Pinnacle LF-2230 Compressor

Transcription

Pinnacle LF-2230
Compressor
Installation, Operation, and Maintenance Manual
Visit us at www.sundyne.com
Rev. --, Effective May 2001
Pinnacle LF-2000 IOM Manual
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COPYRIGHT
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise without the prior permission of Sundyne Corporation.
© 2001 Sundyne Corporation
WARRANTY
Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being
placed in service (but not to exceed eighteen (18) months after the date of shipment) that the
equipment at the time of shipment will be free from defects of design, material and workmanship. If
any defects or malperformance occur during the warranty period, Sundyne’s sole obligation shall be
limited to alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or
equipment, which upon return to Sundyne and upon Sundyne’s examination prove to be defective.
Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and
by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to
equipment caused by abnormal conditions, vibration, failure to properly prime or to operate
equipment without flow or caused by corrosives, abrasives or foreign objects. THE FOREGOING
WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY
OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable for
consequential or incidental damages.
Using This Manual:
This manual is part of the final data package for the Sundyne Pinnacle LF-2000 compressor. In
addition to this manual, the final data package includes such information as the following:
Drawings, Sundyne specification sheet with test performance curves, test data, inspection data,
material certificates if required; and auxiliary equipment information.
This manual explains procedures for the Sundyne compressor, including how to: install it, maintain it,
service it, troubleshoot problems; and order parts. Whenever you talk or write to your Sundyne
representative, provide your compressor’s unique serial number.
Throughout these instructions, item numbers are provided in parenthesis. Refer to the Compressor
Gearbox drawing CG01GC03 (see Section E in this manual) for a cross-section view with item
numbers identified, and the unit BOM (see Section E in this manual) for part numbers corresponding
to each item number.
This manual is divided into sections for ease of use, each with their own page numbering and table
of contents, as follows:
Section A:
General Installation and Operation Instructions
Section B:
Compressor End Assembly and Disassembly
Section C:
Gearbox Assembly and Disassembly
Section D:
Operating Logic
Section E:
Unit Specific Data
Icons Used in this Manual
The following icons (symbols) are used to indicate specific types of information.
Good ideas to use. A reminder to do something.
Equipment use alert. Unless you follow these procedures correctly, the equipment may be
damaged.
Safety alert. Failure to follow these procedures can endanger the safety of you or others.
Electrical hazard. Failure to follow these procedures can endanger the safety of you or
others.
General Installation and Operation
Section A
Section A
Instructions
Section A
TABLE OF CONTENTS – SECTION A
Section Description
I.
Page No.
SAFETY............................................................................................................................................................................1
SAFETY W ARNING .............................................................................................................................................................. 1
SUGGESTED SAFETY INSTRUCTIONS................................................................................................................................ 1
II.
INTRODUCTION TO THE SUNDYNE COMPRESSOR ........................................................................................3
INTRODUCTION TO THE SUNDYNE COMPRESSOR......................................................................................................... 3
III.
LIFTING INSTRUCTIONS.......................................................................................................................................4
LIFTING OF UPPER HOUSING ............................................................................................................................................. 5
LIFTING OF GEARBOX A SSEMBLY..................................................................................................................................... 5
LIFTING OF COMPRESSOR END A SSEMBLIES................................................................................................................... 6
LIFTING OF ENTIRE COMPRESSOR AND GEARBOX A SSEMBLY .................................................................................... 7
IV.
INSPECTION, STORAGE, AND INSTALLATION.............................................................................................8
INSPECTION .......................................................................................................................................................................... 8
SHORT -TERM STORAGE − 1 DAY TO 6 MONTHS............................................................................................................ 8
LONG-TERM STORAGE − 6 MONTHS OR MORE ............................................................................................................... 8
INSTALLING THE SUCTION AND DISCHARGE PIPING.................................................................................................... 9
SEAL ENVIRONMENT CONTROL SYSTEM ..................................................................................................................... 10
BASEPLATE M OUNTING................................................................................................................................................... 11
DRIVER AND COUPLING.................................................................................................................................................... 11
V.
SERVICING...................................................................................................................................................................13
GENERAL REQUIREMENTS............................................................................................................................................... 13
GEARBOX OIL SPECIFICATION........................................................................................................................................ 13
REGULAR M AINTENANCE ................................................................................................................................................ 15
VI.
START-UP/OPERATION/SHUTDOWN.............................................................................................................15
SURGE CONTROL ............................................................................................................................................................... 16
SUCTION THROTTLING .................................................................................................................................................... 16
DISCHARGE THROTTLING ................................................................................................................................................ 16
SPEED CONTROL ............................................................................................................................................................... 16
VII.
TROUBLESHOOTING...........................................................................................................................................18
GEARBOX AND COMPRESSOR........................................................................................................................................... 18
COMPRESSOR M ECHANICAL SEALS................................................................................................................................ 21
VIII.
SPARE PARTS.........................................................................................................................................................22
GENERAL ............................................................................................................................................................................. 22
RECOMMENDED SPARE PARTS ....................................................................................................................................... 22
REPAIR KITS....................................................................................................................................................................... 22
ORDERING SPARE PARTS.................................................................................................................................................. 22
I.
Section A, Page 1
Safety
Safety Warning
Sundyne Corporation manufactures pumps and compressors to exacting International Quality
Management System Standards (ISO 9001 - 1987) as certified and audited by Lloyd’s Register
Quality Assurance Limited. Genuine parts and accessories have been specifically designed and
tested for use with these products to ensure continued product quality and performance. As
Sundyne Corporation cannot test all parts and accessories sourced from other vendors, incorrect
design and/or fabrication of such parts and accessories may adversely affect the performance and
safety features of these products. Failure to properly select, install, or use authorized Sundyne
Corporation parts and accessories is considered misuse, and damage or failure caused by misuse is
not covered by Sundyne Corporation’s warranty. Additionally, modification of Sundyne
Corporation products or removal of their original components may impair the safety of these
products and their effective operation.
Suggested Safety Instructions
During installation, maintenance, or repair operations of Sundyne Corporation pumps or
compressors, systems for safety shall be applied before the commencement of work. Failure to
take responsibility for safety may lead to operator injury.
Personal Protective Equipment (PPE) safety glasses with side shields shall be worn by all personnel
installing or performing maintenance or repair on the equipment. If equipment to be manually lifted
is over 7kg (15 pounds), or if pallet jacks or forklifts are to be used, the person shall wear safety
toed shoes. When testing the equipment, hearing protectors (ear defenders) are recommended to
be worn if noise levels exceed 85 dB over the work day. Chemical resistant gloves shall be used if
chemical use is required (see Chemical Use below for additional information). If chemicals have
warnings regarding fumes and/or dust/mists, a dust mask respirator shall be worn.
When selecting one piece of PPE to be used with another, consider the compatibility between them.
For example, safety glasses should not interfere with the seal from hearing protectors to protect
hearing. Be sure to clean the PPE after each use.
Use of Forklifts: All forklift drivers must have a current recognized license. If using a forklift, first
ensure that the lift is in safe operating condition.
Section A, Page 2
Electrical Safety: Installation, Service, Repair: Ensure all electrical sources are off and safe to
install, service, and/or repair the equipment. A recognized Lockout/Tagout program should be
followed - Locks and/or tags should be provided warning employees that the equipment is being
installed, serviced, and/or repaired. Once the work is completed, the person installing the lock
and/or tag shall remove it and inform others of start-up. Should there be a shift change, the lock
and/or tag shall be removed by the first authorized person and the lock and/or tag shall be installed
by the second shift authorized person.
Testing Equipment: Persons in the immediate area shall be warned when a test is to be performed.
Tools: Tools shall be insulated from electrical shock. Ensure all tools are clean and free of oil and
the insulation is not damaged in any way.
Chemical Use: Any chemicals to be used shall be accompanied by a relevant Hazard Data Sheet, in
accordance with your government legislation. If applicable, chemical proof gloves shall be used.
An eye wash station (or equivalent) should be available in the event of injury. If any hazardous or
flammable chemicals have flowed through the equipment a complete decontamination of the
equipment is required.
Fall Protection: When working over six feet from the ground, fall protection is required.
Machine Guarding: Guards shall remain in place on all equipment. Only during maintenance/repair
can the guards be removed, and prior to start-up, the guard must be replaced.
Lock-out/Tag-out Guidelines: Follow Your Companies Lock-Out / Tag-Out Procedure When
Servicing Sundyne Compressors. Never remove a lock or tag applied by someone else. Additional
locks or tags should be applied if multiple groups are working on the equipment. Each responsible
work group leader should apply a lock or tag. Always treat conductors and equipment as if they are
energized.
II.
Section A, Page 3
Introduction to the Sundyne Compressor
Introduction to the Sundyne Compressor
Sundyne Pinnacle LF-2000 compressors have 1 to 4 compressor stages mounted to an integral
gearbox, which increase the pressure of a continuous flow gas by applying centrifugal action.
Sundyne Pinnacle LF-2000 compressors are most commonly used in chemical process plants to
increase the pressure in a recycle loop. They are also used in refineries, petrochemical plants, and
power generation plants. Within these facilities, Sundyne Compressors are used in booster,
regeneration, vapor recover, boil-off, and other gas process applications.
Sundyne Pinnacle LF-2000 compressors offer industrial quality in a compact unit that features high
reliability and ease of operation. It provides high-energy performance and competitive efficiencies.
For detailed specifications for Sundyne Pinnacle LF-2000 compressors, see the specification sheet
and bill of materials or consult Sundyne Compressors. For the primary components, see Section E,
Unit Specific Data.
For information about additional custom equipment for the basic Sundyne LF-2000 products, see
the brochure that accompanies this manual.
III.
Section A, Page 4
Lifting Instructions
It is extremely important for the safety of personnel that proper lifting procedures be
followed for the Sundyne product. Lifting should only be done by trained personnel, using adequate
lifting equipment, and by connection to proper lifting points on the Sundyne equipment. The
following are instructions specific to utilizing the proper lifting provisions for the Sundyne equipment,
and are meant to supplement your company’s training, experience, and procedures.
Table 2
Approximate Component Weights
Component
Approx
Weight (lbs)
Upper Gearbox Housing (101) only
1000
Lower Gearbox Housing (101) Assembly,
with Input Shaft Assembly (120),
High Speed Shafts (130 & 140), and Bearings (154)
4500
Input Shaft Assembly (120)
1000
Entire Gearbox Assembly, without Compressor Ends
5500
Compressor Case (1), P/N HO03GC01 (4”x12”)
800
Compressor Case (1), P/N HO03GC03 (6”x15.5”)
1325
Compressor Case (1), P/N HO03GC05 (6”x19”)
1675
Entire Compressor End Assembly, 6”x4”x12”
1500
Entire Compressor End Assembly, 6”x6”x15.5”
2250
Entire Compressor End Assembly, 8”x6”x19”
2900
Section A, Page 5
Lifting of Upper Housing
Two lifting eyes (851) are provided on top of the upper gearbox housing (101 upper), capable of
lifting the upper housing alone, NOT for the entire gearbox assembly. The housing center of gravity
lies between these lifting eyes, and therefore the housing will not tip forward or backward when the
lifting eyes are used.
Lifting Eyes for Upper
Housing Only
Lifting of Gearbox Assembly
Four lifting lugs (852) are provided on the lower gearbox housing (101 lower), two at each end,
capable of lifting the entire gearbox assembly including upper and lower housings, shafts, gears, and
bearings. The assembly center of gravity lies between these lifting eyes, and therefore the housing
will not tip forward or backward when the lifting lugs are used (as long as there are not any
compressor ends attached – see Lifting of Entire Compressor Assembly).
DO NOT ATTEMPT TO LIFT
BY UPPER HOUSING EYES
Lifting Lugs for Gearbox
Assembly
Lifting Lugs for Gearbox
Assembly
Section A, Page 6
Lifting of Compressor End Assemblies
Each compressor case (1) has four lifting lugs welded at 90 degree positions around the outside of
the case, each of which is capable of lifting the entire compressor end assembly including inlet
housing, diffuser, shroud, seals, and seal housing. Use the lug that is positioned at the top of the
assembly.
The cases and compressor end assemblies will hang at an angle when lifted by the lug. This
means that when removing from the gearbox mounting, the assembly may move abruptly from the
mounting orientation to a hanging angle, and can potentially cause harm during this process. Be
extremely careful of the assembly movement during lifting.
