for each specific compressor frame threaded axis, consult ASME B18.15.
serial number. Ariel can provide the weight, • Verify lifting tackle, spreader bars, and crane
center of gravity, and lifting hook locations capacity are adequate, properly attached
for the compressor via the Ariel Performance and properly rigged for the load. Keep
software, or by contacting the Ariel Response compressor level when lifting and setting.
Center. Heavier cylinders and/or blank throws can
• If you are not experienced in lifting large significantly affect center of gravity.
compressors, Ariel recommends using quali-
fied professional riggers/movers.
• Ariel-supplied eyebolts (attached to cross-
head guides), brackets (attached to cylinder
nozzles) and lifting lugs (attached to frame
walls) are designed to lift the Ariel
compressor only, with no other equipment
such as bottles, skid, etc. Do not attempt to
lift the compressor when it is attached to the
skid, driver, or piping. Do not use these lifting
attachments on other equipment.
• On frames with lifting lugs, install lugs with
the proper Grade 8 cap screws and tighten to
the torque listed in the appropriate Ariel
Maintenance and Repair Manual or the Ariel
Torque App. If lifting lugs are already
installed, recheck bolt torque prior to lifting.
• For compressors with no lifting lugs, lift by
the eyebolts installed by Ariel at the cross-
head guides. Ariel-installed eyebolts are
locked in position with Loctite® thread locker
to help prevent turning.
• Verify eyebolts, brackets and lifting lugs are
free of any visual defects that could affect
serviceability. Remove and destroy all defec-
tive eyebolts, brackets, and lifting lugs. Use
only Ariel-supplied brackets and lifting lugs.
• Standard lifting lug and eyebolt materials can
fail when subject to shock loads at low
ambient temperatures. Follow ASME B18.15
guidelines. If necessary, eyebolts may be
replaced with forged eyebolts of materials
more suitable for low temperatures per ASME
B18.15 and ASTM F541.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Throw and Data Plate Locations

When contacting Ariel with compressor questions, know throw locations and information on data
plates fastened to the machine. This data helps Ariel representatives answer quickly and accurately.
Contact Ariel for replacement if any data plates are missing.

Figure: Separable Guide Compressor Throw and Data Plate Locations - Typical

1 VVCP Dimension Plate 5 VVCP Serial Number, MAWP, and 8 Compressor Data Plate
2 VVCP Data Plate Hydrotest Stamp 9 Force Feed Lubricator Pump Data
3 Rotation Direction Plate 6 Cylinder Serial Number, MAWP, Plate
and Hydrotest Stamp 10 Force Feed Lubricator Data Plate
4 Cylinder Data Plate
7 Mechanical Inspector Plate and 11 Oil Filter Change Instruction
Frame Serial Number Stamp Plate

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Other Ariel Resources

Ariel Website • Packager Standards provide detailed

requirements and recommendations on the
Visit www.arielcorp.com to view and print the installation of an Ariel compressor.
latest documentation, such as: • Application Manual provides detailed infor-
mation on the use of Ariel compressors in
• Customer Technical Bulletins (CTB’s)
different applications.
provide important information on changes,
corrections, or additions to Ariel products or
services. Read these bulletins before oper- Ariel Technical and Service
ating or servicing equipment.
• Engineering References (ER’s) provide stan- Schools
dard procedures and other useful informa-
Ariel schedules several in-plant schools each
tion for operation, maintenance, or repair of
Ariel compressors or components. Read and year, which include classroom and hands-on
follow these procedures for long and trouble- training. Ariel also sends representatives to
free service from your Ariel compressor. provide customized training on location. Contact
• Maintenance and Repair Manuals provide Ariel for details.
detailed maintenance and repair information
on specific Ariel compressor models.

Ariel Contact Information

Contact Telephone Fax E-Mail

Ariel Response Center 888-397-7766 (toll-free USA & 740-397-1060 arc@arielcorp.com

Canada) or 740-397-3602
Ariel Parts Sales (International) 740-393-5054 parts@arielcorp.com

Order Entry 740-397-3856 -

Ariel World HQ 740-397-0311 740-397-3856 info@arielcorp.com

Technical Services fieldservice@arielcorp.

com

Ariel Response Center Technicians or Emergency Service. Calls are answered by

Switchboard Operators answer telephones voice mail.
during Ariel business hours, Eastern Time - USA 2. Leave a message: caller name and telephone
or after hours by voice mail. Contact an number, serial number of equipment in ques-
authorized distributor to purchase Ariel parts. tion (frame, cylinder, unloader), and a brief
Always provide Ariel equipment serial number(s) description of the emergency.
to order parts. The after-hours Telephone
3. Your voice mail routes to an on-call represen-
Emergency System works as follows:
tative who responds as soon as possible.
1. Follow automated instructions to Technical
Services Emergency Assistance or Parts

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Tools
A variety of tools are required for safe and effective maintenance of Ariel compressors. Standard hand
tools are readily purchased from hardware stores or industrial supply companies. Ariel makes certain
special tools available where needed.

Ariel Optional Tools

Ariel offers an optional tool kit with every compressor. For KBK:T compressors, it contains the tools
shown below, which are specifically designed for use on Ariel units. Clean all tools before use and verify
full tool engagement with the part being removed or installed. If the Tool Kit is missing or if a single
tool is missing, worn, or broken, call your distributor. Do not use worn or broken tools, or substitutes
for Ariel furnished tools. See Parts List for individual tool part numbers.

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KBK-KBT Maintenance & Repair Manual – Tools 04/03/2023

Figure: Optional Furnished Tools for KBK:T Compressors

1 Tool Box 11 3/4 Allen Wrench (1 provided) 20 Connecting Rod Cap Removal
2 Peg Wrench 12 1/2 Allen Wrench (2 provided) Tool
3 Piston Nut Spanner 13 3/8 Allen Wrench (1 provided) 21 Ariel Bore & Thread Gauge
4 9/16 Socket Piston Turning Tool 14 3/16 Allen Wrench (5 provided) 22 Piston Rod Entering Sleeve
(included only for compressors 15 Main Bearing Removal Tool 23 Piston Entering Sleeve (included
with small cylinders) only for compressors with forged
16 Valve Removal Tool (included
5 Cylinder Bolt Torque Adapter steel, tail-rod cylinders with step
only for compressors with forged
to bore)
6 4-Inch Open End Wrench steel cylinders - tool size and
(included only for compressors style varies with cylinder size and 24 Bearing Cap Installa-
with hex crosshead balance nuts) valve center connection) tion/Removal Tool
7 5/8 x 3/4 UNF Valve Tool 17 Forged 5/8 - 11 UNC Eyebolts (2 25 Connecting Rod Bolt 110° Turn
provided) Indicator Tool
8 5/16 x 1/2 UNF Valve Tool
18 Forged 1/2 - 13 UNC Eyebolts (2 26 Crosshead Pin Alignment Tool
9 1/4 x 3/8 UNF Valve Tool
provided) 27 Crosshead Installation Tool
10 3/4 x 1" UNC Valve Tool (for CP
valves) 19 Forged 3/8 - 16 UNC Eyebolts (6 28 ER-63 Fastener Torque Chart (not
provided) shown)

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KBK-KBT Maintenance & Repair Manual – Tools 04/03/2023

Ariel Separately Purchased

Tools
Figure: Ariel Separately Purchased Tools for KBK:T Compressors
1 Hand Pump for hydraulic
crosshead balance nut
torquing tool and piston rod
tensioning tool (includes
hand pump, hose, coupler,
and gauge)
2 KBK:T Hydraulic Piston Rod
Tensioning Tool
3 Hydraulic Crosshead Balance
Nut Torquing Tool (includes
tool and ram)
4 Force Feed Lubricator
Bearing Housing Wrench
5 Force Feed Lubrication Hand
Purge Pump

Ariel Separately Purchased 2. Ariel SAE Hand Tool Kit

Tool Kits a. 15-piece combination open/box end

wrench set, 5/16” to 1-1/4”
1. Ariel SAE Hand Measurement Tool Kit
b. 8-piece slot and Phillips screwdriver set
a. 0.0005 in. needle type dial indicator
c. 3/8" square drive wrench set, including:
b. 0.001 in. 1-inch travel dial indicator
• 12-piece, 12-point socket set, 5/16” to
c. Magnet base for dial indicator 1”
d. 3/8” drive calibrated torque wrench, 40 to • 7” ratchet
200 in x lbs
• Speed handle
e. 3/8” drive calibrated torque wrench, 10 to
• Extensions, 1-1/2”, 3”, 6”, and 12”
100 ft x lbs
• Ball type universal joint
f. 1/2” drive calibrated torque wrench, 50 to
250 ft x lbs • 3/8” to 1/2" drive adapter
g. 3/4” drive calibrated torque wrench, 120 • 1/4” hex key socket
to 600 ft x lbs • 8-1/2” breaker bar
h. 1” drive calibrated torque wrench, 200 to d. 1/2" square drive wrench set, including:
1000 ft x lbs • 14-piece, 12-point socket set, 7/16” to
1-1/4” with clip rail
• Extensions, 1-1/2”, 5”, and 10"
• Drive adapters: 1/2” to 3/8" and 1/2”
to 3/4"

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KBK-KBT Maintenance & Repair Manual – Tools 04/03/2023

• 1-1/4” open end crow’s foot adapter 3. Flashlight

• 10-1/4” ratchet
4. Small mirror on a flexible extension rod
• Speed handle
• Ball type universal joint 5. Small magnet on a flexible extension rod
• 18” breaker bar 6. Electric and/or pneumatic drill
• 1/2” and 5/8” hex key sockets
7. Twist drill set
e. 3/4" square drive wrench set, including:
• 18-piece, 12-point socket set, 3/4” to 8. Torque multiplier
2”
• Extensions, 3-1/2”, 8”, and 16”
• Drive adapters: 3/4” to 1/2", 3/4” to 1",
and 1” to 3/4"
• 24” ratchet
• 22” breaker bar
f. 1" square drive wrench set, including:
• 14-piece, 12-point socket set, 1-7/16”
through 2-5/8”
• 30” ratchet
• Extensions: 8” and 17”
• 22” sliding T
g. Adjustable wrenches: 12" and 18"
h. Dead blow semi-soft faced hammers: 3 lb.
and 6 lb
i. 3/4” x 36” pry bar
j. 12” long feeler gauge set
k. 12” machinist scale with 0.01 in. incre-
ments
l. 13-piece Allen wrench set, 0.050 in. - 3/8”

Recommended Tools
Ariel compressor maintenance and repair
normally requires only Ariel furnished tools and
separately purchased tools and tool kits.
However, Ariel also recommends purchasing the
additional tools below. Contact Ariel for
questions about tools for Ariel units.
1. 12-point box end torque adapter extension
wrench set
2. Tape measure

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Instrumentation
Several optional instruments can aid in the CAUTION
operation of an Ariel compressor. Through the
DO NOT drill holes in cylinders or other pressure
data they provide, some instruments can help containing components for any purpose. Pressure
decrease maintenance costs and downtime, and containing components include cylinders, valve caps,
help diagnose lubrication and other types of cylinder heads, unloaders, gas passage caps, and
flanges.See "Attachment of Wiring, Tubing, or Pipe
problems. The use of “alarm” instead of Clamps to Ariel Compressor Cylinders".
“shutdown” for any minimum instrumentation
requirement may result in equipment damage.
CAUTION

NOTE: Ariel recommends the use of shipboard or Any arc welding on the skid and/or associated
armored cabling as opposed to wiring in conduit to equipment and piping can permanently damage solid-
minimize nuisance shutdowns due to wire chafing state electronic equipment. Welding can cause
immediate failure or reduce electronic equipment life
and shorts. Cable in cable trays also facilitates main- and void the warranty. To protect electronic equipment
tenance access. prior to any arc welding (including repair welding),
disconnect all electrical connections including ground,
and remove batteries, or completely remove the
electronic equipment from the compressor.
It is good practice to attach the welding ground clamp as
close as possible to the area where the welding will
occur and to use the lowest practical welder output
setting. Welding must not cause a current flow across
any compressor bearing surface, including but not
limited to crankshaft and crosshead bearing surfaces.

Table: Required Instrumentation Summary

INSTRUMENT SUPPLIER SETTING/REQUIREMENT

Frame Oil System (see "Frame Oil System Components")

Oil Pressure Packager

- Start Permissive with Pre-lube Pump 30 psig (2.1 barg) for 2 minutes

- Run Permissive 45 psig (3.1 barg) within 10 seconds of start

- Alarm 50 psig (3.4 barg)

- Shutdown 45 psig (3.1 barg)

Oil Filter Differential Ariel Change at 10 psi (0.7 bar) for KBK:T/2/4 or 15 psi (1.0 bar) for
KBK:T/6 or 6 months of operation, whichever occurs first. Do
not exceed 12 month installed period for filter element.

Oil Temperature Packager

- Minimum, to start-up or to load See "Viscosity" for max. oil viscosity based on frame size.

- Minimum, operating 150°F (66°C)

- Maximum, shutdown 190°F (88°C)

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

INSTRUMENT SUPPLIER SETTING/REQUIREMENT

Crankcase Level Packager 1/2 to 2/3 sight glass level

- Low Level Shutdown 1/4 sight glass level

Main Bearing Temp. Ariel Recommended, but optional.

- Alarm +20°F (11°C) above normal not to exceed 220°F (104°C)

- Shutdown +30°F (17°C) above normal not to exceed 230°F (110°C)

- Differential Alarm 20°F (11°C)

- Differential Shutdown 30°F (17°C)

Packing Case Temp. Ariel Optional

- Alarm +20°F (11°C) above normal

- Shutdown +30°F (17°C) above normal

Packing Case Vent Packager Optional

- Vent Flow Alarm 2 - 4 scfm (per throw)

- Vent Flow Shutdown > 4 scfm (per throw)

Scrubber Liquid Level Packager

- High Liquid Level Control

- High Liquid Level Shutdown

Gas Conditions Packager

- Inlet Temperature Indicator, each cylinder

- Inlet Pressure Indicator, each stage

- Discharge Pressure Indicator, each stage

- Discharge Temperature Indicator, each cylinder

- High Discharge Temperature Shutdown, each 10% above normala (Not to exceed the maximum temperatures
cylinder below)

- Lubricated Cylinders 350°F (177°C)

- Non-Lube/PRC Cylinders 325°F (163°C)

- Hydrogen Rich > 50% < 0.41 Specific Gravity 300°F (149°C)

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

INSTRUMENT SUPPLIER SETTING/REQUIREMENT

- Air Not to exceed autoignition temperature of cylinder lubricant at

discharge pressure

- Relief Valve Setting above normal operating • Up to 150: 15 psig (1.0 barg)
pressure (not to exceed MAWP) • to 2500: 10%
• to 3500: 8%
• to 5000: 6%
• Over 5000: As agreed
• See "Relief Valves" in the Packager Standards Manual.

Cyl. Rod Load Protection Packager

High Vibration Shutdown Packager As close to a normal level as practical. See "Vibration
Protection" in the Packager Standards Manual.

Over Speed Packager 10% over rated speed for shutdown

a Example: Normal Discharge Temp. = 270°F; Shutdown Setting = 270 x 1.1 = 297°F.

Notes 3. Mount overhead lube oil supply tanks high

enough to provide oil flow to the level control
1. Install the compressor frame low lube oil
at all ambient temperatures.
pressure shutdown set to stop the unit if oil
pressure downstream of the filter falls below 4. On multi-nozzle cylinders, Ariel strongly
45 psig (3.1 barg). Compressor operation for recommends a temperature device in both
only a few seconds without oil pressure discharge nozzles.
causes major damage. Normal oil pressure is
5. Install the high lube oil inlet temperature
about 60 psig (4.1 barg) at full rated speed
shutdown at the filter inlet connection.
and normal operating temperature. The low
oil pressure shutdown must activate after oil 6. At a minimum, install one vibration shutdown
pressure exceeds 45 psig (3.1 barg) at start- for two and four throw frames and two for six
up. Ariel provides a 1/4 inch tubing fitting to throw frames. Mount vibration devices near
connect the low lube oil pressure shutdown the top of the frame with the sensitive axis
and ties a tag to this connection before each parallel to the piston rod axis.
compressor ships. Do not operate the
7. Install all safety shutdowns, controls, instru-
compressor for prolonged periods at less
mentation, ignition systems, electrical
than 50 psig (3.4 barg) oil pressure.
devices, and high temperature piping (gas
2. Automated pre-lube systems require a start discharge and engine exhaust) in accordance
permissive to sense minimum required pres- with good engineering practice and appli-
sure/time at oil gallery inlet.See “Compressor cable codes for the area classification at the
Pre-lube System”. Unit must shut down if the end user location. Ensure compatibility of all
system fails to achieve 45 psig (3.1 barg) oil systems for area classification.
pressure within 10 seconds after crankshaft
starts to turn.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

8. If packing vent temperature is monitored, DNFTs utilize an LED to indicate each cycle of the
confirm alarm and shutdown set points divider valve, which allows easy adjustment and
through vent flow rates. monitoring of lubrication rates. Programmable
models display total pints, cycle time of divider
valve, total cycles of divider valve, or pints per
Digital No-Flow Timer (DNFT) day pump flow rate on a liquid crystal display and
operators can adjust alarm time from 20 to 255
CAUTION
seconds.
Any arc welding on the skid and/or associated
equipment and piping can permanently damage solid-
state electronic equipment. Welding can cause
immediate failure or reduce electronic equipment life
and void the warranty. To protect electronic equipment
prior to any arc welding (including repair welding),
disconnect all electrical connections including ground,
and remove batteries, or completely remove the
electronic equipment from the compressor.
It is good practice to attach the welding ground clamp as
close as possible to the area where the welding will
occur and to use the lowest practical welder output
setting. Welding must not cause a current flow across
any compressor bearing surface, including but not
limited to crankshaft and crosshead bearing surfaces.

A DNFT is a totally enclosed electronic device,

combining the latest technology in
microprocessor and transistor components to
detect slow-flow and no-flow of divider block
lubrication systems. The DNFT uses an oscillating
crystal to accurately monitor the lubrication
system cycle time to enable precision timed
shutdown capability. The magnet assembly and
control housing mount directly to a divider valve.
Lubricant flow through a divider valve assembly
forces the piston to cycle back and forth causing
a lateral movement of the DNFT magnet linked to
the piston. The DNFT microprocessor monitors
piston movement and resets the timer, lights the
light emitting diode (LED), and allows the unit to
continue operation, indicating one complete
cycle of the lubrication system. If the
microprocessor fails to receive this cycle within a
predetermined time, a shutdown occurs. The
DNFT automatically resets the alarm circuit when
normal divider valve operation resumes.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

DNFT Installation 1. Loosen the Allen set screws on the DNFT and
remove magnet housing. Do not remove
Figure: Typical DNFT Magnet Assemblies magnet, spring, or spacer from magnet
housing.
2. Remove piston enclosure plug from the end
of desired divider valve. The DNFT installs on
any of the divider valves of the divider block.
The DNFT requires the correct magnet
assembly to match the divider valve
manufacturer.
NOTE: Do not install a DNFT on Lincoln divider valves
with cycle indicator pins.
3. If applicable, verify O-ring or metal gasket is
in place on magnet housing. Thread magnet
housing into the end of the divider valve.
Torque to 15 lbs x ft (20 N•m) maximum.
4. Slide DNFT all the way onto hex of magnet
1 Trabon Style O-ring Seal 7/16-20
housing. Torque Allen set screws on the hex
of magnet housing to 25 lbs x inch, (2.8 N•m)
2 Trabon Metal Gasket Seal 7/16-20 (1994 or earlier)
maximum.
3 Lincoln O-Ring Seal 7/16-20 Extended Nose
5. The LED on the DNFT indicates each divider
Figure: Typical DNFT Installation valve cycle to allow lubricator pump
adjustment for Ariel recommended cycle
time and oil consumption. If the LED fails to
blink during compressor operation or by
manually pumping oil into the divider valve,
then the DNFT requires adjustment.
6. The divider valve must cycle during DNFT
adjustment. To cycle, either run the
compressor or manually pump oil through
the distribution block with a purge pump.
7. To adjust, slide DNFT all the way onto hex of
magnet housing. Tighten Allen set screws to
1 Divider Valve Piston
25 lbs x inch (2.8 N•m) maximum. A blinking
2 Magnet LED indicates correct adjustment. If the LED
3 Magnet Housing fails to blink with divider valve cycling, slide
4 Set Screws (2) DNFT back on the hex of the magnet housing
5 LED in 1/16" increments until it does.
6 Control Housing
8. Make all conduits and connections
7 Wire Leads
appropriate for area classification. Insulate
8 O-Ring unused wires from the ground, other wires,
9 Divider Valve and the case. Support conduit and fittings to
10 Piston Enclosure Plug avoid bending the magnet housing.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

9. After DNFT installation and before

compressor start-up, purge all air from the
divider block lubrication system with a purge
pump.
NOTE: When installing multiple DNFTs, wire each to a
separate alarm circuit of the control panel, annunci-
ator, or PLC to simplify lubrication system and DNFT
troubleshooting. Always secure the green ground
wire to "earth ground" in the control panel. Do not
ground to electrical conduit or skid. Improper
grounding can result in unreliable monitor operation.
Figure: A-10754 Programmable DNFT Wiring Connections for Unit in Operation

Figure: A-10753 and A-10772 DNFT Wiring Connections for Unit in Operation

Figure: A-20513 24 VDC Programmable DNFT Wiring Connections for Unit in Operation

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

Figure: A-20514 24 VDC DNFT Wiring Connections for Unit in Operation

Programmable DNFTs CAUTION

Figure: Typical Programmable DNFT Program DNFT before installing it on a divider valve. DO
NOT insert programming magnet into 1/8” recessed
opening while the compressor is operating; it causes the
DNFT to shut down the compressor. Programming
modes cannot be changed while the compressor is
operating. To program a DNFT, first remove it from the
divider valve.

To program:
1. Insert the programming magnet into the 1/8"
recessed opening on the face of the DNFT.
1 Magnet The current programming mode (1, 2, 3, or 4)
2 Magnet Housing
immediately displays on the LCD followed by
"0" 2 seconds later. "0" indicates the current
3 Allen Set Screws
mode is ready for programming.
4 LED
5 Control Housing 2. If the desired programming mode does not
6 LCD display, remove and re-insert the
7 1/8" recessed opening for programming magnet programming magnet into the recessed
8 Wire Leads
opening until it does. Leave the programming
magnet in the recessed opening when the
9 Programming Magnet
desired programming mode displays.
Programmable DNFTs come with a small liquid
3. Select one of the programming modes below:
crystal display (LCD) screen to display total
a. Mode 1 - LCD displays total divider
divider valve cycles (Mode 1), cycle time of
valve cycles; program alarm time.
divider valve in seconds (Mode 2), total pints of
• To set alarm time, press and release
oil used (Mode 3), or pump flow rate in pints per the spring-loaded magnet assembly
day (Mode 4). Operators can also adjust alarm until the desired alarm time in
time in Mode 1. seconds displays on the LCD. Set
alarm time from a minimum of 20
seconds to a maximum of 255

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

seconds. If not set, the device defaults Mode 1 or Mode 3, and presses the spring-
to 120 seconds. loaded magnet assembly. This action resets the
unit to zero and allows entry of a new value.
• Remove programming magnet. DNFT
displays total divider valve cycles if NOTE: Power interruption to the DNFT requires
left in this mode and alarm time is reprogramming Mode 1 and Mode 3.
now set.
b. Mode 2 - LCD displays the cycle time of
the divider valve in seconds.
DNFT Battery Replacement
• Remove programming magnet when
Mode 2 displays. LCD counts each Figure: Typical Digital No-Flow Timer Switch
divider valve cycle in seconds, (DNFT)
counting up from zero until the
divider valve completes one full cycle.
When divider valve completes one full
cycle, the LCD resets to zero and
repeats the count until another cycle
is completed. The LED blinks in all
modes to indicate each divider valve
cycle. This blink enables the operator
to set pump flow rate.
c. Mode 3 - LCD displays total pints used;
program divider valve total.
• To set divider valve total, add the sizes 1 Magnet Housing
of the divider valve sections on which
2 Magnet
the DNFT will be installed. Example:
3 O-Ring
24 + 24 + 24 = 72.
4 Control Housing
• Press and release the spring-loaded
5 Polarized Connector
magnet until the divider valve total
6 Field Replaceable Battery
displays on the LCD. Maximum value:
7 1/2" Pipe Plug
120. If not set, device defaults to zero
and prevents Mode 4 flow rate display. 8 #22 AWG 18" (0.46 m) Leads
9 Spring
• Remove programming magnet. The
10 Spacer
DNFT displays total pints on the LCD if
left in this mode. 11 Allen Set Screws

d. Mode 4 - LCD displays pump flow rate in

pints per day. The DNFT operates on a field-replaceable lithium
battery that should last six to ten years. If the
• Remove programming magnet with
Mode 4 displays. LCD displays pump battery voltage drops below 2.5 VDC, the DNFT
flow rate in pints per day based upon shuts down and the compressor cannot be
the divider valve total set in Mode 3. restarted until the battery is replaced.
Mode 4 requires a minimum 4 second
cycle time.
The DNFT stores all programmed information
until the operator inserts the programming
magnet into the recessed opening, selects

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CAUTION • LED does not blink and control panel indi-

cates lube no-flow. (see also Erratic Shut-
Do not open a DNFT in an explosive gas atmosphere. down)
• ARV bypasses or rupture disk bursts and
1. Shut down the compressor. divider valve seizes after DNFT installation.
2. Disconnect DNFT wiring. • Erratic shutdown or LED blink.
Troubleshooting: DNFT Lube No-Flow

3. Use 1/8 inch Allen wrench to loosen Allen set

screws and remove control housing to a safe Problem
atmosphere.
LED does not blink and control panel indicates
4. Use 3/8 inch ratchet wrench to remove pipe lube no-flow. (see also Erratic Shutdown)
plug.
5. Remove the battery and disconnect from the
Possible Cause
polarized connector.
6. Test battery. The voltage should read 3.6 Improperly adjusted DNFT.
VDC.
Solution
7. Connect the new battery to the polarized
connector. 1. Loosen set screws, slide DNFT all the way
onto hex of magnet housing and torque to 25
8. Insert the new battery and reinstall the pipe lbs x inch (2.8 N•m) max.
plug. Apply Teflon tape to plug threads and
(Do not over tighten).
torque to 25 ft x lb (34 N•m).
2. Either pump clean oil through lubrication
9. Place DNFT control housing on the magnet
system with a purge pump or run the
housing in its original position and tighten set
compressor to cycle the divider valve.
screws. Reattach wiring and conduit.
3. If necessary, slide DNFT back in 1/16“
10. Programmable DNFTs require
increments until LED blinks with each divider
reprogramming of the alarm time (Mode 1)
valve cycle.
and divider valve total (Mode 3) after a power
interruption. See the programming section of
this document. Possible Cause
11. To verify DNFT operation, pre-lube the Broken spring or magnet in magnet housing.
system and check for LED blink.
Solution
Troubleshooting DNFT’s 1. Loosen set screws, remove DNFT from
magnet housing.
NOTE: When installing multiple DNFTs, wire each to a 2. Remove magnet housing from divider valve.
separate alarm circuit of the control panel, annunci-
3. Remove magnet, spring, and spacer and
ator, or PLC to simplify lubrication system and DNFT
check for damage.
troubleshooting. See ER-105.3.1 for DNFT bench test
procedures. 4. Replace damaged components.
5. Re-install magnet housing on divider valve
Problem: and DNFT on magnet housing.

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6. If necessary, adjust DNFT, check for LED Solution

blink.
1. Loosen set screws and remove DNFT from
7. Purge air from system with purge pump. magnet housing.
2. Check for correct magnet housing for divider
Possible Cause valve manufacturer.
Low battery voltage. 3. Remove and replace with correct magnet
housing.
Solution
4. Re-install DNFT on new magnet housing.
1. Remove battery from DNFT and test it. 5. If necessary adjust DNFT, check for LED
2. Replace battery with a factory blink.
recommended replacement lithium battery 6. Purge air from system with purge pump.
if voltage is below 2.5 VDC.

Possible Cause
Possible Cause
Air or debris in divider valve assembly.
Bent magnet housing.
Solution
Solution
1. Check system pressure to verify oil flows to
1. Loosen set screws, remove DNFT from divider valves.
magnet housing.
2. If needed, install pressure gauge to monitor
2. Check for damaged or bent magnet housing. lubrication system operation:
3. Remove magnet assembly from divider a. Loosen outlet plugs in front of valve
valve. blocks.
4. Replace magnet housing, magnet, spring, b. Purge lubrication system with a purge
and spacer. pump until clean, clear, air-free oil flows
5. Re-install new magnet housing on divider from plugs.
valve and DNFT on magnet housing. c. Loosen, but do not remove, each piston
enclosure plug individually to purge air
6. If necessary, adjust DNFT, check for LED
from behind piston. To ensure proper
blink.
lube system operation, all tubing and
7. Purge air from system with purge pump. components MUST be filled with oil and
free of air before start-up.
Troubleshooting: DNFT ARV Bypasses

Problem d. Tighten all divider valve plugs.

e. Adjust proximity switch.
ARV bypasses or rupture disk bursts and divider Troubleshooting: DNFT Erratic Shutdown

valve seizes after DNFT installation.

Problem

Possible Cause Erratic shutdown or LED blink.

Wrong magnet housing installed on divider

valve. Possible Cause

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

Faulty wiring from DNFT to control panel or air in Possible Cause

system (see air in system). Overtightened divider valves
Solution Solution
Part numbers: A-10753, A-10772, and A-20513 1. Step-torque divider valves to 75 lb x in (8.5
N•m) to the backplate.
Normally Open
1. Attach ohmmeter to red wires.
2. Should read 10MΩ in operation and less than Proximity Switch A-18255
10Ω in alarm.
CAUTION
Normally Closed
Any arc welding on the skid and/or associated
1. Attach ohmmeter to orange wires. equipment and piping can permanently damage solid-
state electronic equipment. Welding can cause
2. Should read less than 10Ω in operation and immediate failure or reduce electronic equipment life
open loop in alarm. and void the warranty. To protect electronic equipment
prior to any arc welding (including repair welding),
Part number: A-10754, and A-20514 disconnect all electrical connections including ground,
and remove batteries, or completely remove the
Normally Open electronic equipment from the compressor.
It is good practice to attach the welding ground clamp as
1. Attach ohmmeter to orange wires; insulate close as possible to the area where the welding will
violet wires from each other. occur and to use the lowest practical welder output
setting. Welding must not cause a current flow across
2. Should read 10Ω or less in alarm.
any compressor bearing surface, including but not
limited to crankshaft and crosshead bearing surfaces.
Normally Closed
1. Attach ohmmeter to orange wires. A proximity switch installs into a divider valve in
2. Short violet wires together. place of a piston end plug and can be used to
3. Should read open loop in alarm. actuate any device. It consists of a reed switch
and a magnet. When installed, the magnet rests
against the divider valve piston and parallel to
Possible Cause
the reed switch. With every divider valve cycle,
Faulty lube pump. the piston moves the magnet, which opens and
closes the reed switch contacts.
Solution
The time for the proximity switch to repeat a
1. Check system pressure to verify oil flows to
contact transition (ex. from open to closed) is
pump and divider valves. If needed, install
pressure gauge to monitor lubrication known as the cycle time of the divider valve
system operation. assembly. The proximity switch must work with a
PLC or some other counter/timer device to
2. Check gauge to verify pump builds sufficient
pressure to inject oil into cylinder. Do not produce a shutdown. See "Instrumentation" in
remove tubing from check valve and pump the Ariel Packager Standards for interpretation of
oil to atmosphere to check oil flow into proximity switch pulse output.
cylinder.
3. Replace pump.

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Proximity Switch Installation Figure: Typical Proximity Switch Installation

Figure: Typical Magnet Assemblies

1 Divider Valve Piston

2 Magnet
3 Magnet Housing
4 Allen Set Screw (2)
5 Spacer
1 Trabon Style O-ring Seal 7/16-20
6 Spring
2 Trabon Metal Gasket Seal 7/16-20 (1994 or earlier)
7 Switch Housing
3 Lincoln O-Ring Seal 7/16-20 Extended Nose
8 Wire Leads (yellow)
9 Ground Wire (green)
10 O-Ring
11 Divider Valve
12 Piston End Plug

1. Loosen the Allen set screws on the proximity

switch housing and remove magnet housing.
Do not remove magnet, spring, or spacer
from magnet housing.
2. Remove piston enclosure plug from end of
desired divider valve. The proximity switch
installs on any of the divider valves of the
divider block. The proximity switch requires
the correct magnet assembly to match the
divider valve manufacturer.
NOTE: Do not install a proximity switch on Lincoln
divider valves with cycle indicator pins.
3. If applicable, verify O-ring or metal gasket is
in place on magnet housing. Thread magnet
housing into end of divider valve. Torque to
15 lbs x ft maximum.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

4. Slide proximity switch all the way onto hex of 8. Make all conduit and connections
magnet housing. Torque Allen set screws on appropriate for area classification. Support
hex of magnet housing to 25 lbs x inch, conduit and fittings to avoid bending the
maximum. magnet housing.
5. Connect an ohm meter across the two yellow 9. After proximity switch installation and before
switch leads exiting the proximity switch compressor start-up, purge all air from
housing. divider block lubrication system with a purge
6. The divider valve must cycle during proximity pump.
switch adjustment. To cycle it, either run the NOTE: When installing multiple proximity switches,
compressor or manually pump oil through wire each to a separate alarm circuit of the control
the distribution block with a purge pump. panel, annunciator, or PLC to simplify lubrication
7. To adjust, slide proximity switch all the way system and proximity switch troubleshooting. Always
onto hex of magnet housing. Tighten Allen set secure green ground wire to "earth ground" in the
screws to 25 lbs x inch maximum. The ohm control panel. Do not ground to electrical conduit.
meter showing the switch changing state as Improper grounding can result in unreliable monitor
the divider valve cycles indicates correct operation.
adjustment. If the switch state fails to
change, slide proximity switch back on the
hex of the magnet housing in 1/16"
increments until it does.
Figure: A-18255 Proximity Switch Wiring Connections for Unit in Operation

Troubleshooting Proximity • Switch does not cycle and control panel indi-
cates lube no-flow. (also see Erratic Opera-
Switches tion)
• ARV bypasses or rupture disk bursts and
NOTE: When installing multiple proximity switches, divider valve seizes after proximity switch
wire each to a separate circuit in the control panel, installation.
annunciator, or PLC to simplify lubrication system • Erratic Operation.
and proximity switch troubleshooting. Troubleshooting: Proximity Switches Lube No-Flow

Problem:

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

Problem Solution

Switch does not cycle and control panel indicates 1. Loosen set screws, remove proximity switch
lube no-flow. (see also Erratic Operation) from magnet housing.
2. Check for damaged or bent magnet housing.
Possible Cause 3. Remove magnet assembly from divider
valve.
Improperly adjusted proximity switch.
4. Replace magnet housing, magnet, spring,
Solution and spacer.
1. Loosen set screws, slide proximity switch all 5. Re-install new magnet housing on divider
the way onto hex of magnet housing and valve and proximity switch on magnet
torque to 25 lbs x inch max. (Do not over housing.
tighten). 6. If necessary, adjust proximity switch and test
2. Either pump clean oil through lubrication switch functionality.
system with a purge pump or run the 7. Purge air from system with purge pump.
compressor to cycle the divider valve. Troubleshooting: Proximity Switches ARV Bypasses

3. If necessary, slide proximity switch back in Problem

1/16“ increments until the switch
opens/closes with each divider valve cycle. ARV bypasses or rupture disk bursts and divider
valve seizes after proximity switch installation.
Possible Cause
Possible Cause
Broken spring or magnet in magnet housing.
Wrong magnet housing installed on divider
Solution valve.
1. Loosen set screws, remove proximity switch
from magnet housing. Solution

2. Remove magnet housing from divider valve. 1. Loosen set screws and remove proximity
switch from magnet housing.
3. Remove magnet, spring, and spacer and
check for damage. Replace damaged 2. Check for correct magnet housing for divider
components. valve manufacturer.
4. Re-install magnet housing on divider valve 3. Remove and replace with correct magnet
and proximity switch on magnet housing. housing.
5. If necessary, adjust proximity switch and test 4. Re-install proximity switch on new magnet
switch functionality. housing.
6. Purge air from system with purge pump. 5. If necessary adjust proximity switch and test
switch functionality.

Possible Cause 6. Purge air from system with purge pump.

Bent magnet housing.

Possible Cause
Air or debris in divider valve assembly.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

Solution Solution
1. Check system pressure to verify oil flows to 1. Check system pressure to verify oil flows to
divider valves. pump and divider valves. If needed, install
pressure gauge to monitor lubrication
2. If needed, install pressure gauge to monitor
system operation.
lubrication system operation:
a. Loosen outlet plugs in front of valve 2. Check gauge to verify pump builds sufficient
blocks. pressure to inject oil into cylinder. Do not
remove tubing from check valve and pump
b. Purge lubrication system with a purge
oil to atmosphere to check oil flow into
pump until clean, clear, air-free oil flows
cylinder.
from plugs.
c. Loosen, but do not remove, each piston 3. Replace pump.
enclosure plug individually to purge air
from behind piston. To ensure proper
lube system operation, all tubing and
Main Bearing Temperature
components MUST be filled with oil and Alarms and Shutdown
free of air before start-up.
Main bearing thermocouples or RTD temperature
d. Tighten all divider valve plugs.
sensors are optional for KBK:T frames.
e. Adjust proximity switch.
Troubleshooting: Proximity Switches Erratic Operation

Problem Thermocouples - J (Iron-

Erratic Operation.
Constantan) or K (Chromel-
Alumel)
Possible Cause A thermocouple is two dissimilar conductors
Faulty wiring from proximity switch to control joined together at one end to form a sensor that
panel or air in system (see air in system). produces a thermoelectric voltage as an accurate
function of temperature. Appropriate controls
Solution interpret the thermocouple voltage as
temperature.
1. Check electrical wiring and connections for
damage or poor contact. See Figure: A-18255
Proximity Switch Wiring Connections for
Unit in Operation.

Possible Cause
Faulty lube pump.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

Resistance Temperature Devices To simplify wiring, RTD's come with two green
(RTD) wires and one black for one element, and two red
wires and one white for the other. See Figure:
Figure: Typical Dual Element RTD Wiring Typical Dual Element RTD Wiring Diagram.
Diagram A Zone 1 environment may require the
installation of proper, intrinsically safe or
equivalent protection to fulfill electrical
requirements.

Testing RTD’s and Thermocouples

Ariel uses resistive temperature devices (RTD) or
thermocouples (TC) to monitor main bearing and
packing temperatures. An RTD has either three or
six wires; a TC has two. Both types of devices are
tested on the assembly floor after installation,
but before the run-test.

RTD Testing
1 Element 1
2 White Wire Figure: Typical RTD/Thermocouple
3 Red Wire
4 Element 2
5 Black Wire
6 Green Wire

An RTD is a sensor that produces electrical

resistance as an accurate function of
temperature. Appropriate controls interpret the
electrical resistance as temperature. A typical
1 Temperature Probe
measurement technique sends a small constant
2 Tube Bend
current through the sensor and measures voltage
3 Transition Piece
across the sensor with a digital voltmeter to
4 PTFE Insulated Foil Shield, FEP Jacket
indicate resistance by a computer and wave- 5 Element Wires (3 or 6 for RTD; 2 for TC)
fitting equations.
Ariel uses two types of RTD: single and dual
For main or thrust bearing temperature sensing, element. Single element consists of one white
Ariel supplies dual element, six-wire, 100 Ohm (at wire and two red wires. Dual element consists of
0°C) RTD’s. Dual element RTD’s allow rewiring one element of one white wire and two red wires,
instead of sensor replacement if an element fails. and another of one black wire and two green
Insulate unused wire ends from each other and wires.
conduit ground.

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After RTD installation: Thermocouple Testing

1. Set multimeter to the 100 Ohms resistance Ariel uses two types of TC: Type J (-328 to 2192°F),
scale. which has a red and a white wire, and Type K (-
2. Touch one multimeter lead to the white 328 to 2501°F), which has a red and a yellow wire.
element wire, and the other lead to one of the TC’s generate a very low voltage that is difficult to
red element wires. measure with a multimeter. A digital
• The multimeter should read between 100 thermometer attached to the TC measures the
Ohms (RTD at 32°F) to 112 Ohms (RTD at voltage and converts it to a temperature reading
90°F).
based on the thermocouple type.
• Test the other red wire with the white
wire. Resistance should be similar for After TC Installation:
both red wires. Resistance outside the
specified range indicates a damaged or 1. Turn ON the digital thermometer.
broken element. 2. Select the thermometer test lead with
3. For dual element RTD’s, perform step 2 with colored alligator clips that match the element
the black and two green wires. wire colors of the TC being tested.