DO NOT ATTEMPT TO LIFT
BY PIPING
Lifting Lugs for
Compressor End Assembly
(4 per case, use top lug)
Section A, Page 7
Lifting of Entire Compressor and Gearbox Assembly
Four lifting lugs (852) are provided on the lower gearbox housing (101), two at each end, capable
of lifting the entire compressor and gearbox assembly, including upper and lower housings, and
compressor ends.
Lifting Lugs for Entire
Compressor Assembly
Inlet Flanges for Lifting
Compressor Assembly
With compressor ends mounted to the
gearbox, the assembly center of gravity may lie
outside of these lifting eyes, especially with
two compressor ends on one side and none on
the other side to provide counter balance.
Therefore two of the lugs will become
ineffective as the assembly tilts forward. To
account for this, attach chains around the inlet
flanges of the compressor end assemblies,
while also utilizing the two rear lifting lugs. The
front two lifting lugs may be utilized if desired,
but are not necessary.
IV.
Section A, Page 8
Inspection, Storage, and Installation
Inspection
1.
When you receive the Sundyne LF-2000 compressor, check for any
damage. If you find any, inform the carrier and Sundyne Corporation
promptly.
2.
Use Outline drawing, Compressor and Gearbox drawings and bill of
materials to ensure that all auxiliary items are properly included.
3.
Check the input shaft carefully. Seal drag may cause it not to turn
freely at first. This is normal. But if the shaft binds, it may be
damaged.
Short-term Storage − 1 day to 6 months
1. If the compressor is to be stored near strong chemicals or salt water,
protect it immediately. To do this, follow steps 8 through 11 from the
long-term storage procedures. Failure to protect the compressor and
the auxiliary equipment could result in damaged parts.
2.
Protect the unit from moisture and dust.
3.
Make sure that the factory’s shipping covers for the housing flanges
and the seal ports are securely in place.
4.
Carefully follow the instructions provided by the manufacturer of the
motor or turbine driver. If the motor was provided by Sundyne, then
the motor manual is included in the Final Data package.
Long-term Storage − 6 months or more
If you store the LF-2000 for a long period, the methods you use are very
important. Please contact Sundyne at +1 303 425-0800, Arvada,
Colorado, U.S.A. or +33 3 8038 3300, Longvic Cedex, France and ask
for the Field Service Department for further instructions. Failure to store
the Sundyne equipment correctly can cause damage to the components.
1. The best way to store the unit is to purge the gearbox and lube oil
system with Nitrogen to prevent condensation and dust from
penetrating into internal components. Otherwise, be sure the storage
area has:
♦ Relative humidity of 80% maximum; and
♦ Temperature range from 45° − 85°F (7° − 29°C).
2. Make sure drain valves are open to allow any condensation to drain.
Section A, Page 9
3.
Coat internal parts of gearbox, wet end, and lube oil reservoir with oil
soluble rust preventative.
4.
If the auxiliary lube system is available, circulate the oil and manually
spin the bull gear once a month.
5.
Do not allow contact of airborne chemicals with the internal
components of the unit.
6.
If the unit is being stored near strong chemicals or salt water, protect it
immediately.
7.
Protect the unit from moisture and dust.
8.
Make sure that the factory’s shipping covers for housing flanges and
seal ports are securely in place.
9.
Store the unit indoors.
10. Use desiccant bags to absorb moisture.
11. After long-term storage, have an authorized Sundyne service engineer
inspect all components to be sure that they work properly. Any
components not made by Sundyne (except mechanical seals) must be
inspected or replaced by the manufacturer’s authorized personnel, at
the purchaser’s expense.
Because the storage location and unknown factors at the site of
storage are beyond our control, Sundyne Corporation does not
accept any liability for damage to the equipment during storage, nor
do we guarantee the quality of the equipment during and after the
storage period.
Installing the Suction and Discharge Piping
Guidelines:
1. Clean the suction line.
2.
Install a suction strainer to protect the impeller from damage by mill
scale, welding slag, or other foreign particles.
3.
Make sure that the piping is aligned with the compressor flanges. A
general rule is to align the flanges with 1/16 inch (1.6 mm) maximum
misalignment between parallel flange faces.
4.
Support all piping independently of the compressor.
5.
When you move the piping into place, never use excessive force at the
flanged suction and discharge connections. This could strain the unit.
Section A, Page 10
6.
Use suction pipe that has a diameter at least as large as the diameter of
the suction inlet of the compressor.
7.
Make sure that the suction and discharge piping have no unnecessary
elbows, bends, and fittings. These increase the losses caused by
friction. Also, be sure that all piping and fittings are large enough to
minimize losses caused by friction.
8.
Before you connect the piping to the compressor, tighten the holddown bolts on the compressor.
Leave a straight length of pipe, which is at least ten times the diameter
of the pipe, between an elbow and the suction flange. If you use
elbows at all, use only long-radius elbows.
9.
Use block valves on both suction and discharge pipes to isolate the
compressor during shutdown, minimize process leakage, and reduce
the likelihood of backflow through the compressor, which can cause
reverse rotation.
Seal Environment Control System
For the seal used with the compressor, always maintain the environment
shown on the specification sheet for your unit. For some arrangements and
applications, you may need a system to control the seal environment. For
many applications, you can obtain a standard system from the factory.
Make sure that the system is installed properly and that the ports are open
or plugged. See Process and Instrumentation Diagram (P&ID) on the
outline drawing provided in the final data package.
You must drain all case drain ports and all gas tubing lines for liquid and
reclose all drain ports previously identified before startup. Any liquid in the
process loop can cause damage to the compressor components. Any liquid
or contaminants in the seal system can damage the gas seals.
The gas seal system is shown in the outline drawing. The logic description is
located withing this manual in Section D, Compressor Operating Logic.
Section A, Page 11
Baseplate Mounting
The baseplate must be leveled on the foundation using the leveling screws
mounted in the base’s beam bottom flanges. Use steel leveling pads
between the leveling screws and concrete foundation. Level the baseplate
so that the compressor and motor machined pads are within .002 in/ft (.17
mm/m). After leveling fasten all of the anchor bolts.
Figure 1.1, Cross-section for Baseplate Mounting (Grout Optional)
Driver and Coupling
The motor and compressor coupling is installed at the factory if the motor
was provided by Sundyne (to locate the motor foot holes). Otherwise, the
motor foot holes will have to be drilled in the field. In either case, the motor
will require realignment at the field site.
Alignment of the compressor and motor will take place after grouting and
before connecting the suction and discharge piping. Ensure that the
compressor is fastened to its mounting plate. Using the motor jack screws
and motor foot shims align the motor to the compressor with the coupling
installed and connecting the two machines. During alignment thrust the
compressor-input shaft toward the motor. It is recommended that laser
alignment equipment be used to perform the alignment.
Section A, Page 12
Alignment Parameters
Parallel misalignment allowed
.004 in (.101 mm)
Equivalent Angular
displacement allowed
Axial displacement allowed
.004 in (.101 mm)
+/- .010 in (+/- .254 mm) from
nominal axial length
Do not use tolerances given by the coupling manufacturer as these
tolerances indicate the maximum values the coupling can survive. Too large
tolerances will cause added vibration, bearing damage, etc., and therefore it
is recommended to align the motor as close to perfect as possible.
Temperatures have considerable influence on alignment and should be
considered during alignment. Thermal growth of compressor can be
estimated by the equation ∆H α. ( ∆T. H ) during cold alignments.
The following is the expected thermal growth of a Pinnacle LF-2000
gearbox, which is independent of the process temperatures:
Thermal Equations and Cold Offset Calculation
Description
Thermal growth coefficient (for
steel)
SI units
(K = Kelvin)
α = 1.512
-5
1
English units
(R = Rankine)
α
K
Expected change in LF-2000
gearbox temperature
∆ T = 33.3 K
∆T
Height of LF-2000 gearbox
shaft from mounting pad
H = 647.7 mm
H
The change in LF-2000 shaft
height due to thermal growth
∆H
∆H
Cold Offset (of motor shaft
above LF-2000 shaft)
∆ H = 0.3261 mm
8.4 10
α. ( ∆T. H )
-6 1
R
60 . R
25.5 . in
α. ( ∆T. H )
∆ H = 0.0129 in
Section A, Page 13
After cold alignment is complete and all systems are connected properly the
motor and compressor should be operated until running temperatures are
reached (approximately 2 hours). Shut down the unit and check to ensure
the alignment is still within tolerances. If tolerances are out then adjust the
alignment to be true in the hot condition. Draw up a record for future
checks.
V.
Servicing
Lock-out/Tag-out Guidelines
Follow Your Companies Lock-Out / Tag-Out Procedure When Servicing Sundyne Compressors.
Never remove a lock or tag applied by someone else. Additional locks or tags should be applied if
multiple groups are working on the equipment. Each responsible work group leader should apply a
lock or tag. Always treat conductors and equipment as if they are energized.
General Requirements
To increase the operating life of your compressor and keep it in good operating
condition, you should inspect and service it regularly. Measure all of the operating
parameters as documented in the specific maintenance procedures and log your
measurements.
Make sure that all major equipment, such as lubricating pumps, heat exchangers,
and instrumentation, perform according to the manufacturer’s recommendations.
Whenever you find a deviation from specifications, identify its source immediately,
and take any corrective steps that are needed.
Gearbox Oil Specification
The oil used in Sundyne gearboxes must meet the specifications presented
in Field Engineering Bulletin 40.2.04. In general, an ISO viscosity grade 32 oil will
meet these specifications. Before using any oil, you should verify its properties by
consulting its manufacturer. Failure to use the proper gearbox lubricant will void the
warranty. The following page shows Revision C of Engineering Bulletin 40.2.04.
Refer to Section D, Compressor Operation Logic, for lube system info specific
to your unit.
Section A, Page 14
FIELD ENGINEERING BULLETIN
Effective August 1998
40.2.04 Rev. C
GEARBOX LUBRICANT RECOMMENDATIONS
For years the preferred gearbox lubricant for Sundyne compressors and compressors has been automotive
automatic transmission fluid (ATF). However, over time the additives in automatic transmission fluid have
changed to coincide with the technical improvements in automobile transmissions. The additives in the new
formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne gearboxes
and could compromise mechanical integrity and reliability of the equipment.
ISO Viscosity Grade 32 general purpose or synthetic oils are the recommended lubricants for the Sundyne
gearboxes. Gearbox lube oil should be changed twice yearly or more frequently in severe environments
which may be detrimental to the lubricant. Oxidized oil is frequently characterized by a darkening and/or
thickening of the oil. Operating of gearboxes with oxidized lubricant should be avoided.
Synthetic oils possess different characteristics than conventional oils which make them desirable for
various extreme conditions such as high and low temperature operation. Synthetic oils offer very low pour
points, high temperature oxidation stability and a higher viscosity index.
The operation of Sundyne equipment in high or low ambient conditions may require special consideration of
gearbox lubricant and/or supplemental protective equipment such as heat exchangers or gearbox heaters.
The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that contains
an inert additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne gearboxes.
Use of lubricants containing inert additives will void the product warranty.
Recommended gearbox lube oil specifications:
Gravity, API
Pour Point, °C (°F)
Flash Point, °C (°F)
Viscosity,
CSt at 40°C
CSt at 100°C
SUS at 100°F
SUS at 210°F
Viscosity Index
ISO Viscosity Grade
Color, ASTM D 1500
Neutralization Number, Maximum
Rust Protection, ASTM D 665, A & B
Demulsibility, ASTM D 1401
Time to 0 ml emulsion
at 54°C (130°F) after 30 min.
at 82°C (180°F) after 60 min.
Foam Limits, ASTM D 892
Sequence 1
Sequence 2
Sequence 3
Note: No other additives are recommended.
28 – 37
-7 (20) max.
204 (400) min.
28.8 to 35.2
5.2 min.
150 to 180
44 min.
95 min.
32
1 to 5
0.20
Pass
Pass
Pass
25/0 max.
50/0 max.
25/0 max.
Section A, Page 15
Regular Maintenance
1. Gearbox oil: Check the level of the oil in the gearbox immediately
before and after initial startup, and regularly while the compressor is
running. Be sure to keep the level of the oil within the design limit. You
can add oil while the compressor is running.
2. Oil pressure : In normal operation, the oil pressure supplied to the
gearbox should be between 2.1 − 4.1 barg (40 − 60 psig).
3. Changing the gearbox oil and filter: Change the oil in the reservoir
and the oil filter elements every 6 months.
4. Seal leakage: Check the gas seal flow rates. If the flow rate exceeds
150% of the value that is established as normal then investigate. The
seal may need to be replaced.
5. Driver: Inspect the driver to make sure that it performs according to
the manufacturer’s specifications, found in the Final Data package if the
motor was provided by Sundyne.
6. Coupling: Inspect the coupling according to the manufacturer’s
specifications, found in the Final Data package if provided by Sundyne.
Never operate the compressor without first checking the coupling guard. A
compressor with a missing or incorrectly installed guard can allow rotating shafts to
contact clothing, body parts, tools or other loose items, and result in severe
personal injury or loss of life.
VI.
Start-up/Operation/Shutdown
If a Sundyne supplied control panel is to be used with the Sundyne Pinnacle LF-2000 compressor,
use the control panel recommended start-up procedure in addition to these instructions.
Some form of control is required for the majority of Sundyne compressor applications. The purpose
of control is twofold: 1) to achieve the desired performance as required by process conditions and
2) to protect the compressor from mechanical damage due to surge or overload conditions.
This section is a general guideline on controls. Refer to Section D, Compressor Operating
Logic, for detailed information on operation of your unit.
Section A, Page 16
Surge Control
It is recommended that a surge control system be installed whenever there is any chance
that the process flow could decrease appreciably from design flow. In most surge control
systems, a flow sensor is placed in the suction line to the compressor. The signal from this
sensor is input to a controller which controls a valve in the bypass loop. When the minimum
safe flow is reached, this valve opens and the flow through the compressor is kept above
the surge point. Again, the recycled gas must be cooled to prevent heat build-up. Both
pneumatic and electrical surge control systems are available.
Suction Throttling
Suction throttling is generally the most economical control method with a constant speed
drive. Throttling the control valve on the suction side causes a reduction of inlet pressure to
the compressor. Although the compressor creates the same compression ratio as if it were
unthrottled, the discharge pressure is reduced. The reduction of inlet pressure
correspondingly decreases inlet gas density, and thus, power consumption. Suction throttling
also has the advantage of slightly lowering the compressor surge point.
Discharge Throttling
Discharge throttling is control by means of a valve placed at the compressor discharge. A
constant speed compressor will always operate on its design head-flow curve. For a given
system operating point, the compressor will operate at the system flow rate, thus producing
more head than the system requires. This excess head is throttled by the discharge valve.
Since the throttling occurs downstream of the compressor, there are no power savings by
this method. Discharge throttling offers no real advantages over suction throttling, but is
nonetheless an acceptable control method.
Speed Control
Speed control is the most efficient means of compressor control. To operate at points
below the design head-flow curve, the driver speed may be reduced accordingly. This
creates an infinite “family” of head-flow curves on which the compressor may operate.
Since consumed horsepower, assuming constant inlet conditions, varies as the cube of the
speed, substantial power savings can be realized. Also, the compressor surge point is
lowered proportional to the speed decrease. This method is used mainly on turbine driven
units although variable speed motors or mechanical drives are available. Since the main lube
oil pump in the Sundyne compressor is driven by the gearbox input shaft, provision must be
made so the speed is not reduced to a point where adequate lube oil pressure is no longer
present.
Flow Bypass
Flow bypass requires a recycle line from the compressor discharge to suction. The
compressor is operated at the desired flow or discharge pressure and the excess flow not
required by the process is recycled through the bypass. A cooler is required in the loop to
Section A, Page 17
cool the recycled gas to normal suction temperature. This method is generally less efficient
than other methods discussed, but may be warranted in some special situations.
Compressor Control During Start-Up
A.
Suction throttling (preferred method). Start compressor with the discharge valve
open while throttling the suction valve to bring the compressor to the design
operating point.
B.
Discharge throttling. Start the compressor with the suction valve completely open
while throttling the discharge valve to bring the compressor to the design operating
point.
C.
Other Methods – Insure that the compressor does not go into surge (flow too low)
or that the design horsepower is not exceeded (flow too high) while starting or
operating the compressor. Check the unit specification sheet for flow limits
Run-In of the Compressor
If the compressor is to be run-in or mechanically tested under conditions which are
considerably different from those that the unit is designed for (such as gas molecular weight,
suction pressure, flow rate, etc.) Sundyne should be consulted to insure that the run-in
conditions are compatible with the compressor.
VII.
Section A, Page 18
Troubleshooting
Gearbox and Compressor
Many factors affect the performance of your compressor. Among them are suction pressure,
temperature, molecular weight, driver speed, flow rate, and discharge control. You need to check
all of these when there is a problem with the compressor and when you are analyzing the
performance of the system. For details on the performance of the compressor including the
performance curve, refer to the final data package, sections 1 and 2, and specification sheets.
Table 10.1 provides information for analyzing gearbox and compressor problems.
Table 10.1 Troubleshooting for Gearbox and Compressor
Trouble
Possible Cause
Investigative and Corrective Action
The compressor produces no
flow and no pressure at start-up
A component of the drive, such as
the coupling, has failed, or an item is
missing from the assembly
Disassemble and inspect the failed
component, if it is present. If not, add the
required component to the assembly.
The drive shaft rotates in the wrong
direction
Make sure that the drive shaft is rotating in
the direction shown by the arrow on the
compressor gearbox.
The suction valve or the discharge
valve is closed.
Check the valving (see Section D,
Compressor Operating Logic).
The flow is too high.
Check the head rise and the flow rate
against the performance curve.
The driver shaft is rotating in the
wrong direction.
Make sure that the drive shaft is rotating in
the direction shown by the arrow on the
compressor gearbox.
The suction pressure is low.
Check the Sundyne specification sheets.
Recirculation from the discharge to
the inlet is excessive.
Check the flow through the external piping,
such as the bypass
The molecular weight is not that for
which the compressor was
designed.
Check the molecular weight against the
value given on the specification sheet. Low
molecular weight will cause low discharge
pressure.
The driver speed is too low.
Check the speed against the value listed on
the Sundyne specification sheets.
The pressure gauges or the flow
meters are in error
Calibrate the instrumentation.
The oil pressure in the gearbox
is low.
The pressure gauge is faulty.
Check the accuracy of the gauge.
The main lubricating pump has failed.
Remove the pump and check for damage.
Driver overloaded.
Molecular weight higher than values
listed on specification sheet
Check actual molecular weight against value
listed on specification sheet.
Electrical failure in electric power
unit.
Check circuit breaker heater size and
setting.
The head rise is insufficient.
Check voltage.
Section A, Page 19
Current for each phase should be balanced
within three percent.
Section A, Page 20
Table 10.1 Troubleshooting for Gearbox and Compressor (continued)
Trouble
Possible Cause
Investigative and Corrective Action
Driver overloaded.
Mechanical failure in driver, gearbox,
or compressor.
Disconnect spacer coupling and check for
freedom of rotation of compressor, driver,
and gearbox shafts.
(continued)
Drain oil and remove gearbox oil level sight
glass and inspect bottom of sump for wear
particles. Bearings are probably not
damaged if no wear particles are present.
Disassemble compressor end and search
for any mechanical failure.
Corrosion pitting on surface of
diffuser adjacent to impeller blades.
Head rise is reduced by this
condition.
Disassemble and inspect. Check diffuser
section of process end for irregularities.
Clean these areas of all obstructions and
restore surfaces to a smooth polished finish
(use emery cloth), free of all corrosion
pitting. If damage is more severe (i.e. impeller
is deformed or has come in contact with
diffuser) replace the damaged parts.
High suction pressure.
Check specification sheet. (Increased
suction pressure and corresponding mass
flow rate will result in increased
horsepower consumption).
Flow rate too low (surge).
Increase flow rate through compressor. Add
controlled bypass to suction, if necessary.
Defective flow control valve.
Check control valve.
Change of gearbox lube oil color
from normal color to milky pink
or yellow.
Gearbox oil contaminated with water
or process fluid.
Inspect gearbox heat exchanger for leakage.
Shaft sleeve rubs on inside
diameter of seal.
Gearbox journal bearing failure.
Replace bearing, and inspect rotating
components for additional damage.
Excessive gearbox lube oil
consumption.
Input shaft labyrinth seal (125)
leakage.
Check separation gas supply to labyrinth
seal and condition of labyrinth seal.
High-speed shaft cartridge seal (60)
leakage.
Check for seal leakage, replace cartridge
seal if necessary.
Leakage through heat exchanger into
cooling fluid.
Pressure test heat exchanger and replace if
required.
High oil level.
Shut down the unit and check oil level.
Low gearbox temperature.
Adjust coolant to heat exchanger, keeping oil
temperature at 120°F. (49°C).
Excessive discharge pressure
pulsation.
Excessive oil foaming.
Check for excessive compressor seal
leakage.
Section A, Page 21
Compressor Mechanical Seals
Table 10.2 provides information on problems with single, double, and tandem seal units.
Table 10.2 Troubleshooting for Compressor Mechanical Seals
Trouble
Possible Cause
Investigative/Corrective Action
Leakage around the seal
suddenly increases
The system is operating at a low flow
rate or a low inlet pressure, causing
vibration of the high-speed shaft,
bouncing on the face of the seal, and
chipping on the nose of the carbon
seal.
Make sure that the compressor
always operates above the specified
minimum flow rate and/or inlet
pressure.
The action of the stationary face
spring on the seal is rough and sticky
If contamination in the process gas
(from entrained solids) causes a
sticky seal, there may be need for a
seal flush, double seals, or tandem
seals.
The seal is worn or damaged.
Replace cartridge seal.
The seal on a low-temperature
compressor is icing, or there is heavy
condensation on the atmospheric
side of the seal.
Purge the atmospheric side of the seal
with dry nitrogen gas.
Section A, Page 22
VIII. Spare Parts
General
Assemblies, subassemblies and components of the Sundyne compressor are illustrated on the
cross sectional and unit outline drawings found in Section E, Unit Specific Data. Part
numbers for gearbox and compressor end components may be found in the bill of materials
(BOM), also found in Section E, Unit Specific Data. Refer to the unit outline drawing for a list
of the major kit bills of material.
Recommended Spare Parts
Refer to your final data package for recommended spare parts identified for your particular unit.
Repair Kits
O-ring repair kits are not illustrated herein, but may be purchased directly from Sundyne
Corporation. O-ring repair kits contain all o-rings necessary for maintenance or overhaul of the
compressor. The use of these kits reduces maintenance time, prevents assembly mistakes,
simplifies stocking and inventory, and reduces delivery time.
Ordering Spare Parts
When ordering spare parts, provide the unit serial number and list each part by the part number
as shown on the Bill of Material which is included in Section E, Unit Specific Data (preferred
method), or list each part by item number (as listed in this manual), including part name and
compressor model. Specify quantities desired.
Order parts from your Fluid Handling representative or directly from Sundyne Corporation at one
of the following locations.
Sundyne Corporation
Arvada, Colorado, USA
Phone Number:
Fax Number:
+1-303-940-2989
+1-303-940-2826
Sundyne Europe
Dijon, France
Phone Number:
Fax Number:
+32-2-721-5045
+32-2-725-9820
Or visit our Genuine Service and Parts site at www.sundyne.com.
Section B
Section B
Compressor End
Assembly and Disassembly
Section B
TABLE OF CONTENTS – SECTION B
Section Description
Page No.
I.
Required Special Tools and Supplies............................................................................ 1
II. Torque Requirements................................................................................................... 2
III. Compressor End Assembly.......................................................................................... 3
1) Install Seal Housing (30) into Compressor Case (1). ................................................ 4
2) Mount Compressor Case (1) onto Lower Gearbox Housing (101). .......................... 5
3) Install Seal Cartridge (60)........................................................................................ 8
4) Install Backing Ring (61) if required ....................................................................... 12
5) Install Impeller (2). ................................................................................................ 13
6) Install Shroud (7) into Diffuser (13)........................................................................ 16
7) Lift Assembly of Shroud (7) and Diffuser (13)........................................................ 18
8) Check Clearance Between Shroud (7) and Impeller (2).......................................... 19
9) Install Assembly of Shroud (7) and Diffuser (13) into Compressor Case (1)............ 22
10) Install inlet housing (6) into compressor case (1)................................................... 23
IV. Compressor End Disassembly.................................................................................... 24
1) Remove Inlet Housing (6) from the Compressor Case (1)....................................... 25
2) Remove assembly of shroud (7) and diffuser (13) from compressor case (1)........... 26
3) Remove shroud (7) from diffuser (13) (if required). ................................................ 26
4) Remove Impeller (2).............................................................................................. 27
5) Remove Backing Ring (61) (if required)................................................................. 29
6) Remove Seal Cartridge (60). ................................................................................. 30
7) Remove the Compressor Case (1) from the Gearbox Housing (101). ..................... 32
8) Remove the Seal Housing (60) from the Compressor Case (1). .............................. 33
I.