4. Set the multimeter to check for continuity 3. Plug the test lead into the top of the
( ). thermometer. Take care to align the blades to
the appropriate hole.
5. Isolate all element wires from the tube bend
and transition piece. Check for continuity 4. Press the TYPE button until “J” or “K” appears
between each wire and these components. on the screen as appropriate. If “°C” displays,
press the C/F button to change the display to
• The multimeter displays “1.” to indicate “°F”.
the circuit is not continuous.
• It displays a value between .001 and .010 5. Attach the red alligator clip to the red
and beeps to indicate a continuous element wire and the other alligator clip to
circuit. the remaining element wire (either white or
yellow).
• Only the white wire tested with either red
wire and (for dual element RTD’s) the • If the connections are reversed, the ther-
black wire tested with either green wire mometer displays inaccurate tempera-
should yield a continuous circuit. ture (about 2°F less at room temperature
and 135°F less at 150°F).
• A continuous circuit between any
element wire and any component indi- • The temperature displayed should be
cates a damaged RTD that needs about room temperature before TC instal-
replaced. lation. If displayed temperature is not
room temperature or seems odd, verify
test setup.
6. Detach alligator clips from TC.
7. Set the multimeter to check for
continuity ( ).
8. Isolate both element wires from the tube
bend and transition piece. Check for
continuity between each wire and these
components.

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KBK-KBT Maintenance & Repair Manual – Instrumentation 04/03/2023

• The multimeter displays “1.” to indicate

the circuit is not continuous.
• It displays a value between .001 and .010
and beeps to indicate a continuous
circuit. Only the two TC element wires
should yield a continuous circuit.
• A continuous circuit between an element
wire and any component indicates a
damaged TC that needs replaced.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Maintenance
Ariel compressors, like all industrial equipment, • Detailed records of all maintenance.
require maintenance. The severity of compressor To avoid contamination, keep all covers in place
service directly influences the frequency and where access is not required. Use paper towels
amount of maintenance needed. Below are during internal maintenance.
recommended intervals for inspections and
replacements to help determine appropriate WARNING
intervals for a given compressor application.
To reduce risk of injury or death, only trained personnel
Careful documentation of inspection results is who have read and thoroughly understand the
critical to establish whether recommended appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
intervals are adequate or require more or less
Prior to performing any maintenance activities:
frequency. • Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
Continuous Duty: The compressor operates tional procedures.
continuously, 24 hours a day, shutting down only • Never tighten or loosen any fastener while the unit is
for short durations, usually for maintenance and operating or pressurized.
• Verify neither driver nor compressor can turn during
unexpected shut-downs. maintenance.
• Follow packager instructions to completely isolate
Short-Term Intermittent Duty: The compressor
and vent the system; call the packager for assis-
operates for short durations, starting and tance.
stopping perhaps several times per day, such as • Verify each compressor cylinder is relieved to atmo-
in many CNG filling station applications that spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
require operation based on consumer demand. on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
Long-Term Intermittent Duty: The compressor AND/OR FLAMMABLE.
operates continuously for extended durations, Before resuming operation, purge the entire system with
with extended shut-down periods, such as in the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
some storage/withdrawal applications and fuel mixture under pressure can explode and cause severe
gas booster applications. injury or death.

Many factors affect bearing life including the

number of starts, starting conditions, and run
Initial Maintenance
hours. Consider site-specific conditions when
adjusting maintenance intervals. Comply with Ariel Packager Standards and the
compressor Start Up Check List. Adhere to all
As part of your maintenance program, Ariel
items before and after start-up.
recommends:
• Consistent adherence to safety policies, For cold alignment, account for the difference in
procedures, and equipment warning labels. thermal growth height between the compressor
• Daily operational checks. and driver. Table: Thermal Growth of KBK:T
• Routine trending and review of operational Compressors lists compressor centerline height
parameters. change based on 6.5 x 10-6/°F (11.7 x 10-6/°C).
• Routine oil analysis and trending.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Figure: Thermal Growth

1 HOT Centerline
2 Thermal Growth
3 COLD Centerline

Table: Thermal Growth of KBK:T Compressors

NOTE: Thermal growth numbers were calculated
Initial Frame Temp. °F Thermal Growth Inch using 170°F (77°C) as the frame operating tempera-
(°C) (mm) ture. Initial frame temperature is the temperature of
0 (-18) 0.019 (0.48) the frame during cold alignment. Obtain driver
thermal growth predictions from the driver manufac-
10 (-12) 0.018 (0.45)
turer.
20 (-7) 0.017 (0.42)

30 (-1) 0.015 (0.39) Figure: Angular Coupling-Hub Face Alignment

40 (4) 0.014 (0.37) Limits
50 (10) 0.013 (0.34)

60 (16) 0.012 (0.31)

70 (21) 0.011 (0.28)

80 (27) 0.010 (0.25)

90 (32) 0.009 (0.23)

100 (38) 0.008 (0.20)

110 (43) 0.007 (0.17)

120 (49) 0.006 (0.14)

130 (54) 0.004 (0.12)

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Center the coupling between the driver and 2. Check fastener torque on gas nozzle flanges,
compressor so it does not thrust or force the valve caps, cylinder heads, piston rod
crankshaft against either thrust face. packing flanges, crosshead guide hold down,
frame hold down, crosshead guide to
To ensure parallel and concentric drive train
cylinder, and crosshead guide to frame
alignment, position connected equipment so
bolting, if applicable. See Appendix A for
misalignment is as close to zero as possible.
correct torques.
Limits for Total Indicator Reading (TIR):
• Maximum rim (outside diameter), (parallel) 3. Repeat torque check after 750 hours. Recheck
misalignment is 0.005 inch (0.13 mm). fasteners found loose in any of these intervals
• Face (angular) misalignment must be within after an additional 750 hours. If loosening
0.005 inch (0.13 mm) for hub diameters up to continues, contact your package supplier
17 inches (430 mm). For hubs greater than 17 immediately.
inches (430 mm), use the following formula:
Hub O.D. x 0.0003 = max angular misalign-
ment. See Figure: Angular Coupling-Hub Face Daily Maintenance
Alignment Limits.
1. Log and trend the following:
For laser alignment tools:
• Operating RPM, gas pressure and
• Maximum parallel misalignment is 0.0025 temperatures - determine if the unit is
inch (0.064 mm). operating within design parameters and
• Maximum angular misalignment is 0.0003 expectations.
inch/1 inch (0.03mm/100mm). NOTE: Verify high and low pressure shutdowns
are set as close as practical to normal operating
NOTE: If laser is adjusted to display TIR, use TIR limits. conditions. Set points must protect the machine
from exceeding compressor limits.
After running a new, relocated, reconfigured, or • Bearing temperatures - if the unit is
overhauled compressor for 24 hours, shut down, equipped with main bearing temperature
vent the gas system, and perform the following sensors.
maintenance: • Compressor frame oil pressure - at oper-
1. Perform a hot alignment check within 30 ating temperature (190°F (88°C) max. inlet
minutes of shutdown as described above. oil temperature), it should be 50 to 60 psig
(3.5 to 4.2 barg) at the filter gauges. If
Adjust discharge bottle supports and head
pressure falls below 50 psig (3.5 barg),
end supports, if applicable. shut down the compressor then deter-
NOTE: To avoid cylinder distortion, lift discharge mine and correct the cause.
bottles only 0.003 to 0.005 inch (0.08 to 0.13 mm) • Compressor frame inlet oil temperature.
using the supports.
• Cylinder valve cap temperatures.
• Compressor frame oil filter differential
pressure - differential pressure exceeding
the filter change value indicates a need
for a filter change. See filter information
plate on top cover or “Oil Filter” in Frame
Oil System Components for procedure.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

2. Check compressor frame oil level. It should Recommended Maintenance

be about mid-level in the sight glass and free
of foam when running. If not, determine and Intervals for Continuous Duty
correct the cause. Do not overfill. Check oil
makeup tank for sufficient oil supply. For dry
Operation
sump frames, check the package sump oil Ariel compressors, like all industrial equipment,
level. Do not add oil to the crankcase through require maintenance. The severity of compressor
the breather hole while the unit runs. This
service directly influences the frequency and
causes oil foaming and unnecessary no-flow
shutdowns in the force feed lubrication amount of maintenance needed. What follows
system. are the recommended intervals for inspections
and replacements for continuous duty
3. Check force feed lubricator box oil level. It
should be full to the overflow line. operation. This will help you determine the
appropriate intervals for a given compressor
4. Log and trend piston rod packing vent/drain
application.
temperature and check distance piece and
VVCP vents for leakage. If the piston rod
packing vent/drain temperature is trending NOTE: For intermittent duty service, see "Appendix
high, then verify leak rate before performing J".
maintenance.
5. Verify all cylinder high discharge gas NOTE: Careful documentation of inspection results is
temperature shutdowns are set to within 10% critical to establish whether recommended intervals
or as close as practical above the normal are adequate or require more or less frequency.
operating discharge temperature. Do not
exceed the maximum discharge temperature
shutdown setting for the application. Monthly Maintenance
6. Check lubricator block cycle time. See
1. Perform all Daily maintenance.
lubricator box data plate for correct cycle
time. Changes in gas composition may 2. Verify safety shutdown functionality.
require a review of cycle time. Check lube 3. Sample compressor frame oil and send it to a
sheet for units not running at the speed on reputable lubricant lab for analysis. See "Oil
the data tag. If applicable, verify auto relief Maintenance" for a list of what an oil analysis
valve indicator does not show sign of over- should provide. If analysis results indicate
pressurization. increasing levels of lead, tin, or copper
7. Check for gas, oil, and coolant leaks. particles in the oil, shut down unit. Remove
frame top cover and crosshead guide side
CAUTION
covers. Visually inspect for debris. Do not
Do not attempt to repair leaks while the unit is operating disassemble further without good reason. If
or pressurized. debris indicates, replace affected parts, then
change oil, oil filter, and clean the strainer
8. Check for unusual noises or vibrations. with a suitable solvent.
9. See packager documentation for additional NOTE: Operate the unit to bring oil temperature to a
recommended checks, i.e. scrubber liquid minimum operating temperature of 150°F (66°C) to
levels, dump valve operation, cooler louver drive off any entrained water.
positions, etc. 4. Check and log cylinder clearance devices in
use and their settings.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Six-Month (4,000-Hour) 8. Grease VVCP stem threads at grease fitting,

with 2 to 3 pumps of cylinder lube compatible
Maintenance grease using a standard manual grease
1. Perform all Daily and Monthly maintenance. pump. Turn VVCP adjustment handle all the
way in and all the way out to lubricate the
2. Shut down unit and allow sufficient time for threads. Measure or count turns to return the
components to cool. handle to its original position.
3. Inspect crankcase breather filter and clean 9. Check for adequate cylinder lubrication. See
with suitable solvent. “Cylinder Lubrication Paper Test” for
4. Drain and replace force feed lubricator box procedure.
oil. 10. Re-tighten hold down fasteners to proper
5. Where applicable, replace force feed torque (compressor frame feet and
lubricator inlet filter in independent supply crosshead guide/distance piece support
system. feet). Inspect for frame twist or bending to
verify main bearing bore alignment. See
6. Change compressor oil filter. See top cover Appendix H for flatness and soft foot
filter information plate or “Oil Filter” in Frame requirements.
Oil System Components for procedure. Do
not exceed 12 month installed period for filter 11. Perform a coupling alignment (see "Initial
element. Maintenance").
NOTE: For replaceable element style filters, drain the 12. Remove and inspect inlet screens on each
canister completely before removing the element. stage; clean if clogged with debris or replace
Inspect elements for cleanliness and damage. Do not if damaged. Clean inlet screens regularly to
install dirty or damaged elements. avoid increased pressure that may collapse
7. Change compressor oil. Extremely dirty them. More debris in the screen may dictate
environments, oil supplier more frequent inspections. Inlet screens may
recommendations, or oil analysis results may be removed if they catch little or no debris
dictate a different oil change interval. Follow and the gas stream is clean (optional).
these steps:
a. Drain oil from frame, associated piping, One-Year (8,000-Hour)
and oil cooler. Maintenance
b. Clean oil strainer with a suitable solvent.
In dry sump applications, the strainer is 1. Perform all Daily, Monthly, and Six-Month
located at the oil reservoir. maintenance.
c. Remove frame top cover and crosshead 2. Open force feed lubricator box and visually
guide side covers. Visually inspect for inspect pump followers, cams, and gears for
debris. Do not disassemble further wear.
without good reason. If debris indicates, 3. Pressure test distribution blocks. See
replace affected parts, then change the oil “Divider Valve Bypass Pressure Test” for
filter and clean the strainer with a suitable procedure.
solvent.
4. Measure, log, and trend the following:
d. Refill compressor frame with fresh, clean
oil. • Main bearing, connecting rod bearing,
and crankshaft jack and thrust clear-
ances. See "Main Bearing Vertical Jack Clear-
ance Measurement", "Connecting Rod

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Bearing Vertical Jack Clearance Measure- 9. Inspect cylinder bores for damage or wear.
ment", and "Crankshaft Thrust (End) Clear- Replace the cylinder body or restore the bore
ance Measurement" in Section 4. if any of the following conditions exist:
NOTE: Clearance trends along with oil analysis • Bore surface blemishes or gouges.
and crankcase visual inspection can indicate the
• Bore out of round more than 0.001 inch
need for bearing replacement. Do not disas-
per inch of bore diameter (0.001 mm/mm)
semble to check clearances. Disassemble only if
or tapered.
clearance checks indicate excessive clearance.
Contact Ariel for original assembly clearances. • Main bore is worn to counterbore diam-
eter or larger.
• Crosshead to guide clearances. See
“Crosshead Installation” in Section 4. 10. Inspect piston rings and wearband:
• Piston rod runout. See “Piston Rod a. Measure and log piston ring condition,
Runout” in Section 4. end gap, side clearance, and piston
groove width.
If any of the above items are outside limits speci-
fied in Appendix B, find the cause and correct it. It b. Replace rings that are damaged or
may require part replacement. outside limits listed in Appendix B.
5. Remove valves and valve gaskets: c. When replacing rings, re-measure and log
NOTE: If using CP/CPs/XP valves, valve maintenance ring side clearance to check for groove
may be extended to the 2 year (16,000 hour) interval. wear.
d. Measure and log radial projection of wear
a. Visually inspect valve pockets for
band.
damage. Verify all old valve seat gaskets
are removed. 11. Inspect piston rods for damage and excessive
b. Have a qualified valve repair shop disas- wear. Replace rod if any of these conditions
semble, visually inspect, and refurbish exist (see “Piston and Rod Removal” in
the valves where needed. Provide the Section 4):
valve repair shop an Ariel torque chart • Gouges or scratches on the rod.
and valve service guide. • Under size more than 0.005 inch (0.13
c. Visually inspect cylinder gas passages and mm).
clean them of all debris. • In the packing travel length, out of round
more than 0.001 inch (0.03 mm).
6. If applicable, remove, disassemble and
visually inspect the variable volume • Anywhere in the packing travel area,
clearance pockets (VVCP). Check for damage tapered more than 0.002 inch (0.05 mm).
or wear of all sealing components and 12. Rebuild piston rod pressure packing cases.
surfaces, and repair or replace if necessary. See “Piston Rod Packing” in Section 4 for
7. If applicable, visually inspect suction valve procedure.
unloader actuator stems for damage or wear. 13. Re-install valves, retainers, and valve caps
Visually inspect stem seals for damage or using new valve seat gaskets and valve cap O-
wear and confirm that the actuator moves rings/seals. See “Valve Installation” in
freely. Section 4. Use proper installation techniques
8. If applicable, visually inspect pneumatic and torque procedures for valve caps.
clearance pockets for damage or wear 14. Check and re-calibrate all required
(seating surface and stems/stem seals). instrumentation.
Confirm that actuator moves freely.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

15. Clean crankcase breather filter with suitable 4. If applicable, use new piston and stem seals
solvent. to rebuild actuators on suction valve
16. Check and, if needed, adjust drive chains. See unloaders and fixed volume pneumatic
“Chain Adjustment” in Section 4 for pockets. Replace piston stem assemblies
procedure. where stem is damaged or worn.

17. If the compressor is equipped with crankcase 5. Check auxiliary end chain drive for undercut
over-pressure relief valves, visually inspect sprocket teeth and chain for excessive
and exercise valves to manufacturer stretching. Replace as required.
recommendations.
18. Check fastener torques of gas nozzle flanges, Four-Year (32,000-Hour)
head end head or unloader, valve caps, Maintenance
piston rod packings, crosshead pin thru-
bolts, crosshead guide to frame, frame hold 1. Perform all Daily, Monthly, Six-Month, One-
down, crosshead guide to cylinder, cylinder Year, and Two-Year maintenance.
mounting flange to forged steel cylinder, 2. Remove crosshead pins.
distance piece to cylinder, distance piece to
crosshead guide, and tandem cylinder to a. Measure and log crosshead pin to cross-
cylinder. head pin bore and connecting rod
bushing bore clearances.
b. Check crosshead pin end caps and thru-
Two-Year (16,000-Hour) bolt for wear.
Maintenance c. Replace if needed.
1. Perform all Daily, Monthly, Six-Month, and 3. Check for bushing wear in the auxiliary end
One-Year maintenance. drive chain tightener.
2. If using CP/CPs/XP valves, remove valves and 4. Check for ring groove wear in pistons.
valve gaskets:
a. Visually inspect valve pockets for Six-Year (48,000-Hour)
damage. Verify all old valve seat gaskets
are removed.
Maintenance
b. Have a qualified valve repair shop disas- 1. Perform all Daily, Monthly, Six-Month, One-
semble, visually inspect, and refurbish Year and Two-Year maintenance.
the valves where needed. Provide the
2. Replace lubricator distribution blocks.
valve repair shop an Ariel torque chart
and valve service guide. 3. Replace crosshead bushings and connecting
c. Visually inspect cylinder gas passages and rod bushings. See “Crossheads” and
clean them of all debris. “Connecting Rods” in Section 4.

3. Rebuild oil wiper cases. 4. Replace connecting rod bearings. See

“Connecting Rods” in Section 4.
5. Replace main bearings. See “Crankshaft” in
Section 4.
6. Service or replace auxiliary end torsional
damper, if applicable. See assembly drawing
in compressor build book for procedure.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Frame Oil Viscosity

There are several oil specifications, maintenance The minimum allowable viscosity of the oil
procedures, and operating conditions which entering the frame is 16 cSt. Typically, this is the
affect oil performance. For optimal performance, viscosity of ISO 150 grade oil at about 190°F
ensure the oil meets the specifications below and (88°C).The maximum viscosity at this
is suitable for the given application, and temperature is 60 cSt. For KBK:T frames, the
diligently complete maintenance procedures. maximum viscosity to start the compressor is
3,300 cSt and the maximum viscosity to load the
compressor is 1,000 cSt. See Figure: Viscosity vs.
Temperature Graph of Different Lubricants.
Figure: Viscosity vs. Temperature Graph of Different Lubricants

Oil Pressure up to 60 psig (4.1 barg) at the lower of the frame

or cylinder rated speed, or driver speed at normal
The factory sets normal pressure on the operating temperature. Adjust the oil pressure
discharge side of the oil filter at 60 psig (4.1 barg) after the filter to 60 psig at minimum operating
for compressors tested mechanically complete speed and normal operating temperature.
(inspector tag displayed). If factory tested as
mechanically incomplete (no inspector tag), the
packager sets normal oil pressure at initial start-

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Ariel uses the pump safety relief valve to regulate For proper operation of the thermostatic control
pressure into the compressor. If oil pressure into valve, the maximum differential pressure
the compressor at minimum operating speed between the hot oil supply line and the cooled oil
and normal operating temperature does not read return line is 10 psid (0.7 bard).
about 60 psig (4.1 barg), adjust the pump safety
relief valve. With compressor running at
Oil Sampling Valve
minimum operating speed, turn the adjustment
screw clockwise to increase oil pressure, or Ariel equips KBE:K:T:C:D:F frames with an oil
counter-clockwise to decrease it. The sampling valve.
compressor requires a 45 psig (3.1 barg) low oil
pressure shutdown for protection.
Dry Sump
NOTE: If oil pressure drops below 50 PSIG (3.4 barg) Compressors subject to transient motion, roll,
when crankshaft speed equals or exceeds minimum and yaw on board a ship or a floating platform
rated operating speed, find the cause and correct it.
may require a dry sump (“dry” crankcase and
separate oil reservoir). See the table for limits,
which are based on the angle where the
Oil Temperature crankshaft/connecting rods will contact the oil
Maintain frame inlet oil temperature as close to level causing foaming. The limits assume that the
170°F (77°C) as possible. Minimum lube oil running oil level is maintained between one half
operating temperature is 150°F (66°C) to drive off and two-thirds the height of the sight glass when
water vapor. Maximum allowable oil the frame is level.
temperature into the compressor frame is 190°F
(88°C). Higher temperatures increase the
oxidation rate of mineral oil. Every 18°F (10°C)
within the operating range doubles the oxidation
rate of mineral oil.

Table: Maximum Angle from a Horizontal Plane Allowed in Transient Motion without Dry Sump

Framea 1 or 2 Throw 4 Throw 6 Throw

KBK 3° Use Dry Sumpa Use Dry Sumpa

KBT 7.5° 2° 1°

a Use dry sump as noted if compressor is subject to transient motion.

With a dry sump, drains are supplied at each end in the pump suction line at the outlet of the
of the compressor frame and an additional oil separate lube oil reservoir (unmounted strainer
pump chain oiler is provided by Ariel. The is provided by Ariel with a new dry sump
packager must provide a lube oil reservoir sized compressor). Refer to the Ariel outline drawings
and located so that the oil pump has oil suction for connection sizes and locations.
regardless of the tilt of the ship or floating
platform. An oil sump strainer must be installed

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Oil System Cleanliness For all compressors with oil piping systems
greater than 50 feet (15 m), cleaning and flushing
Clean the compressor frame oil piping system must result in a cleanliness level to ISO-4406,
and components of all foreign matter such as Grade 13/10/9 and/or NAS-1638, Class 5 (see
sand, rust, mill scale, metal chips, weld spatter, Table: Oil Flush Cleanliness Requirements ), prior
grease, and paint. Use proper cleaning to start-up.
procedures with proper cleaners, acids, and/or
mechanical cleaning to meet cleanliness Table: Oil Flush Cleanliness Requirements
requirements. Ariel recommends flushing all oil- ISO-4406 GRADE 13/10/9
piping systems with an electric or pneumatic
Particle Size
driven pump and filtered, clean production oil. Grade
µm/ml Oil
Particles
Requirement Allowed
Ariel thoroughly cleans all compressor frame Sample
cavities prior to assembly and test runs /13 Greater than 4 40 to 80
compressors with a filtered closed loop lube
/10 Greater than 6 5 to 10
system.
/9 Greater than 14 2.5 to 5
NOTE: Ariel recommends not disturbing lube oil
piping downstream of the installed oil filter. Contam-
inants that enter this piping or open ports flush into NAS-1638 GRADE 5
the bearings causing catastrophic damage. If contam- Particle Size Range Grade 5 Maximum
ination is suspected in the supply piping downstream µm/100ml Oil Sample Particles Allowed
of the oil filter or in the oil gallery, remove the supply 5 to 15 8,000
piping and thoroughly clean both the piping and
gallery. Before performing this work, contact Ariel 15 to 25 1,424
Technical Service for best practices and procedures. 25 to 50 253
To remove or alter piping, cover the inlets to the oil
gallery, the ends of the piping, and the filter outlet so 50 to 100 45
no contaminants enter. Before reinstallation, chem- Over 100 8
ical and mechanical cleaning is required. Flush the
pipe in accordance with Ariel cleanliness require- 1. Prior to assembling lube oil piping, remove
ments (see Table: Oil Flush Cleanliness Requirements scale, weld slag, rust and any other matter
).
that could contaminate lube oil. Confirm:
• Complete and closed lube oil system.
Prior to start-up, flush all compressors installed
• Crankcase filled to the correct level with
with an electric or pneumatic powered pre-lube
appropriate oil.
pump and less than 50 feet (15 m) of oil piping as
• Proper and correctly installed lube oil
outlined below. Include cooler oil passages in the filters.
flushing loop. While oil systems for compressors
• Operational and viewable oil pressure
without an electric or pneumatic powered pre- transducer or gauge, oil filter differential-
lube pump and less than 50 feet (15 m) of oil pressure transducers or gauges, and oil
piping must be clean, oil flushing is desirable, but temperature RTD or indicator.
not required.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

2. Start pre-lube pump. Record oil pressure, oil

filter differential-pressure, and oil tempera-
ture. Minimum oil pressure is 30 psig (2.1
barg) for effective flushing. Do not exceed 90
psig (6.2 barg).

3. Flush continuously for one hour. Oil filter

differential pressure must not increase more
than 10% of measured oil pressure into the
filter. Record the oil pressure, oil filter differ-
ential pressure, and oil temperature every 15
minutes. Oil temperature increases of more
than 10°F (5.5°C) during an hour of flushing
invalidate the system cleanliness test, due to
oil viscosity change.

4. After one hour of pre-lube flushing, if differen-

tial pressure or temperature increases
exceed the limits above, continue flushing. If
the lube oil filter differential pressure exceeds
change filter limits, stop the pre-lube pump
and change the oil filter. To ensure system
cleanliness, re-set time and continue flushing
until the compressor achieves a continuous
hour of flushing within differential pressure
and temperature increase limits.
See ISO-4406 "International Standard - Hydraulic
fluid power - Fluids - Method for coding level of
contamination by solid particles" and/or NAS-
1638 "National Aerospace Standard, Aerospace
Industries Association of America, Inc. -
Cleanliness Requirements for Parts Used in
Hydraulic Systems" for complete information.
Use a competent oil lab for sample testing. To
flush the entire oil system see “Flushing
Procedure”.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Frame Oil System Components

Figure: Standard Frame Lube Oil Schematic

Oil Connections (see Ariel outline drawing for details) System Components
A1 Packager connection from oil pump 1 Y-Strainer
A2 Packager connection to oil filter 2 Compressor driven oil pump (with safety relief valve for
A3 Oil connection from compressor crankcase (oil sump) pressure regulation, or in models with a separate regulating
A4 Lube oil compressor inlet connection to gallery tube -Oil valve (7), for relief)
flows to crankshaft main bearings, connecting rod bearings, 3 Thermostatic control valve, 170°F (77°C) nominal rating -
crosshead pins, and bushings. required
A5 Pressure regulating valve return connection to oil sump 4 Pre-lube oil pump - required (shown with oil heating circuit,
(when applicable) when applicable), or auxiliary pump.
A6 Filter vent return connection to oil sump (when applicable 5 Optional duplex oil filter
on some models) 6 Oil filter
A7 Oil tubing connections from frame gallery tube to top and 7 Oil cooler - required
bottom of crosshead guides to lubricate crossheads. 8 Check valve
A8 Compressor crankcase oil drain (oil sump drain) 9 Heater (when applicable).
A9 Pre-lube/recirculation/heater connections (4) 10 Temperature indicator
11 Pressure indicator (dirty side)
12 Pressure indicator (clean side)
13 Pressure indicator/shutdown connection

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Figure: Optional Dry Sump Frame Lube Oil Schematic - Typical

Oil Connections (see Ariel outline drawing for details) System Components
A1 Packager connection from compressor-driven oil pump 1 Separate lube oil reservoir (oil sump) - required, vent reser-
A2 Packager connection to oil filter voir to above frame height
A3 Packager connection - oil from compressor crankcase 2 Heater
A4 Lube oil compressor-inlet-connection to gallery tube and 3 Y-Strainer - required (supplied unmounted by Ariel)
bearings 4 Check valve
A5 Pressure regulating valve return connection to crankcase 5 Compressor driven oil pump (with safety relief valve for
(when applicable on some models) pressure regulation)
A6 Filter vent return connection to the crankcase (when appli- 6 Oil cooler - required
cable on some models) 7 Thermostatic control valve, 170°F (77°C) nominal rating -
A7 Oil tubing connections from frame gallery tube to top and required
bottom of crosshead guides to lubricate crossheads 8 Pre-lube oil pump - required (with oil heating circuit, when
A8 Compressor crankcase oil drain applicable), or auxiliary pump
9 Optional duplex oil filter
10 Temperature indicator
11 Pressure indicator (dirty side)
12 Oil filter
13 Pressure indicator (clean side)
14 Pressure indicator/shutdown connection

NOTE: See "Dry Sump" for further details about dry

sump lubrication systems.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Oil Strainer Oil Pump & Regulating Valve

An oil strainer installed upstream of the pump The oil pump constantly supplies oil to all journal
prevents debris from entering the pump and bearings, bushings, and crosshead sliding
damaging it. Ariel supplies a 30 mesh (595 surfaces. The crankshaft drives it by a chain and
microns) or 40 mesh (400 microns) on all frames, sprocket to provide adequate oil flow to bearings
depending on frame size. It is located on the when the compressor operates at the minimum
auxiliary end of the crankcase below oil level. speed rating (typically half of maximum rated
Remove the strainer basket and wash it in an speed).
appropriate solvent whenever lubricating oil is
changed. Figure: Typical KBK:T Lube Oil Pump

1 Discharge
2 Safety Relief Valve
3 Dust Cap
4 Suction
Smaller compressor models have
threaded suction/discharge connections.

KBK:T compressors maintain oil pressure with a Oil Cooler

spring-loaded safety relief valve within the pump
head (see Figure: Typical Lube Oil Pump ). With An oil cooler is required to remove heat from the
the unit running at minimum operating speed frame lube oil. When sizing an oil cooler, consider
and the frame lube oil at operating temperature, temperature and flow rate of both cooling
170°F (77°C), remove the dust cap to expose the medium and lube oil. Insufficient cooling water
safety relief valve adjustment screw and set it so flow rate is the primary cause of high oil
the pressure gauge on the clean side of the oil temperatures. Mount cooler as close to the
filter reads 60 psig (4.1 barg). compressor as possible with piping of adequate
size to minimize pressure drop of both lube oil
When installing a new oil pump on a compressor and cooling medium.
or after maintenance on an existing oil pump,
Ariel recommends priming the pump (wetting The Application Manual lists required cooling
the gears with oil) before start-up to ensure water temperature and flow rate to properly cool
proper operation. Upon compressor start-up oil with Ariel supplied coolers. The Ariel
after oil pump replacement, oil pressure should Performance Program lists oil heat rejection data
immediately reach 50-60 psi. If oil pressure fails for each frame in the frame details section
to reach 50-60 psi immediately, shut down the (contact Ariel for details).
compressor and correct the problem. Dry oil
pump gears sometimes contribute to the
problem.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Oil Temperature Control Valve

The lube oil system requires a thermostatic valve
to control compressor oil temperature. A
thermostatic valve is a three-way valve with a
temperature sensitive element. As the oil heats,
the sensing element opens the third port in the
valve.

Figure: Thermostatic Valve in Mixing Mode

Thermostatic control valve configuration may
vary from this schematic depending on valve
size. Valve connections A-B-C are marked on
the valve.
1 Lube oil from main oil pump
2 Thermostatic Control Valve
3 Lube oil to main oil filter
4 Lube Oil Cooler

Ariel recommends a thermostatic valve with a and tear the filter media, sending dirty oil to
170°F (77°C) element. Install the valve in mixing crankshaft bearings.
mode to more directly control oil temperature • With canister style filters, always drain oil
into the frame (see Figure: Thermostatic Valve in filter housing before element removal or dirty
Mixing Mode). KBE:K:T:C:D:F compressors have a oil will be sent to crankshaft bearings.
thermostatic valve integrated into the lube oil • Keep new filter elements sealed in their orig-
inal packaging during storage. Visually
system as standard.
inspect filter internal/external surfaces prior
to installation. Do not install damaged,
Oil Filter corroded, or contaminated filters.
• Do not exceed 12 month installed period for
All compressor frames require oil filters to filter element.
remove particle contamination that can damage • When using a remotely mounted duplex filter,
equipment and oil. Contaminants that damage leave the frame mounted spin-on or canister
equipment include wear particles from filter in place as a polishing filter. At a
equipment, airborne particles such as dust or minimum, leave frame mounted filters in
place until they are verified free of solid
sand, and particulates in new oil. Contaminants
contaminants of any size.
that damage oil include oxidized oil components
and air bubbles.
• Ariel filters are not designed for reverse flow
often caused by pumping oil out of the
compressor through the filter. This can invert

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

KBK:T/2/4 compressors ship with simplex, spin- CAUTION

on, non-bypassing, resin-impregnated filters as
Before oil filter replacement, use the frame-mounted
standard. Spin-on filters carry a 5 micron pressure gauges to confirm system depressurization. Be
nominal and 17 micron absolute rating. The Beta careful - hot oil may cause burns! Wear proper personal
ratings are ß5 = 2 and ß17 = 75. Many spin-on protection equipment.
filters fit an Ariel compressor, but very few meet
filtration ratings of Ariel filters. Do not use Oil Sampling
aftermarket filters.
A consistent oil analysis program is the most
KBK:T/6 compressors ship with simplex or effective way to determine when to change frame
duplex cartridge style pleated synthetic filters as oil on the basis of need rather than a scheduled
standard. Cartridge filters are rated as 1 micron interval. Depending on service, oil analysis can
nominal and 12 micron absolute filters. The Beta significantly extend oil change intervals.
ratings are ß1 = 2, ß5 = 10 and ß12 = 75.
The packager installs an oil sampling valve on
Pressure gauges monitor pressure drop across most frames between the oil pump and filter at
the filter. High differential pressure indicates a an easily accessible location. Ariel equips KBK:T
plugged filter. Ariel recommends lube oil filter frames with an oil sampling valve.Minimize dirt
replacement every 6 months of operation or or debris that can collect around it.
when oil filter differential pressure at normal
Collect and analyze oil samples to verify
operating temperature reaches 10 psid (0.7 bard)
suitability for continued service. Oil analysis
for spin-on filters or 15 psid (1.0 bard) for
should include:
cartridge filters, whichever comes first. On start-
up, differential pressure may exceed the filter • Viscosity testing at 104°F (40°C) and 212°F
(100°C). This verifies that oil has not mixed
replacement limit until the oil reaches operating
with cylinder oils or process gas.
temperature.
• Particle counting to the latest version of ISO
4406.
Oil Maintenance • Spectroscopy to determine wear metals,
contaminants, and additives.
Proper oil maintenance is vital to the efficient
• FTIR (Fourier Transform Infrared Spectros-
operation of the compressor. The severity of
copy) to check for oxidation, water or coolant
compressor service affects the frequency of oil contamination, and additive depletion. This
and filter changes. is more important if the sump oil is not
consumed by the force feed system.
Oil Filter Replacement
Collect oil samples with the compressor running
Replace oil filters or elements with only genuine at operating temperature (see Figure: Ariel Oil
Ariel parts. See parts list or name plate for part Sampling Valve). To collect an oil sample with an
numbers. Ariel oil sampling valve:
1. Remove dust cap.
2. Loosen lock ring to release button.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

CAUTION 4. Press button to collect oil sample in a new

sample bottle.
A loosened lock ring allows valve outlet rotation. Aim
outlet carefully to avoid spilling hot oil.
5. Tighten lock ring against button.

3. Press button to purge a small amount of oil 6. Re-install dust cap.

into a waste container.

Figure: Ariel Oil Sampling Valve

1 Lock Ring
2 Button
3 Dust Cap

Simplex Spin-on Filter Replacement When filter differential pressure reaches 10 psid
(0.7 bard) or once every six months, whichever
Figure: Mounted Thermostatic Valve Drain Plug
comes first, replace oil filter with a genuine Ariel
filter.
1. Remove 1/2 inch NPT drain plug and drain oil
completely.
2. Remove old filter, clean filter head surfaces,
and verify old gasket is removed.
3. Inspect new filter for damage or debris. Do
not install damaged or dirty filters. Never
operate a unit with a damaged or leaking
oil filter.
4. Apply clean oil to the filter gasket and thread
the filter with gasket onto the head.
5. Tighten the filter one turn after the filter
gasket contacts the head. Install 1/2 inch NPT
drain plug.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

6. Use the compressor pre-lube pump to fill the CAUTION

oil filter with oil and purge air from the oil
system. Manually filling the filter with oil can Before replacement, verify system is depressurized with
frame-mounted pressure gauges. Hot lube oil may cause
introduce debris on the clean side of the
burns! Wear proper personal protection equipment.
filter. This debris can damage the compressor
to the point of bearing failure.
7. After starting the unit, check for leaks, and NOTE: Replaceable filter elements are delicate and
retighten if necessary. require proper storage to prevent material degrada-
tion, flash rust inside, contamination, etc. Inspect
Simplex Filter Cartridge Replacement filter elements for cleanliness and damage. Do not
install dirty or damaged filter elements.
Figure: Typical Oil Filter Vessels
1. Remove drain plug to drain oil.
2. While oil drains, open vent.
3. After oil drains completely, remove top cover,
spring plate assembly, and filter element.
During handling, avoid damage to top cover
o-ring sealing surface.
CAUTION

Carefully lift filter element out of vessel and place it in a

drip pan. Once unseated, do not let filter element oil
drain back into vessel.

4. Inspect filter vessel interior for debris. Clean if

needed.
5. Place new filter element over filter seat in
bottom of filter vessel.
B:V:Z:U JBE:K:T/6, KBK:T/6, KBC:D:F/4/6 6. Re-install spring plate assembly.
JGC:D:F/4/6

CAUTION
1 Vent
2 Top Cover The spring plate assembly on JGC:D:F/4/6, JGE:K:T/6,
KBK:T/6 is a two-piece assembly (spring and plate). Fit
3 Top Cover O-Ring
the nose of the plate inside the I.D. of the filter element
4 Spring Plate Assembly for a tight seal between the bottom of the flange and the
5 Filter Element element gasket. Place the large end of the spring on top
6 Filter Vessel with the small end mating with the top cover. Failure to
do either causes oil to bypass the filter element and
7 Filter Seat
catastrophic bearing failure.
8 Drain Plug

7. Inspect top cover o-ring for wear. Replace if

When filter differential pressure reaches 15 psid needed.
(1.0 bard) or once every six months, whichever
8. Reinstall drain plug.
comes first, replace element with a genuine Ariel
filter element. See parts list or name plate for
element part number.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

9. Use new oil to lubricate the top cover o-ring Compact Duplex Filter Cartridge
and install cover. Do not rotate top cover Replacement
once it contacts the o-ring. Torque nuts to 75
Lb x Ft (102 Nm). Reinstall vent. Figure: Typical Compact Duplex Filter Vessels
10. Use compressor pre-lube pump to fill filter
vessel with oil and purge air from oil system.
Manually filling filter vessel can introduce
debris on the clean side of the filter. Debris
can cause damage to the point of
catastrophic bearing failure.
11. Release trapped air through vent. Check for
leaks.

1 Filter Vent
2 Transfer Valve Indicator
3 Filter Head
4 Filter Housing
5 Filter Element
6 Filter Gasket
7 Drain Plug

1. The triangle indicator on top of the transfer

valve handle points toward the active filter.
Turn transfer valve handle until it stops to
make the inactive filter the active filter.
2. Loosen the inactive filter vent to relieve any
pressure.
3. Drain the inactive filter housing.
4. Remove the filter housing, clean and inspect.
5. Remove the filter element and properly
dispose of.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

6. Inspect new filter element and place it over 4. Verify no oil is flowing through the inactive
the seat in the top of filter head. It requires a filter. Vent trapped air, if necessary.
small amount of force to seat the element
5. Follow steps of "Simplex Filter Cartridge
onto the filter head.
Replacement" for the inactive filter
7. Install drain plug in the filter housing.
8. Inspect and replace the filter gasket if
damaged. Install the gasket and attach the
filter housing. Step torque the bolts to 40 Lb x
Ft (54 N•m).
9. Determine unit state:
• If unit is shut down: Crack open the
filter vent. Use compressor pre-lube
pump to fill the oil filter. Close vent
once air is purged. Manually filling the
filter with oil can introduce debris on
the clean side of the filter. Debris can
damage the compressor to the point
of bearing failure.
• If unit is running: Crack the vent of
the empty vessel. Rotate transfer
valve slightly to slowly fill empty
vessel. Close vent once air is purged.
Allow additional flow to the new
element to push any remaining air
downstream. Position transfer valve
handle to put desired filter in service.
10. Check for leaks.

Duplex Filter Cartridge Replacement

NOTE: Replaceable filter elements are delicate and

require proper storage to prevent material degrada-
tion, flash rust inside, contamination, etc. Inspect
elements for cleanliness and damage. Do not install
dirty or damaged elements.