Section B, Page 1
Required Special Tools and Supplies
For Compressor End Assembly/Disassembly:
•
Pinnacle Tool Kit, supplied with unit, including:
§ Diffuser Lifting Tool
§ High-Speed Shaft Rotation Tool
Used For: rotating high-speed shaft during seal install
§ 1-1/2” Open End Wrench , 4-way Angle Head
Used For: nuts attaching compressor case (1) to gearbox (101)
§ Seal Installation/Removal Kit
Including seal backing rings and alignment rods
§ Shroud Lifting Eyes, ½”-13UNC, Quantity = 3
§ 5/8”-18 UNF Left Hand Thread Nuts, Quantity = 2
Used For: removal of impeller stud (3) from high-speed shaft (130 or 140)
§ Lead solder wire roll, .06”-.12” diameter
Used for impeller clearance measurement
§ Anti-Seize Thread Lubricant,
Type: “Silver Goop”,Crawford Fitting Co.
§ Silicone o-ring Lubricant
Type: Dow Corning 111 Silicone Lubricant
§ MoS2 Dry Film Lubricant
Type: Dow Corning 321 Dry Film Lubricant (with MoS2)
II.
Section B, Page 2
Torque Requirements
Table 1
Torque Specifications for Fasteners
(unless otherwise specified)
Size
Torque (ft-lbs)
¼”-20 UNC
6.3
3/8”-16 UNC
23
½”-13 UNC
55
5/8”-11 UNC
110
¾”-10 UNC
200
1”-8 UNC
480
III.
Section B, Page 3
Compressor End Assembly
This section provides the procedure for assembling the LF-2000
compressor gas end. The procedure applies to all stages.
Follow your organization's lockout/tag-out instructions before working on
the compressor. Failure to follow adequate lockout/tag-out procedures
could result in severe personal injury or loss of life.
Use proper lifting devices and methods. Failure to do so could result in
serious injury to you or others.
Summary of Compressor End Assembly:
A summary of the assembly steps is listed below, followed by detailed descriptions and images.
These steps are to be followed for each stage of the compressor, as required. Item numbers
are provided in parenthesis. Refer to the Compressor Gearbox Drawing, found in Section E,
for a cross-section view with item numbers identified, and the unit BOM for part numbers
corresponding to each item number.
1. Install seal housing (30) into compressor case (1).
2. Mount compressor case (1) onto lower gearbox housing (101).
3. Install seal cartridge (60).
4. Install backing ring (61), if required.
5. Install impeller (2).
6. Install shroud (7) into diffuser (13).
7. Lift assembly of shroud (7) and diffuser (13).
8. Check clearance between shroud (7) and impeller (2) and shim as required.
9. Install shroud (7)/diffuser (13) assembly into compressor case (1).
10. Install inlet housing (6) into compressor case (1).
Section B, Page 4
Detailed Description of Compressor End Assembly:
Detailed descriptions of the assembly steps are listed below. These steps are to be followed for
each stage of the compressor. Item numbers are provided in parenthesis. . Refer to the
Compressor Gearbox Drawing, found in Section E, for a cross-section view with item numbers
identified, and the unit BOM for part numbers corresponding to each item number. This section
assumes the gearbox is complete and shaft end-play dimensions are within tolerance:
1) Install Seal Housing (30) into Compressor Case (1).
1a) Lift compressor case (1) using
welded on lifting lug, and set on its side
with the discharge flange oriented as it will
be when mounted to the gearbox.
1b) Apply silicone based lubricant to o-ring
(900), and install on the seal housing (30)
that will insert into the compressor case
(1). Slide the o-ring (900) down the post
OD until it seats in the corner.
1c) Lift the seal housing (30) with its flanges
oriented approximately relative to the case
(1) as required.
TIP: Use a hoist with lifting strap around the
upper pipe of the seal housing, in line with
the center line of the seal housing.
1d) Install seal housing (30) into compressor
case (1).
Section B, Page 5
1e) Lubricate the eight ¾”-10 mounting
screws (501) with Anti-Seize Thread
Lubricant and install to mount the seal
housing to the case. Torque to the value
specified in Table I.
1f) Install the drain pipe (800) into the seal
housing (30). The port is oriented with the
slot in the mounting face of the compressor
case (1). The port and pipe are an NPT
connection, and the pipe may be tightened
using a pipe wrench on its exposed length
beyond the case mounting surface.
1g) Apply silicone based lubricant to o-ring
(901), and install into groove on the nose
of seal housing (30) that will insert into the
gearbox housing (101).
2) Mount Compressor Case (1) onto Lower Gearbox Housing (101).
2a) Apply Locktite 242 Thread-locker (blue)
to the six case studs (500), and install into
mounting face of compressor case (1).
Thread in until they bottom out in tapped
hole.
Apply Anti-Seize Thread Lubricant to the
exposed end of thread where the nut
(700) will go.
Section B, Page 6
2b) The compressor case (1) and compressor
end assembly should only be lifted by the
lifting lug attached to the compressor case
(1).
2c) Using a hoist and adequate connection to
the lifting lug of the compressor case (1),
lift the case into position near the gearbox
(101) mounting face.
Use caution to avoid hitting the end of
the high speed shaft with any part of the
compressor end assembly.
2d) Align studs (500) with holes in gearbox
(101) mounting face, and insert until studs
are extending through the holes by several
threads only.
NOTE: There is not enough clearance behind
the mounting face to put nuts onto the
studs when they are extending all the way
through the mounting holes.
Section B, Page 7
2e) Slide 6 nuts (700) behind the gearbox
(101) mounting face, and thread them onto
the studs (500) as far as possible.
2f) Several iterations of moving the
compressor case closer to the gearbox,
and threading the nuts onto the studs, may
be required before compressor case
mounts flush to the gearbox.
When tightening nuts to pull the case onto
the gearbox, be sure to alternate tightening
of the nuts to keep the case square to the
gearbox. Excessive force should not be
used to tighten the nuts.
If excessive force is required to tighten
the nuts before the case contacts the
gearbox mounting face, then STOP. The
case may not be square to the gearbox,
and damage may be caused to the case,
seal housing, and/or gearbox. Loosen the
nuts and start over.
2g) Tighten the 6 nuts (700) (1”-8)to
complete mounting of compressor case (1)
to gearbox (101). Use an alternating
sequence to tighten the nuts, starting at
snug tight, and advancing to full strength
tightening. Because of the limited
clearance for turning the wrench at some
of the nut locations, a special wrench (11/2” open end 4-way angle head) is
provided in the Tool Kit to facilitate
tightening.
Section B, Page 8
3) Install Seal Cartridge (60).
3a) The seal cartridge (60) has a 2 piece
installation plate mounted to the
compressor side of the seal (away from
the gearbox).
The seal installation plate must not be
removed until after the seal is mounted
onto the shaft and into the seal housing
(30).
Remove the plastic shipping cover from
the opposite end of the seal cartridge (30).
3b) The seal drive pins (562) on the
output shaft (140) must be oriented
properly relative to the seal when the seal
is installed. Otherwise the seal may shear
or otherwise damage the pins upon
installation.
Use a straight edge tool, such as a small
ruler, to align one of seal drive pins (562)
on the output shaft (140) with the seal
housing (30) mounting hole that is just
slightly to the right of 12 o’clock. Rotate
the shaft (140) if required, using the shaft
rotation tool supplied in the Tool Kit.
Section B, Page 9
3c) Remove plastic shipping cover from the
seal cartridge (60), and Krytox o-ring
lubricant to the 5 o-rings (906, 907, and
908) on the OD of the seal cartridge (60).
Krytox o-ring lubricant is
recommended by seal manufacturer,
instead of silicone based lubricant. Avoid
excessive amounts of lubricant, as it could
contaminate the seal faces.
The seal cartridge installation plate,
mounted to the front of the seal cartridge
(60), has a deep scribe across both pieces
aligned with one mounting hole. When
installing the seal cartridge (60), align the
scribe with same hole in the seal housing
(30) that the drive pins (562) were aligned
with.
3d) Slide seal cartridge (60) into seal housing
(30) until it is several inches away from
complete installation. Use two hands, with
palms on the installation plate and fingers
behind the seal cartridge flange. Getting
the seal started into the seal housing may
present some difficulty because of the
multiple o-rings and matching steps in bore
and on the seal OD. Moderate pressure
and slight rocking back-and-forth of the
seal will facilitate the installation.
Section B, Page 10
3e) To prevent rotation of the seal
during the final part of the installation
(when the drive pins (562) will engage),
two pieces of 3/8-16 UNC “All-Thread”
studs, approximately 6” long, should be
installed into two mounting holes 180°
apart. Two nuts jammed together at the
ends will facilitate removal of the studs.
3f) Push the seal cartridge (60) in as far as
possible.
Section B, Page 11
3g) Remove the two “All-Thread” studs.
3h) Lubricate the twelve screws (502) (3/8”16) with Anti-Seize Thread Lubricant and
install 2 screws in place of the studs (at
180° apart). Use these to pull the seal
cartridge (60) into place, by alternately
turning each about a ½ turn until the seal is
completely seated.
If excessive force is required to tighten
the screws before the seal is seated, then
STOP. The seal may not be square to the
seal housing, and damage may be caused
to the seal or shaft. Remove the screws,
utilize the jack screw holes in the seal to
back the seal off, and start the installation
over.
Install the rest of the twelve seal mounting
screws (502) (3/8”-16) and tighten to the
torque specified in Table I.
3h) Remove the outer portion of the seal
installation plate (part of the seal cartridge
(60) assembly) by removing the 6
attachment screws (#10-24 x .62”LG).
Lift carefully away from seal.
Section B, Page 12
3j) Remove the inner portion of the seal
installation plate (part of the seal cartridge
(60) assembly) by removing the 6
Lift carefully away from seal.
3k) Set aside the 2 piece installation/removal
plate and 12 screws to use if the seal is
ever removed.
NOTE: These pieces are supplied as part
number TK01GC02 for new compressor
assemblies with seals installed at the
factory.
4) Install Backing Ring (61) if required
Refer to your BOM to determine which
stages, if any, require a backing ring.
4a) Place backing ring (61) onto seal cartridge
(60).
Section B, Page 13
4b) Install the 6 mounting screws (508) (#1024 x .5”LG) to mount the backing ring to
the seal. Torque to the value specified in
Table I.
5) Install Impeller (2).
5a) Check the impeller (2) by first inspecting
the blades and shroud for any rubs or
material build-up.
If any physical discrepancies are found,
have the impeller re-balanced at a qualified
Sundyne facility.
Inspect nose face, where impeller nut
contacts, for evidence of galling. Stone
surface if required.
5b) Check the hirth coupling on the impeller
(2) for any raised material on the teeth or
debris in alignment hole. Ensure the teeth
are clean and free of any deformation.
Section B, Page 14
5c) Apply Anti-Seize Thread Lubricant to
threads on both ends of impeller stud (3).
Install impeller stud (3) into end of output
shaft (140) by inserting the end of the stud
that has approximately ¼” thread relief at
the tip.
Insert impeller stud (3) until it bottoms
out in output shaft (140).
NOTE: The impeller studs (3) and impeller
nuts (5) will have LH (left-hand) threads
for compressor Posts A and C, and RH
(right-hand) threads for compressor Posts
B and D.
5d) Approximately align the alignment hole in
the hirth of the impeller with the pin in the
hirth of the shaft (140). Install impeller (2)
over stud (3) until hirth teeth on impeller
(2) and shaft (140) lightly contact. Rotate
gently back and forth until the hirth teeth
and alignment pin and hole engage.
5e) Apply a thin layer of MoS2 Dry Film
Lubricant to the flat mating faces of the
impeller nut (5), and the impeller (2), to
prevent galling between the two parts.
Sundyne has determined that the MoS2
Dry Film Lubricant prevents galling at this
interface much better than Anti-Seize
Thread Lubricant.