1. Open equalization valve to equalize pressure

between the filters.
2. The triangle indicator on top of the transfer
valve handle points toward the active filter.
Turn transfer valve handle until it stops to
make the inactive filter the active filter.
3. Close equalization valve.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Figure: Typical Duplex Oil Filter

1 Filter Cartridge
2 3/4 NPT Drain (Dirty Side) Use for routine
filter changes.
3 3/4 NPT Drain (Clean Side) Not used for
normal maintenance.
4 Triangle Indicator
5 Equalization Valve Handle
6 Transfer Valve Handle

Transfer Valve Seal Replacement

CAUTION

Do not twist the valve plug during removal or

installation. It causes permanent damage to the valve
plug and/or valve body machined surfaces.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Valve Disassembly tolerances. Inspect and replace all seals. Quad-

ring removal may require a solvent such as MEK.
Figure: Typical Transfer Valve
Valve Assembly
Figure: Typical Valve Plug

1 Handle
2 Valve Plug
3 Retaining Ring
4 Valve Body
5 Roll Pin

1. Bring the arrow on the valve plug to the

extreme left or right position. Remove the 1 Groove areas requiring adhesive.
handle.
2. Clean top and bottom of valve assembly of all
contaminants. NOTE: Cleanliness helps ensure proper sealing and
long seal life. Clean all parts before assembly. Foreign
3. Remove top retaining ring from valve body. particles, dirt, metal chips, etc. in the valve may cause
NOTE: The retaining rings are in a honed valve body leakage, damage the seals, and reduce seal life.
and require special care at removal. Improper
handling may permanently damage the valve body
1. Valve must be clean and dry before installing
and void the warranty
seals. Install the three o-rings and two quad-
4. Install 1/2-13 NC eye bolt (supplied with valve rings on valve plug. Avoid twisting seals
plug seal kit) into tapped hole at stem side of during assembly.
valve plug and slowly pull the plug straight a. After seal installation, place valve plug in
out. If required, lightly push or tap on the a horizontal position.
bottom center of the plug with a non-metallic
b. On each straight run (2 places) of each
hammer or rod.
installed quad-ring, carefully lift quad-
NOTE: DO NOT twist the valve plug!
ring partially out of the groove and spar-
Check for any damage to the valve plug and valve ingly apply a coating of adhesive (about
body. Do not attempt any parts repair without
factory consultation. Parts are machined to close

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

2” long) to the bottom of the machined

groove. NOTE: The pre-lube return into the frame must be
upstream of the oil filter.
c. Place quad-ring back into groove.
NOTE: Avoid eye and skin contact with adhesive.
For on-demand compressor applications, the
2. Apply a lubricant compatible with seals and pre-lube pump can circulate oil continuously
fluid used on the valve plug and inside the through the bearings while on standby.
clean valve body.
3. Hold valve plug by the eye bolt and verify the Ariel requirements are based on a pre-lube pump
arrow is in the original left or right position. sized for 25% of frame oil pump flow to ensure oil
Align roll pin with the slot in the bottom of the flow to bearings, bushings, and oil-filled
plug and push or lightly tap the valve plug clearances prior to turning or start-up (see
assembly into the valve body until it stops. Appendix C for frame oil pump flow rates).
NOTE: DO NOT twist plug while reinstalling!
The following statements depend on oil supply
4. Install retaining ring.
and sump viscosities, which depend on oil
5. Unscrew eye bolt and install handle. temperature. Oil supply temperature at the filter
6. Test for any binding or leakage. If assembled head or frame oil gallery is not always a true
properly, valve is ready for use. representation of total oil sump temperature.
See Figure: Viscosity vs. Temperature Graph of
CAUTION
Different Lubricants to determine oil viscosity
During unit installation, proper alignment of inlet/outlet based on temperature.
piping ensures proper valve operation. When tightening
piping, check valve handle rotation periodically for • During a cold start of the unit when oil supply
smooth operation. Any misalignment may cause torque viscosity is greater than 50 cSt, pre-lube pres-
on the valve and valve plug binding. If binding occurs, sure should be 30 psig (2.1 barg) at the oil
loosen piping and re-check alignment.
gallery for a minimum of 2 minutes prior to
turning or starting.
• During a hot re-start of the unit when oil
Compressor Pre-lube System supply viscosity is less than 50 cSt, pre-lube
Ariel compressors must be pre-lubed anytime the pressure should be 20 psig (1.4 barg) at the oil
gallery for a minimum of 2 minutes prior to
crankshaft is turned and prior to starting. Ariel
turning or starting.
strongly recommends an automated pre-lube
system to extend driveline component life. NOTE: A 10 to 15 minute pre-lube is required after:
• Any major drive line maintenance
Ariel requires automated pre-lube systems for
• The main lube oil system is drained
compressors that meet any of the following • Oil filter replacement
criteria:
• Electric motor driven compressors. Instrumentation: Automated pre-lube systems
• Unattended-start compressors, regardless of require a start permissive logic and
driver type. instrumentation to satisfy the minimum required
• Compressor models KBK:T. pressure and duration at the oil gallery inlet.
See Figure: Standard Frame Lube Oil Schematic
for pre-lube circuit design.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

It is highly recommended that the compressor Flushing Procedure

low oil pressure shutdown be Class B. Inhibited
time shall be no longer than 10 seconds after idle Below is a general flushing procedure
speed is achieved on gas engines or start recommended to change from mineral or PAO
initiation for electric motors. oils to a synthetic PAG lubricant.

If the compressor fails to achieve 45 psig (3.1 1. Drain old oil from frame while the oil is still
warm.
barg) oil pressure within 10 seconds after
reaching engine idle speed or electric motor start 2. Drain all supply and return lines upstream of
initiation, ensure shutdown and correct the the frame lube oil filter, filter housing (if
applicable), coolers, and other peripheral
cause. Repeat pre-lube before each start
equipment in the lubricant supply loop.
attempt.
3. Remove standing oil in the frame and guide
NOTE: If a compressor fails to start or shuts down at compartment low points. Remove as much
start-up due to low oil pressure, DO NOT re-start until oil as possible with a vacuum hose. If heavy
the cause is corrected. deposits are visible, remove them as best as
possible by hand using clean, dry, lint-free
rags.
4. Install new frame lube oil filters.
Flushing to Change to a PAG
5. Remove and either clean or replace the Y-
Lubricant strainer element.
Cylinder and frame lubrication systems require 6. Reconnect oil piping and install drain plug in
flushing when changing to or from a PAG frame.
lubricant or when applying a PAG lubricant to 7. Connect a diaphragm pump upstream of the
newly installed equipment. frame mounted oil filter.
8. Feed the diaphragm pump flushing oil (see
"Recommended Flushing Oil") from a clean
Recommended Flushing Oil reservoir and prime the lube oil system.
The preferred flushing oil is soluble in both the Prime until old oil is purged from oil passages
original oil and PAG lubricant. A linear diester is and flushing oil steadily flows from all
bearings and crosshead bushings.
preferred, such as Shell Corena DE 150 or Mobil
Rarus 829. If this is unavailable, use the desired 9. Drain frame. Remove standing oil in the
PAG lubricant fill oil as the initial flushing oil. frame and guide compartment low points.
Remove as much oil as possible with a
vacuum hose.
10. Remove diaphragm pump and plug
connection upstream of frame mounted oil
filter.
11. Install drain plug in frame.
12. Refill the frame with flushing oil (see
"Recommended Flushing Oil").

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

13. Circulate flushing oil for at least four hours, feed lubricator box with the same oil used to
and up to 24 hours if needed, to loosen all lubricate the compressor cylinders/packings. To
debris and existing deposits. Monitor lube oil change the lubricator box lubricant from a
filter differential pressure during flushing. mineral oil or synthetic PAO lubricant to a PAG
The filter may need to be taken off line or synthetic lubricant:
changed several times during flushing, as a. Drain old oil from lubricator box.
loosened deposits tend to plug the filter b. Rinse lubricator box with flushing oil (see
quickly. "Recommended Flushing Oil").
14. Drain the first flushing oil from the frame c. Fill lubricator box with PAG lubricant to
while the oil is still warm. Take care to also be used for the cylinders.
drain all supply and return lines, filter
housing, and other peripheral equipment in
the lubricant supply loop. If standing oil
Flushing the Force Feed
remains in the frame, remove as much as Lubrication System - Common Oil
possible with a vacuum hose. Supply
15. Refill the frame with the PAG lubricant of the
1. Drain the lube line upstream of the force feed
recommended viscosity for the application.
pump inlet.
At this time, as much as 2-3% of the initial oil
may still remain in the system. Circulate this 2. Drain tubing/manifold feeding the force feed
fill for at least four hours and up to 24 hours if pump(s).
possible. Replace filters as needed. 3. Remove the purge/vent connection on the
NOTE: If the PAG lubricant is clear and bright after outlet of each force feed pump.
circulating and no debris or emulsion is visible, it may
be possible to skip the final steps and simply begin 4. Use a purge pump filled with clean/filtered
normal operation. However, a second flush is flushing oil (see "Recommended Flushing
preferred (see steps 16 and 17). Oil") to prime each force feed pump by
forcing oil through the pump inlet and out the
16. Drain second flushing (PAG lubricant) oil from purge/vent connection.
the frame while the oil is still warm.
5. Reconnect the purge pump to the force feed
17. Refill frame with PAG lubricant of the pump purge/vent outlet connection. If
recommended viscosity and circulate for at pumps are paired together at their outlets,
least four hours. At this point, the initial oil close one of the purge/vent connections.
remaining in the system should be less than
0.5%. Sample the oil and examine it for any 6. For the zone fed by the force feed pump being
emulsion or debris. If the oil is clear and primed, disconnect lube lines at the inlet of
bright (a slight haze is acceptable), then the double-ball check valves.
continue normal operation and top off as 7. Place paper towels or suitable collection
needed. If significant emulsion or debris containers beneath each disconnected lube
remains, then conduct one more drain and line to catch flushing oil during priming.
flush.
8. Prime flushing oil from the force feed pump
If the frame uses the same oil as the force-feed purge/vent connection to downstream
cylinder lubrication system, the overflow line on
tubing, divider blocks, and check valves.
the lubricator box can remain attached to the
frame auxiliary end cover. If the frame oil and 9. Prime until no air bubbles appear in the
cylinder oil are incompatible or of different ISO flushing oil at all disconnected lube lines in
grades, disconnect overflow line on the lubricator the zone.
box (see “Independent Oil Supply”). Fill the force-

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

10. Reconnect lube lines to double ball check 11. Continue to prime 2 fluid ounces of flushing
valves in the primed zone. oil per throw through the primed zone.
11. Continue to prime 2 fluid ounces of oil per 12. Disconnect the purge pump and install cap
throw through the primed zone. for purge/vent connection.
12. Repeat steps 5 thru 11 for remaining zones. 13. Repeat steps 5 thru 11 for remaining zones.
14. Install a new oil filter.
Flushing the Force Feed 15. Reconnect lube lines between daytank and
Lubrication System - Independent pump inlets.
Oil Supply 16. Place a collection container beneath the
disconnected lube line near the force feed
1. Drain daytank, oil filter, and lube lines pump inlet connection.
upstream of the force feed pump inlet. Oil
trapped in piping can be vacuumed out or 17. Add enough flushing oil to the daytank to
flushing oil can be pumped through these prime the system up to the disconnected line
lines to displace the old oil. in step 16.

2. Drain tubing/manifold feeding the force feed 18. Collect oil until no air bubbles appear in the
pump(s). flushing oil.

3. Remove the purge/vent connection on the 19. Reconnect feed line to force feed pump.
outlet of each force feed pump. 20. Bleed trapped air by loosening tube
4. Use a purge pump filled with clean/filtered connections nearest each pump inlet.
flushing oil (See "Recommended Flushing
Oil") to prime each force feed pump by
forcing oil through the pump inlet and out the
Cylinder and Packing
purge/vent connection. Lubrication
5. Reconnect the purge pump to the force feed The cylinder lubrication system injects
pump purge/vent outlet connection. If
lubrication into cylinder bores and packings. The
pumps are paired together at their outlets,
close one of the purge/vent connections. system consists of an oil supply, an oil filter, a
force feed lubricator pump, divider blocks,
6. For the zone fed by the force feed pump being
pressure indicators, check valves, and flow
primed, disconnect lube lines at the inlet of
the double-ball check valves. monitoring shutdown devices. The system is
progressive; each piston in the divider block
7. Place paper towels or suitable collection
must complete a cycle before the system cycles
containers beneath each disconnected lube
line to catch flushing oil during priming. again. This type of system offers better
lubrication precision and eases monitoring.
8. Prime flushing oil from the force feed pump
purge/vent connection to downstream
tubing, divider blocks, and check valves.
9. Prime until no air bubbles appear in the
flushing oil at all disconnected lube lines in
the zone.
10. Reconnect lube lines to double ball check
valves in the primed zone.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Force Feed Lubricator

The force feed lubrication system oils the
compressor cylinders and piston rod packings.
Oil flows to the suction side of the force feed
lubricator pump directly from the pressure side
of the frame lubrication system, or from an
overhead tank. A self-contained oil reservoir oils
the force feed lubricator worm gear and cam. The
force feed lubricator sight glass shows the
reservoir oil level.

Figure: KBK:T Force Feed Lubricator

1 Auto-Relief Valve (ARV)
2 ARV Manifold
3 Priming Stem
4 Pump Plunger Stroke Adjustment Screw
5 Lock Nut
6 Lubricator Oil Fill Connection
7 Sight Glass
8 Mounting Flange Capscrews (4)
9 Drain Plug
10 Purge/Vent Connection
11 Pump Outlet to Distribution Block
12 Inlet to ARV
13 Lubricator Overflow
14 Force Feed Lubricator Sprocket
15 O-ring

Pressure Relief the equipment:

This equipment stays pressurized until pressure 1. Stop lubricator pump.

is manually relieved. To prevent serious injury 2. If installed, close oil supply valve located
from pressurized fluid, such as skin injection, upstream from pump.
splashing fluid, and moving parts, follow this
procedure before cleaning, checking, or servicing

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

• If the supply valve cannot be closed, de- 3. Orient pump so the roller bearing on the
energize and relieve pressure of pressur- bottom of the pump aligns with the cam
ized oil supplies feeding the pump. inside the reservoir.
3. Slowly crack open fluid line fittings to relieve 4. Align the pump mounting holes with the
pressure. reservoir cover mounting holes.
5. Install washers and bolts. Tighten the bolts
Pump Installation securely, then torque each bolt to 50 Lb x In
Before installation, verify the lubricator box and (5.65 N•m).
lube system are sized appropriately for the
Pump Setup
selected pressure. Verify a pressure relief device
suitable for the application is installed in the Before setup, relieve all pressure from the force
system. Refer to Figure: Pump Installation during feed system (see "Pressure Relief").
installation.
The pump has an internal discharge check valve
Figure: Pump Installation that has a cracking pressure of 55 psi (3.79 bar).
Any oil pressure greater than this cracking
pressure allows unrestricted oil flow through the
pump, even in a pump at rest or adjusted to zero
stroke. Pumps fed 60 psig (4.13 barg) oil from the
compressor frame must pass through a 14 psi
(0.96 bar) check valve installed at the lube oil
gallery connection.

Specifications

Max. Outlet
Piston Dia. In. Max. Flowa In.3
Pressure psi
(mm) (cm3)
(bar)
3/16 (4.76) 7500 (517) 0.012 (0.196)

1/4 (6.35) 6000 (414) 0.021 (0.344)

3/8 (9.53) 3500 (241) 0.048 (0.786)

1 Reservoir Cover Mounting Hole
2 Pump Mounting Hole • Inlet Size: 1/4” - 18 NPTF
3 Washer • Outlet Size: 1/8”- 27 NPTF
4 Mounting Bolt • Strokes/Minute: Max. 50; Min. 3
5 Pump Gasket • Stroke Length: Max. 1/2 inch (12.7 mm)
6 Pump Body • Weight: 2.7 lbs (1.22 kg)
1. Clean pump body. • Wetted Parts: carbon steel, stainless steel,
aluminum, PTFE, fluoroelastomer
2. Remove protective film from gasket and
• Max. allowable inlet pressure for priming: 150
adhere gasket to pump body.
PSI (10.34 bar)

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

• Allowable viscosity range independent of 5. Introduce oil into the inlet line using a clean
temperature: 80-5000 SUS (16-1100 cSt) priming pump filled with cylinder oil
connected to the purge/vent connection. If
Priming the Pump installed, open oil supply valve from day tank
(located upstream from pump).
Use filtered oil when priming the pump and force
6. Wipe the pump priming stem clean and
feed system (minimum 5 micron nominal filter).
lubricate with oil.
Refer to Figure: Pump Priming and Adjustment
during priming. 7. Manually prime pump by using a priming
pump or by pressing the pump priming stem
Figure: Pump Priming and Adjustment repeatedly (if connected to a day tank) until
clean, air-free oil flows from the outlet fitting.
8. Connect outlet line to outlet fitting.
9. Manually prime pump by using a priming
pump until clean, air-free oil flows from the
outlet line at the cylinder and packing lube
points.
10. Connect the outlet line to the lube point.
11. After start-up, adjust individual pumps to
meet required flow rates. See "Pump
Adjustment".

Pump Adjustment
The flow adjustment screw controls pump flow
rate; turning it changes the length of the piston
stroke which changes the pump discharge
1 O-ring volume. Refer to "Figure: Pump Priming and
2 Flow Adjustment Screw Locknut Adjustment" during adjustment.
3 Flow Adjustment Screw
1. Loosen the flow adjustment screw locknut.
4 Pump Priming Stem
5 Pump Inlet 2. Lubricate the o-ring beneath the adjustment
6 Pump Outlet screw locknut with oil.
1. Remove and discard the plastic plugs in the 3. Turn the flow adjustment screw.
pump inlet and outlet. Counterclockwise increases flow and
decreases cycle time; clockwise decreases
2. Apply thread sealant (user supplied) to inlet flow and increases cycle time.
and outlet line fittings.
4. Check force feed lubricator data plate or Ariel
3. Install the inlet and outlet fittings on the lube sheets for correct cycle time. Adjust flow
pump. until desired cycle time is achieved with the
4. Connect the inlet line to the inlet fitting. force feed system operating.
5. Repeat Steps 2 and 3 as needed.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

6. After adjustment to the proper cycle time, Solution

tighten the adjustment screw locknut.
1. Replace pump.
NOTE: Inconsistent flow can occur if pump stroke is
set below 20% of maximum stroke. A dust seal inside
the flow adjustment screw holds the priming stem Possible Cause
stationary during operation.
Damaged or worn inlet check ball and/or seat.
Pump Troubleshooting Solution
Relieve all pressure from the system before 1. Replace pump.
cleaning, checking, or servicing the equipment.

Pump Problem: Possible Cause

• No flow Stuck piston.
• Low flow or erratic operation
• Low discharge pressure Solution
• Fluid flows from pump outlet when not 1. Replace pump.
running
Pump No flow

Possible Cause
Problem
Stuck pump priming stem.
Pump no flow.
Solution

Possible Cause 1. Clean and lubricate the priming stem.

Replace pump if priming stem is corroded.
Stroke adjusted to zero.

Solution Possible Cause

1. Adjust pump stroke for desired output. See Insufficient oil supply.
"Pump Adjustment".
Solution

Possible Cause 1. Check for line and filter restrictions

upstream of pump. Verify pump inlet is free
Plugged pump outlet. of debris.

Solution
Possible Cause
1. Clean/flush pump outlet.
Air bubbles in the oil.

Possible Cause Solution

Damaged outlet check valve. 1. Prime pump. See "Priming the Pump".

Possible Cause
High oil viscosity.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Solution Solution
1. Decrease flow restrictions upstream of 1. Check for line and filter restrictions
pump. upstream of pump.
2. Heat oil to maintain viscosity ‹1100 cSt. 2. Verify pump inlet is free of debris.
3. Consult oil supplier for temperature. 3. Check/inspect lube box cam gear for wear.
Low Flow or Erratic Pump Operation

Problem Possible Cause

Low flow or erratic pump operation. Air bubbles in the oil.

Solution
Possible Cause
1. Prime pump. See "Priming the Pump".
Stroke adjusted to minimal travel.

Solution Possible Cause

1. Adjust pump stroke for desired output. See High oil viscosity.
"Pump Adjustment".
Solution
Possible Cause 1. Decrease flow restrictions upstream of
pump.
Damaged or worn inlet check ball and/or seat.
2. Heat oil to maintain viscosity ‹1100 cSt.
Solution 3. Check/inspect lube box cam gear for wear.
Low Pump Discharge Pressure

1. Replace pump.
Problem
Possible Cause Low discharge pressure.
Damaged or worn outlet check ball and/or seat.
Possible Cause
Solution
Worn piston and bore.
1. Replace pump.
Solution
Possible Cause 1. Replace pump.
Sticking piston or priming stem.
Possible Cause
Solution
Damaged or worn inlet check ball and/or seat.
1. Replace pump.
Solution
Possible Cause 1. Replace pump.
Insufficient oil supply.
Fluid Flows From Pump Outlet

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Problem Damaged or worn outlet check ball and/or seat.

Fluid flows from pump outlet when not running. Solution

1. Replace pump.
Possible Cause
Inlet pressure exceeds cracking pressure of Auto-Relief Valve (ARV)
pump outlet check valve. An auto-relief valve (ARV) is a mechanical valve
that protects force-feed lubrication systems from
Solution
over-pressure conditions. Unlike a rupture disk
1. Reduce inlet pressure to below the cracking assembly, the ARV is reusable and does not expel
pressure. See "Pump Setup". oil onto the compressor skid.

Possible Cause

Figure: Auto-Relief Valve Components

1 Spring Barrel 6 Spring Piston 11 ARV Inlet

2 O-ring 7 O-ring Retainer 12 Adapter
3 Washer 8 Manifold 13 E-Clip
4 Indicator Pin 9 Pressure Pin 14 ARV Outlet (Bypass Port)
5 Spring 10 Intermediate Barrel

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

ARV Operation Intermittent blockage downstream of the

pump - A brief condition or one-time event that
Figure: ARV Operation prevents the shutdown device from timing out
and allows the compressor to continue to
operate.

Significant blockage downstream of the pump

- A condition of long enough duration to cause
the shutdown device to timeout and shutdown
the compressor.

After downstream blockage/restriction removal,

the indicator pin can be manually reset by
depressing the indicator pin until it is flush with
the ARV housing.

1 Normal Pressure (pin does not protrude) Distribution Blocks

2 High Pressure (pin protrudes)
Distribution blocks consist of three to seven
3 Pressure Relieved (pin not reset)
divider valves and an optional bypass block
When a force-feed pump encounters a fastened to a segmented baseplate. Viton O-rings
downstream restriction, pump discharge (90 Durometer) seal between the divider valves
pressure increases. If discharge pressure exceeds and baseplate and between baseplate segments.
ARV cracking pressure, the ARV bypasses excess Check valves are installed at all lube port outlets.
oil back to the low-pressure inlet side of the
pump (Figure: ARV Operation – High Pressure).
Bypassing oil limits the pressure created by the
pump. The pump will operate in bypass
condition until either the divider valve no-flow
device times out due to lack of flow or pressure
downstream of the pump decreases allowing the
ARV to close (Figure: ARV Operation– Pressure
Relieved).

When the ARV begins bypassing, an indicator pin

protrudes from the top of the ARV indicating an
over-pressure condition. The indicator pin is a
“tattle tale” and remains protruding after the
ARV bypasses oil (Figure: ARV Operation–
Pressure Relieved ). Two bypass conditions are
possible:

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Figure: Typical Distribution Block

1 Piston
2 Crossport Plate
3 Inlet Port
4 Inlet Block
5 O-Rings
6 Check Valve
7 Intermediate Blocks
8 Outlet Port (correct position is off-center
toward inlet block)
9 End Block
10 Tie Rod Nut
11 Tie Rod
12 Divider Valve
13 Valve Screw

Divider valves contain metering pistons that Bypass blocks can replace a divider valve section
discharge a predetermined amount of oil with to eliminate the lubrication points. Plug both
each cycle in a single line, progressive lubrication outlets below the bypass block. A bypass block
system. can mount in any baseplate location, but it
requires at least three working divider valves in
NOTE: Pistons are matched to a specific divider valve. the block assembly (i.e. bypass blocks cannot be
Do not try to place a different piston into a divider used on 3-section baseplates).
valve.
The baseplate contains the divider valve inlet
Single or twin valves may be externally singled or and outlet connections, interrelated
cross-ported. Plug unused outlets when singling passageways, and built-in check valves. All
or cross-porting. lubricant piping to and from the distribution
block connects to the baseplate. The baseplate
consists of one inlet block, three to seven

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

intermediate blocks, one end block, and three tie Divider Valve Bypass Pressure Test
rods. The number of baseplate intermediate
Lubricant can leak (by-pass) from a divider valve
blocks determines the number of divider valves
when the divider valve piston becomes worn.
allowed. Each distribution block requires a
Pressure test or replace all divider valves every
minimum of three divider valves.
twelve months. Testing verifies the piston fits
tightly enough in the divider valve bore for
Distribution Block Assembly
adequate pressure to force oil into the injection
point. The supplier pressure tests all new Ariel
NOTE: See specific frame Parts Book for available
divider valve assembly drawings, parts lists, and divider valves.
repair kits.
To test distribution blocks for valve by-passing
requires a manual purge pump with a pressure
1. Thread three tie rods into inlet block until the
gauge capable of developing 5000 psig (350
ends flush with the top surface of the block.
barg). Ariel offers an optional force feed
2. Slide Intermediate blocks onto tie rods. Verify lubrication hand purge pump with a pressure
all O-rings are installed and discharge ports
gauge (see Section 1). Pressure test each divider
are off center toward the inlet block.
valve one at a time, complete with pin indicators
3. Slide end block onto tie rods. installed.
4. Lay base plate assembly on a flat surface. Use
"Recommendations for Torque Accuracy" to
tighten the tie rod nuts to the correct torque
listed in Appendix A.
5. Mount the divider valves with O-rings onto
the base plate. Use "Recommendations for
Torque Accuracy" to tighten the tie rod nuts
to the correct torque listed in Appendix A.

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Figure: Pressure Testing Divider Valves

1 "S" Divider Valve - one side 3 Divider Block Inlet 6 One side Plugged to test a "T"
plugged with 1/8" NPT pipe plug 4 Base outlets open - oil flows valve - all other outlets open
2 Purge Pump freely 7 Both sides plugged to test an "S"
5 Optional Resettable Pin Indica- valve - all other outlets open
tors

1. For new divider valves, verify working piston 3. The divider block assembly should cycle at
section fastener torque is 75 lb x in (8.5 N•m). less than 300 psi (2068 kPa) while purging at a
Loosen the section fasteners, then step- steady rate. Cycle pressures above 300 psi
torque them first to 40 lb x in (4.5 N•m), and (2068 kPa) indicate inhibited piston
then to 75 lb x in (8.5 N•m). Used divider movement, possibly caused by the piston
valves can be tested “as is”, with approximate rubbing the bore, oil contamination, part
section fastener torque verified after testing. geometry, or bore distortion due to over-
2. Place the distribution block in an open tightening the section fasteners. If re-
container with all base outlets open. Connect torquing the valve section fails to improve
purge pump filled with room temperature cycle pressure, replace the divider valve
[65°F (18°C)] 10 wt. (ISO 32) mineral oil to the section. Do not attempt to alter the
divider block inlet. Pump the purge pump to piston/bore fit by polishing components
purge air from the divider block assembly. 4. For divider valves stamped with a “T” (for
Verify that oil flows freely from all outlets (see “twin”), use a 1/8 inch (3.2 mm) pipe or tubing
Figure: Pressure Testing Divider “Divider plug to plug only one base outlet when
Block All Outlets Open”). Testing with 10 wt. testing that side of the piston, and leave all
mineral oil at 65°F (18°C) simulates divider other outlets open. Plug and test each base
block operation at 120°F (49°C) with 40 wt. outlet of divider valves stamped with a “T”
(ISO 150) mineral oil. If 10 wt. (ISO 32) mineral one side at a time. See Figure: Pressure
oil is unavailable, use 40 wt. (ISO 150); Testing Divider “Testing ‘T’ Divider Valve”.
however, the pressure test will be less Individual testing of each outlet ensures both
sensitive in detecting a bypassing divider sides of the piston build adequate pressure.
valve. For all divider valves stamped with an “S” on

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

the front (for “single”), plug the working Balance Valves

outlet as well to test both sides of the piston
for by-passing simultaneously. See Figure: Install balance valves on low-pressure lube lines
Pressure Testing Divider “Testing ‘S’ Divider to artificially increase lube line pressure and
Valve”. reduce differential pressure between lube points
5. Pump the purge pump until the pressure downstream of a divider block. Important
gauge indicates 3000 psi (20684 kPa). Hold considerations:
this pressure for 5 seconds, then increase it to
• Set and maintain balance valves downstream
3500 psi (24132 kPa). Stop pumping at 3500
of a divider block within 500 psi (3400kPa) of
psi (24132 kPa).
each other or less. The closer the balance
6. Start timer and monitor the pressure drop valve set pressures, the more reliable the
from 3500 psi (24132 kPa) for 30 seconds. system.
Check discharge outlet(s) plug(s) to confirm • Avoid situations in which the balance valve
no external leaks. Also check O-rings for set pressure is the greatest contributor of
external leakage. If the valve bypasses pressure to the divider block immediately
rapidly, repeat the test to ensure the bypass upstream.
wasn’t due to trapped air. New valves should • With a balanced divider block, the upstream
not exceed a 400 psi (2758 kPa) pressure drop divider block pressure gauge should exhibit
in 30 seconds. Used valves should not exceed no erratic needle movement as the divider
1000 psi (6895 kPa) pressure drop in 30 block cycles.
seconds. If pressure drops exceed these
limits, the divider valve fails the test. To maintain the force feed lube system, record
7. Repeat Steps 4 thru 6 for the remaining the maximum injection pressure indicated at
outlets on the divider block assembly. each divider block gauge, balance valve set
pressures, and divider block cycle time at least
NOTE: Test distribution blocks at higher pressures if once a day for each zone in the system. See
the application dictates higher system operating
Appendix E.
pressure.
Do not adjust balance valves prior to operating
If a divider valve fails, replace it. Discard worn the unit. Verify the tightness of all fittings and fix
divider valves. If the tested valve passes the test, any known leaks. To remove any trapped air or
relieve the pressure, move the plug to the next gas in the force feed lube system, use a high-
outlet, and repeat the test for all divider valves. pressure hand purge pump and the same oil
When all divider valves either pass this pressure recommended for the cylinder application to
test or are replaced, reassemble the distribution purge it. DO NOT USE ANY OTHER FLUIDS FOR
block, purge it with the proper force feed PURGING! Call the Ariel Response Center for
lubricant, and put it into service. details about purchasing a hand purge pump. To
prepare for balance valve adjustment:
Ariel recommends periodic tests for proper
cylinder bore lubrication rates and/or 1. Start the compressor and bring the cylinders
aftermarket devices that measure flow. up to normal operating pressure.
2. Allow operating pressures to stabilize.

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

3. See the cylinder lube sheets for balance valve is also true for the inner lube point on
locations and proper spring type for each high-pressure, two lube point packings.
device. c. For the outer lube point on high-pressure,
two lube packings, assume lube line pres-
Selecting Balance Valves and Pressure sure is zero.
Gauges d. For intermediate packing lube points on
long two-compartment distance pieces,
Balance valves are used in high differential the lube line pressure is zero.
pressure distribution block applications to e. For inlet gas flushing lines, commonly
reduce system problems such as bypassing, no- used in sour gas applications, lube line
flow switch errors, or blown rupture disks. Since pressure equals suction pressure.
9/98, Ariel supplies balance valves and pressure f. The bore lube line pressure of each
gauges on new compressors with high cylinder in a tandem pair equals suction
differential force feed lube pressures. Balance pressure of the low-pressure cylinder in
valves add pressure to distribution block the pair.
discharge ports when differential pressure 2. Determine pressure differentials between
exceeds 1200 psi (8300 kPa). each individual lube line and the highest lube
line pressure for the distribution block
If a compressor experiences excessive system. For example, if pressure at a lube
distribution block differential pressure, select point is 700 psig (5500 kPa) and the highest
and install balance valves (and pressure gauges, cylinder mean pressure is 2000 psig (13800
if required) by the following procedure: kPa), then a balance valve must be added to
the 700 psig (5500 kPa) lube line to achieve a
1. Determine lube point line pressures, either by pressure differential below 1200 psig (8300
measurement on the compressor with a kPa). Select a valve spring (see Table: Balance
calibrated pressure gauge, or by calculation Valve Springs) by multiplying the highest lube
of expected pressures for a given distribution line pressure by 0.85 to calculate the balance
block system: valve set pressure. For example, if the highest
a. Expect cylinder bore lube line pressure lube line pressure is 2000 psig (13800 kPa),
midway between suction and discharge the valve set pressure is 2000 x 0.85 = 1700
pressure. Calculate: P = (Pd + Ps) ÷ 2. The psig, which requires an orange spring.The
bore line pressure of double-acting Ariel part number for the balance valve
forged steel (VS) cylinders equals the without springs is CA-8005. The highest
suction pressure of the cylinder. pressure lube point requires no balance valve
or pressure gauge.
b. For single lube packings, expect lube line
pressure to equal suction pressure of a
double-acting or crank end cylinder. This

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Table: Balance Valve Springs Table: Rupture Disk Data

Set Pressure Rupture Disc Rated Pressure Blowout Orifice
Ariel Spring
Spring Color Range psig Color psig (kPa) Dia. in. (mm)
(only) Part No.
(kPa)
Purple 3250 (22400) 1/4 (6)
A-9662 Purple 750 to 1500
(5000 to 10000) Yellow 3700 (26000) 1/8 (3)

A-8087 Orange 1501 to 2250 Red 4600 (32000) 1/8 (3)

(10001 to 16000) Orange 5500 (38000) 1/8 (3)
A-8007 Brown 2251 to 3000 Aluminum 6400 (44000) 1/8 (3)
(16001 to 21000)
Blue 7300 (50000) 1/8 (3)
A-9912 White 3001 to 4000
(21001 to 28000)
Table: Pressure Gauges - Back-mounted, 1/4
A-9911 Red 4001 to 5000
(28001 to 34000) inch - NPT
Pressure Range, psig
Ariel Part No.
3. Balance valves and pressure gauges are not (kPa)
required for pump to point systems, zoned A-8727 0 to 3000 (0 to 20000)
systems, or any system that does not exceed
A-8728 0 to 5000 (0 to 32000)
1200 psi (8300 kPa) differential pressure.
Tandem cylinder compressors with only one A-9093 0 to 7500 (0 to 50000)
tandem bore lube point that exceeds 1200 psi
(8300 kPa) differential pressure require no
balance valves or pressure gauges. With more Installing Balance Valves and Pressure
than two balance valves applied to a single Gauges
divider block assembly, it is advisable to
Before balance valve and pressure gauge
install a pressure gauge upstream of each
balance valve. Pressure gauges aid in the installation, a mechanic should verify correct
setting and adjustment of balance valves. balance valve, spring, appropriate fittings, and
Select a pressure gauge with the maximum pressure gauge quantities. The highest pressure
pressure on the gauge face greater than or lube point of a given pump system requires no
equal to rupture disk pressure (see Table: balance valve or pressure gauge.
Rupture Disk Data and Table: Pressure
Gauges - Back-mounted, 1/4 inch - NPT). The 1. Install balance valves with the flow direction
only exception to this rule is the 3000 psig arrow properly positioned in the direction of
(20000 kPa) gauge used with the 3250 psig oil flow toward the compressor cylinder.
(22400 kPa) rupture disk. 2. Install a pressure gauge, if required,
upstream of each valve (between the balance
valve and distribution block).
3. Verify the maximum pressure on the gauge
face is greater than or equal to rupture disk
pressure – see Table: Rupture Disk Data. The
only exception to this rule is the 3000 psig
(20000 kPa) gauge used with the 3250 psig
(22400 kPa) rupture disk.

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4. Install the proper spring in each balance 4. Calculate the balance valve set pressure by
valve as determined in the selection multiplying the maximum recorded pressure
procedure above for each applicable by 0.85.
pressure lube point line, and install the valve
5. Set balance valve(s) downstream of the
cap.
selected divider block to the pressure
5. Tighten the cap against the spring, but do not calculated in step 4 by rotating the
compress the spring. adjustment cap clockwise to increase
6. Tighten the lock nut against the cap, hand pressure. Set pressure within ±50 psi (3.5 bar)
wrench tight. of the calculated value.
6. Monitor the divider block gauge for one
Adjustment of Balance Valves Fed by a minute and record the minimum and
Divider Block maximum pressures in Appendix E. The
difference between the minimum and
Figure: Balance Valves Fed by Divider Block maximum should not exceed 1200 psig (82.7
barg). If it does, repeat steps 2 through 6.
7. Tighten the balance valve lock nut. DO NOT
lock wire the adjustment cap.
8. Repeat steps 2 through 7 for any remaining
divider block that feeds one or more balance
valves nearest the compressor
cylinder/packing.
9. After setting all balance valves in the force
feed system, operate the system for 4 to 6
hours, then repeat step 6 for each divider
1 Balance Valve block.
2 Balance Valve Pressure Gauge
3 Adjustment Cap
4 Lock Nut
5 Divider Block Pressure Gauge
6 Divider Block

1. Select one divider block that feeds one or

more balance valves nearest the compressor
cylinder/packing.
2. For each balance valve downstream of the
selected divider block, loosen the balance
valve lock nut and rotate the adjustment cap
counter-clockwise until the cap is loose.
Some residual pressure may remain on the
balance valve gauge.
3. Monitor the selected divider block gauge for
one minute and record the minimum and
maximum pressures in Appendix E.

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Adjustment of Balance Valves Fed by 3. Repeat steps 1 and 2 for any remaining
Primary/Secondary Divider Blocks secondary divider blocks that feed one or
more secondary balance valves nearest the
Figure: Primary/Secondary Divider Block compressor cylinder/packing.
System 4. Select one primary divider block that feeds
one or more primary balance valves located
prior to a secondary divider block or lube
point.
5. For the selected primary divider block and
balance valves, perform steps 2 through 7 in
"Adjustment of Balance Valves Fed by a
Divider Block".
6. Repeat steps 4 and 5 for any remaining
primary divider block that feeds one or more
balance valves located prior to a secondary
divider block or lube point.
7. After setting all balance valves in the force
feed system, operate the system for 4 to 6
hours, then repeat steps 3 through 7 in
"Adjustment of Balance Valves Fed by a
Divider Block" for each primary or secondary
1 Primary Balance Valve
divider block.
2 Primary Balance Valve Pressure Gauge
3 Adjustment Cap
4 Lock Nut
5 Primary Divider Block Pressure Gauge
6 Primary Divider Block
7 Secondary Divider Block Pressure Gauge
8 Secondary Divider Block
9 Secondary Balance Valve
10 Secondary Balance Valve Pressure Gauge

NOTE: Set secondary balance valves before setting

primary balance valves. If the system contains no
secondary balance valves downstream of a
secondary divider block, proceed to step 4.

1. Select one secondary divider block that feeds

one or more secondary balance valves
nearest the compressor cylinder/packing.
2. For the selected secondary divider block and
secondary balance valves, perform steps 2
through 7 in "Adjustment of Balance Valves
Fed by a Divider Block".

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Subsequent Compressor Start-Up 7. Monitor the selected divider block gauge for
one minute and record the minimum and
Table: Balance Valve Part Numbers maximum pressures in Appendix E.
Description Ariel Part No. 8. See "Selecting Balance Valves and Pressure
Gauges" if any of the conditions below occur:
Balance Valve without CA-8005
Spring a. The difference between the maximum
and minimum recorded divider block
Balance Valve Springs See "Table: Balance Valve
Springs"
pressures exceeds 1200 psig (82.7 barg).
b. The maximum recorded balance valve
Balance Valve Seal Repair A-8005-K
Kit
pressure exceeds 85% of the maximum
recorded divider block pressure.
Balance Valve Plug A-10330
c. The divider block gauge exhibits erratic
Pressure Gauges See "Table: Pressure needle movement as the divider block
Gauges - Back-mounted, cycles.
1/4 inch - NPT"

1. Verify tightness of all fittings and fix any Force Feed System Design,
known leaks. Purge force feed lube system.
Operating Parameters, and
2. If the force feed lube system has been
disassembled or parts replaced since the last Conditions
start-up, purge the force feed lube system
See specific packager data to confirm designed
with a high-pressure hand purge pump. When
purging the system, use the same oil that is gas composition, operating pressures, and
recommended for the cylinder application, to speed. If operating outside design conditions,
remove any trapped air or gas in the system. system may need to be reviewed. To optimize
DO NOT USE ANY OTHER FLUIDS FOR force-feed lubrication system operation, Ariel
PURGING! Call the Ariel Response Center for uses these general guidelines:
details about purchasing a hand purge pump.
1. Maintain lube rates within prescribed limits
3. Start the compressor and bring up to normal and cycle times as low as possible (normally
operating pressure.
10 sec minimum) to lubricate each point as
4. Operate the unit for 2 to 3 hours to allow the frequently as possible.
operating pressures to stabilize. DO NOT
2. Multiple pumps may be manifolded to
adjust the balancing valves immediately after
start-up. It is possible that some lube point achieve required lubrication rates.
injection pressures will fluctuate after a short 3. Do not operate pumps below 20% of full
period of run time and the system pressures
stroke or they become inconsistent. When
will stabilize as components increase in
temperature. two or more pumps are manifolded to feed
one distribution block, adjust them equally.
5. See the cylinder lube sheets for balance valve
Start with pumps wide open, and adjust them
locations and proper spring type for each
device. together so that when break-in cycle time is
set, the pumps stroke about the same. After
6. Select one divider block that feeds one or
break-in period, adjust the pumps in the
more balance valves.
same manner, provided the final pump

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

stroke is not too short. Try to keep the stroke 7. Prime the force feed lubrication system with
greater than 20% of maximum; a shorter a proper priming pump just prior to starting
stroke produces unreliable pump output. If the compressor (see "Force Feed Lubricator"
needed, close one pump to stop its flow and for pump illustration). Use clean force feed
open the other(s) to make the “normal” cycle lubricating oil of same type and grade as used
time, and maintain a stroke greater than 20% in service. Do not use any other fluid type or
in the functioning pump(s). grade to prime.
4. In some applications, one divider valve 8. For recently overhauled units, adjust force
delivers lubrication to both a packing and a feed cycle time for maximum delivery.
cylinder to optimize lubrication system oper- Loosen adjusting screw locknut. Turn
ation. In some applications, cross-ported plunger stroke adjustment screw to the full
divider valves deliver the proper proportion up position. Tighten adjusting screw locknut.
of lubricant to a given point. After two hours of operation or before leaving
site, reset to “normal” cycle time.
5. During operation, verify oil fills the lubricator
reservoir sight glass to the overflow line.
Reservoir oil lubricates the worm gear and Common Oil Supply
cam; it does not flow through the system. The
Figure: Force Feed Lubrication System Common
reservoir also catches force feed lube pump
Oil Supply shows the force feed lube system
leakage. Add oil only if needed to raise reser-
installation when compressor frame lube oil is
voir oil level. See Table: Force Feed Lubri-
also used for cylinder and packing lubrication.
cator Reservoir Oil Capacity.