Section B, Page 15
5f) Lubricate the impeller nut o-ring (902) with
a silicone based lubricant, and bottom it on
the pilot of the impeller nut (5).
If PTFE static seals are utilized in the unit,
this position will utilize a spring energized
PTFE seal. When installing the seal on the
nut pilot the open end of the seal will face
the mating face of the impeller nut.
5g) In order to torque the impellers (2),
rotation of the shafts must be prevented.
This is done by inserting a rod through the
holes in the upper gearbox housing and
one of four holes in the bull gear. Do not
rotate the shaft any more than necessary to
align the closest hole in the gear with the
rod hole, so that rubbing of the seal faces
is minimized.
Remove the pipe plugs (850) from both
sides of the upper gearbox housing (101).
5h) Insert a rod entirely through the upper
gearbox housing (101) and the bull gear
on the low speed shaft (120). If at first a
hole on the bull gear is not aligned with the
holes, rotate the input shaft using a strap
wrench.
Paint the holding rod red and make extra
long for increased visibility as a reminder
to remove before operation of unit.
Section B, Page 16
5j) Install the impeller nut (5) (with o-ring and
lubricated face) onto the exposed thread
of the impeller stud (3) until the nut
contacts the impeller. Torque to 160 ftlbs.
NOTE: Impeller studs (3) and impeller nuts
(5) will have LH (left-hand) threads for
compressor Posts A and C, and RH
B and D.
5g) The holding rod for the bull gear must be
removed after applying torque to the
impellers. Serious damage to the unit will
occur if a start-up is attempted without
removing the rod. Replace the pipe plugs
(850) into both sides of the upper gearbox
housing.
6) Install Shroud (7) into Diffuser (13).
6a) Orient diffuser (13) with flange side up.
6b) Insert 2 pieces of .062” thick shim stock
(158) into diffuser (13), aligning the
diffuser pins (503) with the corresponding
holes in the shim stock.
Installing shim stock during the initial
clearance check ensures that there will be
initial impeller clearance, and the impeller
will not be damaged
Section B, Page 17
6c) Install lifting eyes (provided in the Tool
Kit) into each of the 3 threaded holes (½”13UNC) in end of shroud (7) (opposite
the impeller profile surface).
6d) Lower shroud (7) into diffuser (13),
aligning the diffuser pins (503) with the
corresponding holes in the shroud (7).
6e) Remove the 3 lifting eyes from the shroud
(7).
6f) Install the screws (504) to attach the
shroud (7) to diffuser (13). Quantity and
size will vary by unit. Torque to the value
specified in Table I.
Section B, Page 18
7) Lift Assembly of Shroud (7) and Diffuser (13).
7a) Attach the Diffuser Lifting Tool, provided
in the Tool Kit, to diffuser (13) by inserting
one end of “C” into diffuser opening and
securing with a ½”-13UNC x 3.00” LG
screw through the slot on the tool into one
of the threaded jack screw holes on the
diffuser flange. Attach an eyebolt through
one of the holes in the other end of the
tool, such that the diffuser hangs
approximately horizontally when lifted.
7b) Slowly lift the diffuser by the eyebolt on
the Diffuser Lifting Tool, using a suitable
strap or other connection
Section B, Page 19
8) Check Clearance Between Shroud (7) and Impeller (2).
8a) Using about a 3 foot length of lead solder
wire (.06”-.12” dia), create a circular ring
at the base of the shroud profile, attaching
with standard masking tape along its
length. Cut off excess wire where the
circle joins back together.
8b) Carefully slide the assembly of shroud (7)
and diffuser (13) into the compressor case
(1) (which is already mounted on the
gearbox). The mounting provisions
between the diffuser (13) and compressor
case (1) are not used for this assembly.
8c) Lubricate o-ring (904) with silicone
lubricant, and install on the smallest
diameter groove of the shroud (7).
If PTFE static seals are utilized in the unit,
this position will utilize a spring energized
PTFE seal. When installing the seal on the
shroud the open end of the seal will face
the mating face the step on the shroud.
Section B, Page 20
8d) Lift the inlet housing (6) using a hoist and
an eyebolt installed into the 5/8”-18 UNC
threaded hole on OD of flange.
8e) Assemble inlet housing (6) to compressor
case (1) over compressor case studs
(505).
8f) Install four of the compressor case nuts
(705) and tighten to the torque specified in
Table I.
8g) Remove the four compressor case nuts
(705) and inlet housing (6) from
compressor case (1).
Section B, Page 21
8h) Remove the assembly of the diffuser (13)
and shroud (7), using the Diffuser Lifting
Tool.
8i) Remove the lead solder wire, which should
have “pinched” impressions from each of
the impeller blades (if not, the initial shim
stack was too large).
8j) Measure several of the “pinched”
impressions in the wire and calculate the
mean value for the clearance between the
impeller (2) blades and the shroud (7).
If the measurements vary more than +/.003”, redo the impression after verifying
the following:
- ensure that the lead circle was attached
at a constant shroud diameter.
– ensure that the shroud was seated
squarely in the diffuser. Verify using a
depth micrometer from the diffuser flange
to the shroud flat surface.
Shimming/Clearance Setting Note:. The relation between the installed shim thickness and
the desired running clearance will depend upon the thrust position and the end-play of the high
speed shaft. The lead impression height represents the impeller being thrust towards the
gearbox, and does not factor in the end-play. The clearance setting will vary from unit to unit
and from stage to stage within the same unit. For setting the clearance of a particular stage on a
particular unit, the Build Sheet (form number ISO2840, found in Section E) and the calculations
below must be referred to.
Calculations:
Factory Impeller Clearance (A) from Build Sheet = _______________
Subtract measured clearance from lead impression
Add Shaft End Play (H) from Build Sheet
SUBTOTAL = required additional shim
− _______________
+ _______________
= _______________
Add measured shim thickness (already installed) + _______________
TOTAL = required total shim thickness
= _______________ ± .003”
Section B, Page 22
8k) Based upon the lead impression
measurements, and the Build Sheet
instructions (see note above), install the
required thickness of shim pack (158).
8m) Confirm the clearance by repeating steps
8a through 8k. Repeat as necessary until
correct clearance is obtained
9) Install Assembly of Shroud (7) and Diffuser (13) into Compressor Case (1).
9a) Follow the instructions from steps 7a, 7b,
8a, and 8b.
Section B, Page 23
10) Install inlet housing (6) into compressor case (1).
10a) Lift the inlet housing (6) using a hoist and
an eyebolt installed into the 5/8”-18 UNC
threaded hole on OD of flange.
10b) Assemble inlet housing (6) to
compressor case (1) over compressor
case studs (505).
10c) Install the compressor case nuts (705)
onto the case studs (505). Quantity and
size will vary by unit. Torque to the value
specified in Table I. Use a crossing
pattern to alternately tighten nuts, first to
snug tight, then to specified torque (see
example below for an 8 nut configuration).
7
1
6
3
4
8
5
2
IV.
Section B, Page 24
Compressor End Disassembly
This section provides the procedure for disassembling the LF-2000
compressor gas end. The procedure applies to all stages, and can be taken
as far as required to access the particular component desired.
Follow your organization's lockout/tag-out instructions before working on
the compressor. Failure to follow adequate lockout/tag-out procedures
could result in severe personal injury or loss of life.
Use proper lifting devices and methods. Failure to do so could result in
serious injury to you or others.
Be sure to de-pressurize the gas process loop and seal system in the correct
order. Besides the danger to personnel, reverse pressure on the gas process
seal may cause the seal to fail. See the seal system narrative in the
Startup/Operation/Shutdown section of Section E.
Summary of Compressor End Disassembly:
A summary of the disassembly steps is listed below, followed by detailed descriptions and
images. These steps are to be followed for each stage of the compressor, as required. Item
numbers are provided in parenthesis. Refer to the Compressor Gearbox Drawing, found in
Section E, for a cross-section view with item numbers identified, and the unit BOM for part
numbers corresponding to each item number. For various service requirements, the complete
disassembly need not be followed, only those steps required to access the desired element, such
as the impeller or seals.
NOTE: Only follow as many steps as required to access desired component.
1. Remove inlet housing (6) from compressor case (1).
2. Remove shroud (7)/diffuser (13) assembly from compressor case (1).
3. Remove shroud (7) from diffuser (13) (if required).
4. Remove impeller (2).
5. Remove backing ring (61) (if required).
6. Remove seal cartridge (60).
7. Remove compressor case (1) from lower gearbox housing (101).
8. Remove seal housing (30) from compressor case (1).
Section B, Page 25
Detailed Description of Compressor End Disassembly:
Detailed descriptions of the disassembly steps are listed below. These steps are to be followed
for each stage of the compressor. Item numbers are provided in parenthesis. . Refer to the
Compressor Gearbox Drawing, found in Section E, for a cross-section view with item numbers
identified, and the unit BOM for part numbers corresponding to each item number. Suction,
discharge, and seal support piping do not need to be disconnected, unless the compressor case
will be disassembled from the gearbox. The unit should be allowed to cool down before
performing any disassembly.
1) Remove Inlet Housing (6) from the Compressor Case (1).
1a) Remove the compressor case nuts (705)
from the case studs (505). Quantity and
size will vary by unit.
1b) Support the inlet housing (6) using
a hoist and an eyebolt installed into the
5/8”-18 UNC threaded hole on OD of
flange.
1c) Slide the inlet housing (6) away from the
compressor case (1) over the compressor
case studs (505).
The lifting point is not at the center-ofgravity of the inlet housing, so the housing
will tend to swing out when leaving the
assembly. Be extremely careful as it is
removed.
Section B, Page 26
2) Remove assembly of shroud (7) and diffuser (13) from compressor case (1).
2a) Start to slide the diffuser (13) out
of the compressor case (1), by using the 3
jack screw holes in the diffuser flange and ½”13UNC x 3.00” LG screws.
2b) Attach the Diffuser Lifting Tool, provided
in the Tool Kit, to the diffuser (13) by inserting
one end of the “C” into the diffuser opening,
and securing with a ½”-13UNC x 3.00” LG
screw through the slot on the tool into one of
the threaded jack screw holes on the diffuser
flange. Attach an eyebolt through the hole in
the other end of the tool, and support with a
hoist. Carefully slide the diffuser (13) out of
compressor case (1).
The lifting point may not be at the
center-of-gravity of the diffuser, so it may tend
to swing out when leaving the assembly. Be
extremely careful as it is removed.
3) Remove shroud (7) from diffuser (13) (if required).
NOTE: The shroud should only be removed if
it needs service or replacement, or if
shimming for impeller clearance needs to
be redone.
3a) Set the diffuser (13) on a flat surface, with
the flange side up.
3b) Remove the screws (504) that attach the
shroud (7) to diffuser (13). Quantity and
size will vary by unit.
Section B, Page 27
3c) Install lifting eyes (provided in the Tool
Kit) into each of the 3 threaded holes (½”13UNC) in exposed end of shroud (7).
3d) Raise shroud (7) out of diffuser (13), using
a hoist and the three lifting eyes.
3e) Set the shroud (7) on a flat surface, being
careful to avoid damaging the impeller
profile surface.
3f) Inspect impeller profile surface of the
shroud (7) for any rubs, material build up,
or damage. Buff out small discrepancies,
but contact Sundyne if any significant
damage is present.
4) Remove Impeller (2).
4a) In order to remove the impeller (2),
rotation of the shafts must be prevented.
This is done by inserting a rod through the
holes in the upper gearbox housing and
one of four holes in the bull gear. Do not
rotate the shaft any more than necessary to
align the closest hole in the gear with the
rod hole, so that rubbing of the seal faces
is minimized.
Remove the pipe plugs (850) from both
sides of the upper gearbox housing (101).
4b) Insert a rod entirely through the upper
gearbox housing (101) and the bull gear
on the low speed shaft (120). If at first a
hole on the bull gear is not aligned with the
holes, rotate the input shaft using a strap
wrench.
Paint the holding rod red and make extra
long for increased visibility as a reminder
to remove before operation of unit.
Section B, Page 28
4c) Remove the impeller nut (5) from the
impeller stud (3) by unscrewing in the
proper direction (see note below).
NOTE: Impeller studs (3) and impeller nuts
(5) will have LH (left-hand) threads for
compressor Posts A and C, and RH
B and D.
4d) Remove impeller (2) by sliding off over
stud (3)..