Table: Force Feed Lubricator Reservoir Oil

Capacity
Lubricator Type Ariel
US Gallons (Liters)
Designs

Single Pump 0.25 (1)

Dual Pump 0.5 (1.75)

Four Pump 0.8 (3)

6. Ariel primes the force feed system with

mineral oil. If tubing is missing, or if the
system is drained, fill and prime the system
through a 1/8 inch plug on the discharge end
of the force feed lubricator pump.

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Figure: Force Feed Lubrication System Common Oil Supply

A To other cylinders and pack-
ings
B Drain to crankcase
1 Frame Oil Gallery
2 Single Ball Check Valve
3 Sintered Bronze Filter (if
applicable)
4 Force Feed Lubricator Pump
5 ARV or Rupture Disk
6 Pressure Gauge
7 Divider Valves/Distribution
Block
8 Fluid Flow Monitor No-Flow
Timer Shutdown Switch
9 Double Ball Check Valve
10 Top Cylinder Injection Point
11 Bottom Cylinder Injection
Point
12 Packing Injection Point

Independent Oil Supply • Increase pipe and fitting size from tank to
force feed pump.
When cylinders and packing require oil different • Heat the oil.
from frame oil, the force feed lubricator system • Heat trace and insulate the line from the tank.
requires an independent oil supply system (see • Pressurize the supply tank (tank must be
Figure: Force Feed Lubrication System designed for pressure).
Independent Oil Supply). An elevated tank must
supply pressurized force feed lube oil at a
minimum of 1 psig (0.07 barg) to the force feed
pump inlet manifold.

To prevent force feed oil from contaminating

compressor frame oil, disconnect lubricator box
overflow tubing from compressor frame and
direct it to a suitable drain system.
Independent force feed lube systems require oil
with a viscosity below 1100 cSt at the lubricator
pump inlet (e.g. ISO 320 at 73°F (23°C), contact
lube supplier about specific lubricants). Possible
ways to ensure force feed pump is fed oil during
suction stroke:

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

Figure: Force Feed Lubrication System Independent Oil Supply

A NOTE: System must provide
positive pressure to force
feed lubricator pump.
B 1/4-inch NPT (female) over-
flow. Pipe or tube to appro-
priate isolated customer
connection. Do not drain to
crank case.
1 Oil Supply Tank
2 Oil Filter (max. 5 micron)
3 System Inlet 1/4-inch NPT
(female) customer connec-
tion
4 Sintered Bronze Filter (if
applicable)
5 Force Feed Lubricator Pump
6 ARV or Rupture Disk
7 Pressure Gauge
8 Divider Valves Distribution
Block
9 Fluid Flow Monitor No-Flow
Timer Shutdown Switch

Force Feed Lubrication Cycle Time

Conditions Lubricant flow rates are measured in seconds per
cycle of the distribution block. The calculated
CAUTION break-in and normal cycle times are stamped on
To prevent personal injury, verify driver or compressor the lubricator box data plate. These cycle times
cylinder gas pressure cannot turn compressor are calculated based on the gas analysis,
crankshaft during maintenance. Before any
maintenance or component removal, relieve all pressure operating conditions, and applied speed
from compressor cylinders. See Packager’s instructions specified in the compressor order. If gas
to completely vent the system. After maintenance, purge conditions were not supplied with the
the entire system with gas prior to operation to avoid a
potentially explosive air/gas mixture. compressor order, the data plate/lube sheet
rates default to clean, dry, 0.65 specific gravity,
sweet gas and cylinder MAWP. If the applied

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KBK-KBT Maintenance & Repair Manual – Maintenance 04/03/2023

speed is not specified, the cycle time is based on To set proper force-feed lubricator pump flow
maximum rated speed of the frame or cylinders, rate, read or measure the cycle time from the
whichever is less. The lube sheets in the Ariel installed device. For a magnetic cycle indicator
Parts Book state gas conditions and list the base assembly, time the cycle from initial indicator pin
rate multiplier at each lube point. movement at the fully retracted position to the
time when the pin returns to the fully retracted
Break-in Rate - Set the break-in lube rate about
position and just begins initial movement out
twice the recommended daily rate (150%
again. Adjust the lubricator pump to provide the
minimum); i.e. set the break-in cycle time about
required cycle time.
half the normal cycle time (67% max.) to increase
lube rate. Maintain break-in rate for 200 hours of NOTE: Pump output can become inconsistent if flow
operation for new equipment. Contact Ariel if rate is set too low. See “Force Feed System Design,
existing pump is incapable of minimum flow rate Operating Parameters, and Conditions”.
required.

Lube Rate and Speed - Recommended lube Changes in operating conditions (such as gas
rates for break-in or normal operation, in properties or pressures, temperatures, flow
seconds per cycle, are calculated at the frame requirements, or cylinder re-configuration)
rated speed (RPM) stamped on the frame data require lubrication rate re-calculation and
plate or the cylinder rated RPM stamped on the possible force-feed lubrication system
cylinder data plate, whichever is lower. Lube rate alteration. Consult the Ariel Packager Standards,
decreases with speed, (as compressor actual the Packager, and/or Ariel.
running speed decreases, cycle time increases,
reducing lube rate): Under/Over Lube
(RPMmax ÷ RPMactual) x cycle time seconds from Inadequate lubrication causes premature wear
lube plate = cycle time seconds at actual running of piston and packing ring materials. Indications
speed. of under lubrication are black, gummy deposits
in the distance piece, packing case, cylinder, and
See the Ariel Parts Book Lubrication Sheets for
valves. When symptoms indicate under
the Cycle Time (seconds) vs. RPM (compressor
lubrication:
speed) table at various running speeds at stated
gas operating conditions and lubricant. • Verify proper operation of force feed lubri-
cator pumps.
Adjusting the cycle time changes the lubrication • Confirm distribution block cycle time
rate for all the compressor cylinders and matches the lube sheet or force feed lubri-
packings supplied by a particular pump. To cator data plate.
change the lubrication rate for only one cylinder • Verify all tubing and fitting tightness; check
or packing requires individual divider valve for leakage. Check fittings inside cylinder gas
passages.
changes. Contact your packager or Ariel for
• Pressure test or replace divider valves to
information.
ensure they do not bypass.

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Over lubrication can result in excessive oil Coolant System Requirements

carryover into the gas stream, and increased
valve and gas passage deposits. Valve plate Coolant flow = number of packing cases x 1 US
breakage and packing failure may also indicate gallon per minute (gpm), minimum for each inch
over-lubrication. of piston rod diameter (No. cases x 0.149 l/min for
each mm of piston rod diameter). Based on using
a solution of 50/50 treated water/glycol solution.
Cylinder Lubrication Paper Test See Figure: Typical Packing Cooling System.
1. Remove head end head and position piston
for the desired cylinder at inner dead center.
2. Using light pressure, wipe the cylinder bore
with two layers of regular unwaxed cigarette
paper together. Begin at the top and wipe
downward about 20° along the bore
circumference. The paper against the bore
surface should be stained (wetted with oil),
but the second paper should not be soaked
through.
3. Repeat the test at both sides of the bore at
about 90° from the top, using two clean
papers for each side. Paper against the bore
surface not stained through may indicate
under-lubrication; both papers stained
through may indicate over-lubrication. In
either case, Ariel normally recommends
changing lubrication rate accordingly and
repeating all paper tests until passed.
4. Repeat this procedure for all cylinders. If the
test indicates a lubrication rate reduction or
increase for a cylinder, change in 5%
increments by adjusting cycle time at the
force feed lube pump (see "Pump
Adjustment"). Repeat oil film testing, for
affected cylinders, after 24 hours of
operation. For a formal lube rate reduction
program, see Ariel ER-125.
NOTE: The paper test indicates only oil film quantity.
Aftermarket devices exist that measure flow. Neither
method indicates viscosity quality. Oils diluted with
water, hydrocarbons, or other constituents may
appear to produce an adequate film or flow, but dilu-
tion will reduce lubricant effectiveness below require-
ments.

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Figure: Typical Packing Cooling System

PI Pressure Indicator
TI Temperature Indicator
FI Flow Indicator
LG Level Gauge
1 Packing Case
2 Throttling Valve
3 Isolation Valve
4 Surge Tank
5 Strainer
6 Water Pump
7 Cooler

Example: JGK/2 with 2.0 inch (50.8 mm) diameter

piston rod.
• 2 packing cases x 1 gpm per inch of rod diam-
eter x 2.0 inch rod diameter = 4 gpm
• (2 packing cases x 0.149 l/min per mm of rod
diameter x 50.8 mm rod diameter = 15.1
l/min)
Cooler size = number of cases x 70
BTU/minute/inch of rod diameter (number of
cases x 0.05 kW/mm of rod diameter). Pressure
drop depends on several factors including flow
rate and fluid, but should generally be 10-30 psi
(0.7-2.1 bar). Coolant into the packing must not
exceed 130°F maximum (54°C max.). Lower
coolant temperature increases heat transfer
from the packing and may be required in high-
pressure applications.

Coolant inlet pressure should be 40-80 psig (2.8-

5.5 barg). 300 psig (20.7 barg) is the maximum to
preserve the o-ring seal between the cups.

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Part Replacement
Major frame assembly components include the Relieving Gas Pressure
crankcase, crankshaft and bearings, connecting
rods, chain drive system, crossheads, and Before conducting maintenance on the
guides/distance pieces. Removable end covers, compressor, it is vital to ensure the cylinders
an aluminum top cover, and crosshead guide contain no gas pressure. During maintenance,
side covers provide easy access to internal unrelieved gas pressure could cause equipment
components. Below are general guidelines to damage, personal injury, or even death.
follow during maintenance.
1. Cleanliness during part replacement: Isolation
• Use lint-free wiping cloths.
Isolate the compression system from all energy
• When not working on a frame with access
sources prior to any maintenance. To ensure the
covers removed, cover it to protect the
interior from rain, dust, and other system remains isolated during maintenance, a
airborne debris. lock out procedure is required. This is a
• Place removed components in a safe requirement of most corporate policies and
place away from work area to prevent occupational safety regulatory agencies. The
damage. Take precautions to keep parts extent of the isolation depends on the system.
from rusting.
2. Gasket maintenance:
Depressurization
• When dismantling the machine, carefully
inspect gaskets at non-pressure loca- Fully depressurize the compression system prior
tions. If damaged, replace them. to any maintenance. If the application involves a
• Always replace pressure-retaining corrosive or poisonous gas, purging is necessary
gaskets. to remove the hazard. There are many different
• Always apply an anti-seize lubricant to configurations of compression systems, so refer
both sides of metallic gaskets. to the information provided by the system
3. For major overhauls, drain and flush the provider for depressurization. In general, the
crankcase. following steps are required:

If replacing a connecting rod assembly, piston, 1. Isolate inlet gas from entering the system.
piston and rod assembly, crosshead-balance 2. Isolate discharge gas from entering the
nuts, or crosshead, weigh component parts and system.
compare to the Compressor Balancing Record 3. Vent and isolate scrubber dump lines, vent
included in the parts manual with each and drain lines, flare vent lines, and any
compressor. If there are weight changes, common blow-down lines to prevent back-
recalculate opposing throw reciprocating weight flow into the system.
differential. See "Opposed Throw - Reciprocating
Weight Balancing” in Appendix C. 4. Open the system blow-down line and reduce
the system pressure to atmospheric.

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5. If so equipped, open the indicator valves on crossheads slide toward the crankcase as far as
the individual cylinders to remove any possible. In the outer dead center position, the
residual pressure in the cylinder(s). crossheads slide away from the crankcase as far
as possible (see figure below). Some procedures
require a dial indicator with magnetic base to
WARNING locate the precise inner or outer dead center. At
Process gas from these valves can be under high other times, a procedure may require turning the
pressure if the system is not depressurized properly and crankshaft so a throw occupies its highest or
can be flammable and/or poisonous depending on the lowest position. In the figure below, the throw on
application.
the left is in its highest position and the throw on
the right is in its lowest position.
Positioning a Throw
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Component replacement often requires

manually turning the crankshaft to position a
throw in one of two positions: inner dead center
or outer dead center. During normal operation,
crossheads slide back and forth in the crosshead
guides. In the inner dead center position, the

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Figure: Throw Positioning

1 Inner Dead Center Position 2 Outer Dead Center Position 3 Highest/Lowest Throw Position

Variable Volume Clearance

Pocket (VVCP)
A VVCP changes the clearance volume of the
head end of a cylinder. The amount of clearance
depends on the position of the clearance pocket
piston. Users turn the piston/stem assembly
counterclockwise to increase clearance, and
clockwise to decrease it. In the event that gas
begins to leak from the VVCP vent, replace the V-
packing or seal within the VVCP.

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VVCP Removal Figure: Typical VVCP

WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
1 Cylinder
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE. 2 Eyebolt
Before resuming operation, purge the entire system with 3 VVCP Vent
the gas being compressed to avoid a potentially 4 Locking Handle
explosive gas/air mixture in the system. A gas/air
5 Adjustment Handle
mixture under pressure can explode and cause severe
injury or death. 6 Flange Bolts
7 Bellows Thread Protector

1. After venting the cylinder, loosen the locking

handle so the adjustment handle can turn
freely. Turn the adjustment handle.
CAUTION

A hard to turn adjustment handle or piston stem may

indicate pressurized gas trapped within the VVCP. See
VVCP Disassembly caution.

2. Tighten the locking handle.

3. Disconnect the VVCP vent.
4. Remove plastic plug from eyebolt hole and
thread an eyebolt into the eyebolt hole.
5. Use the Ariel supplied eyebolt to support the
weight of the VVCP.

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6. Remove all flange bolts and slide the VVCP

out from the cylinder. The Ariel Performance
Program contains approximate VVCP
weights.
If the VVCP does not slide out easily, loosen the
valve cap bolts. If it still does not slide out easily:
a. Remove head end valves.
b. Clean the area between the VVCP head
and the cylinder.
c. Loosen discharge bottle supports.
7. Discard the head gasket and transport the
VVCP to a suitable work area for disassembly.

VVCP Disassembly
The VVCP piston ring is not gas-tight to allow a
nearly balanced gas pressure, which eases VVCP
adjustment with the cylinder pressurized. Gas
pressure behind the VVCP piston normally vents
when the cylinder vents. Process debris or rust
around the piston ring can form a seal that traps
gas within the VVCP assembly, sometimes at
substantial pressure.

CAUTION

Trapped gas pressure can present a personal safety

hazard when servicing the VVCP. Work in a well-
ventilated, non-sparking area, particularly with sour gas
applications. Do not breathe gas emission from VVCP
when venting trapped gas.

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Figure: VVCP Disassembly/Assembly

A V-Packing Seal 5 Locking Handle 12 Piston 19 Backup Ring

B Spring Engerized Seal 6 Grease Fitting 13 Piston Ring 20 V-Packing or Seal
C See Note 1 7 Adapter 14 O-Ring (see Note 2) 21 Seal
1 Locknut 8 Match Mark 15 Retaining Plate 22 Seal Carrier
2 Adjustment Handle 9 Piston Stem 16 Snap Ring 23 O-Ring
3 Adjustment Handle Lip 10 Socket Head Bolt 17 Spring Retainer
4 Bellows Thread 11 Head 18 Compression Spring
Protector

1. Place the VVCP on a table, adapter up. 5. Thread the locking handle off of the piston
2. The bellows thread protector grips a lip on stem. Leave the bellows thread protector
the adjustment handle. Use pliers to pull the attached to the locking handle.
bellows from the adjustment handle lip. Do 6. Depending on size, a VVCP may have two to
not tear the bellows. four socket head bolts. Use a marker to draw
3. Remove locknut. match marks on the side of the VVCP where
the adapter and head join at each socket
4. Remove adjustment handle. The adjustment head bolt location. Loosen the socket head
handle is a tapered fit onto the piston stem; bolts evenly and incrementally to release any
use a soft hammer or puller to break the fit. potentially high-pressure gas. Do not
breathe gas emission from VVCP.

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7. Remove socket head bolts and turn the vii) Remove nut from threaded rod.
adapter counterclockwise to thread it off of Remove threaded rod and
the piston stem. Place adapter flange up next washers from adapter main
to the head. bore.
8. Remove the piston stem and piston assembly Figure: Spring Compression for Snap Ring
from the head. The piston stem and piston Removal
are permanently joined; do not attempt to
disassemble them.
9. Remove the piston ring from the piston.
10. Depending on VVCP size, Ariel machines a
groove for the o-ring into either the face of
the head or the base of the adapter. Remove
and discard the o-ring.
NOTE: Steps 11-13 apply only to VVCP's with a V-
packing seal.
11. Some adapters use a bolted retaining plate
while others use a snap ring and spring
retainer:
• Retaining Plate - Remove retaining plate
bolts and retaining plate.
• Snap Ring and Spring Retainer 1 Washer
i) Thread a nut onto a threaded 2 Snap Ring
rod that is a few inches longer 3 Threaded Rod
than the adapter height. 4 Nut
ii) Slide a washer wider than the 5 Backup Ring
main bore of the adapter down 6 Spring Retainer
to the nut. 7 Compression Spring
iii) Insert the threaded rod end with 8 V-Packing or Seal
no nut into the main bore of the
12. Remove spring retainer, compression spring,
adapter until it protrudes from
and backup ring from the adapter
the base of the adapter.
counterbore.
iv) Slide a washer wide enough to
overlap spring retainer but less 13. Remove V-packing or seal from adapter
wide than the snap ring onto the counterbore. Find a strong, foot-long metal
protruding threaded rod. 3/16 inch rod or pipe and bend about .75 inch
at 90°. Insert the rod into the adapter
v) Thread a nut onto the threaded
counterbore and slide the .75 inch beneath
rod protruding from the base.
the V-packing or seal. Pull up on the rod or
Tighten nut until compression
pipe to pull the V-packing or seal from the
spring compresses enough to
adapter counterbore.
separate spring retainer from
snap ring. NOTE: Steps 14-15 apply only to VVCP's with a spring
energized seal.
vi) Use snap ring pliers to remove
snap ring.

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14. Using an appropriate puller tool, remove the 9. Some adapters use a bolted retaining plate
first seal from the seal carrier bore. Be careful while others use a snap ring and spring
not to damage the seal housing surfaces. retainer:
15. Remove the four socket head bolts, seal • Retaining Plate
carrier, and second seal from the adapter i) Place the retaining plate on top
bore. Remove the O-ring from the seal carrier. of the spring retainer and press
down to compress the compres-
sion spring.
VVCP Reassembly
ii) Install retaining plate bolts
Clean all VVCP parts of all debris, rust, etc. through the retaining plate and
Replace worn or damaged parts. Rebuild kits are into the adapter.
available through your Ariel Parts Distributor. iii) Tighten the retaining plate bolts
hand tight.
1. With flange up, place the head on a table.
With flange up, place the adapter beside the • Snap Ring and Spring Retainer
head. i) Compress the compression
spring (see Figure: Spring
2. Depending on VVCP size, Ariel machines a
Compression for Snap Ring
groove for the O-ring into either the face of
Removal).
the head or the base of adapter. Oil and insert
a new O-ring into O-ring groove. ii) Use snap ring pliers to install the
snap ring above the spring
3. Install the piston ring onto the piston. retainer.
4. Oil the head bore, then insert stem and piston iii) Remove the nut from the
assembly into the head cavity. threaded rod, then remove the
NOTE: Steps 5-9 apply only to VVCP's with a V-packing threaded rod and washers from
seal. the main bore of the adapter.
5. Oil the adapter counterbore and insert V-
packing or seal. The V-packing or seal NOTE: Steps 10-12 apply only to VVCP's with a spring
consists of five partitions; insert V-packing or energized seal.
seal into the counterbore with the thickest
partition down and the thinnest partition up. 10. Lightly oil and install a new seal in the VVCP
NOTE: When properly installed, a V-packing gives adapter bore with the spring facing up.
resistance when the stem is inserted. If there is no Lightly oil and install a new O-ring on the seal
resistance, remove the stem and use a solid cylinder carrier.
of wood or metal to tap the V-packing or seal two or 11. Install the seal carrier in the VVCP adapter,
three times into the counterbore to ensure proper tightening the four socket-head bolts to the
seating. torque listed in Appendix A
6. Insert backup ring into adapter counterbore. 12. Lightly oil and install a new seal in the seal
7. Insert compression spring into adapter carrier with the spring facing up.
counterbore. 13. Grease piston stem threads and install
8. Place spring retainer on top of the adapter onto piston stem. Install adapter as
compression spring. far as possible on the piston stem, then turn
the adapter counter-clockwise to align the
socket head bolt match marks on the adapter
flange with the match marks on the head.

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14. Install the socket head bolts. Tighten socket 16. Slide thread protector bellows onto the
head bolts to the torque listed in Appendix A. adjustment handle lip and verify that it grips
15. Use the adjustment handle to turn the piston securely.
stem counter-clockwise to tighten the seal 17. Apply 3-4 pumps of all-purpose petroleum
between the adapter and head, then lock the grease with a grease pump at the grease
locking handle. fitting.

VVCP Installation
Install the VVCP prior to installing valves and
torqueing valve caps. Use the Ariel supplied
eyebolt to support the weight of the VVCP.

Figure: VVCP Installation

1 Cylinder
2 Head Gasket
3 Eyebolt
4 VVCP Vent
5 Flange Bolts

1. Apply an anti-sieze lubricant to both the new 4. Reconnect VVCP vent. Verify piston end
head gasket and the cylinder seating surface. clearances. See Appendix B.
Stick the new head gasket to the cylinder
5. Install valves and torque the valve caps. See
seating surface.
"Compressor Valves - Removal and
2. Slide the VVCP into the cylinder and align the Installation".
adapter flange bolt holes with the cylinder
bolt holes.
3. Lubricate and torque flange bolts per
Appendix A.

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VVCP Adjustment in operating pressures, temperatures, RPM, or

gas composition may require alternate valve
Users may change VVCP clearance volume with configuration including springing and lift.
the compressor running or stopped. The Contact your Packager and/or Ariel for help in
expected change in compressor flow and valve selection.
absorbed power depends on compression ratio
and properties of the compressed gas. Consult
packager instructions regarding where to set the Required Tools and Materials
VVCP. Also see the VVCP data sheet in the Ariel • Appropriate Ariel parts list
Parts Book. To open VVCP to a desired • Appropriate Ariel Maintenance and Repair
percentage: manual
Figure: VVCP Dimension Plate • Calibrated torque wrench with the appro-
priate range for target values
ARIEL CORPORATION A-12927
• Lubricant specified in Appendix A
FULLY CLOSED A =
• Appropriate personal protection equipment
FULLY OPEN A =
A A VVCP S.N.
• Bottle brush
REMOVE ALUMINUM THREAD PROTECTOR WHERE APPLICABLE
• Pressurized liquid solvent
1. Loosen the locking handle or adjustment • Valve Tool
locknut so the piston stem can turn freely.
2. Find the VVCP dimension plate.
3. Subtract fully closed dimension from fully
open dimension. The Ariel Performance
program also lists these dimensions if the
VVCP dimension plate is missing.
4. Multiply the step 3 result by the desired
percentage expressed as a decimal.
5. Add the step 4 result to the fully closed
dimension.
6. Turn the adjustment handle until the
measurement from the base of the locking
handle, when locked, to the top of the
adjustment handle equals the step 5 result.

Compressor Valves - Removal

and Installation
Before servicing any valve, see the correct valve
assembly drawing, parts list, and service
literature in the Ariel Parts Book. The cylinder
cover sheet in the Ariel Parts Book lists the valve
originally supplied with each cylinder. Changes

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Valve Cap Removal

Valve Caps on Cast Iron Cylinders or

High-Pressure Caps without Spring
Energized Seals

WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

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Figure: Valve Cap Assembly

Cast Iron Cylinder High-Pressure without Spring Energized Seal

1 Cap Screw 1 Valve Cap

2 Valve Cap 2 Valve Retainer
3 O-Ring 3 Valve Assembly
4 Valve Retainer 4 Valve Seat Gasket
5 Valve Assembly 5 Metallic Wire Gasket
6 Valve Seat Gasket

1. Slightly loosen all valve cap fasteners in steps

and evenly; the cap should stay in its original
WARNING
position. If it pushes outward, STOP!
Completely vent the cylinder. See Warning Even with the above precautions, the cylinder bore
could still be pressurized if the valve assemblies are
above. fouled with deposits from the gas stream. Continue to
2. Continue to turn the cap screws out, for a use caution until at least one complete valve assembly
has been removed from each acting end of the cylinder,
total of three complete 360° turns. Pry the
which completely assures there is no gas pressure.
valve cap out, observing cap movement to
ensure there is no gas pressure. Perform
CAUTION
steps 1 and 2 for a suction and discharge
valve cap on each acting end of the cylinder. Valve cap, retainer, and valve may fall out of bottom
pockets if not supported. Support them after cap screw
3. Remove cap screws and valve cap. Take care removal to prevent personal injury.
to prevent damage to fasteners.

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Removal of Valve Cap with Spring 7 Valve Gasket

Energized Seal 8 Keeper Bolt
9 2-Piece Wedge Lock Washer
WARNING 10 Spring Energized Seal

To reduce risk of injury or death, only trained personnel 1. Remove cap nuts from long studs.
who have read and thoroughly understand the 2. Slightly loosen all hex nuts on each valve cap
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
in steps and evenly. With all the nuts loose,
Prior to performing any maintenance activities: the cap should stay in its original position. If it
• Always wear appropriate personal protection equip- pushes out of its own accord, STOP!
ment and follow your company safety and opera- Completely vent the cylinder. See Warning
tional procedures. above.
• Never tighten or loosen any fastener while the unit is
operating or pressurized. 3. After the above safety checks and with hex
• Verify neither driver nor compressor can turn during nuts still in place but loosened, remove hex
maintenance. nuts from short studs.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
4. Evenly back off hex nuts on long studs while
tance. pulling the valve cap from the cylinder. Use a
• Verify each compressor cylinder is relieved to atmo- pair of pry bars, one on each side of the cap,
spheric pressure. To relieve residual cylinder bore to remove the cap. Ensure the spring
pressure after blowdown, open the “Kiene” valves energized seal completely disengages from
on the indicator ports, if so equipped. the cylinder before removing the hex nuts
WARNING: RELEASED GAS MAY BE POISONOUS from long studs.
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
NOTE: Long studs are assembled with thread locker
the gas being compressed to avoid a potentially to eliminate the possibility of the studs backing out of
explosive gas/air mixture in the system. A gas/air the cylinder while the hex nut is removed.
mixture under pressure can explode and cause severe
injury or death. 5. Remove long stud hex nuts and valve cap.
6. Inspect seal for damage. If undamaged, the
Figure: High-Pressure Valve Cap Assembly with spring energized seal is re-usable.
Spring Energized Seal
CAUTION

Valve cap, retainer, and/or valve may fall out of bottom

pockets if not supported. Support them carefully after
removing hex nuts to prevent personal injury.

Valve Removal
1. With the valve cap removed and the valve
retainer still in place, install a valve tool onto
the valve center bolt or threaded washer. See
1 Hex Nut Section 1 for an illustration of the tool.
2 Cap Nut 2. It may be necessary to loosen the plastic
3 Valve Cap thumb screws in the valve retainers. In some
4 Seal Keeper cylinder classes, the discharge valve retainer
5 Retainer is held in place with an O-ring - simply pull the
6 Valve retainer out to remove it.

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3. For high pressure applications that use a 5. In most cases, the flat metal gasket remains
metallic wire gasket seal under the valve cap, in the pocket. It is difficult to see. A flashlight
the cylinder vents upon loosening the cap and a small mirror on an adjustable rod are
screws. Use the valve tool to unseat the the best tools to see the gasket clearly. On
metallic wire gasket. cylinders with horizontal valves, the gasket
4. Remove the valve and retainer together. may fall into the gas passage. Use a small
magnet on a flexible extension rod to remove
gasket from cylinder.
6. Head end tandem cylinders may require
removal of suction and discharge piping and
the cylinder head to access the concentric
valve. A concentric valve combines suction
and discharge valves in one assembly.

Valve Installation
Figure: Typical Valve Assemblies
A Suction Valve
B Discharge Valve
C 1/8" (3mm)
1 12-Point Capscrew (Center Bolt)
2 Threaded Washer
3 Valve Retainer
4 Seat
5 Guard
6 Valve
7 Cylinder Bore
8 Valve Seat Gasket
9 Valve Cap Bolt
10 Retainer-Keeper (Thumbscrew)
11 Valve Cap O-Ring
12 Valve Cap

1. Coat valve seat gasket with Never Seez. Either cylinder bore (see Item 1, Figure: Typical
insert it into the valve pocket or stick it on the Valve Assemblies). If a valve is not marked for
valve. In either case, do not allow the gasket suction or discharge, manually depress the
to fall into the gas passage. Replace valve valve plate to verify the type. Preferably, use
seat gaskets anytime a valve is removed from a tool softer than the valve plate material or
a cylinder, if the unit has been in service. exercise care to prevent damage to the plate.
2. Install suction valves only in suction pockets A suction valve plate may be depressed only
and discharge valves only in discharge from the valve fastener (bolting) side of the
pockets. The valve pockets have valve; a discharge valve plate may be
identification plates. Install all valves with depressed only from the side of the valve that
valve fastener(s) positioned away from the faces the cylinder bore.

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3. Use the valve tool to insert the valve and See Appendix A for critical information on torque
retainer into the pocket together (see tools accuracy. Valve cap bolt failures can occur if the
for your compressor model in Section 1). cap is torqued improperly. Draw bolting to full
Verify the valve seats properly in the pocket. torque in even, gradual steps, without bias on
When installed correctly, the valve rotates
one bolt or cocking the valve cap in the bore.
freely by hand.
Such bias or cocking can unevenly crush the
4. Plastic thumbscrews or o-rings hold valve gasket, which may cause leakage and/or bolt
retainers in position in bottom valve pockets.
failure. In correct assemblies with new valves, the
Tighten thumbscrews just enough to provide
friction so retainers and valves in bottom distance from the underside of the cap to the
pockets stay in position during valve cap surface of the cylinder is a uniform 1/8 inch (3
installation. Do not replace plastic mm). The distance is slightly less with re-worked
thumbscrews with metal. valves. Proper tightening of gas containment
5. Lubricate a new O-ring with oil and install it in fasteners is critical to ensure safe and reliable
the groove on the valve cap nose. Some high operation.
pressure cylinders use a soft metallic wire
gasket or spring-energized seal in lieu of the CAUTION
O-ring. Continue to "Valve Cap Installation".
Severe personal injury and property damage may result
from improperly torqued valve cap bolts. See Appendix
Valve Cap Installation A for correct torque and detailed recommendations.

Depending on the application, Ariel compressor Installation of Valve Caps on Cast Iron
cylinders utilize different styles of valve caps. Cylinders or High-Pressure Caps
Cast iron cylinders utilize valve caps in which an
without Spring Energized Seals
O-ring on the valve cap seals gas within the
cylinder.Forged steel cylinders utilize a valve cap 1. Install valve assembly (and high clearance
with either a spring-energized seal or a round spacer, if applicable), with the valve seat
gasket and valve retainer in the valve pocket.
metallic gasket to seal gas within the cylinder.
See "Valve Installation".
The valve cap presses the round metallic gasket
into a triangular cross section during the torque 2. For high-pressure valve caps only: Place a
new, round, metallic wire gasket. Always use
procedure.
a new wire gasket when installing a high-
Ensure all threads are clean and free of debris or pressure valve cap; gaskets are not re-
burrs. Use a bottle brush and pressurized liquid useable.
solvent to clean threaded holes thoroughly. 3. Oil and install a new O-ring on the valve cap.
Avoid sending debris into cylinder gas passage. Install the valve cap.
Bolts should thread into hole and bottom out on 4. For standard fasteners in iron cylinders,
the valve cap by hand without resistance or use lubricate threads and bolt seating surfaces
of a wrench. If bolts do not thread into hole with mineral oil. For stainless steel fasteners
freely, contact ARC for thread repair instructions. or in steel cylinders, lubricate threads and
bolt seating surfaces with Never Seez regular
grade. Do not use Never Seez on standard
fasteners. See Appendix A for correct valve
cap bolt torque.

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5. For high-pressure applications, the valve cap

joint design requires pressing a round
metallic wire gasket into a triangular cross
section (see Figure: Gasket Crush). This
requires multiple passes in a crisscross
pattern with the torque wrench. See
Appendix A

Figure: Gasket Crush

A Before Torque
B After Torque
1 Cylinder
2 Valve Cap
3 Metallic Wire Gasket
4 Valve Retainer

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Installation of Valve Cap with Spring Energized Seal

Figure: High-Pressure Valve Cap Assembly with Spring-Energized Seal
1 Valve Gasket
2 Valve
3 Retainer (openings aligned with gas
passage)
4 Thumb Screws
5 Roll Pins
6 Seal Keeper
7 Spring Energized Seal
8 Valve Cap
9 Hex Nut
10 Cap Nut

1. Install valve assembly with valve seat gasket 6. Continue to torque the valve cap at 100%
and valve retainer in the valve pocket. See torque value until no bolt movement is
"Valve Installation". Verify valve retainer observed. Even minute bolt movement
openings are aligned with the cylinder gas warrants another pass around the valve cap
passage. Re-tighten thumb screws, if in a crisscross pattern.
applicable.
7. Tighten cap nuts on long studs, hand wrench
2. Inspect and lightly lubricate spring energized tight.
seal with petroleum oil.
3. Install valve cap so the roll pins engage the
clearance slots in the seal keeper. Be careful
not to gouge the bore, or distort or damage
the gasket.
4. Liberally coat the valve cap stud threads and
hex nut seating surface with Never-Seez.
5. See Appendix A for correct valve cap fastener
torque.

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Gas Containment Fastener Torque Piston and Rod Removal

Checks
WARNING
Per Per Section 5 (start-up checklists) and
To reduce risk of injury or death, only trained personnel
Section 3 (Recommended Maintenance
who have read and thoroughly understand the
Intervals), Ariel recommends checking all gas appropriate Ariel Technical Manual and Packager
containment fastener torques by the schedule information should attempt any maintenance.
Prior to performing any maintenance activities:
below. Gas containment components include
• Always wear appropriate personal protection equip-
cylinders, valve caps, cylinder heads, unloaders, ment and follow your company safety and opera-
gas passage caps, flanges, and packings. Include tional procedures.
this schedule in your computerized maintenance • Never tighten or loosen any fastener while the unit is
operating or pressurized.
management system (CMMS): • Verify neither driver nor compressor can turn during
1. Prior to start-up maintenance.
• Follow packager instructions to completely isolate
2. 24 hours after start-up and vent the system; call the packager for assis-
tance.
3. 750 hours after start-up • Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
4. Every 8,000 hours after start-up pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
Per Section 3, re-check any fasteners found loose
WARNING: RELEASED GAS MAY BE POISONOUS
in any of these intervals after an additional 750 AND/OR FLAMMABLE.
hours. If loosening continues, contact your Before resuming operation, purge the entire system with
packager immediately. the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.
Piston and Rod
Most piston and rod assemblies consist of NOTE: See Section 1 for illustrations of tools
separable pistons that attach to the piston rod mentioned below. For non-lube cylinders, see
with a crank-end collar and a head-end nut. Appendix F.
Some cylinder classes require other designs,
including one-piece (integral) piston/piston rods, 1. Loosen cylinder head bolts. Remove cylinder
and there are some multi-piece assemblies that head and all crosshead guide side covers.
do not use a crank-end collar. 2. Move crosshead to inner dead center. Back
off, but do not remove, the crosshead
balance nut set screws. Loosen crosshead
Piston Rod Inspection balance nut with the special slugging wrench.
Use the open end wrench for hex nuts or the
At the specified recommended maintenance
peg wrench for round nuts, or use the
interval, inspect piston rods for damage and separately purchased hydraulic crosshead
excessive wear. balance nut torque tool.
• For condemning limits, see Section 3.

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3. In tandem cylinders, where the outboard Handle all piston rings carefully with clean
cylinder bore is smaller than the inboard tools and hands to protect them from nicks,
bore, remove the outboard cylinder. Support marring, and bending. Despite their
such cylinders during removal and toughness in service, some rings are fragile
installation, to avoid excessive weight on the when removed.
piston and rod assembly that may bend
8. The weight of the piston and rod assembly is
them.See ER-118 for outboard cylinders with
stamped on the head end. Support the piston
removable liners.
either manually or with a crane as
4. Measure piston to cylinder clearance at appropriate as it slides from the cylinder
bottom of piston with a feeler gauge. See bore. The piston rod must remain parallel
Appendix B for tolerances. If out of tolerance, with the bore until it leaves the bore
replace wearband. completely. Take care not to ding any
5. Move crosshead to outer dead center, then surfaces.
use the piston nut spanner to turn the piston
and rod assembly out of the crosshead. The Hydraulic Tensioner Tool
two dowels on the tool fit the piston nut
holes. Remove the crosshead nut from the Proper preload is essential for piston nuts. Ariel
piston rod. offers a hydraulic tensioner tool as an option to
6. Slide the piston rod entering sleeve over the assemble and disassemble only KBK:T piston rod
piston rod threads. With extreme care, slowly assemblies that require the tool.
slide piston rod through packing so as not to
damage wiper or packing rings.
7. For one-piece piston rings, slide the piston
rod assembly from the cylinder, then
carefully remove the piston rings. For two-
piece piston rings (in high pressure
applications), slide the piston rod assembly
out of cylinder until a fraction of the first ring
clears the cylinder. Hold the first ring in the
piston groove by hand, or use a band for
larger sizes, until the ring clears the cylinder,
then carefully remove the ring. This prevents
the ring from popping out of the groove and
damaging the ring. Remove succeeding two-
piece rings and wear band in the same way.

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Figure: Typical Hydraulic Piston Nut Tensioner Tool for KBK:T Frames
A If piston has an undercut,
assemble toward head end.
1 Piston Nut (with 2 setscrews)
2 Dowel Drive Pin
3 Tensioner Tool (separately
purchased, not a part of stan-
dard tool box)
4 Puller Screw Threads
5 Spanner Ring
6 3/4-inch Hex
7 Tool Piston
8 Piston Return Spring
9 Piston Seals
10 Snap Ring
11 Adapter Foot Plate (3
Provided)

Hydraulic Tensioner Tool Setup two pairs of different size dowel drive pins to
match each puller screw, and three adapter foot
Set up tensioner tool with correct adapter foot
plates. A change in puller screw size requires a
plate, dowel drive pins, and puller screw insert
change in dowel drive pins. Puller screws with
for the particular piston and rod per Tables:
wrench flats and dowel drive pins with recessed
Hydraulic Tensioner Tool A-24512 Setup and
Allen sockets facilitate removal and installation.
Hydraulic Tensioner Tool A-28362 Setup. The
tool comes with multiple puller screw inserts,

Table: Hydraulic Tensioner Tool A-24512 Setup

Thread
Frame Thread Size Foot Plate Puller Screw Dowel Pin
Projection, In.

JGH:E:K:T 7/8-9 A-24533a A-24524 A-24529 15/16

JGH:E:K:T, KBE 7/8-9 A-24531 A-24524 A-24529 15/16

KBK:T 1"-12 A-24531 A-24525 A-24529 1

JGC:D:F 1"-8 A-24532 A-24526 A-24530 1

JGC:D:F 1"-8 A-25106b A-24526 A-24530 1

KBC:D:F 1-3/8-12 A-24532 A-24526 A-24530 1-3/16

a. For 4-5/8 H:E class pistons only.

b. Optional plate for 5-3/8C-HE class pistons only. Not included with A-24512 tool.