4e) Remove impeller stud (3) from end of
output shaft (140) by unscrewing in the
proper direction (see note below). Two
nuts may be jammed together on exposed
threads to facilitate removal. Left-hand
thread nuts are provided in the Tool Kit.
Threads are 5/8”-18 UNF.
NOTE: The impeller studs (3) and impeller
nuts (5) will have LH (left-hand) threads
for compressor Posts A and C, and RH
B and D.
Section B, Page 29
4f) Check the impeller (2) by first inspecting
the blades and shroud for any rubs or
material build-up.
If any physical discrepancies are found,
have the impeller re-machined and/or rebalanced at a qualified Sundyne facility.
4g) Check the hirth coupling on the impeller
(2) for any raised material on the teeth or
debris in alignment hole. Ensure the teeth
are clean and free of any deformation.
5) Remove Backing Ring (61) (if required).
Refer to your BOM to determine which
stages, if any, require a backing ring.
5a) Remove the 6 mounting screws (508)
from the backing ring (61).
Section B, Page 30
5b) Remove backing ring (61) from seal
cartridge (60).
6) Remove Seal Cartridge (60).
6a) Locate the 2 piece installation/removal
plate and 12 screws.
NOTE: For seals that were installed in the
unit at the factory, these pieces are
supplied as part number TK01GC02. If
the seals were installed by the end-user,
these pieces should have been stored for
later seal removal.
6b) The inner rotating member of the
seal cartridge has a radial scribe line on its
face, as does the inner portion of the
installation plate. These two lines must be
aligned, otherwise damage to the shaft
drive pins (562) will occur during reinstallation of the seal cartidge (60).
Install the inner portion of the seal
installation plate to the seal cartridge (60),
using the 6 attachment screws (#10-24 x
.75”LG).
Section B, Page 31
6c) Install outer portion of the seal installation
plate to the seal cartridge (60) using the 6
Be sure to align the scribe line on the outer
portion with that on the inner portion.
6d) After installing the installation plate,
remove the 12 screws (502) that mount
the seal cartridge (60) to the seal housing
(30).
6e) Use two of the seal mounting screws
(502) as jacking screws in the two
threaded holes in the seal cartridge (60)
flange. Unseat far enough to grab the
flange, and pull to remove the seal
cartridge (60) from the seal housing (30).
The seal weighs approximately 20 lbs,
and therefore must be carefully supported
when removing, to avoid dropping and
damaging the delicate internals of the seal.
Section B, Page 32
7) Remove the Compressor Case (1) from the Gearbox Housing (101).
7a) Support the compressor case (1) using a
hoist attached to the welded on lifting lug.
7b) Loosen the 6 nuts (700) on the
compressor case studs (500), behind the
gearbox (101) mounting flange, and back
them off as far as possible. They will not
come off yet since the end of the studs are
inserted into counter-bore holes in the wall
of the gearbox (101).
Keep fingers away from the ends of the
studs and nuts (only contact the nut
wrench flats), to avoid injury if the
compressor case should unexpectedly shift
as the nuts are backed off.
7c) Several iterations of moving the
compressor case (1) away from the
gearbox (101), and backing the nuts (700)
off of the studs (500), may be required
before the the nuts (700) are able to be
removed from the studs (500).
Keep the compressor case square with
the gearbox mounting to avoid damaging
the shaft and seal.
Section B, Page 33
7d) Using a hoist and adequate
connection to the lifting lug of the
compressor case (1), lift the case away
from the gearbox (101), and set down
carefully with the seal housing (60)
exposed for removal.
Do not attempt to lift the
compressor case by the seal housing
piping, as the piping will break and severe
injury may result.
Use caution to avoid hitting the end of
the high speed shaft with any part of the
compressor end assembly.
8) Remove the Seal Housing (60) from the Compressor Case (1).
8a) Attach a lifting strap around the upper
pipe of the seal housing, in line with the
center line of the seal housing, and support
with a hoist during disassembly.
8b) Remove the 8 mounting screws (501)
used to mount the seal housing (60) to the
case (1).
8c) Remove the seal housing (60) from the
compressor case (1), by pulling it out
while supported by the hoist.
Two jack screw holes which will accept
the mounting screws (501) are provided if
required for removal.
Section C
Section C
Gearbox
Assembly and Disassembly
Section C
TABLE OF CONTENTS - SECTION C
Section Description
Page No.
I.
Required Special Tools and Supplies............................................................................ 1
II. Torque Requirements................................................................................................... 2
III. Gearbox Assembly....................................................................................................... 3
1) Clean Gearbox Housing (101). ................................................................................ 4
2) Install Output Bearings (151A & B, or C & D)........................................................ 5
3) Install Input Bearings (151E & F). ........................................................................... 6
4) Install Output Shafts (130 or 140)............................................................................ 8
5) Shim Output Bearings (151A&B and 151C&D) to Specified Endplay.................... 10
6) Install Output Bearing Probe Brackets and Probes. ................................................ 14
7) Install and Position Lube Oil Spray Bars (if required).............................................. 16
8) Install Input Shaft Assy (120)................................................................................. 18
9) Install Input Bearing Probe Brackets and Probes.................................................... 20
10) Apply Sealant to Split Line Surface of Lower Gearbox Housing (101).................. 20
11) Assemble Upper and Lower Gearbox Housings (101). ........................................ 22
12) Assemble Retainer (162) to Gearbox Housing (101). ........................................... 25
13) Assemble Adapter Flange (161) to the Lube Pump (160)..................................... 26
14) Assemble Lube Pump Pinion Gear (164) to the Lube Pump (160)........................ 27
15) Assemble the Lube Pump (160) to the Retainer (162). ......................................... 28
16) Assemble the Labyrinth Seal (125) to the Retainer (162)...................................... 28
17) Install the Front Input Shaft Cover (102) to Gearbox Housing (101)..................... 29
18) Install the Output Shaft Covers (181) to Gearbox Housing (101).......................... 30
19) Install the Inspection Window Covers (180) to Gearbox Housing (101)................ 32
IV. Gearbox Disassembly................................................................................................. 33
1) Remove the Output Shaft Covers (181) from the Gearbox Housing (101)............... 34
2) Remove the Front Input Shaft Cover (102) from the Gearbox Housing (101).......... 35
3) Unfasten the Retainer (162) from the Upper Gearbox Housing (101)...................... 36
4) Remove the Upper Gearbox Housing (101) from the Lower Gearbox Housing (101).
................................................................................................................................. 37
5) Remove/Replace the Input Bearings (151E & F).................................................... 38
6) Remove/Replace the Output Bearings (151A & B, or C & D)................................ 40
I.
Section C, Page 1
Required Special Tools and Supplies
For Gearbox Assembly/Disassembly:
•
Pinnacle Tool Kit, supplied with unit, including:
§
Bull Gear Locking Tool
§
¾”-10 UNC “All Thread”, approximately 2 feet long, Quantity = 2
Used For: alignment of the upper and lower gearbox housings(101)
§
Anti-Seize Thread Lubricant,
Type: “Silver Goop”,Crawford Fitting Co.
§
Silicone o-ring Lubricant
Type: Dow Corning 111 Silicone Lubricant
§
Loctite 242 Thread-locker (blue)
§
Permatex #2 Gasket Sealant, Non Hardening #30515
II.
Section C, Page 2
Torque Requirements
Table 1
Torque Specifications for Fasteners
(unless otherwise specified)
Size
Torque (ft-lbs)
¼”-20 UNC
6.3
3/8”-16 UNC
23
½”-13 UNC
55
5/8”-11 UNC
110
¾”-10 UNC
200
1”-8 UNC
480
III.
Section C, Page 3
Gearbox Assembly
This section provides procedures for reassembly of the LF-2000 gearbox.
Follow your organization's lockout/tag-out instructions before working on the
compressor. Failure to follow adequate lockout/tag-out procedures could result in severe
Use proper lifting devices and methods. Failure to do so could result in serious injury to
you or others.
A summary of the assembly steps is listed below, followed by detailed descriptions and images.
Item numbers are provided in parenthesis. Refer to the Compressor Gearbox Drawing for a
cross-section view with item numbers identified, and the unit BOM for part numbers
corresponding to each item number:
1. Clean Gearbox Housing (101).
2. Install Output Bearings (151A & B, or C & D).
3. Install Input Bearings (151E & F).
4. Install Output Shafts (130 or 140).
5. Shim Output Bearings to Specified End-Play.
6. Install Output Bearing Probe Brackets and Probes.
7. Install and Position Lube Oil Spray Bars (if required).
8. Install Input Shaft Assembly (120).
9. Install Input Bearing Probe Brackets and Probes.
10. Apply Sealant to Split Line Surface of Lower Gearbox Housing (101).
11. Assemble Upper and Lower Gearbox Housings (101).
12. Assemble Retainer (162) to Gearbox Housing (101).
13. Assemble Adapter Flange (161) to the Lube Pump (160).
14. Assemble Lube Pump Pinion Gear (164) to the Lube Pump (160).
15. Assemble the Lube Pump (160) to the Retainer (162).
16. Assemble the Labyrinth Seal (125) to the Retainer (162).
17. Install the Front Input Shaft Cover (102) to Gearbox Housing (101).
18. Install the Output Shaft Covers (181) to Gearbox Housing (101).
19. Install the Inspection Window Covers (180) to Gearbox Housing (101).
Section C, Page 4
Detailed Description of the Gearbox Assembly:
Detailed descriptions of the assembly steps are listed below. Item numbers are provided in
parenthesis. . Refer to the Compressor Gearbox drawing CG01GC03 for a cross-section view
with item numbers identified, and the unit BOM for part numbers corresponding to each item
number:
1) Clean Gearbox Housing (101).
1a) Thoroughly clean each half of the gearbox
housing (101), inside and out, of old oil
and foreign materials. All sealant material
on the split line surfaces must be removed
using a scraper, then the surfaces must be
cleaned thoroughly, and stoned. Remove
any sealant that may have extruded around
the edges or into any slots or holes.
Carefully inspect the mating surfaces of the
gearbox halves, all the bores, and o-ring
grooves. Clean and deburr as needed.
If the gearbox is mounted to the baseplate and integral oil sump, care must be
taken to avoid dropping any material into
the oil sump, especially old sealant and
debris.
Split Bearing Functional Note: All the bearings (151A through F) on this unit have a split
body design, enabling them to be removed one half at a time while the shafts and compressor
ends remain intact. A radial pin extending from the bearing OD sits within a slot on the lower
gearbox housing (101) split line to orient the bearing during operation. In order to remove a
bearing half, the upper gearbox housing (101) must be removed, and the bearing rotated to a
position where its own split line is horizontal. In this position the two socket head cap screws
that hold the halves together may be removed, and then the bearing half itself may be removed.
Each bearing will require a different degree of rotation to achieve this position.
Section C, Page 5
2) Install Output Bearings (151A & B, or C & D)
It is a good idea to mark each bearing half and end plate with a letter
corresponding to it’s Post position (A, B, C, or D). When they are separated later for
endplay shimming, they will need to be kept together for proper re-assembly. It is also
important that they are installed at the proper location, since they have a particular rotation
direction (see rotation arrow on bearing) and load carrying orientation. Anti-rotation pins
on the bearing fit OD ensure that the bearing is oriented correctly when installed at the
proper location, by fitting into a groove on split line of the lower gearbox housing.
2a) Having the vibration probe bearing
brackets already installed on the bearings
facilitates handling of the bearings.
Carefully lower the bearing into the bore,
with the bracket at the top of the bearing
facing the inside of the gearbox. Slide the
bearing toward the outside of the gearbox
until the bearing flange seats properly.
Repeat for all the output bearings (151A
& B for a single pinion machine, and C &
D for a double pinion machine).
Be extremely careful with the temperature element and vibration probe leads extending
from the bearings, especially when rotating. When the bearing is rotated with probes
mounted in brackets, the lube supply pipe to the bearing will be very close to the probes
2b) Rotate the bearing in the bore until the
bearing split line is horizontal, and the
recessed socket head cap screws holding
the halves together are accessible. This
may require the bracket to be rotated to
the bottom.
2c) Remove the 2 recessed socket head cap
screws (#8-32UNC) holding the halves of
the bearing together.
Section C, Page 6
2d) The bearing halves are pinned together,
and require some effort to separate. Use
the pry grooves, located within the lube
annulus feature, to begin the separation.
A simple pry bar may be constructed
to make the separation easier. Use an allen
wrench, ground down to a flat “screw-driver”
tip at the end.