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Table: Hydraulic Tensioner Tool A-28362 Setup

Thread
Frame Thread Size Foot Plate Puller Screw Dowel Pin
Projection, In.

JGH:E:K:T 7/8-9 A-28365a A-24524 A-28367 15/16

JGH:E:K:T, KBE 7/8-9 A-28363 A-24524 A-28367 15/16

KBK:T 1"-12 A-28363 A-24525 A-28367 1

JGC:D:F 1"-8 A-28364 A-24526 A-28368 1

JGC:D:F 1"-8 A-28366b A-24526 A-24530 1

KBC:D:F 1-3/8-12 A-28364 A-24527 A-28368 1-3/16

a. For 4-5/8 H:E class pistons only

b. Optional plate for 5-3/8C-HE class pistons only. Not included with A-28362 tool.

Piston & Rod Disassembly with 1. Remove the two Allen set screws from the
Hydraulic Tensioner Tool piston nut and discard.
2. Clean and lubricate threaded hole in piston
CAUTION rod.
Trapped gas pressure can present a personal safety 3. Ensure the tool hydraulic cylinder is de-
hazard when disassembing the piston and rod. Work in a energized and fully retracted. Use the
well-ventilated, non-sparking area, particularly with
inspection gauge to verify the puller screw
sour gas applications. Do not breathe gas emission when
venting trapped gas. has the proper projection (see Figure: Typical
Inspection Gauge).
Figure: Typical Inspection Gauge 4. Position tensioner tool with the two dowels
inserted into the piston nut. Tighten puller
screw until tensioner tool is completely tight
against the piston rod assembly, then back
off 1/2 turn.
NOTE: The puller screw of the tensioner tool has a 3/4
inch hex to tighten or loosen the puller screw.

CAUTION

If tool fails to completely tighten against piston

assembly, STOP. Inspect tool to find the cause. Correct
the problem and try again. Configure tool properly.

1 Tensioner Tool
2 Puller Screw
3 Inspection Gauge

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5. Apply hydraulic pressure to the tensioner tool 3. Inspect piston rod threads and collar
to stretch piston rod (see Appendix A). Use shoulder. Clean and de-burr threads. Install
clean ISO 32 hydraulic fluid in pump/tool collar and nut onto piston rod to verify inside
system. Ariel offers an appropriate 10,000 psi diameter fits and rotates freely. Turn piston
manual pump kit for use with the tool. nut until rod threads protrude to verify
freedom of thread engagement. Remove nut
CAUTION
and collar.
Do not overpressure torque tool. It can cause tool failure
and/or excessive piston rod pre-load, which may cause
4. Apply a thin coat of Never-Seez Regular Grade
piston rod failure and/or personal injury. to piston rod shoulder, rod collar locating
band, and collar face in contact with piston,
6. Loosen piston rod nut.Turn spanner ring a then slide collar onto rod.
minimum 1/4 turn with a 1/2" drive breaker 5. Apply a thin coat of Never-Seez Regular Grade
bar. Release hydraulic pressure, remove to piston rod threads at the piston end, then
tensioner tool, and then remove the piston slide piston onto rod and collar.
nut. NOTE: If one end of the piston has an undercut, and
NOTE: Half-inch square holes are provided on the the piston has the same number of piston ring
outside of the tool for breaker bar/reaction bar. The grooves on each side of the wearband, assemble with
puller screw 3/4" hex can also be used for a reaction the undercut toward the head end. For pistons with a
bar. different number of piston ring grooves on each side
of the wearband, assemble with the side of fewer
Piston & Rod Reassembly with piston ring grooves toward the head end. See Figure:
Hydraulic Tensioner Tool Typical Inspection Gauge.
6. Apply a thin coat of Never-Seez Regular Grade
1. Clean all piston and rod assembly parts
to piston nut threads and piston mating face.
thoroughly.Verify piston is internally clean
Install nut and hand tighten to make up the
and dry.
piston rod assembly.
NOTE: Any reassembly of used parts requires re-
cleaning and re-lubrication of threads and seating 7. Mark a line across piston and nut prior to
surfaces. torquing to ensure the nut turns. Ensure the
tool hydraulic cylinder is de-energized and
2. Inspect collar (or collar area on rod, when
fully retracted. Use the inspection gauge to
collar is integral and not separable), piston,
verify the puller screw has the proper
and piston nut for nicks, burrs, or scratches.
projection (see Figure: Typical Inspection
Replace if surfaces are damaged, worn, or
Gauge). Verify the threaded hole in the piston
galled. Inspect piston ring grooves. If
rod is clean and oiled.
damaged, or ring groove width is out of
tolerance, replace the piston (see Appendix B 8. Position tensioner tool with the two dowels
for tolerances). Dress surfaces with a fine grit inserted into the piston nut.Tighten puller
stone as required. Fit collar and nut into screw until tensioner tool is completely tight
piston to verify the outside diameter fits and against the piston rod assembly, then back
turns freely by hand in the piston. off 1/2 turn.
CAUTION

If tool fails to completely tighten against piston

assembly, STOP. Inspect tool to find the cause. Correct
the problem and try again. Configure tool properly.

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9. Apply hydraulic pressure listed in Appendix A 13. Use a punch within 1/16 inch (1.5 mm) of set
to tensioner tool to stretch the piston rod. To screw threads to deform the threads and
tighten piston rod nut, use a calibrated stake set screws in place (see Figure: Staking
torque wrench to torque the spanner ring to a Set Screw).A dimple is provided to properly
the torque listed in Appendix A. Keep the locate the stake on piston nuts.
torque wrench perpendicular to the tool 14. Use a calibrated scale to weigh piston rod
housing. assembly with piston rings and wear band.
NOTE: Half-inch square holes are provided on the Stamp weight on piston head end. Flatten
outside of the tool for breaker bar/reaction bar. The any raised lips to avoid clearance
puller screw 3/4" hex can also be used for a reaction measurement errors. Record weight on a new
bar. balance sheet and send to Ariel. See
CAUTION
“Opposed Throw - Reciprocating Weight
Balancing” in Appendix C for approximate
Maintain clearance between the torque wrench and the component weights.
tensioner tool window opening when torquing spanner
ring. Proper seating torque will not be applied to the
spanner ring if the torque wrench hits the window
opening. Do not overpressure torque tool. It can cause
tool failure and/or excessive piston rod pre-load, which
may cause piston rod failure and/or personal injury.

NOTE: Periodically calibrate hydraulic pressure

gauges for the required pressure. Use optional
Ariel hydraulic hand pump kit.
10. Release hydraulic pressure. Re-apply
hydraulic pressure, use a breaker bar to
loosen piston nut without disassembling, and
then re-tighten to the recommended torque.
This double-torquing ensures piston
assembly integrity.
11. Release hydraulic pressure and remove
tensioner tool. Inspect the piston rod at the
end of the piston; it should not protrude more
than 0.010 inch (0.25 mm) past the piston
face. The nut should be flush or recessed.
Verify piston nut has turned a minimum of 95°
to achieve proper pre-load by comparing the
marks made earlier across the piston and nut
faces.
12. Apply a thin coat of Never-Seez Regular Grade
to two new Allen set screws. To install a set
screw, use the torques in Appendix A.
Figure: Staking a Set Screw

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Piston and Rod Installation

Figure: Typical Piston and Rod Installation
1 Crosshead
2 Crosshead Nut
3 Set Screw
4 Piston Nut Spanner

1. Install piston rings in cylinder main bore 5. Verify the balance nut and crosshead mating
without piston to measure end gaps. Ariel surfaces are flat and free from dings or other
recommends replacing piston rings when the disparities. If necessary use a flat stone to
end gap equals three times its original smooth the surfaces.
specification. See Appendix B for
6. Lubricate piston rod and crosshead threads
specification.
with Never-Seez Regular Grade. Apply a thin
2. Except for non-lube cylinders, liberally coat of oil to either the balance nut or
lubricate the cylinder bore, piston rod, piston crosshead mating surface. Do not apply
rings, wearbands and piston with compatible Never-Seez to the mating surfaces. Install
cylinder oil. Install rings on piston with ring crosshead-balance nut on piston rod. Turn
gaps staggered. the piston rod into the crosshead. Visually
a. For cylinders requiring two-piece piston center the packing flange around the piston
rings or wear bands, verify that they are a rod and torque packing bolts per Appendix A.
set by the match marks. Two-piece rings 7. Set piston end clearance (see Appendix B):
use dots as match marks - verify the dots
a. Using the piston nut spanner, turn the
face the pressure side of cylinder. Two-
piston rod into the crosshead.
piece piston rings and wear bands are
manufactured as matched sets; mixing b. Place a long feeler gauge equal to the
ring halves may result in incorrect end crank end clearance required in the crank
gaps. end top valve pocket between the piston
and the crank end head.For 13 in. (330
b. For all other rings, see "Piston Rings".
mm) and larger cylinders, insert feeler
3. Slide the piston rod entering sleeve over the gauge through a bottom valve pocket.
piston rod threads. Slide piston rod with c. Tighten piston against the feeler gauge so
piston rings and wear band into cylinder the feeler gauge cannot be pulled out.
bore. Damage to the packing rings is likely if
an entry sleeve is not used. d. Tighten the crosshead nut against the
crosshead.
4. Using a dial indicator, position the crosshead
e. Tighten the crosshead nut by the slugging
at the inner dead center position.
method or by hydraulic torquing device.

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See "Crosshead Installation" for hydraulic Piston Rod Runout

torquing device.
f. Tighten the balance nut set screws and be Table: KBK:T Max. Piston Rod Runout, Inch
sure to remove the piston nut spanner. (mm)a
8. See "Crosshead Installation" for details to re- Vertical 0.0020 (0.051)
attach piston rod to crosshead, check piston
end clearance, piston rod runout and Horizontal 0.0010 (0.025)
crosshead clearances, and re-assemble to a Machines with readings falling outside the limits
close cylinder and crosshead guide. See require disposition by Ariel.
Appendix B and "Piston Rod Runout".
CAUTION Check piston rod runout after new unit
installation, unit relocation, or maintenance that
Ariel recommends leaving distance piece covers off after
any piston rod or rod packing ring maintenance. Verify may affect rod runout.
no ignition sources exist in the area, pressurize the unit,
and check for gas leaks before distance piece cover Position the stem of a 0.0001 inch (0.001 mm)
installation. This protects against crosshead guide over- increment calibrated dial indicator against the
pressure and possible ignition due to incorrect piston rod, close to the packing case. Set the
installation of packing case or components. When
checking for leaks, take proper precautions in process indicator to zero with the piston toward the
gas applications, such as H2S. crank end. Bar over crankshaft and record
indicator readings with the piston at mid-stroke
and H. E. positions, in both vertical and
horizontal directions. Record upward vertical rod
movement as positive and downward as
negative. Record horizontal rod movement
toward the auxiliary end of the frame as positive
and toward the drive end as negative. Copy the
table below to record readings and compare to
Table: KBK:T Max. Piston Rod Runout, Inch (mm)
values.

Table: Piston Rod Runout, Inches

Throw 1 2 3 4 5 6

Vertical (0°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

Horizontal (0°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

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If a vertical reading is greater than the are within 0.0003 inch of the original runout
maximum acceptable, use this procedure to readings above, the rod is acceptable - break the
determine component acceptability: Break the balance nut loose. Re-set C.E. clearance and re-
balance nut loose. Looking from the head end, torque the balance nut. If rod runout is not within
turn the piston 90º counter-clockwise, and re- 0.0003 inch of the original reading above, contact
torque the balance nut. Record both vertical and Ariel.
horizontal readings in the table below. If readings

Table: Alternate Piston Rod Runout, Inches

Throw 1 2 3 4 5 6

Vertical (90°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

Horizontal (90°) Piston @ C. E. 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000

Mid-Stroke

Piston @ H. E.

Vert. Runout Differencea

Horiz. Runout Differencea

a Piston @ H. E., original minus alternate.

Piston Rings NOTE: On tandem cylinders with a combination of

seal-joint rings and other ring styles, always position
Most cylinders use one-piece angle-cut filled
the seal-joint rings farthest from the pressure side.
PTFE piston rings. High-pressure cylinders use See Figure: Seal-Joint, Straight-Cut, and Angle-Cut
two-piece thermoplastic rings. Ariel Piston Ring Installation Orientation.
recommends replacing rings when the end gap
increases to three times the new dimension. To
measure end gaps, insert rings in the cylinders Straight-Cut Chamfered Piston
without pistons (see Appendix B for minimum Rings
end gap dimensions).
Straight-cut chamfered piston rings are
directional and require correct installation.
Seal-Joint Piston Rings
Install them with chamfers or dots toward the
Seal-joint piston rings are directional and require pressure and with the end gaps staggered.
correct installation.

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Figure: Seal-Joint, Straight-Cut, and Angle-Cut Piston Ring Installation Orientation

1 Frame Side
2 Pressure
3 Seal-Joint Ring
4 Chamfers or Match Marks
toward Pressure, End Gaps
Staggered
5 Match Mark Side toward
Pressure
6 Typical for Tandem Cylinder
7 Angle Cut or Straight Cut
Rings
8 Typical for Double Acting
Cylinder - with or without
Wearband

High-Pressure Face-Cut Piston Gas pressure in the wear band area escapes past
Rings the piston rings via the face cuts during the
suction stroke to prevent loading the wear band
Face-cut piston rings are typically used in and increase service life. Also, do not align the
cylinders with 2500 psi MAWP or higher, and ring end gaps; stagger them to minimize gas
generally with notched and fluted wear bands. leakage.
The rings install with the face cuts toward the
highest pressure, or toward the nearest head.

Figure: High-Pressure Face-Cut Piston Ring Orientation

1 Piston Rod
2 Crank End
3 Piston
4 Piston Rings
5 Wear Band
6 Head End
7 Notches
8 Staggered End Gaps
9 Frame Side
10 Pressure

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Three-Piece Piston Rings with expander chamfer facing the nearest head
or highest pressure (see Figure: Three-Piece
This ring style consists of two “outer” rings Piston Ring Installation Orientation). Install outer
installed over an “inner” ring. The first outer ring rings with match marks facing the nearest head
has double match marks and the second outer or highest pressure and end gaps staggered to
ring has single match marks. The inner ring rests prevent leakage.
in the bottom of the piston ring groove; install

Figure: Three-Piece Piston Ring Installation Orientation

1 Double Match Marks 4 Second Outer Ring 7 Inner Ring

2 Staggered End Gaps 5 Single Match Marks 8 Match Marks toward Pressure
3 Pressure 6 First Outer Ring 9 Frame Side

Five-Piece Piston Rings

A five-piece ring set consists of two outer rings
cut in half and an inner ring with a single cut. In
the five-piece design, Ariel uses two different
styles: face-cut (notched) and non-face-cut. Ring
orientation is critical to proper function.

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Figure: Five-Piece Piston Ring Installation Orientation

Non-Face-Cut Rings Face-Cut Rings Piston Rod Assembly

1 Inner Ring 5 Second Outer Ring 9 Face-Cut
2 Chamfer (where applicable) 6 Staggered End Gaps 10 Frame Side
3 First Outer Ring 7 Single Match Marks 11 Match Marks toward Pressure
4 Double Match Marks 8 Pressure

Face-Cut (Notched) Rings: When the inner ring Wear Bands

is chamfered, the chamfer faces the nearest head
or highest pressure. The first outer ring has no Most cylinders use one-piece angle-cut filled
face-cut (notch) and double match marks, and PTFE wear bands. High-pressure cylinders use
the second outer ring has a face-cut (notch) and two-piece thermoplastic bands (see Figure: High-
single match marks. Install both outer rings with Pressure Face-Cut Piston Ring Orientation).
match marks facing the nearest head or highest During installation, check and record wear band
pressure. When the match marks are correct, the end gap and projection. To measure end gap,
end gaps of the outer rings do not align. insert one or two-piece wear band into cylinder
Non-Face-Cut Rings: When the inner ring is without the piston then measure the total gap
chamfered, the chamfer faces the nearest head while the band maintains full contact with the
or highest pressure. The first outer ring has cylinder bore. See Appendix B for end gap
double match marks and the second outer ring dimensions.
has single match marks. Install both outer rings To measure wear band projection, install the
with match marks facing the nearest head or entire piston assembly or remove the head to
highest pressure. When the match marks are check during maintenance. Measure the gap
correct, the end gaps of the outer rings do not between the piston and cylinder bore at the
align. bottom of the cylinder. Compare the wear band
projection to the as-new condition (recorded at
new wear band installation or found in Appendix
B). Replace the bands if there is any indication
the next planned run time may fully degrade the
wear band and allow the piston to contact the
cylinder bore.

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Piston Rod Packing 4. Typically, the small nuts are not removed
from the studs as they hold the packing case
The piston rod packing prevents gas from together for removal as an assembly.
entering the crosshead guide. Piston rod rings However, some packings are too big to fit
within the packing wear over time and need through the distance piece or crosshead
guide doors, so removal of the small nuts and
replacement.
the packing flange is necessary. For certain
longer, higher pressure rating packing cases,
Piston Rod Packing Removal knurled nuts hold the remaining packing
assembly together to assist with installation
and removal.
WARNING
5. Remove the pressure packing and take it to a
To reduce risk of injury or death, only trained personnel
who have read and thoroughly understand the clean place for disassembly.
appropriate Ariel Technical Manual and Packager 6. Set pressure packing on a clean surface on its
information should attempt any maintenance.
nose cup or cylinder end. Usually, packing
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
cups are marked to represent the assembly
ment and follow your company safety and opera- order starting with the cup closest to the
tional procedures. cylinder as number 1. If the cups are not
• Never tighten or loosen any fastener while the unit is matchmarked, then match mark the outside
operating or pressurized. diameter of the cups and flange for proper
• Verify neither driver nor compressor can turn during reassembly. Long tie studs hold the pressure
maintenance. packing together. The stud holes are
• Follow packager instructions to completely isolate
unequally spaced to prevent misalignment of
and vent the system; call the packager for assis-
tance. the stack of parts. Remove the nuts and
• Verify each compressor cylinder is relieved to atmo- unstack the pressure packing. Replace these
spheric pressure. To relieve residual cylinder bore nuts each time the pressure packing is
pressure after blowdown, open the “Kiene” valves serviced.
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
7. To check ring wear, place assembled rings
AND/OR FLAMMABLE. (note match-marks) on the piston rod. Check
Before resuming operation, purge the entire system with end gap clearance. If the ends butt, or nearly
the gas being compressed to avoid a potentially butt, replace the rings. See "Types of Piston
explosive gas/air mixture in the system. A gas/air Rod Packing Rings" for correct ring
mixture under pressure can explode and cause severe orientation.
injury or death.
8. Pry loose the metal or spiral-wound gasket
1. Remove piston and piston rod. See "Piston on the end cup with a sharp awl. Do not
and Rod Removal". scratch the sides of the gasket groove.
Discard the used gasket.
2. Remove packing diaphragm (if applicable)
and oil wiper packing. 9. Before reassembly, clean all parts
thoroughly.
3. Disconnect all tubing and instrumentation (if
applicable) from packing flange. Ensure there
is no debris in the tubing between the check
valve and packing flange. Remove the twelve-
point cap screws that hold the pressure
packing gland to the crank end of the
cylinder/head.

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Piston Rod Packing Reassembly and Installation

Figure: Piston Rod Packing Case Lube Cups
1 Lube cup identification axial
groove (after 2005).
2 1/4 in. (6mm)

1. Refer to the pressure packing assembly in 5. Verify proper position of each rod ring and
your parts book. Ariel supplies parts books cup and, unless non-lube, coat rings liberally
with each unit. Contact your distributor to with new, clean lubricant before reassembly.
obtain a parts book. Each pressure packing Use only the same lubricant in the force feed
re-build kit includes a pressure packing lube system. If non-lube cylinders, see
assembly drawing. Appendix F.Ensure tie studs are completely
2. Take care not to scratch mating surfaces of threaded into end cup. Examine all parts for
the cups. Cup surfaces must be clean and dry unusual nicks or burrs which may interfere
for re-assembly. with the free floating of the rod rings in the
cups. Take particular care with rod rings
3. To install a new set of rod rings in an existing made of soft materials, such as bronze or
packing case, inspect case parts for wear. PTFE. It is extremely important to handle and
Cups should be smooth and flat on the back install wiper rings carefully to prevent
side where the rod rings must seal. If cups or damage to scraping edges. If packing case is
grooves are concave or tapered, regrind or cooled, see “Reassembling and Testing
relap them. Contact Ariel for appropriate Cooled Packing Cases”.
rework thickness dimensions. It is rarely
necessary to alter the crosshead side of cups, 6. Lay out parts on a work bench for progressive
but if necessary, take care not to destroy the installation, with each part in its correct
correct side clearance for the renewal rings. position and the rod rings with their proper
faces toward the pressure. Long tie studs
NOTE: If premature wear is suspected, see “Force
hold the pressure packing together. The stud
Feed Lubrication Conditions”.
holes are unequally spaced to prevent
4. Before a packing case installation, misalignment of the stack of parts. Note that
disassemble and thoroughly clean it in an all rod ring segments are carefully lettered;
appropriate solvent for the intended service. assemble them accordingly. This is most
important for proper sealing. Center side-
loaded WAT and AL rings prior to tightening

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tie stud nuts. Install tie stud nuts and tighten 10. Reinstall packing diaphragm (if applicable)
to the torques in Appendix A. Manually verify and wiper packing.
all rings move freely, radially, in their
11. Reinstall piston and rod. See "Piston and Rod
grooves. Side-loaded rings are tight, but
Installation".
should still move manually. Center these
rings. 12. After tightening the crosshead nut, visually
Packing reassembly: align the packing, to maintain a uniform
clearance between the packing case bore and
a. With no gasket installed, install the studs the piston rod.Tighten rod packing bolts
into the end cup (cup # 1). evenly in a criss-cross pattern to the
b. Using cylinder oil, lubricate the cup and recommended torque in Appendix A. This
the pressure breaker ring or ring set, then procedure squares the pressure packing on
install them into cup (see pressure its nose gasket. Rod packing bolt tightening
packing assembly drawing for correct on high pressure cylinders requires a torque
orientation). multiplier.
c. Install cup # 2 and repeat Step b for the NOTE: Repeat final torque for rod packing bolts until
seal ring sets. the bolts no longer turn. Re-check torque on these
fasteners at the next service interval.
d. Repeat steps above for cups #3, #4, etc,
until packing case is reassembled per the 13. Retighten tie stud nuts. Reinstall tubing
pressure packing assembly drawing. connections and instruments (if applicable).
e. Using a clean oil pump filled with cylinder Take care not to cross-thread tubing nuts.
oil, squirt oil into the lube fitting(s). If the Tubing nuts must be tight.
packing is assembled correctly, the oil will NOTE: After pressure packing installation, see “Force
come out the lube cup. If not, disassemble Feed Lubricator” in Section 3 to prime the force feed
the packing and correct the error. lube system and obtain recommended lubrication
rates for new machine break-in. Priming may be
f. Using pressurized air, repeat the above
necessary after extended down time. Break-in lube
process for vent and purge lines.
rates are approximately twice the normal rates, or
g. For cooled packings the cooling circuit half the normal cycle time.
must be pressure tested (see "Testing").
CAUTION
7. For new installations, carefully clean all
accumulated dirt in the lines and Ariel recommends leaving distance piece covers off after
compressor. Any foreign material lodges in any piston rod or rod packing ring maintenance. Verify
the packing and becomes destructively no ignition sources exist in the area, pressurize the unit,
and check for gas leaks before distance piece cover
abrasive.
installation. This protects against crosshead guide over-
8. Verify the gasket surface in the packing pressure and possible ignition due to incorrect
counter bore on the crank end of the installation of packing case or components. When
checking for leaks, take proper precautions in process
cylinder/head is clean and not scratched.
gas applications, such as H2S.
Install a new end cup gasket. Round wire
gaskets will fit tightly in the gasket
groove.Spiral-wound or other gasket styles
require application of grease (or adhesive for
non-lube applications) to hold them in place.
9. Reinstall complete packing case assembly
with oil supply point on top. Use rod packing
bolts to pull packing into place.

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Reassembling and Testing Cooled Cooled cases are lapped. Take special care not to
Packing Cases scratch cup mating surfaces; it can cause
significant problems. Cup surfaces must be clean
In the event of disassembly, the procedures and dry for reassembly.
below detail the reassembly of cooled rod
1. The cups are numbered on the outside
packing cases and testing for proper assembly. diameter. Assemble them in consecutive
See also "Piston Rod Packing Reassembly and order, starting with the end cup. The offset
Installation" and "Types of Piston Rod Packing studs allow the cups to fit only one way.
Rings". 2. Ensure the tie studs thread completely into
the end cup. Install the proper ring facing the
Reassembly proper direction in the groove. Do not scratch
lapped faces when sliding parts onto tie
Figure: Cooled Packing Turnaround Cups studs.
3. Install next cup. Install the rings and verify
installation of the two (2) small O-rings
around the coolant holes.
4. Repeat step 3 to assemble remaining parts in
consecutive order per the packing case
drawing.
5. Install tie stud nuts. Tighten 10-24 nuts to 20
Lb x In (2.3 N•m), 1/4-20 to 72 Lb x In (8.1 N•m),
and 5/16-18 to 144 Lb x In (16 N•m). Verify all
rings move freely, radially, in the grooves.
Side loaded WAT and AL rings are snug, but
should move manually.

Testing
1. Verify 100% function for all internal passages.
1 Coolant turnaround cup circumferential identifica-
tion groove (all - beginning 2006)
Blow dry, oil-free compressed air through the
connection taps on the flange and verify that
2 O-Ring Grove
air exits at the proper holes. Air applied to the
connection tap stamped “Coolant In” should
See pressure packing assembly in the parts book exit the connection tap stamped “Coolant
supplied with the unit. Contact the distributor to Out”. Air applied to the tap stamped “Lube”
obtain a parts book. A pressure packing assembly should exit the appropriate cup on the inside
drawing comes with each pressure packing re- diameter of the case.
build kit. 2. Pressure leak test packing cases as follows:
a. Plug the “Coolant Out” connection.
b. Apply 60 to 100 psig dry, oil-free
compressed air to the “Coolant In”
connection through a ball valve with a

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calibrated pressure gauge located “P” Pressure Breaker

between the ball valve and packing case.
This single ring is cut radially into three equal
c. Close the ball valve and disconnect the air
supply. There should be no pressure drop segments. It breaks down or slows gas flow
for 5 minutes, minimum. without sealing it completely.
3. Disassemble, inspect, correct, re-assemble, Figure: “P” Pressure Breaker
and re-test any case that fails testing. To aid
sealing, bolt a packing case into place in a
cylinder head with properly torqued original
packing retention bolts.

Long Two-Compartment
Intermediate Packing
Compressors supplied with long two-
compartment distance pieces include an
intermediate packing assembly that seals
around the rod between the outboard and
inboard distance pieces. This packing assembly
includes a single AL ring set. 1 Pressure

For lubricated service, the force feed lube oils the

“PB1” Pressure Breaker
top of the ring set at a very low rate because this
ring set is not subject to cylinder pressures and This single ring is cut radially into three equal
temperatures. The end-to-end seal in the cup segments. It breaks down or slows gas flow
and the low lube rate of AL ring sets, ensures without sealing it completely. This ring uses a
newly installed rings run virtually dry for the first solid wire spring.
few hours of operation. To avoid damage to the
Figure: “PB1” Pressure Breaker
rings and rod, copiously oil the ring set during
installation, before rod installation. Use only the
same lubricant in the force feed lube system. If
non-lube, see Appendix F.

Types of Piston Rod Packing Rings

There are several types of piston rod packing
rings depending on the application. Below are
those used in Ariel KBK:T compressors.

1 Pressure

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“UP” Pressure Breaker “BD” Double-Acting Seal Set

This single solid ring breaks down or slows gas This two-ring set consists of tangentially step cut
flow without sealing it completely. rings doweled to stagger the tangential cuts from
one ring to the other. This double acting set seals
Figure: “UP” Pressure Breaker
in either direction. In cylinders operating near
atmospheric pressure, it prevents air from
entering the cylinder. Install with the match mark
letters facing towards the cylinder.
Figure: “BD” Double-Acting Seal Set

1 Pressure

1 Pressure
“P1U” Pressure Breaker
This two-ring set allows controlled leakage in one Double "WAT" Double-Acting Seal Set
direction only and installs in the first or second
In this three-ring PTFE set, the first two rings
packing cup (closest to the piston). The first ring
(pressure side) are radially cut; the third is
(pressure side) is one-piece with a single radial
tangentially step cut. The last two rings are
cut; the second ring is solid and has a bore larger
doweled to stagger the cuts from one ring to the
than the rod diameter.
other. The first ring, along with the center ring,
Figure: “P1U” Pressure Breaker forms a wedge that overcomes rod friction and
holds the ring set against both groove faces
during either direction of rod travel. Use this ring
set primarily for low pressure applications. WAT
rings must be centered when installed in the
packing case.

1 Pressure

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Figure: Double "WAT" Double-Acting Seal Set Figure: “BTS” Single-Acting Seal Set

1 Pressure
1 Pressure

“AL” Double-Acting Seal Set “BTUU” Single-Acting Seal Set

This five-ring PTFE set functions like a double-
This four-ring set seals in one direction only. The
ended “WAT” ring set. AL rings must be centered
first ring (pressure side) is radially cut; the second
when installed in the packing case.
is tangentially step cut. These rings are doweled
Figure: “AL” Double-Acting Seal Set to stagger the cuts from one ring to the other. The
third and fourth are uncut one-piece rings with
clearance over the rod, allowing the joints of the
first two rings to form a gas-tight seal. In many
applications, the uncut rings will deflect under
pressure and seal against the piston rod.
Figure: “BTUU” Single-Acting Seal Set
1 Pressure

“BTS” Single-Acting Seal Set

This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The
second ring is tangentially step cut. These first
two rings are doweled to stagger the cuts from
1 Pressure
one ring to the other. The third ring is called a
back-up ring. It is an uncut one-piece ring with
“CUU” Single-Acting Seal Set
clearance over the rod. It allows the joints of the
first two rings to form a gas-tight seal and This four-ring set seals in one direction only. The
prevents extrusion of the tangent ring. first ring (pressure side) is radially cut; the second
is tangentially cut. These rings are doweled to
stagger the cuts from one ring to the other. The
third and fourth rings are solid and have bores
larger than the rod diameter, allowing the radial
joints of the first two rings to form a tight gas seal.

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Figure: “CUU” Single-Acting Seal Set Figure: “DS” Double-Acting Seal Set

1 Pressure

“RS3” Single-Acting Seal Set

1 Pressure
This three-ring set seals in one direction only. The
first ring (pressure side) is radially cut. The “3RWS” Oil Wiper Set
second ring is tangentially step cut. These first
The three rings in this set are radially cut and
two rings are doweled to stagger the cuts from
doweled to stagger the cuts from one ring to the
one ring to the other. The third ring is called a
other. They keep crankcase oil out of the packing
back-up ring. It is a solid one-piece ring with
and cylinder. Assemble with the blank face
clearance over the rod. It holds the first two rings
towards the oil (crankcase) and the slotted side
perpendicular to the rod, allows their joints to
towards the pressure packing.
form a seal, and prevents extrusion of the
tangent ring. Figure: “3RWS” Oil Wiper Set

Figure: “RS3” Single-Acting Seal Set

1 Oil Side
1 Pressure

“DS” Double-Acting Seal Set Crossheads

This two-ring set consists of tangentially step cut The crosshead assembly consists of the
rings doweled to stagger the tangential cuts from crosshead and crosshead pin bushings, where
one ring to the other. This double acting set seals required. Most crossheads use a layer of soft
in either direction. In cylinders operating near babbitt material on the shoes, which are the
atmospheric pressure, it prevents air from surfaces that slide in the crosshead guide bore.
entering the cylinder. Install with the match mark
letters facing towards the cylinder.

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NOTE: Some small-line and JGH crossheads do not

Crosshead Removal
use a bushing or babbitt.
WARNING

Take care during maintenance to avoid To reduce risk of injury or death, only trained personnel
who have read and thoroughly understand the
damaging the babbitt or the bushings. appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Crosshead

1 Shoe Area
2 Bushing
3 Crosshead Pin
4 End Plate
5 Thru Bolt Lock Nut
6 Crosshead Nut
7 Roll Pin
8 Thru Bolt
9 Set Screw (loosen before
turning nut)

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Figure: Crosshead Bushing Replacement

NOTE: See Section 1 for illustrations of tools
mentioned below.

1. Remove crosshead guide side covers and

head end cylinder head or unloader.
2. Move crosshead to its inner dead center
position. Back off, but do not remove, the
crosshead nut set screws.
3. Loosen crosshead nut with the special
slugging peg or open end wrench (depending
on nut type), or use separately purchased
hydraulic crosshead nut torque tool.
4. Use the piston nut spanner to turn the piston
rod out of the crosshead. The two dowels on
the spanner fit holes in the piston nut.
Remove crosshead nut from piston rod.
Install the piston rod entry sleeve and push 1 Crosshead
the rod end forward towards the cylinder 2 About 3 Tons (27kN) Force Required
until the rod end clears the wiper packing 3 Bushing
assembly. 4 Support Here

5. With crosshead in its outer dead center

position, remove crosshead pin thru-bolt, 10. Slide a metal plate into the gap between the
lock nut, end-plates and pin. Discard old lock crosshead and crosshead guide, 3/16 inch (5
nut. mm) thick (see Figure: Crosshead Bushing
Replacement).
6. Turn crankshaft to its inner dead center
position. 11. Remove diaphragm from crosshead guide
and slide crosshead out of crosshead guide
7. Remove oil wiper packing from crosshead onto the plate.
guide diaphragm.
12. Check crosshead pin to bushing clearance
8. Move crosshead to its outer dead center (see Appendix B). Determine pin wear by
position, free of the connecting rod. Support inspection.
connecting rod so it does not drop and
damage the crosshead guide surface. 13. Replace pin, if necessary.To replace
bushings, hacksaw or file to within 1/32
9. Push crosshead onto crosshead inches (1 mm) of their thickness, then drift
installation/removal tool and rotate them out.
crosshead 90°.
14. New bushing installation requires a press. To
install a bushing in the crosshead, cool the
bushing in 95% alcohol with dry ice solution.
Leave the bushing in the solution long
enough to reach the same temperature as the
solution, about -110°F (-80°C). An alternate

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method of cooling is to submerge the bushing NOTE: Directly support the crosshead side
in liquid nitrogen. When the nitrogen stops receiving the new bushing to prevent the press
bubbling, the temperature has reached from possibly crushing the crosshead (see Figure:
equilibrium, and the bushing is ready to Crosshead Bushing Replacement). Thoroughly
install. clean bushing and crosshead to prevent dirt accu-
mulation between bushing and crosshead bore.
CAUTION
15. Where applicable, verify oil holes in the
Do not touch cold surfaces without proper protection.
Alcohol is flammable; use it only in open air or well-
bushing line up with the holes in the
ventilated buildings. Avoid sparks and open flame. Avoid crosshead.
alcohol vapors which may cause injury to nose and eye 16. Inspect shoe surfaces. Except for light
tissue. Do not return solution to a closed container until
it reaches room temperature or container may explode.
polishing, there should be no wear or de-
lamination.

Crosshead Installation

Figure: Crosshead Installation Figure: Crosshead Alignment Tool

1 Crosshead
2 Alignment Tool
3 Connecting Rod
4 Crosshead Pin
1 Crosshead Installation Tool
2 Metal Plate

2. Mount crosshead installation tool onto

NOTE: Return crossheads to their original throw loca- crosshead guide diaphragm and oil tool
tion. Use frame oil for lubrication where needed. bearing surfaces (see Figure: Crosshead
Installation). Slide crosshead onto tool.
1. Lay an installation plate in the bottom of the NOTE: Long two-compartment crosshead guides
crosshead guide, 3/16 inch (5 mm) thick, and supplied prior to 11/08 require a crosshead installa-
lay crosshead on its side (see Figure: tion tool with a smaller pilot diameter. Contact Ariel
Crosshead Installation).Oil crosshead and for the proper tool.
guide surfaces and push crosshead into
position.

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3. Remove the plate.Rotate crosshead 90°.If 9. Insert a feeler gauge, equal to the required
crosshead becomes wedged, do not force it; crank end clearance, through an open valve
it will damage the crosshead shoe surface. pocket. For 13 in. (330 mm) and larger
Use a box end wrench on the connecting rod cylinders, insert feeler gauge through a
bolt to lever the small end of the connecting bottom valve pocket.Tighten the piston rod
rod into the centered position, then slide the into the crosshead until piston is tight against
crosshead into the guide under the the feeler gauge, and the feeler gauge can be
connecting rod and off of the installation removed manually.
tool. Be careful not to damage crosshead 10. Tighten crosshead-balance nut in one of two
shoe or crosshead slide surfaces during ways:
installation.
a. Strike the special slugging peg or open
4. Remove crosshead installation tool and end wrench with a dead blow semi-soft
reinstall wiper packing. faced hammer until an audible difference
5. Turn crankshaft to its outer dead center can be heard or the wrench “bounces”
position to locate the connecting rod in indicating a tight nut. Some mechanics
position and insert crosshead pin. Deburr and obtain desired tightness in 3 to 4 strikes;
clean the crosshead pin alignment tool for others may require more.This method
use on the opposite side of the crosshead to does not apply to JGZ:U:B:V and
assist pin insertion.Oil crosshead pin, KBK:T:C:D:F:Z:U:B:V compressors.
crosshead, and connecting rod bushing prior b. Use a separately purchased crosshead-
to installation. Install crosshead pin end- balance nut hydraulic torque tool and
plates (be careful to align roll pins with holes hand pump kit. See Appendix A for the
in the end plates), thru-bolt, and a new lock hydraulic pressure to apply to the torque
nut. Tighten thru-bolt and lock nut to the tool. When initially installing the tool,
torque listed in Appendix A. position the spanner wrench adapter
6. Reposition throw to inner dead center and open area toward the spanner wrench as
push the piston rod assembly toward the shown in "Figure: Typical Crosshead
crosshead far enough to remove piston rod Balance Nut Hydraulic Torque Tool".
entry sleeve. Apply hydraulic pressure to the ram to
tighten the crosshead-balance nut. When
7. Lubricate piston rod threads with Never-Seez the ram ends its travel, release pressure
regular grade. Apply a thin coat of oil to either and index the ram to the spanner wrench
the balance nut or crosshead mating surface. slot and/or spanner wrench to adapter,
Do not apply Never-Seez to the mating until the nut stops moving at the specified
surfaces. Install crosshead-balance nut on hydraulic pressure (see Appendix A).
piston rod. During tightening, if the adapter open
8. Push the rod into the crosshead and turn the area turns 90° before the nut is tight,
piston rod assembly until the required crank remove the spanner wrench. Remove the
end piston clearance is reached. bolting in the spanner wrench adapter to
NOTE: At this point, set piston end clearance or the crosshead-balance nut and reposition
serious damage may occur. See required piston crank the adapter so the open area again faces
end clearance on cylinder data plate or Appendix B. the spanner wrench.

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Figure: Typical Crosshead Balance Nut Hydraulic Torque Tool - Tightening Position
1 Spanner Wrench Adapter
mounted on the balance nut
with three special bolts; posi-
tion open side of adapter
toward spanner wrench
2 Special High-Strength
Shoulder Bolt (3)
3 Crosshead Balance Nut
4 Spanner Wrench
5 10,000 psi (690 bar) cylinder
with 1" (25mm) stroke,
single-acting spring return

CAUTION 12. Check piston rod runout and crosshead

clearances upon re-assembly, any time a
Do not allow open areas of the spanner wrench and piston rod is removed. Check crosshead
adapter to overlap, as the spanner wrench can be
sprung. If the wrench becomes sprung, destroy and
guide to crosshead clearance at the top by
replace it. inserting a standard 0.5 inch (13 mm) wide
feeler stock from one side edge of the
When nut is tight, remove feeler gauge. Verify crosshead across to the opposite side - do
removal of all tools from cylinder and cross- this at both ends. Check bottom clearance
head guide. with 0.0015 inch (0.038 mm) feeler stock at
the four corners. If the feeler at the bottom
11. With the head end head or unloader properly
inserts more than 0.5 inch (13 mm), the
installed (closed position) and fasteners
assembly is not acceptable.See Appendix B
tightened, rotate crankshaft 180° to outer
for crosshead clearances.
dead center position of throw. Remove a top
head end valve.Determine required piston 13. Examine top cover and side cover seals. If
head end clearance limits from cylinder data there is doubt about their condition, replace
plate or Appendix B.Measure head end them. Oil the O-ring and apply a light coating
clearance at the top of the head end, using of corrosion inhibitor or marine grease to
feeler gauges through the open valve pocket. mating surface. Replace top cover and
Determine if measured clearance is within crosshead guide side covers. Tighten all cap
tolerance. Tighten the crosshead-balance nut screws hand wrench tight.
set screws. Re-install valve assemblies and
properly tighten fasteners.See "Valve
Installation".

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Connecting Rods shimming, improperly adjusted discharge

bottle wedges, or pipe stress affecting the
A connecting rod assembly consists of a rod with cylinder flange fit. Correct any of these
bushing, a rod cap, rod cap bolts (4), and two half conditions before returning the compressor
bearing shells. The bearing shells join together to to service. If a spacer bar is tight and will not
easily come out, it may help to loosen one
form the connecting rod bearing.
bolt on each spacer bar above the nearest
main bearing caps.
Connecting Rod Removal 3. Move throw to outer dead center position.
4. Remove crosshead as described in
WARNING
"Crosshead Removal".
To reduce risk of injury or death, only trained personnel
5. Turn the crankshaft until the throw is at its
who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager highest point.
information should attempt any maintenance. 6. Loosen all connecting rod bolts
Prior to performing any maintenance activities:
approximately 3/4 in. (19 mm).
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera- 7. Use the connecting rod cap removal tool to
tional procedures. jack against the bolt heads and pull the rod
• Never tighten or loosen any fastener while the unit is cap free from the dowels (see Section 1). If the
operating or pressurized.
cap does not separate easily from the rod,
• Verify neither driver nor compressor can turn during
maintenance.
STOP; the rod cap may be in a bind, which
• Follow packager instructions to completely isolate can break the dowel pins. If binding occurs,
and vent the system; call the packager for assis- re-tighten the connecting rod bolts and
tance. repeat the procedure.
• Verify each compressor cylinder is relieved to atmo- NOTE: Do not pry or chisel at joint of connecting rod
spheric pressure. To relieve residual cylinder bore to separate cap from rod; it damages the connecting
pressure after blowdown, open the “Kiene” valves
rod and can break alignment dowel pins. Do not pry
on the indicator ports, if so equipped.
on any machined running surfaces to separate cap
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE. from rod.
Before resuming operation, purge the entire system with 8. Remove the cap removal tool.
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air 9. Completely loosen the connecting rod
mixture under pressure can explode and cause severe fasteners while holding the rod and cap in
injury or death. position. Slide fasteners back to clear the rod.
Use fasteners as a handle to hold cap in
1. Remove top cover from crankcase and side position.
covers from crosshead guides.
10. While supporting the cap and fasteners, slide
2. Remove the middle frame spacer bar of the the rod toward the cylinder. When the rod is
three over the desired pair of throws. Spacer clear of the crankshaft, carefully rest it in the
bars are compressor and throw dependent. guide.
They are match-marked with the throw
position and machined with a tight fit. After
bolt removal, spacer bars should remove
easily by hand with maybe a slight resistance.
A very loose or tight fit indicates an unlevel
frame, softfoot, incorrect crosshead guide

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11. Rotate the cap up and remove all fasteners,

then remove the rod cap and bearing. Hold
the bearing in the cap while lifting it off the
pin. Do not remove cap with fasteners in
place.
12. Carefully remove the connecting rod through
the crosshead compartment window.

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Connecting Rod Bearing Removal Figure: Rod/Rod Cap Separation

WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance. 1 Top Face
• Verify each compressor cylinder is relieved to atmo- 2 Connecting Rod Bolts
spheric pressure. To relieve residual cylinder bore 3 Threaded Hole for Eyebolt
pressure after blowdown, open the “Kiene” valves 4 Rod Cap
on the indicator ports, if so equipped.
5 Rod
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with 1. Remove frame top cover, all crosshead guide
the gas being compressed to avoid a potentially covers and applicable distance piece covers
explosive gas/air mixture in the system. A gas/air to access the wiper packing gland bolts.
mixture under pressure can explode and cause severe
injury or death. 2. Remove all head end heads.
3. Remove the bolts attaching the wiper
packing housing to the crosshead guide.
Slide the entire wiper packing assembly
towards the cylinder.
4. Remove spacer bars as needed to access
connecting rods. If a spacer bar will not easily
come out, it may help to loosen one bolt on
each adjacent spacer bar. Spacer bars are
compressor and throw dependent. They are
match-marked with the throw position and
machined with a close-tolerance fit. After bolt
removal, spacer bars should remove easily by
hand with maybe a slight resistance. A very
loose or tight fit indicates an unlevel frame,
softfoot, incorrect crosshead guide
shimming, improperly adjusted discharge
bottle wedges, or pipe stress affecting the
cylinder flange fit. Correct any of these
conditions before returning the compressor
to service.

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5. Turn the crankshaft until the throw is Figure: Prying Behind Crosshead
approximately 30° past its highest point (see
Figure: Crank Rotation). Loosen all
connecting rod bolts approximately 3/4 inch
(19 mm).
Figure: Crank Rotation

6. Use the connecting rod cap removal tool to

jack against the bolt heads and pull the rod
cap free from the dowels (see Section 1). If the
cap does not separate easily from the rod,
STOP; the rod cap may be in a bind, which
can break the dowel pins. If binding occurs, 7. After the cap separates from the rod, remove
re-tighten the connecting rod bolts and the cap removal tool and back out the
repeat the procedure. connecting rod bolts completely, but do not
remove them. Do not remove the bolts and
NOTE: Do not pry or chisel at joint of connecting rod
cap until Step Rotate the rod cap around to
cap/rod to separate cap from rod; it damages the
the top of the crankshaft. Remove bolts,
connecting rod and can break the alignment dowel
then remove cap. Always remove the bolts
pins. Do not pry on machined running surfaces when
before the cap to prevent damage to the
separating the cap from the rod. Separate caps by
crankshaft due to bolt dings..
backing out all 4 bolts no more than 1/4 inch (6 mm)
and prying behind the crosshead (see Figure: Prying 8. Support the cap and rod by hand or crane
Behind Crosshead) while another person pries the crank end of
the crosshead toward the cylinder until it
bottoms out.
NOTE: Do not pry on any machined running surfaces.
When the connecting rod is clear of the crankshaft,
rest it on the crosshead guide slide. Do not allow the
rod or cap to drop, as damage can occur.
9. Rotate the rod cap around to the top of the
crankshaft. Remove bolts, then remove cap.
Always remove the bolts before the cap to
prevent damage to the crankshaft due to
bolt dings.

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10. Lift cap while holding bearing in the cap Connecting Rod Bearing
because oil causes the bearing to stick to the
crankshaft pin.
Installation
11. After removing bearings, clean any coking or Figure: Connecting Rod Bearing Installation
debris from both the rod and rod cap surfaces
with a non-metallic Scotch-Brite or similar
scouring pad and solvent. Check for raised
edges on machined surfaces. All surfaces
should be as clean and dry as possible.
Remove high spots from the connecting rod
and cap using a flat stone on flat surfaces or a
round stone on curved surfaces. Remove only
high spots, do not remove excessive material.
12. Continue to "Crank Pin Assessment".

Crank Pin Assessment

Inspect bearings after removal. If bearings
A Apply lube oil liberally to this surface.
indicate scratches or dings on pin, inspect crank
1 Rod
pin, and if needed, carefully stone the pin using
2 Rod Bushing
an Arkansas stone (Ariel part number A-19676).
3 Dowel Holes
Lightly slide the stone around the circumference
4 Rod Notch
of the crank pin surface to remove any high spots; 5 Bearing Shell
do not slide it back and forth over the length of 6 Bearing Shell Tab
the pin. If the pin is scored around the 7 Dowels
circumference, use 600 grit emery cloth to 8 Rod Cap Notch
remove high spots. After dressing, ensure crank 9 Rod Cap
pin is clean and dry. Use only lint-free, clean
paper towels to clean crankshaft pin of any 1. Check new bearing shells for handling
debris after dressing. damage, scratches, burrs, and loose material
at the tabs. DO NOT RUB BEARING SURFACE
WITH FINGERNAIL. New bearing shells and
crankshaft crank pin bearing surfaces must
be absolutely clean. Clean new bearings with
appropriate solvent and clean paper towel.
Paper towels do not leave lint behind
compared to rags. Fit the tab of a new, dry
half bearing shell into the rod notch.
NOTE: Where bearings are identified with an ink
pictograph, connecting rod bearings and main bear-
ings are not interchangeable. DO NOT put main bear-
ings in a connecting rod. Do not mix part numbers on
an individual main or connecting rod. Both bearing
half shells must have the same part number.

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2. Apply clean, new lube oil liberally to the crank NOTE: If replacing main bearings, continue to "Main
pin. Verify oil is compatible with the oil used Bearing Removal". If not replacing main bearings,
in the frame. continue to Step Account for all tools, equipment,
supplies, and parts to ensure none are left inside the
3. Fit the tab of the other bearing shell into the
crankcase..
rod cap notch.
7. Account for all tools, equipment, supplies,
4. Use the following steps to attach the rod cap
and parts to ensure none are left inside the
to the rod:
crankcase.
a. Re-position crankshaft, if needed.
8. Examine top cover and side cover seals. If
b. Carefully lower the connecting rod cap there is doubt about their condition, replace
(WITHOUT BOLTS!) onto the crank pin. them. For O-ring seals, oil the O-ring and
Verify rod bolts are undamaged and free apply a light coating of corrosion inhibitor or
of dirt. Lubricate them per Appendix A, marine grease to mating surface. Replace top
then place all four bolts into the rod cap. cover and crosshead guide side covers.
NOTE: Ensure notches on both the connecting rod Tighten all cap screws hand wrench tight.
and connecting rod cap match. Install with both
notches on top, in the upward position. 9. Reverse lockout procedures.
c. Rotate cap so the bolts align with the 10. After replacing bearings, it is recommended
connecting rod bolt holes, then pull all to pre-lube compressor for at least 10-15
four bolts back. Support the rod cap while minutes at 30 psi (2.1 barg) to ensure bearing
another person carefully supports the lubrication and to help remove foreign
connecting rod and guides it back onto materials from the lube system.
the crankshaft until it bottoms out. Align 11. Run the compressor according to the time
the rod cap dowels with the rod dowel intervals listed on the form in Appendix D.
holes and push the rod cap onto the rod After each run, shut down and remove the
with even pressure. The rod cap fits onto frame top cover. Measure main and
the rod only one way. Do not force the rod connecting rod bearing cap temperatures
cap onto the rod; the dowels should slide with a hand held thermocouple probe or
into the rod holes without difficulty. After infrared thermometer and record them on a
ensuring the rod cap seats properly on the copy of the form in Appendix D. Complete the
rod, tighten all four bolts and pre-torque form and file it in the unit records for future
according to Appendix A. reference.
d. Rotate crankshaft as needed and tighten 12. After each shutdown, visually inspect the
all connecting rod bolts to the torque crankcase for signs of excessive heat in
listed in Appendix A. bearing areas, and babbitt or other debris. If
5. Repeat steps 1-4 for all remaining connecting any are found, find and correct the problem
rods. before continuing.
6. Measure each connecting rod bearing jack
and thrust clearance as detailed in this
document. If clearance readings are not
within tolerances of Appendix B, contact your
packager or Ariel before proceeding.

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KBK-KBT Maintenance & Repair Manual – Part Replacement 04/03/2023

Connecting Rod Bushing Removal Connecting Rod Installation

and Installation 1. To install a new connecting rod, stamp match
1. Check crosshead pin to bushing clearance mark numbers matching the throw location
(see Appendix B). Determine pin wear by on the tops of the connecting rod and bearing
inspection. Replace pin, if necessary. cap (with bearing notches up). See Figure:
Typical Connecting Rod.
2. To replace a bushing, file or hacksaw the
existing bushing to reduce the tightness of 2. Check new bearing shells for handling
the shrink fit. From the inside diameter, file or damage, scratches, burrs, and loose material
saw across the length of the bushing to within at the tabs. DO NOT RUB BEARING SURFACE
1/32 inches (1 mm) of its radial thickness. It WITH FINGERNAIL. New bearing shells and
can then be easily drifted out. DO NOT file or crankshaft crank pin bearing surfaces must
saw into the connecting rod; any bore be absolutely clean. Snap a new, dry half
damage renders the rod useless and bearing shell into the rod and rod cap with
requires rod replacement. the bearing tabs properly located in the rod
and cap notches. Turn the connecting rod pin
3. Use a hydraulic press in a qualified machine to the vertical position and oil crankshaft
shop to install the new bushing. Do not connecting rod pin bearing surfaces with new
hammer bushing into place; it will distort the clean lubricating oil, the same type used in
bushing bore. the frame. Carefully lower the connecting rod
4. Before installation, cool new bushing in a cap (without bolts) onto the pin.
95% alcohol and dry ice solution. Leave NOTE: Connecting rod bearings and main bearings
bushing in solution long enough to reach the are not interchangeable. Connecting rod bearings
solution temperature, about -110°F (-80°C). have a narrower groove or no groove at all. DO NOT
An alternate method of cooling is to put main bearings in connecting rod bearing loca-
submerge the bushing in liquid nitrogen. tions.
When the nitrogen stops bubbling, the NOTE: Caps and rods are numbered by throw
temperature has reached equilibrium, and beginning with number one at the drive end. For
the bushing is ready to install. throw numbering sequence, see Plate Locations.
CAUTION Always install rods with numbers up. Protect
crank pin at all times. Be sure both bearing tabs
Do not touch cold surfaces without proper protection. are on top.
Alcohol is flammable; use it only in open air or well-
ventilated buildings. Avoid sparks and open flame. Avoid 3. Verify rod bolts are undamaged and free of
alcohol vapors which may cause injury to nose and eye dirt, then lubricate them per Appendix A and
tissue. Do not return solution to a closed container until
insert all bolts into rod cap. Rotate the cap
it reaches room temperature or container may explode.
and fit the connecting rod to the rod pin and
snug the bolts, pulling the cap and rod
NOTE: Thoroughly clean bushing and connecting
together evenly.
rod to prevent dirt accumulation between them.
Immediately assemble them so the bushing does 4. Reconnect rod and crosshead with pin. Install
not warm and stick before it is in place. If the end plates, thru-bolt, and new lock nut.
bushing sticks, remove it by notching as in step 2 Tighten lock nut to the torque listed in the
above. Appendix A.
5. Position connecting rod on the press table so
the chamfered edge of the rod bushing bore
is on top. Press bushing into rod bore.

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Figure: Typical Connecting Rod

1 Turn Indicator
2 Correct rod orientation is
with bearing notches on top
joint. NOTE: Install joint
match marks up.

5. Follow the "Recommendations for Torque 8. Reinstall spacer bars. All spacer bars are
Accuracy" in Appendix A to tighten match-marked for proper location; reinstall
connecting rod cap screws to the them in their original location. Tighten all
recommended torque. spacer bar bolts to the torque listed in
6. Place a turn indicator onto the wrench Appendix A.
socket, and slide the socket onto the bolt 9. Examine top cover and side cover seals. If
head. Turn the indicator so the vial faces up there is doubt about their condition, replace
with the bubble centered, then tighten the them.Apply Never-seez Regular Grade to
indicator thumbscrew. Turn connecting rod both sides of the gasket to ease future
cap screws to the angle recommended in removal. Replace top cover and crosshead
Appendix A. guide side covers. Tighten all cap screws
7. Measure each connecting rod bearing to hand wrench tight.
crankshaft jack clearance and connecting rod
thrust (side) clearance (see "Connecting Rod
Bearing Vertical Jack Clearance
Measurement" and "Connecting Rod Thrust
(Side) Clearance Measurement"). Record
measurements on a copy of the form in
Appendix D. If measurements are out of
tolerance after installing new bearings,
contact your packager or Ariel before
proceeding.

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Connecting Rod Bearing Vertical Jack Clearance Measurement

Figure: Typical Connecting Rod Vertical Jack Clearance Measurement

Magnetic stand placement on top Dial indicator placement on Use pry bar to check jack
of adjacent crankshaft web. connecting rod. clearance.

1. Turn the crankshaft pin of the desired throw 5. Repeat measurement process for every rod. If
to its highest position.For KBK:T models, a reading is outside the tolerances of
thread an eye bolt into the connecting rod Appendix B, contact your packager or Ariel.
(see Figure: Typical Connecting Rod Vertical NOTE: Remove eye bolts, magnetic bases, dial indica-
Jack Clearance Measurement). tors, and pry bars after measurement.
2. To ensure measurement of only vertical
movement between the crankshaft and
connecting rod, attach the dial indicator
magnetic base to the crankshaft web
adjacent to the measured connecting rod.
3. Zero the dial indicator. Insert a pry bar into
the eye bolt and pry against the frame to
force the connecting rod up until the dial
indicator needle stops moving. While
maintaining upward pressure, note the
reading.
NOTE: Too much force when prying on the
connecting rod eyebolt may lift the crankshaft
resulting in incorrect readings.
4. Release upward pressure and push
downward on the rod until the indicator
reads zero again. If a zero reading cannot be
obtained, zero the indicator again and repeat
steps 3 and 4. Repeat the measurement
process until the measurement returns to
zero twice in a row to verify accuracy.

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Connecting Rod Thrust (Side) Clearance Measurement

Figure: Typical Connecting Rod Thrust (Side) Clearance Measurement

Dial indicator magnetic stand Dial indicator placement. Thrust rod tight toward and away
placement. from dial indicator.

1. Turn the crankshaft pin of the desired throw Crankshafts

to its highest position.
2. Attach the magnetic base of a dial indicator to The crankshaft is the heart of the compressor.
the crankshaft web adjacent to the With proper maintenance, it should provide
connecting rod. Place the button of the dial years of trouble-free service. If replacing a
indicator against the thrust surface of the crankshaft fitted with torsional detuners, contact
connecting rod (see Figure: Typical the Ariel Response Center with the frame and
Connecting Rod Thrust (Side) Clearance crankshaft serial numbers and the part numbers
Measurement).
and quantity of detuners to ensure compatibility.
3. Use a pry bar to pry gently against the
crankshaft web and thrust the connecting rod
tight toward the dial indicator (do not pry on
rod cap). Release pressure and zero the dial
indicator.
4. Thrust the connecting rod tight in the
opposite direction until the dial indicator
needle stops moving. Release pressure and
note reading. Gently pry connecting rod in
opposite direction to ensure the dial returns
to zero.
5. Repeat the measurement process for every
rod. If a reading is outside the tolerances in
Appendix B, contact your packager or Ariel.
NOTE: Remove magnetic bases, dial indicators, and
pry bars after measurement.

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Main Bearing Removal Installation/Removal Tool). Do not exceed

maximum torque or turn written on the tool.
WARNING If cap is tight after applying force with the
tool, ensure spacer bars are removed or
To reduce risk of injury or death, only trained personnel loosened, adjacent main bearing cross-bolts
who have read and thoroughly understand the
are loosened, and check crosshead guide
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance. shimming for correct pre-load. Remove main
Prior to performing any maintenance activities: bearing installation/removal tool. Remove
• Always wear appropriate personal protection equip- shells from main bearing caps.
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

1. Remove top cover and spacer bars. Spacer

bars are compressor and throw dependent.
They are match-marked with the throw
position and machined with a tight fit. After
bolt removal, spacer bars should remove
easily by hand with maybe a slight resistance.
A very loose or tight fit indicates an unlevel
frame, softfoot, incorrect crosshead guide
shimming, improperly adjusted discharge
bottle wedges, or pipe stress affecting the
cylinder flange fit. Correct any of these
conditions before returning the compressor
to service.
2. Remove the six main (journal) bearing cap
screws. Use main bearing
installation/removal tool to apply force on
the frame rail as close as possible to main
bearing cap being removed (see Figure:
KBE:K:T:C:D:F Main Bearing

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Figure: KBE:K:T:C:D:F Main Bearing Installation/Removal Tool

1 Main Bearing Installation/Removal Tool
2 Main Bearing Cap Screw
3 Crankshaft
4 Main Bearing Cap

3. Inspect bearings. If bearings indicate opposite side. Ariel provides an optional tool
scratches or dings on pin, inspect crankshaft (B-3340) to push the shell out. Do not damage
journal, and if needed, carefully stone the crankshaft bearing surfaces. Replace with
journal using an Arkansas stone (Ariel part new bearing shell, before rotating out the
number A-19676). Lightly slide the stone next main bearing shell.
around the circumference of the journal
5. If any coked oil is observed on bearing cap or
surface to remove any high spots; do not slide
frame saddle surfaces, contact Ariel for
it back and forth over the length of the
instructions. Check for raised edges on
journal. If the crank is scored around the
machined surfaces. Verify all surfaces are
circumference, use 600 grit emery cloth to
clean and dry as possible and no bolting is
remove high spots. After dressing, ensure
damaged.
crank pin is clean and dry. Use only lint-free,
clean paper towels to clean crankshaft
journal of any debris after dressing. Rotate Main Bearing Installation
the crankshaft 180° to expose the other half of
the journal and repeat. 1. Clean new bearings with appropriate solvent
and clean paper towel. Paper towels do not
4. To limit debris entering the system, work on leave lint behind compared to rags. Check
only one main bearing at a time. Remove new bearing shells for damage, scratches,
main journal bearing shells from under the burrs, and loose material at the tab. DO NOT
crankshaft one at a time. If needed, attach RUB BEARING SURFACE WITH FINGERNAIL.
clean nylon straps around the crankshaft and
lift it 0.003 - 0.005 inch (0.076 - 0.127 mm) to
lessen weight on the bearings and allow
easier removal. To remove, rotate shell under
the crankshaft tab side out first, by pushing or
tapping with a non-metallic tool on the

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Keep the backs of shells dry and clean; 7. Account for all tools, equipment, supplies,
installation requires perfectly clean bearing and parts to ensure none are left inside the
shells. Install bearing shells in caps, and crankcase. Examine top cover and side cover
frame journals, properly located in the tab seals. If there is doubt about their condition,
notch, (rotate in the un-tabbed end first). replace them. For O-ring seals, oil the O-ring
2. Apply clean, new lube oil liberally to the crank and apply a light coating of corrosion
journal. Verify oil is compatible with oil used inhibitor or marine grease to mating surface.
in the frame. Replace top cover and crosshead guide side
covers. Tighten all cap screws hand wrench
3. Use main bearing installation/removal tool to tight. Bar compressor over 360° to ensure free
apply force on the frame rail as close as rotation.
possible to the main bearing cap being
installed (see Figure: KBE:K:T:C:D:F Main 8. Reverse lockout procedures.
Bearing Installation/Removal Tool). Do not 9. After replacing bearings, it is recommended
exceed the maximum torque or turn written to pre-lube compressor for 10-15 minutes at
on the tool. If cap is tight after applying force 30 psi (2.1 barg) to ensure bearing lubrication
with the tool, ensure spacer bars are removed and to help remove foreign materials from
or loosened and check guide shimming for the lube system.
correct pre-load.
10. Run the compressor according to the time
4. Main bearing caps have position match- intervals listed on the form in Appendix D.
marks corresponding with frame spacer bars After each run, shut down and remove the
and spacer bar bosses. Install main bearing frame top cover. After each shutdown,
caps with new bearing shells in their correct visually inspect the crankcase for signs of
locations. Verify proper alignment of main excessive heat in bearing areas, and babbitt
bearing cap dowels with the holes in the or other debris. If any are found, find and
crankcase base. Seat the cap by tapping it correct the problem before continuing.
with the handle of a hammer or screwdriver. Measure main and connecting rod bearing
It is a machined fit, not a press fit, and the cap cap temperatures with a hand held
should not rock in the jaw fit when it seats. Do thermocouple probe or infrared
not use bolting to force the cap to thermometer and record them on a copy of
seat.Remove main bearing the form in Appendix D. Complete the form
installation/removal tool. Tighten the cap and file it in the unit records for future
screws. Tighten the main bearing cap bolts in reference.
the pattern and torque listed in Appendix A.
5. Check crankshaft journal bearing jack
clearances and crankshaft thrust clearance to
values in Appendix B (see procedure below).
Record readings on a copy of the form
Appendix D. If readings are out of tolerance
after new bearing installation, contact your
packager or Ariel before proceeding.
6. Install spacer bars so the match mark is up
and next to the same match mark on the
frame rail. Tighten all spacer-bar cap screws
to the torque listed in Appendix A.

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Crankshaft Removal
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Crankshaft

1 Oil Slinger
2 Main Bearing Journals
3 Chain Sprocket
4 Crank Pins
5 Counterweights

1. Remove coupling disk pack. Remove all drive 3. Do not damage the sharp corners on each
end cover mounting bolts. Remove the two end of the crankcase top. They form a
tapered dowel pins from the drive end cover. junction between the end covers, top cover,
2. Remove top cover and spacer bars. and base; keep them sharp and unmarred to
prevent oil leaks.

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4. Detach connecting rods and move them to Crankshaft Installation

their full outer position.See "Connecting Rod
Bearing Removal". 1. Thoroughly clean the oil gallery that runs
from the drive end to the auxiliary end of the
5. Remove chain eccentric adjustment
crankcase and the vertical and horizontal
capscrews. Turn the eccentric to loosen the
intersecting oil passages that lube the main
chain and slip it off the crankshaft sprocket.
bearings and crosshead guides. Any debris
For more clearance while lifting the
left in the oil gallery or intersecting
crankshaft, remove the force feed lubricator
passageways could cause bearing or
drive sprocket.
crosshead failure. Deburr and clean main
6. Remove main bearing caps. See "Main bearing caps to prepare for installation.
Bearing Removal".
2. Thoroughly clean new main bearing half
7. Before removing the crankshaft, prepare shells and install them in the frame saddles.
wooden saddles or blocks of wood with sides Cover bearings with clean paper towels to
high enough to prevent the webs or oil slinger prevent debris contamination.
from touching the floor to store the
3. Remove towels just before seating the crank
crankshaft during maintenance - even if for
in the saddles. Lubricate bearing surfaces
only a short time. Also, protect the crankshaft
with clean crankcase oil.
from above so dropped tools or equipment
cannot mar pin and journal surfaces. 4. Move connecting rods to full outer position if
not already there.
8. Turn the crankshaft so that sling lifting points
are above the shaft center of gravity to 5. Install the crankshaft. While the crankshaft
prevent rotation when lifted. Lift straight up lowers very slowly into the crankcase
with the crankshaft ends parallel to the (suspended by a crane with clean nylon
frame. The crankshaft weight requires two slings), one man wearing clean gloves should
men and a crane to safely remove it. Use grasp the drive end and slowly maneuver the
appropriate sized nylon slings to prevent drive end and auxiliary end straight down
marring the crankshaft running surface. into the crankcase. Both drive end and
NOTE: Lower half bearing shells sometimes stick to auxiliary end journals should touch the
the shaft journals. After lifting the shaft about ¼ inch bottom bearing shells at the same time.
(6mm) clear of the saddles, verify the lower half 6. Before connecting rod installation, measure
bearing shells remain on the saddles. If not, tap them each crankshaft journal bearing jack
back onto the saddles before lifting the shaft further. clearance with a dial indicator (see procedure
9. While one person raises the crane very slowly, on "Main Bearing Vertical Jack Clearance
the second person must grasp the crankshaft Measurement" and allowable clearances in
at the drive end with one hand on the Appendix B).
counterweight or one of the throws and the 7. Reattach connecting rods (See "Connecting
other on the shaft end to keep the crankshaft Rod Installation"), packing diaphragms, and
level. It may be necessary to lower the crank unloaders/head end heads.
and reposition the straps to achieve a
balanced lift. Wear clean gloves for a good 8. Reinstall chain drive. (See “Chain Drive
grip, to avoid cuts from the slinger, and to System”).
avoid marring the running surface. As the 9. Replace spacer bars. Locate spacer bar match
shaft slowly raises, lift the drive and auxiliary mark. Install spacer bar so the match mark is
ends at the same rate. Carefully guide the up and next to the spacer bar boss with the
crankshaft to avoid marring its surfaces. same marking.

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10. Install drive end cover with new gasket using 11. Use a knife to trim excess from end cover
the tapered dowel pins to properly align the gaskets flush to the compressor frame top
cover. Verify at least 0.008 inch (0.2 mm) cover rail.
clearance exists between the dust seal
12. Examine top cover and side cover seals. If
housing and crankshaft. Then install a new
there is doubt about their condition, replace
dust seal.
them.Oil the o-ring and apply a light coating
of corrosion inhibitor or marine grease to
mating surface. Replace top cover and
crosshead guide side covers. Tighten all cap
screws hand wrench tight.

Main Bearing Vertical Jack Clearance Measurement

Figure: Typical Crankshaft Journal Bearing Vertical Jack Clearance Measurement

Dial Indicator magnetic stand Dial indicator placement. Place lifting strap around
placement. crankshaft web - attach strap to
crane.

1. Turn crankshaft until the web adjacent to the 4. GENTLY lift crankshaft. The dial indicator
desired main bearing is vertical (see Figure: needle moves steadily until the crane/hoist
Typical Crankshaft Journal Bearing Vertical overcomes crankshaft oil stiction, at which
Jack Clearance Measurement). point the needle jumps a little. Stop lifting
2. Loop a clean, appropriately sized and rated immediately at this point, and note the
lifting strap around the crankshaft web reading.
adjacent to the main bearing and attach the 5. Release crane/hoist pressure and verify
strap to a crane. indicator returns to zero. Repeat step 4 to
NOTE: If the crane has no fine adjustment, attach a verify measurement.
chain hoist to the crane lifting hook to prevent exces- 6. Repeat measurement process for each main
sive force on the crankshaft and crane. bearing. If a reading is outside tolerances in
3. Attach the magnetic base of a dial indicator to Appendix B, contact your packager or Ariel.
any stable frame surface. Place the point of NOTE: Remove magnetic bases, dial indicators, and
the dial indicator against the top of the web lifting strap after measurement.
adjacent to the measured bearing and zero
the indicator

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Crankshaft Thrust (End) Clearance Measurement

Figure: Typical Crankshaft Thrust Clearance Measurement

Dial indicator magnetic stand Dial indicator placement against Pry against compressor frame to
placement on main bearing cap. the side of crankshaft web. thrust crankshaft back and forth.

1. Attach the magnetic base of a dial indicator to Chain Drive System

any stable frame surface. Place the button of
the dial indicator against the side of the For KBK:T compressors, one chain runs the lube
adjacent crankshaft web (see Figure: Typical oil pump and another runs the force feed
Crankshaft Thrust Clearance Measurement). lubricator. A separate idler sprocket for each
NOTE: Do NOT place magnetic base on end cover- it
chain, each attached to its own eccentric
can flex if pried against, resulting in inaccurate read-
ings. adjustment cap, controls chain tightness. The
lube oil pump chain dips into the crankcase oil
2. Use a pry bar to pry against the compressor and splash action oils the force feed lubricator
frame and thrust the crankshaft tight toward
chain as well. In dry sump applications, an oil
the dial indicator. Release pressure and zero
the dial indicator. sprayer lubricates the chains.

3. Thrust the crankshaft tight in the opposite

direction until the dial indicator needle stops
moving, then release pressure. Note reading.
Repeat steps 2 and 3 to verify measurement
accuracy.
4. If the measurement is outside the tolerances
in Appendix B, contact your packager or Ariel.
NOTE: Remove magnetic bases, dial indicators, and
pry bar after measurement.

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Figure: KBK:T Chain Drive Systems

A Standard Rotation
B Reverse Rotation
1 Force Feed Lubricator
Sprocket
2 Force Feed Lubricator Chain
3 Force Feed Lubricator Eccen-
tric Adjustment
4 Crankshaft Sprocket
5 Oil Pump Chain
6 Oil Pump Sprocket
7 Oil Pump Eccentric Adjust-
ment
8 Cap Screw
7 Dust Plug

Chain and Sprocket Replacement Figure: Measuring to Check Chain Elongation

WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip- 1 X- Measure outside rollers at 10 pitches
ment and follow your company safety and opera- 2 Y - Measure inside rollers at 10 pitches
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized. Replace chain(s) if elongation exceeds 0.084
• Verify neither driver nor compressor can turn during inches (2.13 mm) over a 10 pitch length. Measure
maintenance. the section of chain with vernier calipers while it
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
is stretched tight in position in the compressor.
tance. Add a measurement outside the rollers at 10
• Verify each compressor cylinder is relieved to atmo- pitches (X) to a measurement between the inside
spheric pressure. To relieve residual cylinder bore
of the same rollers (Y), and then divide by two.
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped. Replace the chain if the result exceeds 5.084
WARNING: RELEASED GAS MAY BE POISONOUS inches (129.1 mm).
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with Replace sprockets showing any undercutting or
the gas being compressed to avoid a potentially other damage.
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

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Chain Idler Sprocket Replacement

(Eccentric Adjustment Caps)
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Chain Idler Sprockets (Eccentrics)

A Oil O-ring before assembly.
1 Dust Plug
2 Cap Screw
3 Stat-O-Seal
4 Self-Lock Nut
5 Washer
6 Sprocket
7 Thru Bolt

1. Remove frame top cover. the idler sprocket and remove entire
2. Remove all dust plugs from the eccentric cap assembly from the end cover.
and all cap screws holding the eccentric cap NOTE: Chain idler sprocket location varies for stan-
to the end cover. Rotate eccentric cap to dard versus reverse rotation.
loosen chain for removal. Drop the chain off

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3. Remove and discard lock nut, hex cap screw,

stat-o-seal, washer, and cap O-ring.
4. Reassemble new cap screw, stat-o-seal,
washer, sprocket, and lock nut. Tighten idler
lock nut to recommended torque in Appendix
A.
5. Apply oil and install a new O-ring. Install
assembly and chain.
6. Take care when measuring and adjusting the
force feed idler sprocket; it is thinner than the
force feed lubricator and drive sprockets. To
center the idler sprockets in the chain,
subtract the force feed idler sprocket
thickness from the drive sprocket thickness
and divide the difference by 2. Add this value
to the measurement from the inside face of
the auxiliary end cover to the outside face of
the force feed idler sprocket. Adjust driven
sprockets to the drive sprocket
measurements, aligned within 1/32 inch (1
mm). Non-alignment may require
disassembly and shimming eccentrics.
7. Adjust chain according to "Chain
Adjustment".

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Lube Oil Pump Sprocket

Replacement
WARNING

To reduce risk of injury or death, only trained personnel

who have read and thoroughly understand the
appropriate Ariel Technical Manual and Packager
information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
ment and follow your company safety and opera-
tional procedures.
• Never tighten or loosen any fastener while the unit is
operating or pressurized.
• Verify neither driver nor compressor can turn during
maintenance.
• Follow packager instructions to completely isolate
and vent the system; call the packager for assis-
tance.
• Verify each compressor cylinder is relieved to atmo-
spheric pressure. To relieve residual cylinder bore
pressure after blowdown, open the “Kiene” valves
on the indicator ports, if so equipped.
WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
injury or death.

Figure: Typical Lube Oil Pump Chain Sprocket

1 Gaskets
2 Key
3 Set Screws
4 Sprocket
5 Adapter
6 Pump

1. Remove all pump piping. Remove fasteners from pump mounting flange. After chain

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removal, the pump with sprocket comes free Force Feed Lubricator Dual Chain
through the end cover hole.
Sprocket Replacement
2. To position the new sprocket, use a machinist
rule to measure the exact distance from WARNING
sprocket drive face to pump mounting flange
face (X). Note this measurement for future To reduce risk of injury or death, only trained personnel
who have read and thoroughly understand the
reference. appropriate Ariel Technical Manual and Packager
3. With the oil pump on a bench, use an Allen information should attempt any maintenance.
wrench to remove the sprocket set screws, Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
then pull the sprocket from the shaft.
ment and follow your company safety and opera-
4. Remove the key from the shaft and file the tional procedures.
shaft to smooth burrs raised by the set screw • Never tighten or loosen any fastener while the unit is
cup point. operating or pressurized.
• Verify neither driver nor compressor can turn during
5. Install a new key (see build book for type and maintenance.
dimensions). First verify it fits into the new • Follow packager instructions to completely isolate
sprocket. If too thick, polish the key with and vent the system; call the packager for assis-
emery cloth on a flat surface until it easily tance.
• Verify each compressor cylinder is relieved to atmo-
slides into the notch. The top edge may also
spheric pressure. To relieve residual cylinder bore
require a little polishing. pressure after blowdown, open the “Kiene” valves
6. Install new sprocket to the original on the indicator ports, if so equipped.
measurement between the sprocket drive WARNING: RELEASED GAS MAY BE POISONOUS
AND/OR FLAMMABLE.
face and the pump mounting flange face.
Before resuming operation, purge the entire system with
When in position, tighten set screws. the gas being compressed to avoid a potentially
7. Lubricate both sides of gaskets with anti- explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
seize lubricant or multi-purpose grease to
injury or death.
ease future removal. Install new gaskets.
8. Reinstall pump onto end cover. Using a Dual chain drive systems use a Fenner drive to
straight edge, to within 1/32 inch (1 mm), attach the lubricator sprocket instead of a key
check alignment to crankshaft drive sprocket
and set screw. To replace a sprocket fastened
with crankshaft centered in end play. If
misaligned, adjust sprocket position as with a Fenner drive:
needed. 1. With a good machinist rule, measure exact
9. Adjust chain according to "Chain distance from inside face of auxiliary end
Adjustment". cover to near face of lubricator sprocket.
Note measurement for proper positioning of
10. Reinstall all piping to pump. new sprocket. Remove chain.
2. Remove sprocket/Fenner drive assembly.

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NOTE: JGEKT/6 and JGBV/4/6 frames use a 5/8 ID x Crankshaft Chain Sprocket
1-1/2 OD Fenner while all others use a 5/8 ID X 1” OD.
The 1-1/2 OD Fenner can be difficult to remove due to
Replacement
higher torque.
WARNING
CAUTION
To reduce risk of injury or death, only trained personnel
Do not apply lubricants during installation. Do not use who have read and thoroughly understand the
impact of any kind to move the Fenner drive assembly appropriate Ariel Technical Manual and Packager
along the shaft. information should attempt any maintenance.
Prior to performing any maintenance activities:
• Always wear appropriate personal protection equip-
3. Ensure shaft, new sprocket, and Fenner drive ment and follow your company safety and opera-
are completely free of paint, grease, oil, and tional procedures.
debris of any kind. Return the surfaces to bare • Never tighten or loosen any fastener while the unit is
metal and clean using isopropyl alcohol. operating or pressurized.
• Verify neither driver nor compressor can turn during
4. Insert Fenner drive into sprocket. Center maintenance.
sprocket in the Fenner drive gripping area. • Follow packager instructions to completely isolate
5. Place sprocket/Fenner drive assembly onto and vent the system; call the packager for assis-
tance.
shaft. Position it to the desired location
• Verify each compressor cylinder is relieved to atmo-
measured in Step 1. Verify shaft fully engages spheric pressure. To relieve residual cylinder bore
the Fenner drive gripping area. pressure after blowdown, open the “Kiene” valves
NOTE: At full installation torque, the 1-inch O.D. on the indicator ports, if so equipped.
assembly travels about 0.045 inch (1.1 mm) axially WARNING: RELEASED GAS MAY BE POISONOUS
along the shaft; the 1.5-inch O.D. assembly travels AND/OR FLAMMABLE.
about 0.075 inch (1.9 mm). Position the assembly to Before resuming operation, purge the entire system with
the gas being compressed to avoid a potentially
compensate for this movement.
explosive gas/air mixture in the system. A gas/air
mixture under pressure can explode and cause severe
CAUTION
injury or death.
Torque wrench required. Over-tightening the nut may
damage the Fenner drive and/or sprocket.
CAUTION
6. Firmly hand tighten the nut (clockwise). Then Do not touch hot surfaces without proper protection.
use a torque wrench to tighten the nut to the
specified torque in Appendix A. For KBK:T: Crankshaft sprockets are on a
7. Install chain and adjust according to "Chain removable adapter. Remove the adapter and
Adjustment". sprocket and replace it with a new adapter and
sprocket.

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Chain Adjustment mm) increments, apply finger pressure to

measure the distance from the straight edge
Figure: Typical Chain Deflection Measurement to a chain roller at the center of the span.
Record the measurement and check to see if
it is in tolerance.
4. If adjustment is required, remove the cap
screws and plastic plugs from the eccentric
cap. Rotate the cap clockwise to line up the
first two new cap screw holes. If this tightens
the chain too much, turn the cap
counterclockwise for a different hole
alignment.
5. Replace and tighten the two cap screws hand
wrench tight.
CAUTION

Over tightening may result in bent shafts.

6. Roll the crankshaft to check tightness in

1 Finger Pressure several positions. At its tightest position, the
2 Machinist's Scale chain should deflect within the shaded limits
3 Straight Edge in Figure: Allowable Chain Deflection.
4 Span Length Replace plastic caps to keep the holes clean.