2e) Complete the bearing separation by
holding the lower half down in the gearbox
bore while pulling the upper half off.
2f) For units with two output shafts (130 and
140), repeat all of the steps of this section
for the second set of bearings.
3) Install Input Bearings (151E & F).
3a) The vibration probe bearing brackets
should already be installed on the bearings.
Carefully lower the bearing into the bore,
with the bracket at the top of the bearing
facing the inside of the gearbox. Slide the
bearing toward the outside of the gearbox
until the bearing flange seats properly.
Repeat for the other input bearing.
Section C, Page 7
Be extremely careful with the
temperature element leads extending from
the bearings, especially when rotating.
The temperature element leads on the
input bearings exit the bearing at a location
that would allow them to be sheared off if
the bearing were rotated quickly in the
bore. Therefore, move the lead towards
the inside of the gearbox when rotating the
bearing.
3b) Rotate the bearing in the bore until the
the halves together are accessible.
3c) Remove the 2 recessed socket head cap
3d) The bearing halves are pinned together,
to make the separation easier. Use an
allen wrench, ground down to a flat
“screw-driver” tip at the end.
Section C, Page 8
3e) Complete the bearing separation by
holding the lower half down in the gearbox
bore while pulling the upper half off.
4) Install Output Shafts (130 or 140).
4a) Generously lubricate the bore of
the bearing lower halves with ISO Grade
32 oil (see lube oil recommendations)
Do this for both of the bearings on this
shaft (151A&B or 151C&D).
Section C, Page 9
4b) Orient the shaft so that the shaft ends are
on the correct sides of the gearbox (101).
For a single ended output shaft, this is
easily determined by the hirth connection
location. For double ended output shafts
(hirth attachments on both ends), the shaft
end with the smaller thrust runner OD
points towards the main driver. Carefully
place the output shaft (130 or 140) into
the bearing bores.
There is not much clearance between
the thrust bearings and thrust surfaces on
the shaft, so care must be taken not to
damage the babbit on the thrust bearing
surfaces when installing the shaft into the
bores.
4c) Generously lubricate the portion of the
shaft (130 or 140) exposed in the bearing
bores with ISO Grade 32 oil (see lube oil
recommendations).
Do this for both ends of the shaft, at each
bearing bore.
4d) Place the correct upper bearing half onto
the lower half, aligning the pins. Use a
small rubber mallet to lightly tap together if
required.
Section C, Page 10
4e) Rotate the bearing so that the holes for the
socket head cap screws are facing
upwards.
Be careful of the temperature element
wires when rotating the bearing, especially
when passing near the lube piping below.
4f) Install and tighten the 2 recessed socket
head cap screws (#8-32UNC) holding the
halves together.
4g) Rotate the bearing to the proper running
position, where the anti-rotation pin sits in
the groove in the split line.
Repeat all of the steps in this section for both
of the bearings (151A&B or 151C&D) on
this shaft.
4f) For units with two output shafts (130 and 140), repeat all of the steps found above in this
section for the second shaft and second set of bearings.
5) Shim Output Bearings (151A and 151C) to Specified Endplay.
If endplay had been previously set, only redo this if endplay changes due to a shaft or
bearing change.
5a) Ensure that both bearing flanges are fully
seated against the gearbox housing.
Measure the endplay of the shaft while
firmly pushing/pulling the shaft between the
two thrust bearings. Required endplay is
0.012”+/-.002”. If the measurement is out
of this range, one of the bearings must be
shimmed.
Section C, Page 11
5b) Orient the bearing with the holes for the
socket head cap screws facing upwards.
This may require rotating the bearing in the
bore. Remove the 2 recessed socket
halves together.
Be careful of the probe wires when
rotating the bearing, especially when
passing near the lube piping below.
5c) Remove the upper half of the bearing.
Keep track of which bearing half
belongs at which position, so that when the
lower halves are removed they may be
kept with the proper upper halves and
marked as a matched set.
5d) Carefully remove the shaft by lifting
straight upwards.
5e) Remove the lower half of the bearing that
is opposite of the motor side (post position
A or C) for shimming. The other bearing
lower half may remain in place since it will
not be shimmed.
Section C, Page 12
If the bearing halves and backing plates
have not yet been matched marked, do so
now. Mark each bearing half body and
end plate with a letter corresponding to it’s
Post position (A, B, C, or D).
5f) Place the 2 bearing halves for shimming on
a protected surface, and remove the 3
socket head screws (#8-32UNC) holding
on each backing plate (and passing
through the bearing holding on the thrust
plate).
5g) Remove the end plate and thrust plate
from each half of the bearing.
Be extremely careful when
disassembling bearings with temperature
elements. Observe how the wiring is
routed within the bearing, and be sure to
duplicate when reassembling bearing.
Section C, Page 13
5h) The shim stock is cut in half, with through
holes for the end plate screws, to match
each half of the proper bearing. There is
one set for the CW bearings and another
for the CCW bearings. Be sure to remove
any burrs or raised edges from the shim
stock.
Install required amount of shim stock
behind thrust plate, lining up the through
holes with the screw holes.
5i) Reassemble the end plates and thrust
plates to the bearing.
5j) Reinstall the lower bearing half, then
carefully reinstall the shaft back into the
bearings by following all of the steps of
Section 4, “Install Output Shafts (130 &
140).”
5k) Repeat all of the steps found above in this
section until the specified endplay is met.
5m) For units with two output shafts (130 and 140), repeat all of the steps found above in this
section for the second shaft and second set of bearings.
Section C, Page 14
6) Install Output Bearing Probe Brackets and Probes.
6a) Assemble the axial probe bracket (154) to
the radial probe bracket (152) by installing
the socket head cap screws (1/4”20UNC) with Locktite 242 Thread-locker
(blue). Position approximately so that the
tip of the bracket is not touching the shaft.
Tighten only enough to hold the bracket in
place.
6b) Install the set screw (3/8”-16UNC) with
Locktite 242 Thread-locker (blue), and
tighten only enough to hold the axial
bracket (154) in place.
6c) Adjust the axial probe bracket (154) so
that the probe is aligned approximately
with the center of the thrust face width (on
the shaft (130 or 140)). Verify that there
is at least .060” clearance between the
bottom of the bracket and the shaft (130
or 140).
Tighten the 2 socket head cap screws
(1/4”-20UNC) and the set screw (3/8”16UNC).
Section C, Page 15
6d) Install the radial probes into the radial
probe bracket (152) by backing off the
lock nuts and threading in the probes.
Gap the probes (set the probe tip to shaft
distance reading) per the manufacturer’s
recommended gap voltage. Tighten the
lock nuts.
6e) Install the axial probe into the axial probe
bracket (154) by backing off the lock nut
and threading in the probe. Thrust the
shaft so that the thrust runner face moves
towards the probe tip (minimum gap).
Gap the probe (set the probe tip to shaft
recommended gap voltage, so that the
.012”±.002” end-play may be
accommodated. Tighten the lock nut.
6f) Route the probe and temperature element
cables along the sides of the gearbox,
using the welded on studs and cable
clamps. Refer to the unit outline drawing
for proper exit locations for each cable.
Ensure that cables are securely
fastened, and that there is no possibility of
cables interfering with rotating components
or the clamping of the upper gearbox
housing. Utilize cable ties between the
clamps, where required, to eliminate loose
cables.
Section C, Page 16
7) Install and Position Lube Oil Spray Bars (if required).
7a) The height and location of the lower spray
bar is controlled by an “L” shaped piece
of tubing, sized properly at the factory for
the unit’s gear set. Ensure that all tube
fittings are tight.
7b) Ensure that the drilled holes in the spray
bar (there are 2 rows of 3 holes) are
oriented such that they direct oil to each
side of the exiting gear mesh. The spray
bar is easily oriented by loosening the
closest tube fitting, rotating the spray bar,
then re-tightening the fitting.
Section C, Page 17
7c) The upper spray bar is located by being
installed in one of two ports in the upper
gearbox housing (101) above Post D. An
NPT to tube fitting connects the port to
the spray bar, and allows the bar to be
easily rotated into position. Ensure that
the drilled holes in the spray bar (there are
2 rows of 3 holes) are oriented so that
they direct oil to each side of the exiting
gear mesh. The other port must be
plugged.
If the spray bar is located in the wrong
port, it may damage the gear when the
upper housing is assembled to the lower.
The spray bar should remain in the factory
set location, or it should be assembled
though the inspection window after
assembling the upper and lower housings.
Section C, Page 18
8) Install Input Shaft Assy (120).
8a) Using a suitable hoist and
connecting member, lift the input shaft
assembly (120) (approximately 1000 lbs).
The holes in the gear may be used to
attach a suitable lifting strap.
8b) Generously lubricate the bore of the
bearing lower halves with ISO Grade 32
oil (see lube oil recommendations)
Do this for both of the input bearings
(151E and 151F).
Make sure the input bearing flanges
are seated against the gearbox, because
there is not much clearance between the
thrust bearings and thrust surfaces on the
shaft. Care must be taken not to damage
the babbit on the input thrust bearing
surfaces when installing the shaft into the
bores.
Also, care must be taken to avoid any
impact with the hardened gear teeth during
the assembly.
8c) Generously lubricate the portion of the
shaft (120) exposed in the bearing bores
with ISO Grade 32 oil (see lube oil
recommendations).
Do this for both ends of the shaft, at each
bearing bore.
Section C, Page 19
8d) Place the correct upper bearing half onto
the lower half, aligning the pins. Use a
small rubber mallet to lightly tap together if
required.
Do this for both of the bearings (151E and
151F) on this shaft (120).
8f) Rotate the bearing so that the holes for the
socket head cap screws are facing
upwards.
Be very careful of the temperature
element wires when rotating the bearing,
especially when the exiting wires pass by
the split line, since their exit location makes
it possible for them to be sheared off.
8g) Install and tighten the 2 recessed socket
halves together.
8h) Rotate the bearing to the proper running
position, where the anti-rotation pin sits in
the groove in the split line.
Repeat all of the steps in this section for both
of the bearings (151E and 151F) on this
shaft (120).
Section C, Page 20
9) Install Input Bearing Probe Brackets and Probes.
9a) Assemble the key phasor probe bracket
(153) to the radial probe bracket (152) by
installing the 2 socket head cap screws
(1/4”-20UNC) with Locktite 242 Threadlocker (blue), and tightening.
9b) Install the radial probes into the radial
probe bracket (152) by backing off the
lock nuts and threading in the probes.
Gap the probes (set the probe tip to shaft
lock nuts.
9c) Install the key phasor probe into the key
phasor probe bracket (154) by backing
off the lock nut and threading in the probe.
Gap the probe (set the probe tip to shaft
lock nut.
10) Apply Sealant to Split Line Surface of Lower Gearbox Housing (101).
10a) Thoroughly clean the split line surface on
each half of the gearbox housing (101) of
old gasket sealant, oxidation, debris,
residual oil, etc. (see section 1).
Section C, Page 21
10b) Apply Permatex #2 Gasket Sealant, Non
Hardening #30515, only to the split line
surface of the lower gearbox housing
(101), as follows;
Apply a bead of sealant around the outer
and inner edges of each split line surface.
Run a bead around all of the mounting
holes (this prevents pressurized oil that
may enter the split line from migrating up
the fasteners). Maintain at least a 1/4”
distance from the edges and holes
wherever possible.
10c) On each side of the input shaft bearing
bores there are lube grooves that have a
“dead-end” before reaching the outboard
bore face. This area requires sealant
around the end of the groove, and along
the bore face edges, which are beyond
where the cover o-ring seals (the o-ring
cover o-ring seals within the bearing bore).
Section C, Page 22
11) Assemble Upper and Lower Gearbox Housings (101).
11a) Install “All-Thread” guide studs,
into the center threaded holes at the ends
of the lower housing (101) split line (see
next photo). The length of these guide
studs should be approximately 23” long,
or enough to ensure that the studs engage
the upper housing before reaching the
height of the bull gear profile. This will
keep the assembly aligned as the upper
housing is lowered onto the lower housing.
11b) Using a suitable hoist and
connecting member, lift the upper housing
(101) (approximately 1000 lbs) by the
lifting eyes (851) at the top of the upper
housing.
11c) Push all of the bearings towards their respective thrust runners (towards the center
of the gearbox) to allow clearance as the upper housing is lowered onto the lower housing.
Be sure that all of the bearing anti-rotation pins are seated in the split line grooves.