1. Roll the crankshaft to the tightest position of

the chain. This prevents snugging the chain at
a slack position and breaking rollers, or
ruining the pump and lubricator bearings
when the chain goes through its tightest
position.
2. Use a tape measure to measure the longest
most easily accessible span from sprocket
center to sprocket center, where the
deflection will be gauged. Determine
allowable deflection limits for the measured
span as defined by the shaded area in Figure:
Allowable Chain Deflection.
3. Measure chain deflection from a straight edge
held on the chain rollers where it wraps over
the two sprockets of the span (see Figure:
Typical Chain Deflection Measurement).
Using a machinist’s rule with 0.01 inch or (1.0

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Figure: Allowable Chain Deflection, Inches (mm)

A Deflection B Length of 1 Maximum 2 Minimum Deflec- 3 Allowable

Measured Span Deflection tion Deflection

Component Cleaning & Thread CAUTION

Lube for Non-Lube Denatured alcohol presents health and safety hazards. It
contains methyl alcohol and is poisonous if ingested.
Compressor Cylinders Avoid eye and skin contact. Keep alcohol away from
heat, sparks, flame, and all other ignition sources. Use
Ariel cleans and protects complete non-lube adequate ventilation, neoprene or butyl gloves, mono-
goggles or face-mask, and impermeable apron. Properly
cylinders to non-lube service requirements.
handle and dispose of materials resulting from clean-up.
Clean all internal parts shipped loose, See manufacturer's material safety data sheets for more
contaminated internal surfaces, and repair parts details.
prior to installation, to extend the life of rings and
non-lube compressors. Do not use any lubricants or anti-seize
compounds on parts that may contact the gas
Clean cylinder bore thoroughly with denatured stream.
alcohol until a clean, alcohol-soaked, white
paper towel removes no more debris. This Use very small amounts of Never-Seez regular
includes all surfaces of the bore, counter bore, grade on nut and collar when assembling piston
valve pockets, etc. Do not use Never-Seez on assembly. Thoroughly clean piston (especially
steel gaskets. Apply a light film of oil to cylinder the ring grooves) with denatured alcohol until a
seating surfaces to seal o-rings. clean, alcohol-soaked towel removes no more
debris.

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Disassemble packing case. Wipe all surfaces

clean with denatured alcohol. Re-assemble.
Handle cleaned parts with new or clean "rubber"
or new white cotton gloves.

Before piston rod installation, wipe it with

denatured alcohol. Be careful not to leave
fingerprints on the rod before it contacts the
packing rings. Wipe the rod with denatured
alcohol after installation.

Clean the head end head or unloader

components with denatured alcohol. Use
minimal amounts of oil for the bolt-holes to
ensure oil does not run into the cylinder. Also
install the head end steel gasket without Never-
Seez.

Disassemble and clean the valves with denatured

alcohol, then re-assemble, wipe them again, and
install. Clean retainers and high clearance
assemblies with denatured alcohol. Use only a
thin film of oil for the valve cap O-rings and bolt-
holes.

Assemble cleaned parts immediately to avoid

contamination and corrosion. If cylinder will not
commence immediate service, contact Ariel for
preservation instructions to ER-34.

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Start Up

Warranty Notification - Installation List Data and Start Up Check

Lists for Reciprocating Compressors
Download the Installation List Data and Start Up Check Lists forms, which is designed to ensure a
successful start-up of Ariel reciprocating compressors. Ariel warranty coverage requires these
completed forms be sent to:

Administrative Assistant - Sales, Ariel Corporation

35 Blackjack Road Phone: 740-397-0311 FAX: 740-397-3856
Mount Vernon, Ohio 43050 USA Email: warrantyregistration@arielcorp.com

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Compressor Troubleshooting
Expect minor problems during routine operation of an Ariel compressor. These troubles most often
trace to liquid, dirt, improper adjustment, or operators unfamiliar with Ariel compressors. These
difficulties can usually be corrected by cleaning, proper adjustment, elimination of an adverse
condition, part replacement, or proper training.

Major problems usually trace to long periods of operation with unsuitable lubrication, careless
operation, lack of routine maintenance, or using the compressor for purposes not intended.

Recording inter-stage pressures and temperatures on multistage units is valuable. Any variation when
operating at a given load point indicates trouble in one of the stages. Normally, a decrease in inter-
stage pressure indicates trouble in the lower pressure cylinder. An increase usually indicates trouble
in the higher pressure cylinder. Below is a list of common problems and possible causes.

Problem Possible Causes

Low Oil Pressure • Oil pump pressure regulating valve set too low or
sticking.
• Oil pump or oil pump drive failure.
• Oil foaming from counterweights striking oil
surface (oil level in sight glass too high), or from
vortex at strainer inlet (oil level in sight glass too
low), or from leaks in pump suction line.
• Cold oil.
• Dirty oil filter.
• Interior frame oil leaks.
• Excessive leakage at bearings.
• Improper low oil pressure switch setting.
• Oil pump relief valve set too low.
• Defective pressure gauge.
• Plugged oil sump strainer.
• Improper end clearance in oil pump.
High/Low Suction Pressure • Suction control valve malfunction.
• Faulty pressure gauges.
• Frozen/plugged inlet line.
• Plugged intake screen or filter.
• Scrubber dump valve stuck open.
• Recycle malfunction.
• Site production equipment problems.

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Problem Possible Causes

High/Low Inter-Stage Pressure • Faulty valves or rings.

• Gas leak.
• Frozen cooler section or tubing to panel.
• Faulty pressure gauges.
• Scrubber dump valve stuck open.
• Load change.
Noise in Cylinder • Loose piston.
• Piston hitting cylinder head end head or crank
end head.
• Loose crosshead balance nut.
• Broken or leaking valve(s).
• Worn or broken piston rings or wear bands.
• Valve improperly seated or damaged seat gasket.
• Liquids in cylinder.
Frame Knocks • Loose crosshead pin or pin caps.
• Loose or worn main, crankpin, or crosshead
bearings.
• Low oil pressure.
• Cold oil.
• Incorrect oil.
• Knock is actually from cylinder end.
• Low fluid level in damper.
Excessive Carbon on Valves • Excessive lube oil.
• Improper lube oil.
• Oil carry-over from inlet system or previous
stage.
• Broken or leaking valves causing high tempera-
ture.
• Excessive temperature due to high pressure ratio
across cylinders.
Relief Valve Popping • Faulty relief valve.
• Leaking suction valves or rings on next higher
stage.
• Obstruction, closed or faulty valve in discharge
line.
High Discharge Temperature • Excessive ratio across cylinder due to leaking
inlet valves or rings on next higher stage.
• Fouled inter-cooler piping.
• Leaking discharge valves or piston rings.
• High inlet temperature.
• Improper lube oil and/or lube rate.

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KBK-KBT Maintenance & Repair Manual – Compressor Troubleshooting 04/03/2023

Problem Possible Causes

High Frame Oil Temperature • Faulty temperature gauge.

• Dirty oil filters.
• High oil level.
• Faulty thermostatic element.
• Faulty thermostatic control valve.
• Clogged or blocked oil cooler.
• Binding or tightness in the compressor.
Packing Over Heating • Lubrication failure.
• Improper lube oil and/or insufficient lube rate.
• Worn packing rings.
• Dirt in packing.
• Improper ring side or end gap clearance.
• Scored, tapered or out of round piston rod.
• Excessive piston rod runout.
Excessive Packing Leakage • Worn packing rings.
• Improper lube oil and or insufficient lube rate.
• Dirt in packing.
• Packing rings assembled incorrectly.
• Improper ring side or end gap clearance.
• Plugged packing vent system.
• Scored, tapered or out of round piston rod.
• Excessive piston rod runout.
• Packing not seated or properly run in.
Drive End of Crankshaft Oil Leaks • Clogged vent or vent piping.
• Excessive cylinder packing leakage.
Piston Rod Oil Wiper Leaks • Worn wiper rings.
• Wipers incorrectly assembled.
• Worn/scored rod.
• Improper fit of rings to rod/side clearance.
Force Feed Lubrication Shutdown • Force feed pump or lubricator block failure.
• Loss of oil supply to force feed pump.
• Lubricator drive failure.
• DNFT not programmed correctly.
• DNFT battery failure or power loss.
• Loose or grounded control wiring.
• Pin assembly not completely pushed into the
DNFT housing.

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KBK-KBT Maintenance & Repair Manual – Compressor Troubleshooting 04/03/2023

Problem Possible Causes

Oil Leaks at Pipe Threaded Connections • Joint not tight.

• Pipe sealant was omitted.
• Defective or damaged pipe threads.
• NPTF Dryseal threads not being used.
• Pressure too high for pipe threaded connection
use.
• Pipe thread sealant incompatible with the
synthetic oil used.
• Cracked pipe or fittings.
Vibration Shutdown • Short in wire to panel.
• Incorrectly positioned vibration switch.
• Loose mounting bolts.
• High scrubber level (liquid carry-over).
• Broken valve, piston, or piston rod.
• Main drive-line or coupling failure.

Piston Rod Runout Correction

Figure: Piston Rod Runout Measurement

Piston rod runout may be either positive or rod runout tolerance requires correction for safe,
negative. A positive reading indicates the piston efficient compressor operation (see Appendix B).
drops as it moves to the head end of the cylinder Piston rod runout correction first requires
due to the clearance in the bore. As the piston verification (and correction, if needed) of the
drops, the rod rises, yielding a positive reading crosshead clearance. See flowcharts below.
on the indicator. If the cylinder is not supported
properly, it could droop causing the piston to
drop as it moves to the head end of the cylinder.
A negative reading indicates the piston climbs as
it moves to the head end of the cylinder. When
the piston climbs, the rod drops, yielding a
negative reading. Any reading outside the Ariel

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KBK-KBT Maintenance & Repair Manual – Compressor Troubleshooting 04/03/2023

Figure: Crosshead Clearance Verification/Correction Flowchart

NOTE: Review all steps before troubleshooting. If

issues persist, contact the Ariel Response Center.

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KBK-KBT Maintenance & Repair Manual – Compressor Troubleshooting 04/03/2023

Figure: Piston Rod Runout Verification/Correction Flowchart

NOTE: Verify crosshead clearance is within Ariel specs

per the manual before checking piston rod runout.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Ariel Fasteners and Torques

This document lists fastener lubrication and standard cap screws, contact your packager
torque requirements for proper assembly of or Ariel.
KBK:T reciprocating compressors. For older units • Clean and de-burr all threads.
with lower specified torque values, do not • Do not use molybdenum disulfide lubricants.
assume higher values without consulting the • Do not use Never-Seez for fastener lubrica-
packager and/or Ariel. tion unless specified or excessive stresses
may result with specified torques. See Table:
• Use only Ariel specified fasteners tightened to Fastener Thread & Seating Surface Lubrica-
the correct torque. tion.
• Connecting rod, valve cap, and • Use anti-seize lubricants sparingly; excessive
suction/discharge nozzle (Ariel supplied amounts cause oil analysis to indicate
flange) fasteners are modified to prevent contamination and may unnecessarily
fatigue; do not replace them with standard increase maintenance costs.
cap screws. To replace other fasteners with
• Re-preserve any fasteners subject to corro-
sion after installation.

Table: Fastener Thread & Seating Surface Lubrication

NOTE:Lubricate all fasteners both under the head and on the threads.

Application Lubricant

Forged Steel Cylinders: valve cap, cylinder mounting Never-Seez Regular Grade
flange to cylinder body, packing, crank end and head end
head, gas passage

Cast Cylinders: valve cap, tandem cylinder mounting, Mineral oil (ISO 100-150)
packing, crank end and head end head

Frame: main bearing cap, jack screws Never-Seez Regular Grade

Pistons: piston nuts, set screws, piston collar, crosshead
threads, tandem piston to piston rod
All stainless steel fasteners except valve fasteners
listed in Table: Hoerbiger Valve Assembly Fastener
Torques

Connecting rod cap Lubriplate 630-AA

Crosshead balance nut, crosshead guide to frame to Under the head or mating surface: Mineral oil (ISO 100-
spacer bar, crosshead guide to frame to main bearing cap, 150).
crosshead guide support stud (both ends) and cap nut On the threads: Never-Seez Regular Grade.

All pipe threads Loctite 567

Fasteners specified with Loctite on threads Loctite only with no additional lube

All other fasteners, all O-rings and stat-o-seals Mineral oil (ISO 100-150)

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KBK-KBT Maintenance & Repair Manual – Ariel Fasteners and Torques 04/03/2023

Figure: Bolt Head Grade and Material Identification

CAUTION 5. Always apply a steady, slow force to a torque

wrench, and stop immediately when the
To replace a fastener, see parts list for fastener grade
and part number. Do not use a lesser or greater material wrench clicks. Do not bounce, jerk, or double
grade. Use Ariel parts to replace special fasteners and tap the wrench – it significantly increases the
fasteners with reduced body diameter for fatigue applied torque. Perform final tightening with
resistance. Do not torque fasteners with compressor
running or pressurized. Read technical manual safety a torque wrench.
warnings.
6. Do not break fasteners loose with a torque
wrench - it may overload the wrench and
Recommendations for Torque affect its accuracy.

Accuracy 7. Determine torque wrench accuracy range

before using - most are not accurate at the
1. Critical bolted joints require accurate
extreme lower and higher ends of their range.
fastener pre-stress to ensure safe and reliable
operation. On Ariel compressors, these joints 8. Clean and de-burr all threads before
have specified torque or other engineered assembly. Ensure no oil or debris is in the
tightening methods. Only mechanics prop- bottom of the bolt hole when installing bolts.
erly trained in bolted flange joint assembly Apply oil only to fasteners, not in the bolt
should maintain these joints. hole.
2. When torque is specified for a fastener, use a 9. Inspect all joint mating surfaces for
properly calibrated torque wrench to torque scratches, nicks, gouges, burrs, corrosion and
the fasteners correctly. flatness. This includes the fastener and the
3. Use the correct lubricant on the fastener (see fastener contact area on the bolted part.
Table: Fastener Thread & Seating Surface Address any findings before proceeding.
Lubrication). Figure: Main Bearing Cap or Connecting Rod Cap
Torque Sequence
4. Always turn fasteners in by hand until they
are finger tight and drawn down evenly.
Using a wrench, turn fasteners to draw o-
rings into their bores. Using pneumatic, elec-
tric, or hydraulic drivers and runners can
result in uneven tightening and over-stressed
fasteners. If there is significant resistance,
remove the fastener to determine and correct
the cause.

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KBK-KBT Maintenance & Repair Manual – Ariel Fasteners and Torques 04/03/2023

10. For main bearing cap and connecting rod After 100% torque is reached, continue
cap fasteners: If the bearing cap is stamped passes until all fasteners stop moving.
with torque sequence numbers, tighten • Inspect the gap under the bolted flange (if
fasteners in that sequence. If not stamped, visible) after each pass to ensure a consis-
follow the Figure: Main Bearing Cap or tent gap all around. If the gap is not
consistent, the assembly is cocked –
Connecting Rod Cap Torque Sequence.
disassemble and inspect to determine the
• Where torque and turn IS NOT SPECI- cause, and re-assemble after the cause is
FIED: Apply 50% of specified torque in the corrected.
sequence shown to close joint. Once
closed, apply 100% of specified torque in
the same sequence. Repeat 100% torque
in the same sequence until all fasteners
stop moving.
• Where torque and turn IS SPECIFIED:
Apply 100% of pre-torque in the sequence
shown to close joint. Repeat 100% torque
in the sequence until all fasteners stop
moving. Finally, apply the full turn value
to each fastener one time in the same
sequence.
11. For Ariel pressure containing components,
see Figure:Pressure Containing Joint
Recommended Torque Sequences for
recommended torque sequences (includes
cylinders, valve caps, cylinder heads,
unloaders, gas passage caps, flanges, and
packings):

• Refer to ASME PCC-1 “Guidelines for Pres-

sure Boundary Bolted Joint Flange
Assembly” for commonly accepted prac-
tices.
• Install a new gasket or O-ring.
• For 3-bolt valve caps, tighten in this
sequence: 1-2-3, 2-3-1, 3-1-2. Use the
sequence to close the joint without
exceeding 25% of full torque. Repeat the
three-pass sequence for 25%, 50%, 75%,
and 100% of full torque. Repeat 100%
torque in a circular pattern until all
fasteners stop moving.
• For other pressure containing joints,
tighten the fasteners in four passes using
the appropriate sequence for 25%, 50%,
75% and 100% of the specified torque.

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KBK-KBT Maintenance & Repair Manual – Ariel Fasteners and Torques 04/03/2023

Figure: Pressure Containing Joint Recommended Torque Sequences

A 3 Fasteners F 8 Fasteners J 12 Fasteners N 20 Fasteners

B 4 Fasteners G 9 Fasteners K 14 Fasteners O 22 Fasteners
C 5 Fasteners H 10 Fasteners L 16 Fasteners P 24 Fasteners
D 6 Fasteners I 11 Fasteners M 18 Fasteners Q Obround Flange
E 7 Fasteners

12. When finished, reset torque wrench to its 13. To determine the torque wrench setting
lowest setting to relax the spring. A torque when using a torque multiplier, divide the
wrench left in a high setting stresses the desired fastener torque by the multiplier
spring and decreases accuracy with time. actual mechanical advantage, not the design
mechanical advantage. See manufacturer
documentation for multiplier.

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KBK-KBT Maintenance & Repair Manual – Ariel Fasteners and Torques 04/03/2023

Figure: Torque Wrench with Angled Adapter Tw = Ta x [L ÷ (L + A)]

Tw = Torque wrench setting, Lb x Ft or N·m.
Ta = Torque required at fastener, Lb x Ft or N·m.
L = Length of wrench, ft or m (from square drive end to
center point of force on handle).
A = Wrench length added by adapter, ft or m (measured
to end of adapter on a line parallel to wrench center
line).
14. If using an offset adapter with a torque
wrench, the torque setting is not the actual
torque applied, unless the adapter is 90° to
the torque wrench. To determine the correct
torque setting:

Table: Hoerbiger Valve Assembly Fastener Torques

Type Torque
Nominal Size
Fastener Lb x Ft (N·m), unless Lb x Ft (N·m), unless
Inch - TPI
specified specified

Center Cap Screwa 5/16 - 24 12 Point - Steel Grade 5 14 (19)

Material Parts: SPL3 & 4
3/8 - 24 24 (33)

7/16 - 20 35 (48)

5/16 - 24 12 Point - Steel Grade 5 22 (30)

Material Parts: SPL or SPL5
3/8 - 24 40 (54)

7/16 - 20 65 (88)

5/16 - 24 12 Point - Stainless Steel 14 (19)

Grade B
3/8 - 24 8M Material Parts: SPL6 24 (33)

7/16 - 20 35 (48)

Peripheral Cap Screw #10 - 32 Hex Socket Head 25 Lb x In (2.8)

#12 - 28 43 Lb x In (4.9)

1/4 - 20 110 Lb x In (12)

5/16 - 18 176 Lb x In (20)

3/8 - 16 21 (28)

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Type Torque
Nominal Size
Fastener Lb x Ft (N·m), unless Lb x Ft (N·m), unless
Inch - TPI
specified specified

Single-piece Lock Nuts Nominal Size Torque Lb x Ft (N·m), unless specified

(Greer, Flexloc, Selflock)
Inch - TPI SPLb Other

#12 - 28 96 Lb x In. (11)d -

b
(Microlock, Spiralock )
5/16 - 24 15 (20) 109 Lb x In (12)

3/8 - 24 26 (35) 17 (23)

7/16 - 20 48 (65) 26 (35)

1/2 - 20 67 (91) 41 (55)

5/8 - 18 110 (150) 82 (110)

3/4 - 16 195 (265) 145 (195)

7/8 - 14 295 (400) 230 (310)

Center Stud Drake 2-Piece Inch - TPI Bottom Half Top Half
Beam Lock Nut
1/4 - 28 103 Lb x In (12) 66 Lb x In (7.5)

5/16 - 24 120 Lb x In (14) 66 Lb x In (7.5)

3/8 - 24 16 (22) 96 Lb x In (11)

1/2 - 20 36 (49)c 20 (27)

5/8 - 18 73 (99) 40 (54)

3/4 - 16 130 (175) 70 (95)

7/8 - 14 210 (285) 115 (155)

a Center cap screw valve assemblies have Spiralock® (SPL) threads to prevent loosening. See bottom of valve
assembly for SPL material parts number (3, 4, 5 or 6) and select proper torque from the table. Lubricate both threads
and seating surfaces with mineral oil (ISO 100-150) ONLY. If using older valve assemblies not covered in the table,
see the original torque chart provided in the compressor tool box, or contact Ariel for instructions. Spiralock®
threads cannot be dressed with a standard tap. Clean center cap screws in valve assemblies not marked SPL with
Loctite safety solvent and lock them with one or two drops of Loctite #272 thread locking compound. DO NOT use
petroleum lubricants.
b Microlock and Spiralock nuts are marked "SPL" on one of the flats.
c Use 29 (39) for 1/2 - 20 bottom half Drake lock nut with non-metallic valve plates in liftwasher valves.
d Use this torque only with a 17-4PH 900H material center stud.

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KBK:T Fastener Torques

Torque Lb x Ft (N·m),
Fastener Nominal Size Inch - TPI Type
unless specified

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

Screw

Connecting Rod Cap - Cap 1” - 14 12 Point - Grade 8 120 (165) + 110°

Screw Note: Use Ariel turn
indicator, B-3993

Torsional Vibration 1” - 14 12 Point - Grade 8 530 (715)

Detuner - Cap Screw

Crosshead Pin Thru Cap 1/2 - 20 Hex - Nylon Insert 61 (83)

Screw - Lock Nut

Crosshead Guide to Frame 7/8 - 9 12 Point - Grade 8 280 (380)

- Cap Screw

Crosshead Guide to Frame 7/8 - 9 12 Point - Grade 8 280 (380)

to Spacer Bar- Cap Screw

Crosshead Guide to Frame 7/8 - 9 12 Point - Grade 8 280 (380)

to Main Bearing Cap - Cap
Screw

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

Cylinder
7/8 - 14 Hex Nut 315 (425)

Crosshead Guide to 1” - 14 Cap Nut 395 (535)

Supportk
Head End Cylinder Support 1/2 - 13 Hex - Grade 8 44 (60)
to Cylinder
5/8 - 11 88 (120)

3/4 - 10 160 (215)

7/8 - 9 255 (345)

Eccentric Vernier Cap - Cap 5/16 - 18 12 Point - Grade 8 Hand Wrench Tight
Screw

FVCP Actuator to Unloader 1/2 - 13 12 Point - Grade 8 or 17- 40 (54)

Head - Cap Screw 4PH
5/8 - 11 79 (105)

3/4 - 10 140 (190)

7/8 - 9 230 (310)

1" - 8 345 (465)

1-1/8 - 7 485 (660)

Idler Sprocket Thru Cap 1/2 - 20 Hex - Prevailing 41 (55)

Screw - Lock Nut

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Torque Lb x Ft (N·m),
Fastener Nominal Size Inch - TPI Type
unless specified

Rod Packing - Cap Screwa 3/4 - 10 12 Point Grade 8 or 17-4PH 125 (170)

3/4 - 16 145 (195)

7/8 - 14 230 (310)

Packing Tie Stud Nut #10 - 24 Hex 20 Lb x In. (2.3)

1/4 - 20 72 Lb x In. (8.1)

5/16 - 18 12 Point Flange 144 Lb x In. (16)

Rod Catcher to Packing 1/2 - 20 12 Point Grade 8/17-4PH 51 (69)

Piston Nut 1-3/4 - 12 Ariel Design 4500 psig (310 barg) & 200
(270) on spannerg, h
Piston Nut Set Screw 5/16 - 24 Socket Head 164 Lb x In (19)b
Crosshead Balance Nut 1-3/4 - 12 Ariel Design Slugging Methodc
Force Feed Lube Box - 1-3/8 - 20 - LH Bearing Housing 70 (95)
Bearing Housing

Force Feed Lube Box - Jam 1” - 14 Hex 75 (100)

Nut
1-1/2 - 12 112 (152)

Force Feed Lube Pump 1/4 - 20 Hex - Grade 5 50 Lb x In (5.6)

Mounting

Auto Relief Valve 1/2d Ariel Design 75 Lb x In (8.5)

Auto Relief Valve Manifold #10 - 24 Ariel Design 50 Lb x In (5.6)

Plug
1/4 NPT Hex Hand Wrench Tight

Flywheel to Hub 1” - 14 12 Point - Grade 8 530 (715)

1-1/8 - 12 Hex or 12 Point - Grade 8 740 (1010)

Piston Rod Oil Slinger Bolt - 1/4 - 28 Hex Jam - Prevailing 95 Lb x In (11)
Lock Nut

Valve Cap Assembly 7/8 - 14 Cap Nut Hand Wrench Tight

1" - 14

1-1/8 - 12

Valve Cap Seal Keeper - 5/16 - 18 12 Point - 17-4PH 120 Lb x In (14)

Cap Screw

Cylinder Mounting Flange 1” - 14 12 Pt - Grade 8/17-4PH or 485 (660)

to Forged Steel Cylinder Hex Grade 9
1-1/4 - 12 955 (1290)

Frame Foot & Crosshead 1-1/4 - 7 Hex Nut 850 (1150)e

Guide Foot Hold Down

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KBK-KBT Maintenance & Repair Manual – Ariel Fasteners and Torques 04/03/2023

Torque Lb x Ft (N·m),
Fastener Nominal Size Inch - TPI Type
unless specified

Flywheel/Damper/Sprocke 5/8 - 18 12 Point - Grade 8 125 (170)

t Adapter to Crankshaft
(auxiliary end) - Cap Screw

Lifting Bracket to Frame 1-1/2 - 6 12 Point - Grade 8 1200 (1630)

Fenner Drive at FF Lube 7/8 Hex 200 Lb x In (23)

Sprocket, A-11560

Cap Screw f 5/16 - 18 Hex - Grade 8 or 9, 12 Point 108 Lb x In. (12)

• Valve Cap - Grade 8 or 17-4PH, or
3/8 - 16 Socket Head 193 Lb x In (22)
• Cylinder Head
• Gas Passage Cap 1/2 - 13 40 (54)
• VVCP or eVCP 5/8 -11 79 (105)
i
Adapter to Head 5/8 -18 92 (125)
• VVCP, FVCP, or eVCP
to Cylinder 3/4 - 10 140 (190)
• Ariel supplied 3/4 - 16 160 (215)
companion flanges,
7/8 - 9 230 (310)
except “Peanut”
Dual Nozzle 7/8 -14 260 (350)
• Indicator Port Cover
1” - 8 345 (465)
• Ariel Supplied
Flanged Thermowell 1” - 14 395 (535)
• VVCP Seal Carrier 1-1/8 - 12 560 (760)
• FVCP Passage Plug
to Unloader Head 1-1/4 - 12 780 (1060)

Unloader Actuator to Valve 1/2 - 13 Hex - Grade 8 48 (65)

Cap - Cap Screw

Companion Flange 1/2 - 13 12 Pt Grade 8/17-4PH 53 (71)

“Peanut” Dual Nozzle

ANSI Flange to Cylinder See Cylinder Outline Provided by Packager See ER-127.
Nozzle

Taper-Lok Flangel 1/2 - 13 Hex Nut on Grade 8 Stud or 40 (54)

17-4 stud
1/2 - 20 46 (62)

5/8 -11 79 (105)

5/8 -18 92 (125)

3/4 - 16 160 (215)

7/8 - 9 230 (310)

7/8 -14 260 (350)

1” - 14 395 (535)

1-1/8 - 12 560 (760)

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KBK-KBT Maintenance & Repair Manual – Ariel Fasteners and Torques 04/03/2023

Torque Lb x Ft (N·m),
Fastener Nominal Size Inch - TPI Type
unless specified

Tandem Cylinder to 1/2 - 13 Hex - Grade 8 or 9 or 12 44 (60)

Cylinder - Cap Screwf Point Grade 8 or 17-4PH
5/8 - 11 88 (120)

3/4 - 10 160 (215)

3/4 - 16 180 (245)

1-1/8 - 12 620 (840)

Tandem Piston to Piston 5/8 - 18 12 Point - Grade 8 or 17- 92 (125)

Rod - Cap Screwg 4PH

Stud Seating 3/8 - 16 Dog Point Grade 8 or 17- 107 Lb x In (12)

In valve cap assemblies 4PH
with a spring energized 1/2 - 13 22 (30)
seal, install longer studs 5/8 - 11 44 (60)
with Loctite 242.
3/4 - 10 79 (105)

3/4 - 16 90 (120)

7/8 - 9 130 (175)

7/8 - 14 145 (195)

1” and larger 200 (270)

Distribution Block Tie Rod - 1/4 - 28 Hex 68 Lb x In (7.7)

Nut

Distribution Block Divider 1/4 - 28 Socket Head 75 Lb x In (8.5)j

Valve - Cap Screw
Grade 5 - Hex Cap Screw ALL Hex - Grade 5 Hand Wrench Tight

a Repeat final torque for rod packing bolts until they no longer turn before the torque wrench clicks.
b Stake set screws per manual after tightening.
c Or use 3500 psig (241 barg) hydraulic pressure on separately purchased crosshead (balance) nut torquing tool.
d "1/2" indicates the wrench size. Auto relief valve can swivel in the manifold once torqued. See assembly drawing.
e Minimum torque to stress recommended 1-1/4 - 7 hold-down stud to 55,000 psi (380 MPa). Use studs with an ulti-
mate strength of 100,000 psi (690 MPa) or greater. If greater, increase torque stress to about 55% of ultimate
strength, as specified by packager.
f For studs specified for cylinder applications, tighten nuts to the same torque as cap screws in similar applications.
g Tighten, loosen, then re-tighten to ensure proper torque.
h Use Ariel piston rod hydraulic torque tool A-28362 or A-24512.
i Excludes socket head cap screws, which are installed hand wrench tight.
j Step-torque first to 40 Lb x In. (4.5 N•m), and then to 75 Lb x In. (8.5 N•m).
k See "Stud Seating" for installation of studs.
l See ER-136 for Taper-Lok installation instructions.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Clearances
Table: KBK:T Frame and Running Gear Clearances, in. (mm)
Description Clearance

Crankshaft Journal Bearing (Jack) 0.0015 to 0.0050 (0.038 to 0.127)

Crankshaft Thrust (End) 0.0085 to 0.0200 (0.216 to 0.508)

Connecting Rod Bearing (Jack) 0.0035 to 0.0070 (0.089 to 0.178)

Connecting Rod Thrust (Side) 0.007 to 0.018 (0.178 to 0.457)

Crosshead to Guide 0.008 to 0.013 (0.20 to 0.33) (Feeler Gauge)

Crosshead Pin to Connecting Rod Bushing 0.002 to 0.004 (0.05 to 0.10)

Crosshead Pin to Crosshead Bushings 0.0020 to 0.0042 (0.05 to 0.11)

Shaft Seal Housing, Centered on Crankshaft 0.008 (0.20) (Feeler Gauge All Around)

Table: KBK:T Piston End Clearances, in. (mm)a, b

Cylinder Class Crank End Head End Total

17-7/8, 20-1/8, 22, 24-1/8, 0.055 (1.4) 0.095 to 0.155 (2.4 to 3.9) 0.150 to 0.210 (3.8 to 5.3)
and 26-1/2 K:T

5-3/8 K:T Tandem 0.040 (1.0) 0.060 to 0.160 (1.5 to 4.1) 0.100 to 0.200 (2.5 to 5.1)

All KL:TL 0.300 (7.6) No Set 0.620 to 0.680 (15.8 to 17.3)

All KM:TM and all other K:T 0.040 (1.0) 0.080 to 0.140 (2.0 to 3.6) 0.120 to 0.180 (3.0 to 4.6)

a Measured clearances may not agree because of oil films, assembly tolerances, wear, etc. Do not use plastigages,
solder, etc.
b If total piston end clearance is not within table tolerance, contact your Packager or Ariel.

Table: KBK:T Max. Acceptable Piston Rod Runout, in. (mm)

Description Runout

Vertical Runout 0.0020 (0.0508)

Horizontal Runout 0.0010 (0.0254)

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KBK-KBT Maintenance & Repair Manual – Clearances 04/03/2023

Table: New Uncut Packing Ring Side Table: New Pressure Breaker and Segmented
Clearance, in. (mm), Packing Ring Side Clearance, in. (mm),
(BTUU/CUU/BTU/CU/STU) (BTR/BTS/CR/BD/BT/TR/P/UP/P1U)
Actual Groove Width Side Clearance Actual Groove Width Side Clearance

0.572 to 0.574 (14.53 to 0.023 to 0.028 (0.58 to 0.375 to 0.377 (9.53 to 0.011 to 0.015 (0.28 to
14.58) 0.71) 9.58) 0.38)

0.625 to 0.627 (15.88 to 0.025 to 0.030 (0.64 to 0.447 to 0.449 (11.35 to 0.013 to 0.018 (0.33 to
15.93) 0.76) 11.40) 0.46)

0.750 to 0.752 (19.05 to 0.030 to 0.035 (0.76 to 0.572 to 0.574 (14.53 to 0.017 to 0.022 (0.43 to
19.10) 0.89) 14.58) 0.56)

0.625 to 0.627 (15.88 to 0.019 to 0.024 (0.48 to

15.93) 0.61)

Table: New Wiper Ring Side Clearance, in.

(mm)
Wiper Ring Type Side Clearance

2RWS, 2RUG 0.004 to 0.006 (0.010 to

0.015)

3RWS, 3RUG 0.006 to 0.009 (0.15 to

0.23)

RTV 0.000

Table: Piston Ring Side Clearances, in. (mm)

Actual Groove Width Lubricated PTFE Lubricated PEEK Non-Lubricated PTFE

0.312 to 0.314 (7.92 to 7.98) 0.010 to 0.016 (0.25 to 0.41) 0.010 to 0.016 (0.25 to 0.41) 0.007 to 0.013 (0.18 to 0.33)

0.375 to 0.377 (9.53 to 9.58) 0.012 to 0.018 (0.30 to 0.46) 0.011 to 0.017 (0.28 to 0.43) 0.009 to 0.015 (0.23 to 0.38)

0.438 to 0.440 (11.13 to 0.014 to 0.020 (0.36 to 0.51) - 0.010 to 0.016 (0.25 to 0.41)
11.18)

0.500 to 0.502 (12.70 to 0.015 to 0.021 (0.38 to 0.53) 0.013 to 0.019 (0.33 to 0.48) 0.011 to 0.017 (0.28 to 0.43)
12.75)

0.625 to 0.627 (15.88 to 0.018 to 0.024 (0.46 to 0.61) - -

15.93)

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Table: Wearband Side Clearances, in. (mm)

Actual Groove Width Lubricated PTFE Lubricated PEEK Non-Lubricated PTFE

1.250 to 1.252 (31.75 to 0.033 to 0.040 (0.84 to 1.02) 0.025 to 0.031 (0.64 to 0.79) -
31.80)

1.500 to 1.502 (38.10 to 0.039 to 0.046 (0.99 to 1.17) - 0.027 to 0.034 (0.69 to 0.86)
38.15)

1.750 to 1.752 (44.45 to - - 0.031 to 0.038 (0.79 to 0.97)

44.50)

1.875 to 1.877 (47.63 to - - 0.033 to 0.040 (0.84 to 1.02)

47.68)

2.000 to 2.002 (50.80 to 0.050 to 0.058 (1.27 to 1.47) 0.036 to 0.044 (0.91 to 1.12) 0.035 to 0.042 (0.89 to 1.07)
50.85)

2.250 to 2.252 (57.15 to 0.056 to 0.064 (1.42 to 1.63) - -

57.20)

3.000 to 3.003 (76.20 to 0.074 to 0.084 (1.88 to 2.13) 0.052 to 0.062 (1.32 to 1.57) -
76.28)

3.500 to 3.503 (88.90 to - 0.060 to 0.070 (1.52 to 1.78) -

88.98)

Table: Clearance Specifications for Lubricated K and T Cylinders, in. (mm) (Shaded Blocks =
PEEK; All Other Blocks = PTFE)
PISTON TO CYLINDER PISTON RING END GAP WEAR BAND - NEW

Diametral Radial
Bore New Replace End Gap
Clearance Projection
3.5 (88.9) 0.060 to 0.068 0.062 to 0.089 0.267 (6.78) 0.086 to 0.176 0.019 to 0.028
(1.52 to 1.73) (1.57 to 2.26) (2.18 to 4.47) (0.48 to 0.71)

3.875 (98.4) 0.068 to 0.095 0.285 (7.24) 0.094 to 0.185 0.018 to 0.027
(1.73 to 2.41) (2.39 to 4.70) (0.46 to 0.69)

5 (127) 0.081 to 0.089 0.085 to 0.115 0.345 (8.76) 0.118 to 0.212 0.028 to 0.037
(2.06 to 2.26) (2.16 to 2.92) (3.00 to 5.38) (0.71 to 0.94)

5.375 (137) 0.091 to 0.122 0.366 (9.30) 0.127 to 0.221

(2.31 to 3.10) (3.23 to 5.61)

5.875 (149) 0.081 to 0.089 0.172 to 0.204 0.612 (15.54) 0.239 to 0.334 0.026 to 0.035
(2.06 to 2.26) (4.37 to 5.18) (6.07 to 8.48) (0.66 to 0.89)

6.25 (159) 0.182 to 0.215 0.645 (16.38) 0.254 to 0.350 0.025 to 0.034
(4.62 to 5.46) (6.45 to 8.89) (0.64 to 0.86)

6.75 (171) 0.087 to 0.096 0.196 to 0.231 0.693 (17.60) 0.273 to 0.371 0.028 to 0.037
(2.21 to 2.44) (4.98 to 5.87) (6.93 to 9.42) (0.71 to 0.94)

7.25 (184) 0.210 to 0.246 0.738 (18.75) 0.293 to 0.391

(5.33 to 6.25) (7.44 to 9.93)

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PISTON TO CYLINDER PISTON RING END GAP WEAR BAND - NEW

Diametral Radial
Bore New Replace End Gap
Clearance Projection

7.875 (200) 0.092 to 0.101 0.228 to 0.265 0.795 (20.19) 0.317 to 0.417 0.030 to 0.039
(2.34 to 2.57) (5.79 to 6.73) (8.05 to 10.59) (0.76 to 0.99)

8.375 (213) 0.242 to 0.280 0.840 (21.34) 0.337 to 0.438

(6.15 to 7.11) (8.56 to 11.13)

8.75 (222) 0.090 to 0.098 0.252 to 0.291 0.873 (22.17) 0.351 to 0.453 0.027 to 0.037
(2.29 to 2.49) (6.40 to 7.39) (8.92 to 11.51) (0.69 to 0.94)

9.125 (232) 0.096 to 0.105 0.263 to 0.302 0.906 (23.01) 0.366 to 0.469 0.029 to 0.039
(2.44 to 2.67) (6.68 to 7.67) (9.30 to 11.91) (0.74 to 0.99)

9.25 (235) 0.090 to 0.098 0.266 to 0.306 0.918 (23.32) 0.371 to 0.474 0.026 to 0.036
(2.29 to 2.49) (6.76 to 7.77) (9.42 to 12.04) (0.66 to 0.91)

9.625 (244) 0.096 to 0.105 0.277 to 0.317 0.951 (24.16) 0.386 to 0.489 0.029 to 0.039
(2.44 to 2.67) (7.04 to 8.05) (9.80 to 12.42) (0.74 to 0.99)

9.75 (248) 0.090 to 0.098 0.280 to 0.321 0.963 (24.46) 0.390 to 0.494 0.026 to 0.036
(2.29 to 2.49) (7.11 to 8.15) (9.91 to 12.55) (0.66 to 0.91)

9.875 (251) 0.109 to 0.118 0.284 to 0.325 0.975 (24.77) 0.377 to 0.481 0.036 to 0.045
(2.77 to 3.00) (7.21 to 8.26) (9.58 to 12.22) (0.91 to 1.14)

10.375 (264) 0.298 to 0.340 1.020 (25.91) 0.396 to 0.501

(7.57 to 8.64) (10.06 to 12.73)

10.5 (267) 0.114 to 0.123 0.301 to 0.344 1.032 (26.21) 0.401 to 0.506 0.038 to 0.047
(2.90 to 3.12) (7.65 to 8.74) (10.19 to 12.85) (0.97 to 1.19)

11 (279) 0.315 to 0.359 1.077 (27.36) 0.419 to 0.526

(8.00 to 9.12) (10.64 to 13.36)

12 (305) 0.117 to 0.128 0.343 to 0.389 1.167 (29.64) 0.456 to 0.565 0.039 to 0.049
(2.97 to 3.25) (8.71 to 9.88) (11.58 to 14.35) (0.99 to 1.24)

12.25 (311) 0.350 to 0.397 1.191 (30.25) 0.466 to 0.575

(8.89 to 10.08) (11.84 to 14.61)

12.5 (318) 0.357 to 0.404 1.212 (30.78) 0.475 to 0.585 0.038 to 0.048
(9.07 to 10.26) (12.07 to 14.86) (0.97 to 1.22)

13.625 (346) 0.126 to 0.137 0.389 to 0.438 1.314 (33.38) 0.517 to 0.629 0.042 to 0.051
(3.20 to 3.48) (9.88 to 11.13) (13.13 to 15.98) (1.07 to 1.30)

14.125 (359) 0.403 to 0.453 1.359 (34.52) 0.536 to 0.649

(10.24 to 11.51) (13.61 to 16.48)

15.375 (391) 0.127 to 0.138 0.438 to 0.491 1.473 (37.41) 0.582 to 0.698 0.040 to 0.051
(3.23 to 3.51) (11.13 to 12.47) (14.78 to 17.73) (1.02 to 1.30)

15.875 (403) 0.452 to 0.506 1.518 (38.56) 0.601 to 0.718 0.039 to 0.050
(11.48 to 12.85) (15.27 to 18.24) (0.99 to 1.27)

17.375 (441) 0.179 to 0.191 0.494 to 0.552 1.656 (42.06) 0.657 to 0.777 0.063 to 0.075
(4.55 to 4.85) (12.55 to 14.02) (16.69 to 19.74) (1.60 to 1.91)

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PISTON TO CYLINDER PISTON RING END GAP WEAR BAND - NEW

Diametral Radial
Bore New Replace End Gap
Clearance Projection

17.875 (454) 0.181 to 0.193 0.508 to 0.567 1.701 (43.21) 0.675 to 0.797 0.064 to 0.076
(4.60 to 4.90) (12.90 to 14.40) (17.15 to 20.24) (1.63 to 1.93)

19.625 (498) 0.182 to 0.194 0.557 to 0.620 1.860 (47.24) 0.740 to 0.866 0.066 to 0.077
(4.62 to 4.93) (14.15 to 15.75) (18.80 to 22.00) (1.68 to 1.96)

20.125 (511) 0.571 to 0.635 1.905 (48.39) 0.759 to 0.886

(14.50 to 16.13) (19.28 to 22.50)

22 (559) 0.624 to 0.692 2.076 (52.73) 0.829 to 0.960 0.064 to 0.076

(15.85 to 17.58) (21.06 to 24.38) (1.63 to 1.93)

24.125 (613) 0.181 to 0.194 0.683 to 0.756 2.268 (57.61) 0.908 to 1.044 0.063 to 0.075
(4.60 to 4.93) (17.35 to 19.20) (23.06 to 26.52) (1.60 to 1.91)

26.5 (673) 0.750 to 0.828 2.484 (63.09) 0.997 to 1.137 0.061 to 0.074
(19.05 to 21.03) (25.32 to 28.88) (1.55 to 1.88)

Table: Clearance Specifications for Non-Lubricated PRC K and T Cylinders, in. (mm)
PISTON TO CYLINDER PISTON RING END GAP WEAR BAND - NEW
Diametral Radial
Bore New Replace End Gap
Clearance Projection

8.375 (213) 0.156 to 0.165 0.196 to 0.234 0.702 (17.83) 0.261 to 0.361 0.062 to 0.072
(3.96 to 4.19) (4.98 to 5.94) (6.63 to 9.17) (1.57 to 1.83)

11 (279) 0.173 to 0.182 0.255 to 0.299 0.897 (22.78) 0.339 to 0.446 0.069 to 0.079
(4.39 to 4.62) (6.48 to 7.59) (8.61 to 11.33) (1.75 to 2.01)

15.375 (391) 0.183 to 0.194 0.354 to 0.407 1.221 (31.01) 0.471 to 0.587 0.071 to 0.082
(4.65 to 4.93) (8.99 to 10.34) (11.96 to 14.91) (1.80 to 2.08)

17.375 (441) 0.182 to 0.194 0.399 to 0.457 1.371 (34.82) 0.531 to 0.651 0.068 to 0.080
(4.62 to 4.93) (10.13 to 11.61) (13.49 to 16.54) (1.73 to 2.03)

24.125 (613) 0.181 to 0.194 0.552 to 0.624 1.872 (47.55) 0.733 to 0.869 0.064 to 0.076
(4.60 to 4.93) (14.02 to 15.85) (18.62 to 22.07) (1.63 to 1.93)

Measuring Head End Clearance

for Forged Steel Tandem
Cylinders with Concentric
Valves

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Figure: Position Piston At Outer Dead Center 3. Dimension A: Measure from cylinder head
end to piston head end to the nearest
thousandth inch and record. See illustration.
4. Dimension B: With gasket removed, measure
from head end cylinder face to the gasket
seat and record.

1 Button Dial Indicator

2 Mirror

CAUTION

Completely vent compressor to relieve ALL gas pressure

and remove coupling spacer prior to removing access
covers for compressor internal maintenance. For electric
drive motors, lock out the breaker. Failure to follow
these steps can result in serious personal injury or death.

1. Set crank end piston clearance to the proper

feeler gauge specification stamped on the
cylinder data plate or printed in the Ariel
Technical manual.
2. With head end components removed,
position the piston for the desired cylinder at
outer dead center. Position a dial indicator to
index off of the crosshead or crosshead nut
outer face, with the cylinder near to outer
dead center. Manually turn crankshaft to find
the 0.010 inch (0.25 mm) position, before and
after outer dead center. Then turn crankshaft
to position piston at outer dead center (see
Figure: Position Piston At Outer Dead Center).

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5. Dimension C: 7. Compare calculated head end piston

clearance to clearance tolerances stamped
Norm. Thickness Use
on the cylinder data plate or printed in the
.030 .028 Ariel Technical manual. If tolerances are
unavailable or if calculated clearance is
.060 .055
outside tolerance, contact your packager
.060 .070* or Ariel before proceeding.
* Use when the cylinder has a removable liner with a 8. Measure head end piston clearance prior to
metallic tapered seat gasket between it and the new start up, as required by recommended
cylinder body (see ER-118).
maintenance intervals in Section 3, or after
installation, removal, or replacement of any
6. Calculate Head End Clearance: A - B + C = one of the following:
Head End Clearance
• Crankshaft
A _______________
• Connecting Rod
- B _______________
• Crosshead Guide
+ C _______________
• Piston and/or Piston Rod
= _______________
• Either Tandem Cylinder Body

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• Crosshead and/or Crosshead Nut

9. Re-assemble all components according to
the Ariel Maintenance and Repair Manual
supplied with your compressor. Verify
installation of all gaskets and manually bar
over the compressor to confirm the
crankshaft rotates freely.

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Frame Specifications
For more information, see the Ariel Performance Program.

Table: KBK Frame Specifications

Specification KBK/2 KBK/4 KBK/6

Stroke, in. (mm) 6.00 (152)

Maximum Allowable Speed 1200

a
, RPM

Minimum Speed b, RPM 600

Piston Speed c, FPM (m/s) To 1200 (6.10)

Horsepower, hp (kW) 1840 (1372) 3680 (2744) 5520 (4116)

Maximum Length, in. (m) 59 (1.50) 102 (2.59) 147 (3.73)

Maximum Overall Height, 29 (0.74) to top of aluminum cover

in. (m)

Maximum Width with See appropriate frame, guide, and cylinder outline drawings.
Cylinders

Height - Bottom to 17 (432)

Crankshaft Centerline, in.
(mm)

Approximate Weight with See Ariel Performance Program.

Cylinders

Connecting Rod Centerline 13.75 (349)

to Centerline, in. (mm)

Sump Capacity, US gal. (L) 18 (68) 39 (148) 60 (227)

Oil Pump Flow Rate d, GPM 26 (1.64) 35 (2.21) 48 (3.03)

(L/s)

Oil Heat Rejection BTU/hr 31,000 (9.1) 61,000 (17.9) 92,000 (27.0)
(kW)

Piston Rod Diameter, in. 2.00 (51)

(mm)

Internal Rod Load - Double Acting

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Specification KBK/2 KBK/4 KBK/6

Compression + Tension, 92,000 (409)

lbf. (kN)

Tension, lbf. (kN) 46,000 (205)

Compression, lbf. (kN) 50,000 (222)

Internal Rod Load - Single Acting

Tension, lbf. (kN) 46,000 (205)

a Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous opera-
tion. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than
Maximum Allowable Speed. Do not exceed the lower of frame rated speed, lowest cylinder rated (RPM), or driver
rated speed.
b Minimum Speed is the lowest frame speed needed to provide adequate oil flow to the compressor bearings.
c Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or
frame rated speed may be less, resulting in a lower piston speed rating.
d Flow rate at maximum rated speed and 180°F (82°C) oil.

Table: KBT Frame Specifications

Specification KBT/2 KBT/4 KBT/6

Stroke, in. (mm) 5.00 (127)

Maximum Allowable Speed 1500

a
, RPM

Minimum Speed b, RPM 750

Piston Speed c, FPM (m/s) To 1250 (6.35)

Horsepower, hp (kW) 1840 (1372) 3680 (2744) 5520 (4116)

Maximum Length, in. (m) 59 (1.50) 102 (2.59) 147 (3.73)

Maximum Overall Height, 29 (0.74) to top of aluminum cover
in. (m)

Maximum Width with See appropriate frame, guide, and cylinder outline drawings.
Cylinders

Height - Bottom to 17 (432)

Crankshaft Centerline, in.
(mm)

Approximate Weight with See Ariel Performance Program.

Cylinders

Connecting Rod Centerline 13.75 (349)

to Centerline, in. (mm)

Sump Capacity, US gal. (L) 18 (68) 39 (148) 60 (227)

Oil Pump Flow Rate d, GPM 30 (1.89) 37 (2.33) 61 (3.85)

(L/s)

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Specification KBT/2 KBT/4 KBT/6

Oil Heat Rejection BTU/hr 37,000 (10.8) 74,000 (21.7) 112,000 (32.8)
(kW)

Piston Rod Diameter, in. 2.00 (51)

(mm)

Internal Rod Load - Double Acting

Compression + Tension, 92,000 (409)

lbf. (kN)

Tension, lbf. (kN) 46,000 (205)

Compression, lbf. (kN) 50,000 (222)

Internal Rod Load - Single Acting

Tension, lbf. (kN) 46,000 (205)

a Maximum Allowable Speed is the highest (potential) speed at which the frame design permits continuous opera-
tion. Compressor frame data plate "Frame Rated Speed (RPM)" is application specific, and may be lower than
Maximum Allowable Speed. Do not exceed the lower of frame rated speed, lowest cylinder rated (RPM), or driver
rated speed.
b Minimum Speed is the lowest frame speed needed to provide adequate oil flow to the compressor bearings.
c Average Piston Speed is based on Maximum Allowable Speed (RPM). The cylinder data-plate rated speed (RPM) or
frame rated speed may be less, resulting in a lower piston speed rating.
d Flow rate at maximum rated speed and 180°F (82°C) oil.

Opposed Throw - To exchange opposing throw cylinder locations,

exchange all reciprocating components to the
Reciprocating Weight opposite throw, except the connecting rod
Balancing assemblies. Check the Balancing Record and
recalculate reciprocating weight differential,
Ariel recommends a reciprocating weight including the weight of the connecting rods. If
differential between opposing throws of 2.5 not within recommended limits, the compressor
pounds (1.1 kg) or less for KBK:T compressors. may require new crosshead balance nuts to
To replace a connecting rod assembly, piston, reduce differential.
piston and rod assembly, balance nuts, or If unable to balance opposing throws within
crosshead, weigh component parts on a scale recommended limits, contact the packager or
calibrated to 0.1 pound (0.05 kg) and compare to Ariel.When applying or re-applying a different
the Balancing Record in the compressor Parts cylinder to a throw, recalculate opposing throw
Book. If the weight changes, recalculate reciprocating weight differential; new balance
opposing throw reciprocating weight nuts and/or crossheads may be required. The
differential. If not within recommended limits,
the compressor may require new balance nuts
and/or crossheads.

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KBK-KBT Maintenance & Repair Manual – Frame Specifications 04/03/2023

force feed oil distribution system may also need

resized. Contact the packager or the Ariel
Response Center for detailed information about
recommended reciprocating weight differential
between opposing throws.

Table: KBK:T Approximate Component Weights, Lbs (Kg)

Component Weight Component Weight

Main/Connecting Rod 2 (1) Connecting Rod 91 (41)

Bearing

Top Cover 2-Throw 65 (29) Crosshead Guide (long 1135 (515)

single)

Top Cover 4-Throw 126 (57) Crosshead Guide (long 1330 (603)
two)

Top Cover 6-Throw 195 (88) Crosshead See Note a

Spacer Bar 32 (15) Crosshead Pin 25 (12)

End Cover Drive End 83 (38) Lube Oil Pump 2-Throw 44 (20)

End Cover Auxiliary End 130 (60) Lube Oil Pump 4-Throw 58 (26)

Crankshaft 2-Throw b 580 (263) Lube Oil Pump 6-Throw 110 (50)

Crankshaft 4-Throw b 1160 (526) Frame Assembly w/o See Ariel Performance
Cylinders Program.
Crankshaft 6-Throw b 1755 (796) VVCP
Cylinder Assembly
Main Journal Caps 30 (14)
Piston & Rod Assembly a
a For exact weights, see Balancing Record sheet provided by Ariel in the Parts Book for each compressor.
b Crankshaft weight is without flywheel.

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Compressor Clearance, Oil, & Temperature Record

SERIAL NO. F- MODEL DATE

CRANKSHAFT THRUST (END) CLEARANCE, In. (mm)

Crankshaft Serial Number Thrust Clearance, In. (mm)

CONNECTING ROD THRUST (SIDE) CLEARANCE, In. (mm)

Throw 1 Throw 2 Throw 3 Throw 4 Throw 5 Throw 6

JACK CLEARANCES, In. (mm)

Throw # 1 2 3 4 5 6

Main Bearing

Conn. Rod
Bearing

After new bearing installation, if measured clearances exceed tolerances in Appendix B, contact your
packager or Ariel before proceeding.

OIL PRESSURE AND TEMPERATURE

Date Time RPM Filter Inlet Oil Filter Outlet Oil Temp. into Remarks
Pressure psig Oil Pressure Frame °F (°C)
(barg) psig (barg)

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Throw BEARING CAP TEMPERATURE, °F (°C), AFTER RUN TIME OF a:

3 Minutes Idle Speed (engine, Additional 3-5 Minutes Additional 10-15 Minutes
VFD) Full Speed, No Gas Load Full Speed, Gas Load
1 Minute (single speed motor)
No Gas Load

Main Rod Main Rod Main Rod

a These minimum recommended test intervals may change based on driver restrictions. Regularly inspect running
gear for any debris or signs of abnormality. Bearing cap temperature should not be more than 10°F from each other
(compare mains and rods separately).

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Balance Valve Maintenance Log

Table: Balance Valve Maintenance Log
Div. Block Balance Div. Block
Pressure Gauge Pressure
Date Time Valve Set Cycle Time Notes
Description
Min. Max. Pressure (Seconds)

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Cleaning, Handling, and Assembly Lubricants for Non-

Lubricated Compressor Cylinders
Cleaning and handling are critical to prevent
NOTE: Clean all table surfaces and tools that will
premature wear and failure of non-metallic rings
come in contact with the cylinder, cylinder compo-
and packings in non-lube compressor cylinders. nents, or piston components
Proper cleaning and handling will virtually
eliminate oil and anti-seize compounds from the 1. Handle all cleaned parts with new or clean
cylinder interior, piston rod assembly, valve and “rubber” gloves or new white cotton gloves. If
packing case areas. In non-lubricated gloves become contaminated or dirty,
applications, the non-metallic rings and dispose of them and use a new pair.
packings transfer some material to the metallic 2. Clean cylinder interior surfaces thoroughly
running surfaces. This transferred film provides a with denatured alcohol until a clean, alcohol
“lubricated” surface that enables the soaked, white paper towel or lint-free rag
compressor to function properly. The presence removes no more debris. This includes all
of oil degrades the transferred film, forming an surfaces of the bore, counter bore, valve
pockets, suction and discharge gas passages,
abrasive paste that quickly wears non-metallic
nozzles, etc.
elements during operation. Anti-seize
compounds are oil based and also contain 3. Lubricate the threads, bolt head, and stat-o-
seal of the cylinder nozzle lube bolt with very
abrasive metallic components that cause
small amounts of Never-Seez, regular grade,
premature component wear. and ensure all mating surfaces are coated.
This procedure applies to all non-lube 4. Use a small amount of Loctite 567 Pipe
compressor cylinders. Ariel cleans and protects Sealant on male threads when installing pipe
complete non-lube cylinders to non-lube service plugs.
requirements before shipping. Follow the 5. Very lightly oil bolt threads and head seating
procedure below to clean internal parts shipped surfaces for valve cap, head, and packing
loose, replacement parts before installation, and case mounting bolts, but prevent oil
contaminated surfaces during maintenance. This penetration into the cylinder interior.
extends non-lube compressor component life, 6. Thoroughly clean piston, collar, rod, and nut
and ultimately, cylinder life. with denatured alcohol until a clean, alcohol
soaked paper towel or lint-free rag removes
CAUTION no more debris. Clean piston ring grooves
and wear band grooves especially well. Clean
Denatured alcohol presents health and safety hazards. piston rings and wear bands with denatured
Keep away from heat, sparks, flame and all other
alcohol before assembling.
ignition sources. Use adequate ventilation, neoprene or
butyl gloves, mono-goggles or face-mask, and 7. When assembling piston to rod, use very
impermeable apron. Contains methyl alcohol; small amounts of Never-Seez, Regular Grade
poisonous if ingested. Avoid eye and skin contact.
on the nut and collar, and ensure all mating
Properly handle and dispose of materials resulting from
clean-up. See manufacturer Material Safety Data Sheets surfaces are covered. Do not lube threads for
for details. the piston rod tensioner. Clean threads of
hydraulic tensioner and all other tensioner
surfaces that will contact the piston. Use very

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KBK-KBT Maintenance & Repair Manual – Cleaning, Handling, and Assembly Lubricants for Non-Lubricated 04/03/2023
Compressor Cylinders

small amounts of Never-Seez, Regular Grade clean them with denatured alcohol, then
on piston nut set screws. After assembly, reassemble. If they appear clean, they require
thoroughly wipe off all Never-Seez from the no additional cleaning provided they are
piston rod assembly exterior in the collar and sealed in their original packaging and have
nut areas with denatured alcohol until a not been contaminated.
clean, alcohol soaked, white paper towel or
13. Clean valve caps, retainers, high clearance
lint-free rag removes no more debris.
assemblies, and steel valve gaskets with
8. The manufacturer should provide packing denatured alcohol. Use only a very thin film of
cases cleaned, preserved, and suitable for oil for valve cap O-rings. Do not use anti-seize
non-lube service. Inspect packing cases for compounds or oil on steel valve gaskets.
cleanliness. If they appear coated with an oil- 14. Assemble cleaned parts immediately. If
based preservative, disassemble and clean cylinder will not see immediate service, see
them with denatured alcohol, then Ariel Engineering Reference ER-34 for
reassemble. If disassembly is required for preservation instructions. Contact Ariel for
water-cooled packing cases, re-assemble and latest version of ER-34.
test to Ariel Engineering Reference ER-51.
Contact Ariel for latest version of ER-51. CAUTION

9. Wipe down piston rod with denatured Do not use Ariel non-lube compressor cylinders for
alcohol after rod installation. oxygen service.

10. Clean VVCP or FVCP components with

denatured alcohol. Separate the unloader
head from the adapter/actuator. Clean all
internal surfaces with denatured alcohol
including behind the unloader piston. Do not
remove VVCP unloader stem seal. Clean
piston ring with denatured alcohol. Do not
use anti-seize compounds or oil on the steel
head gaskets. Use a very thin film of oil when
installing O-rings.
11. Clean crank-end head, head-end head, and
steel head gaskets with denatured alcohol.
Do not use anti-seize compounds or oil on the
steel head gaskets. If the crank-end head uses
an O-ring seal, apply a very thin film of oil to
the lead-in chamfer of the cylinder seating
surface to help prevent shearing of the O-
ring.
12. The manufacturer should provide
compressor valves cleaned, preserved, and
suitable for non-lube service. Inspect valves
for cleanliness. If they appear coated with an
oil-based preservative, disassemble and

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Hold-down Bolting to Resist Shaking Forces and Couples

in Reciprocating Compressors

Requirements
Figure: Hold-down Fasteners
1 Crosshead Guide-to-Support
Fastener(see Table: Crosshead Guide-to-
Support Fastener Torques)
2 Crosshead Guide Support Foot and
Frame Foot Hold Down Fastener (see
Table: Crosshead Guide Support Foot &
Frame Foot Hold-down Fasteners)

1. The torque values provided will achieve the 2. The torque values in Table: Crosshead Guide-
minimum clamp load necessary for opera- to-Support Fastener Torques achieve 50,000
tion. psi (345 MPa) prestress in the fasteners. Use
grade 8 or 9 bolting to hold crosshead guides
to supports.

Table: Crosshead Guide-to-Support Fastener Torquesa

Compressor Model Size inch - TPI Torque lb-ft (N•m)

KBK:T 1" - 14 395 (535)

a Guide supports purchased from Ariel ship with guide-to-support fasteners.

3. To use the torques in Table: Crosshead Guide material for metric sizes to meet the
Support Foot & Frame Foot Hold-down minimum clamp load necessary for opera-
Fasteners, the ultimate strength (Su) of the tion. Higher strength materials require higher
stud material must equal or exceed 100,000 torques than shown in the tables for added
psi (690 MPa); higher strength stud material is fastener stretch and preload. Material
preferred. In all cases, torque the nuts to strength and torque are directly propor-
stress the stud to about 55% of the ultimate tional. Example: for 120,000 psi (830 MPa)
strength of the stud material. Torques shown ultimate strength Imperial bolting: 120,000 ÷
in Table: Crosshead Guide Support Foot & 100,000 = 1.2 x min. torque for Imperial size
Frame Foot Hold-down Fasteners are based from table = required torque for given nut
on 100,000 psi ultimate strength material for size. To use a different stud diameter, consult
imperial sizes and 830 MPa ultimate strength Ariel for feasibility and torque.

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KBK-KBT Maintenance & Repair Manual – Hold-down Bolting to Resist Shaking Forces and Couples in Recipro- 04/03/2023
cating Compressors

Table: Crosshead Guide Support Foot & Frame Foot Hold-down Fasteners - Min. Torquesa

Foot Hold- Imperial (basis 100,000 psi) Metric (Class 8.8)c

down Hole
Compressor Min. Nut Recom. Stud Min. Nut
Fastener Diameter
Model Recom. Stud
inch (mm)
Size inch--TPI Torquee lb-ft Sized mm x Torqued lb-ft
Applicationb
(N•m) pitch (N•m)

KBK:T Guide 1-3/8 (35) 1-1/4 - 7 850 (1150) M30x3.5 850 (1150)
Support and
Frame M33x3.5 1170 (1590)

a See #1, "Requirements".

b Crosshead guide support feet and frame feet with counterbored holes are designed to accept 12-point fasteners. To
use hex head fasteners or studs and nuts instead, a washer thick enough to clear the counterbore is required to
provide adequate clearance for the fastener and any tooling used for installation. A washer is also recommended
for feet with holes that are milled flat.
c Ultimate Strength: 830 MPa (120,000 psi); Yield Strength: 660 MPa (95,700 psi).
d Where two sizes appear, the first is the preferred size, and the second is an alternate size.
e For a stud pitch other than those listed above in the same nominal diameter size, use this formula to determine
required torque: Torque = ( fastener torque) x (target fastener root area ÷ fastener root area).

4. Compressor frame foot hold-down studs and

crosshead guide support foot hold-down
studs listed in Table: Crosshead Guide
Support Foot & Frame Foot Hold-down
Fasteners should be as long as possible. Ariel
recommends a minimum 12 to 1 length to
diameter ratio.
NOTE: Fasteners long enough to reach only
through the compressor foot and a deck plate or
flange of an I-beam can loosen if not provided
with engineered devices to maintain fastener pre-
load.
5. Tighten nuts as recommended in step 3 to
maintain fastener pre-load during operation.
Ariel also recommends rolled threads and
hardened spherical washers for hold down
fasteners to help compensate for fastener-to-
frame surface angular misalignment.

6. Re-preserve any fasteners subject to corro-

sion after installation.

7. Follow lubrication guidelines and recom-

mended procedures for torque accuracy in
Appendix A.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Soft Foot and Top Plane Flatness Checks for Proper Main
Bearing Bore Alignment in Reciprocating Compressors
Main bearing bore alignment is critical to main can then be extended to 12 months or 8000
bearing and crankshaft life. Ariel manufactures hours.
the top cover mounting surface of a compressor
NOTE: If at any time frame hold down fasteners are
frame in close tolerance to a flat plane, to the loose, perform soft foot check and top plane flatness
main bearing bores, and to the bottom of the measurement. If a crankcase is damaged, top plane
compressor feet. The main bearing bores align flatness must be within tolerance prior to any
when frame feet are supported so the top cover machining in the shop or on site.
mounting surface is flat within a plane created by
two measurement points on one top rail and one
measurement point on the opposite top rail. Soft Foot Check
After establishing the plane, adjust frame feet to
1. Properly install and torque compressor frame
within acceptable limits. Frame flatness ensures
hold down bolting. See Appendix G for proper
the main bore is straight and not distorted. Level
frame foot and crosshead guide bolt size and
the compressor before flatness adjustment. For
torques.
leveling limits, see Appendix H in the Packagers
2. Loosen each corner hold down bolt individu-
Standards Manual.
ally while checking the frame foot to skid
A best practice is to install and use reference deflection with abcalibrated dial indicator.
pads to measure level and flatness during skid
3. Soft foot measurements on the middle hold
fabrication. Verify skid level and flatness is
down feet (hold down bolts located between
satisfactory on site using the pads. When
two guides) require both feet to be loosened
documented properly and duplicated, this
when taking individual soft foot readings. The
practice reduces labor to re-establish major
close proximity of the two individual feet
component alignment.
results in them acting as one foot. Refer to
KBE:K:T 6-throw frames require both a top plane Figure: Flatness Measurement Locations for
flatness and soft foot check. For KBE:K:T 2 and 4- KBE:K:T:C:D:F Frames to see both feet to
throw frames, the soft foot check is required; the loosen. Soft foot measurements are
top plane flatness measurement is optional. required on each foot individually.

Soft foot checks and top plane flatness 4. Record soft foot measurements on each foot
measurements are required: individually.
• On new installations or if a unit is relocated. 5. Correct any hold down position that deflects
Perform measurements both prior to skid more than 0.002 inches (0.05 mm) when
grouting and at final shaft alignment prior to
released. Retorque the hold down bolt or
initial startup.
bolts and repeat on each frame foot.
• At 6 months or 4000 hours to ensure skid
stability. If no changes are found, the interval

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KBK-KBT Maintenance & Repair Manual – Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore 04/03/2023
Alignment in Reciprocating Compressors

Top Plane Flatness Check based on the frame type as shown in figures
below. For proper alignment, readings
1. Remove or reposition the top cover(s) and
between any two adjacent points must be
gasket(s) to expose the frame top cover
within 0.002 in. (0.05 mm).
mounting surface. Verify it is clean.
NOTE: On frames with O-ring seal top covers, the 3. The ER-82 software tool determines if read-
frame top rail is lightly coated with Cortec VPCI ings meet ER-82 specifications, and if not,
368 corrosion inhibitor or equivalent to protect provides recommendations for shim correc-
the aluminum to cast iron joint. If the top cover is tions as well. Contact Ariel Technical Service
removed, clean both the top rail and the top cover
for the latest version of this tool.
and re-coat the frame top rail with a light coat of
the same compound. If VPCI 368 or equivalent is 4. Frame temperature can greatly affect flat-
not available, use marine grade grease. Apply ness readings. Factors such as direct sunlight
only a light coat of the corrosion inhibitor; do not
on a portion of the frame or cooling after unit
allow excess material to flow into the frame when
the top cover is installed. shut down can cause measurement inaccu-
racy. Ensure frame temperature is consistent
2. Use measurement equipment with a throughout the measurement process. Ariel
published accuracy of ±0.001 inches (0.025 recommends flatness measurement while
mm) over the distance required to measure the frame is at ambient temperatures to mini-
the entire length of both frame rails. Measure mize the effects of thermal expansion.
the top surface of both sides of the frame rails
NOTE: If the unit will not be restarted immediately,
re-preserve the unit in a manner appropriate to the
time duration until restart.

Figure: Flatness Measurement Locations for Frames with Single Anchor Bolts

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KBK-KBT Maintenance & Repair Manual – Soft Foot and Top Plane Flatness Checks for Proper Main Bearing Bore 04/03/2023
Alignment in Reciprocating Compressors

Figure: Flatness Measurement Locations for Frames with Pairs of Anchor Bolts

Figure: Flatness Measurement Locations for KBE:K:T:C:D:F Frames

1 Loosen both when taking soft foot.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Attachment of Wiring, Tubing, or Pipe Clamps to Ariel

Compressor Cylinders
DO NOT drill holes to mount wiring, tubing, secure unloader tubing or instrumentation lines.
instrumentation, or pipe clamps to any pressure The plug is designed for high pressure and will
containing component. Pressure containing not affect existing Ariel cylinder MAWP in any
components include cylinders, valve caps, application. Also, standard cylinder plugs may be
cylinder heads, unloaders, gas passage caps, and replaced with this plug without a hydrotest.
flanges. DO NOT use pressure containment Packagers may purchase this plug (A-28373)
fasteners to mount brackets or other structural through Ariel Parts Sales.
attachments. These practices can compromise
Newer Ariel cylinder designs include 1/4-20 UNC
the integrity of pressure containing components.
tapped holes to the milled pad that contains the
CAUTION cylinder indicator port holes (see Figure: Typical
Cylinder Plugs and Tapped Holes). These extra
Do not drill holes in any pressure containing
components for any reason. tapped holes will provide additional
accommodation to clamp unloader tubing or
Figure: Typical Cylinder Plugs and Tapped Holes instrumentation lines.

Alternate Attachment Method

An alternate method to attach clamps to
compressor cylinders is to use an epoxy resin.
Ariel recommends Loctite 331 or Loctite 332
applied to clean, unpainted metal. Follow all
manufacturer instructions and
1 Standard Plug recommendations to prepare the area for the
2 Plug A-28373 adhesive. The clamp and unpainted surface can
3 New 1/4-20 UNC Tapped Holes be painted after the adhesive cures. This clamp
Ariel offers a 1/2-inch NPT pipe plug with a 1/4-20 attachment method does not compromise
UNC tapped hole to accommodate a tubing cylinder integrity.
clamp or bracket (see Figure: Typical Cylinder
Plugs and Tapped Holes). Installing this plug in
cylinder indicator ports provides locations to

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Recommended Maintenance Intervals for Intermittent

Duty Operation
Ariel compressors, like all industrial equipment, 2,000-Hour Maintenance
require maintenance. The severity of compressor
service directly influences the frequency and 1. Perform Daily and 400-Hour maintenance.
amount of maintenance needed. What follows 2. Drain and replace force feed lubricator box
are the recommended intervals for inspections oil.
and replacements for intermittent duty 3. Where applicable, clean sintered element in
operation. This will help you determine the the small oil filter on the force feed
appropriate intervals for a given compressor lubrication system now or at every main oil
application. filter change. Use a suitable solvent. Where
applicable, replace force feed lubricator inlet
NOTE: For continuous duty service, see "Recom- filter in independent supply system.
mended Maintenance Intervals for Continuous Duty 4. Change compressor oil filter. See top cover
Operation". filter information plate or “Oil Filter” in Frame
Oil System Components for procedure. Do
not exceed 12 month installed period for filter
NOTE: Careful documentation of inspection results is
element.
critical to establish whether recommended intervals
NOTE: For replaceable element style filters, drain the
are adequate or require more or less frequency.
canister completely before removing the element.
Inspect elements for cleanliness and damage. Do not
install dirty or damaged elements.
400-Hour Maintenance 5. Change compressor oil. Extremely dirty
1. Perform Daily maintenance. environments, oil supplier
recommendations, or oil analysis may dictate
2. Sample frame oil and send to a reputable a different oil change interval. Follow these
lubricant lab for analysis. See "Oil Sampling" steps:
for a list of what an oil analysis should
a. Drain oil from frame, associated piping,
provide.
and oil cooler.
• If analysis results indicate increasing
levels of lead, tin, or copper particles in b. Clean oil strainer with a suitable solvent.
the oil, shut down unit. Remove frame top In dry sump applications, the strainer is
cover and crosshead guide side covers. located at the oil reservoir.
Visually inspect for debris. Do not disas- c. Remove frame top cover and crosshead
semble further without good reason. guide side covers. Visually inspect for
• If debris indicates, replace affected parts, debris. Do not disassemble further
then change oil, oil filter, and clean the without good reason. If debris indicates,
strainer with a suitable solvent. replace affected parts, then change the oil
filter and clean the strainer with a suitable
NOTE: Operate the unit to bring oil temperature to a solvent.
minimum operating temperature of 150°F (66°C) to d. Refill frame with fresh, clean oil.
drive off any entrained water
e. Visually inspect the crankcase for debris
or other foreign material. Disassembly is

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KBK-KBT Maintenance & Repair Manual – Recommended Maintenance Intervals for Intermittent Duty Operation 04/03/2023

not recommended unless a reason is Measurement", and "Crankshaft Thrust

found to do so. (End) Clearance Measurement".
f. Check for adequate cylinder lubrication. NOTE: Clearance trends along with oil analysis and
See “Cylinder Lubrication Paper Test” for crankcase visual inspection can indicate the need for
procedure. bearing replacement. Do not disassemble to check
clearances. Disassemble only if clearance checks indi-
6. Grease VVCP stem threads at grease fitting, cate excessive clearance. Contact Ariel for original
with 2 to 3 pumps of cylinder lube compatible assembly clearances.
grease using a standard manual grease
pump. Turn VVCP adjustment handle all the b. Crosshead to guide clearances. See
way in and all the way out to lubricate the “Crosshead Installation” in Section 4.
threads. Measure or count turns to return the c. Piston rod runout. See “Piston Rod
handle to its original position. Runout” in Section 4.
If any of the above items are outside limits , find
the cause and correct it. It may require part
4,000-Hour Maintenance replacement.
1. Perform Daily, 400-Hour, and 2,000-Hour 7. Remove valves and valve gaskets:
maintenance. NOTE: If using CP/CPs/XP valves, valve maintenance
2. Verify safety shutdown functionality. may be extended to the 8,000 hour or 22,000 starts
interval.
3. Inspect crankcase breather filter and clean
with suitable solvent. a. Visually inspect valve pockets for
damage. Verify all old valve seat gaskets
4. Open force feed lubricator box and visually are removed.
inspect pump followers, cams, and gears for
wear. b. Have a qualified valve repair shop disas-
semble, visually inspect, and refurbish
5. Pressure test distribution blocks. See the valves where needed. Provide the
“Distribution Block Assembly” for procedure. valve repair shop an Ariel torque chart
6. Measure, log, and trend the following: and valve service guide.
a. Main bearing, connecting rod bearing, c. Visually inspect cylinder gas passages and
and crankshaft jack and thrust clear- clean them of all debris.
ances. See "Main Bearing Vertical Jack 8. If applicable, visually inspect suction valve
Clearance Measurement", "Connecting unloader actuator stems for damage or wear.
Rod Bearing Vertical Jack Clearance Visually inspect stem seals for damage or
wear and confirm that the actuator moves
freely.
9. If applicable, visually inspect pneumatic
clearance pockets for damage or wear
(seating surface and stems/stem seals).
Confirm that actuator moves freely.
10. Inspect cylinder bores for damage or wear.
Replace the cylinder body or restore the bore
if any of the following conditions exist:
• Bore surface blemishes or gouges.

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KBK-KBT Maintenance & Repair Manual – Recommended Maintenance Intervals for Intermittent Duty Operation 04/03/2023

• Bore out of round more than 0.001 inch 17. Check and re-calibrate all required
per inch of bore diameter (0.001 mm/mm) instrumentation.
or tapered.
18. If the compressor is equipped with crankcase
• Main bore is worn to counterbore diam- over-pressure relief valves, visually inspect
eter or larger. and exercise valves to manufacturer
11. Inspect piston rings and wear bands: recommendations.
• Measure and log piston ring condition, 19. Check auxiliary end chain drive for undercut
end gap, side clearance, and piston ring sprocket teeth and chain for excessive
groove width. stretching. Replace as required. See “Chain
• Replace rings that are damaged or Adjustment” in Section 4 for procedure.
outside limits listed in Appendix B. 20. Check fastener torques of gas nozzle flange,
• When replacing rings, re-measure and log head end head, valve cap, piston rod packing,
ring side clearance to check for groove crosshead pin through bolt, frame hold
wear. down, crosshead guide to cylinder, distance
• Measure and log radial projection of wear piece to cylinder, and tandem cylinder to
band. cylinder.
12. Inspect piston rods for damage and excessive
wear. Replace rod if any of these conditions 8,000-Hour or 22,000 Starts
exist (see "Piston Rod Inspection"):
• Gouges or scratches on the rod.
Maintenance (whichever
• Under size more than 0.005 inch (0.13 occurs first)
mm).
1. Perform Daily, 400-Hour, 2,000-Hour, and
• In the packing travel length, out of round 4,000-Hour maintenance.
more than 0.001 inch (0.03 mm).
• Anywhere in the packing travel area, 2. Replace crankshaft main and connecting rod
tapered more than 0.002 inch (0.05 mm). bearing shells if no replacement has occurred
in the past 8,000 hours or 22,000 starts.
13. Re-tighten hold down fasteners to proper
torque. Visually inspect cylinder gas passages 3. If using CP/CPs/XP valves, remove valves and
and clean them of all debris. Inspect for frame valve gaskets:
twist or bending to verify main bearing bore a. Visually inspect valve pockets for
alignment. See Appendix E for flatness and damage. Verify all old valve seat gaskets
soft foot requirements. are removed.
14. Perform a coupling alignment (see "Initial b. Have a qualified valve repair shop disas-
Maintenance"). semble, visually inspect, and refurbish
the valves where needed. Provide the
15. Rebuild piston rod pressure packing cases valve repair shop an Ariel torque chart
and oil wiper cases. See “Piston Rod Packing” and valve service guide.
in Section 4 for procedure.
c. Visually inspect cylinder gas passages and
16. Re-install valves, retainers, and valve caps clean them of all debris.
using new valve gaskets and valve cap o-
rings/seals. Use proper installation
techniques and torque procedures for valve
caps. See “Valve Installation” in Section 4.

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KBK-KBT Maintenance & Repair Manual – Recommended Maintenance Intervals for Intermittent Duty Operation 04/03/2023

16,000-Hour Maintenance
1. Perform Daily, 400-Hour, 2,000-Hour, 4,000-
Hour, and 8,000-Hour maintenance.
2. Remove crosshead pins.
a. Measure and log crosshead pin to cross-
head pin bore and connecting rod
bushing bore clearances.
b. Check the crosshead pin end caps and
through bolt for wear.
c. Replace if needed.
3. Check for bushing wear in the auxiliary end
drive chain tensioner.

32,000-Hour Maintenance
1. Perform Daily, 400-Hour, 2,000-Hour, 4,000-
Hour, 8,000-Hour, and 16,000-Hour
maintenance.
2. Replace lubricator distribution blocks.
3. Replace crosshead and connecting rod
bushings. See “Crossheads” in Section 4 and
“Connecting Rods” in Section 4.

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KBK-KBT Maintenance & Repair Manual 04/03/2023

Latest Manual Revisions

04/03/2023
Topic Change Description

2,000-Hour Maintenance Inserted #3 'Where applicable, clean sintered...' (inadvertent AEM transition
deletion). Added new #6 'Grease VVCP stem threads...'

4,000-Hour Maintenance #7: Inserted note '• If using CP/CPs/XP valves, valve maintenance may be
extended to the 8,000 hour or 22,000 starts interval.' Inserted #8 'If applicable,
visually inspect suction valve unloader...' (inadvertent AEM transition
deletion). Inserted #9 'If applicable, visually inspect pneumatic clearance
pockets...' (inadvertent AEM transition deletion). #11 - inserted 'and
wearbands' and 'Measure and log radial projection of wear band.'
(inadvertent AEM transition deletions). Inserted #18 'If the compressor is
equipped with crankcase over-pressure...' (inadvertent AEM transition
deletion).

8,000-Hour or 22,000 Starts Added step #3 with sub-steps for CP/CPs/XP valves.
Maintenance (whichever occurs first)

Daily Maintenance #4: inserted 'and VVCP'.

One-Year (8,000-Hour) Maintenance Deleted step #2. #5 (was #6) - Inserted note '• If using CP/CPs/XP valves, valve
maintenance may be extended to 2 year (16,000 hour) interval.' Inserted new
step #6 - 'If applicable, remove, disassemble and visually inspect the variable
volume clearance pockets (VVCP). Check for damage or wear of all sealing
components and surfaces, and repair or replace if necessary.'

Six-Month (4,000-Hour) Maintenance Inserted new step #8: 'Grease VVCP stem threads at grease fitting, with 2 to 3
pumps of cylinder lube compatible grease using a standard manual grease
pump. Turn VVCP adjustment handle all the way in and all the way out to
lubricate the threads. Measure or count turns to return the handle to its
original position.'
Six-Year (48,000-Hour) Maintenance #6: 'Service or replace' WAS 'Replace'.

Two-Year (16,000-Hour) Maintenance #6 - Inserted new #2 with substeps for CP/CPs/XP valves.

VVCP Reassembly 1st ¶: Added 'Rebuild kits are available through your Ariel Parts Distributor.'

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