Care must be taken to avoid any impact with the hardened gear teeth during the
assembly.
Section C, Page 23
11d) Lower the upper housing down onto the
guide studs by aligning them with the
matching holes on the upper housing
(101).
Carefully continue lowering the
upper housing, being sure that all
temperature and vibration leads are clear
of the mating surfaces, including the upper
bearing bores.
Remove the “All-Thread” guide studs from
the assembly.
11e) Ensure that all residual sealant has been
cleaned from taper pin holes in both the
upper and lower housings (101), as it will
tend to extrude into the holes when the
upper is placed onto the lower. Insert the
five taper pins (560) into their
corresponding locations. These should
have a nut and washer as part of their
assembly.
11f) Tap the 5 taper pins (560) securely into
place using a rubber mallet. The nut
should be backed off enough so that when
the pin is tapped into place, there is still
clearance between the nut and washer.
Section C, Page 24
11g) Lubricate the threads of the 10 split line
screws (557) (3/4”-10UNC) with an ISO
Grade 32 oil. Install the 10 split line
screws (557) with the 10 washers (657)
into the gearbox housing (101) until finger
tight.
11h) Lubricate both ends of the 4 input boss
studs (558) (3/4”-10UNC) and the 8
output boss studs (559) (3/4”-10UNC)
with an ISO Grade 32 oil. Install all 12
studs into their respective positions until
they bottom out in the lower housing.
Install the 12 washers (658 and 659),
followed by the 12 nuts (758 and 759)
(3/4”-10UNC) until finger tight.
11j) Snug down the 10 split line screws (557)
and the 12 stud nuts (758 and 759), then
again tap the 5 taper pins (560) securely
into place.
Torque the 10 screws (557) and the 12
stud nuts (758 and 759) to 200 ft-lbs, by
progressing in 70 ft-lb increments. Start
with those closest to the input shaft (120),
and work outwards, while alternating
fasteners on each side, as shown below:
Section C, Page 25
12) Assemble Retainer (162) to Gearbox Housing (101).
12a) Lubricate the o-ring (956) with a silicone
lubricant, and install on the retainer (162).
12b) Install the retainer (162) onto the
gearbox housing (101) by placing over the
input shaft (120) through the hole near the
OD NPT port. The retainer o-ring should
be facing the housing. Carefully align the
retainer boss with the bore on the housing,
and push in until the retainer is flush with
the housing.
12c) Apply Anti-Seize lubricant to the threads
of the 4 retainer screws (556) (5/8”11UNC), install into the housing, and
torque to the value specified in Table 1.
Section C, Page 26
13) Assemble Adapter Flange (161) to the Lube Pump (160)
lubricant, and install into the face groove of
the adapter flange (161).
13b) Install the adapter flange (161) onto the
lube pump (160), mating the face seal oring to the lube pump flange, and aligning
the holes in the adapter flange with the
holes in the lube pump flange.
This is held on loosely until they are
mounted as an assembly onto the retainer
(162).
13c) Lubricate the o-ring (961) with a silicone
lubricant, and install into the boss of the
adapter flange (161).
Section C, Page 27
14) Assemble Lube Pump Pinion Gear (164) to the Lube Pump (160)
14a) Before heating the gear (164), ensure
that the key (163) is a slip-fit in the shaft
keyway. If not, stone the key to the
proper width. Heat the lube pump pinion
gear (164) in a 350° oven until it reaches
temperature.
Handle heated components with
appropriate personal protection equipment
and safety procedures.
14b) Hold the gear (164) flat, and set the shaft
key (163) into the gear key slot, with the
“leg” of the key toward the gear OD.
With the lube pump (160) oriented with
the shaft pointed upwards, carefully slide
the gear (164) and key (163) onto the
shaft. After placing the gear and key onto
the shaft, hold the gear approximately flush
to the end of the lube pump shaft until
cooling of the gear allows it to stay in
place
Section C, Page 28
15) Assemble the Lube Pump (160) to the Retainer (162).
15a) Check to ensure that the o-ring
(961) is installed on the adapter flange.
Carefully insert the lube pump pinion
gear (164) into the lower hole in the
retainer (162) until the pinion gear (164)
contacts and engages the drive gear (124)
on the input shaft (120).
Apply Anti-Seize lubricant to the threads
of the 4 lube pump screws (551) (1/2”13UNC), install into the retainer, and
16) Assemble the Labyrinth Seal (125) to the Retainer (162).
16a) Lubricate the 2 o-rings (953) with a
silicone lubricant, and install into the 2 OD
o-ring grooves of the labyrinth seal (125).
NOTE: There are 3 grooves on the OD
of the labyrinth seal, but only 2 are for orings. The center groove is the annulus for
providing air to the seal, and must not be
filled with an o-ring.
Ensure that the center groove and through
holes are clear of debris.
Section C, Page 29
16b) Install the labyrinth seal (125) by sliding
over the input shaft (120), with the flat
edge of the seal flange facing downwards.
Push the seal into the retainer (162) bore
until the seal flange seats against the
retainer.
16c) Apply Anti-Seize lubricant to the threads
of the 4 labyrinth seal screws (553) (3/8”16UNC), install into the retainer (162),
and torque to the value specified in Table
1.
17) Install the Front Input Shaft Cover (102) to Gearbox Housing (101)
lubricant, and install into the groove on the
OD of the cover (102) boss.
Section C, Page 30
17b) Install the input cover (102) by putting
into place over the input bore on the
gearbox housing (101), then applying
pressure while keeping the cover
perpendicular to the bore until the cover
seats on the bore face.
of the 6 input cover screws (550) (3/8”16UNC), install into the retainer (162)
along with the 6 washers (650), and
18) Install the Output Shaft Covers (181) to Gearbox Housing (101)
OD of the cover (181) boss.
Section C, Page 31
18b) Install the output cover (181) by putting
into place over the output bore on the
gearbox housing (101), then applying
pressure while keeping the cover
perpendicular to the bore until the cover
seats on the bore face.
of the 6 output cover screws (555) (1/2”13UNC), install into the retainer (162)
along with the 6 washers (655), and
18c) For units with multiple locations requiring output covers, repeat all of the steps of this
section for the additional output covers.
Section C, Page 32
19) Install the Inspection Window Covers (180) to Gearbox Housing (101)
bottom of the inspection window cover
(180).
19b) Apply Anti-Seize lubricant to the threads
of the 8 cover screws (552) (1/4”20UNC).
19c) Place the inspection window cover (180)
over the opening on the upper housing,
and insert the 8 screws (552) (1/4”20UNC) and 8 washers (652) to mount.
Ensure that the o-ring remains in the cover
groove. Torque the screws to the value
specified in Table 1.
To prevent the cover from sliding down
the slope of the housing, and risking
dislodging of the o-ring, first insert the 2
upper screws and washers to hold the
cover in place.
IV.
Section C, Page 33
Gearbox Disassembly
This section provides procedures for disassembly of the LF-2000 gearbox, with the primary
objective of removing the bearings. The gearbox has been designed with several innovative
features that facilitate disassembly and servicing. The first is being able to remove the upper
housing, providing access to the gearbox internals, without removing the compressor ends, since
they are mounted only to the lower gearbox. The second is being able to remove bearings
without first removing the shafts that they support (while also leaving the compressor ends
mounted to the gearbox). This is accomplished by a split bearing design.
Follow your organization's lockout/tag-out instructions before working on the
compressor. Failure to follow adequate lockout/tag-out procedures could result in severe
Use proper lifting devices and methods. Failure to do so could result in serious injury to
you or others.
A summary of the disassembly steps is listed below, followed by detailed descriptions and
images. Item numbers are provided in parenthesis. Refer to the Compressor Gearbox drawing
CG01GC03 for a cross-section view with item numbers identified, and the unit BOM for part
numbers corresponding to each item number:
1. Remove the Output Shaft Covers (181) from the Gearbox Housing (101).
2. Remove the Front Input Shaft Cover (102) from the Gearbox Housing (101).
3. Unfasten the Retainer (162) from the Upper Gearbox Housing (101).
4. Remove the Upper Gearbox Housing (101) from the Lower Gearbox Housing (101).
5. Remove/Replace the Input Bearings (151E & F).
6. Remove/Replace the Output Bearings (151A & B, or C & D).
Section C, Page 34
Detailed Description of the Gearbox Disassembly:
Detailed descriptions of the disassembly steps are listed below. Item numbers are provided in
parenthesis. . Refer to the Compressor Gearbox drawing CG01GC03 for a cross-section view
with item numbers identified, and the unit BOM for part numbers corresponding to each item
number. Disassembly may be done up to a certain point with the compressor cases mounted to
the gearbox:
1) Remove the Output Shaft Covers (181) from the Gearbox Housing (101).
This will be done for all the post locations
which do not have compressor ends.
1a) Remove the 6 cover screws (555) and
washers (655), then remove the cover
(181). Jacking screw holes, which accept
the cover screws, are provided to facilitate
removal.
If desired, the covers may be “backed
off” rather than removed. This is done by
removing the 3 screws which insert into
the upper gearbox housing, while “backing
off” the remaining 3 lower screws about a
half inch. Then the cover may also be
“backed off” away from the upper
housing.
Section C, Page 35
2) Remove the Front Input Shaft Cover (102) from the Gearbox Housing (101).
2a) Remove the 6 cover screws (550) and
washers (650), then remove the cover
(102). Jacking screw holes, which accept
the cover screws, are provided to facilitate
removal.
If desired, the covers may be “backed
off” rather than removed. This is done by
removing the 3 screws which insert into
the upper gearbox housing, while “backing
off” the remaining 3 lower screws about a
half inch. Then the cover may also be
“backed off” away from the upper
housing.
Section C, Page 36
3) Unfasten the Retainer (162) from the Upper Gearbox Housing (101).
3a) Remove the upper 2 retainer screws (556)
which fasten the retainer (162) to the
upper gearbox housing (101), and loosen
the lower 2 retainer screws (556) which
fasten the retainer (162) to the lower
gearbox housing (101).
The lube pump retainer (162) must be
backed off slightly to prevent damaging the
face o-ring (956) when removing the
upper housing (as well as when replacing
it).
3b) The lube pump piping, connected by two
SAE type flanges to the lube pump (160),
may either cause the retainer (162) to
back off when loosened due to pipe strain,
or it may prevent the retainer from backing
off due to pipe rigidity. The separation gas
piping at the top of the retainer may also
restrict retainer movement. If the retainer
does not back off when loosened,
disconnect the SAE flanges, and the
separation gas piping if necessary, and
slide the retainer and lube pump away
from the gearbox about ½”.
CAUTION: Before reinstalling the upper gearbox housing (101), make sure that all the
covers and retainer that were backed off or removed in the previous steps remain backed
off or removed to provide clearance when lowering the upper housing back into place. Use
caution to ensure that none of the o-rings on these components are damaged during the
reassembly. The covers and retainer should be reinstalled only after the upper gearbox
housing is reassembled.
Section C, Page 37
4) Remove the Upper Gearbox Housing (101) from
the Lower Gearbox Housing (101).
4a) Loosen the 10 split line screws (557) and
the 12 stud nuts (758 and 759), and
tighten down the nuts for the 5 taper pins
(560) so that the taper pins disengage.
4b) Remove the 10 split line screws (557), the
12 stud nuts (758 and 759), and the 5
taper pins (560).
(Photo shows lifting off already in process)
4c) Install “All-Thread” guide studs, provided
in the Tool Kit, into the center threaded
holes at the ends of the lower housing
(101) split line. Ensure that the length of
these guide studs are long enough to
ensure that the studs remain engaged in the
upper housing until the bull gear is cleared.
Section C, Page 38
Care must be taken to avoid any
impact with the hardened gear teeth during
the disassembly.
4d) Lift the upper gearbox housing
(101) off of the lower gearbox housing
(101), utilizing the lifting instruction
provided in Section A.
4e) Remove the “All-Thread” guide studs
from the lower gearbox housing.
5) Remove/Replace the Input Bearings (151E & F).
(Pictures show assembly without input shaft,
but instructions explain bearing removal with
shaft in place)
Be extremely careful with the
temperature element leads extending from
the bearings, especially when rotating.
The temperature element leads on the
input bearings exit the bearing at a location
that would allow them to be sheared off if
the bearing were rotated quickly in the
bore. Therefore, move the lead towards
the inside of the gearbox when rotating the
bearing.
Section C, Page 39
Use a lifting strap and crane to
support the weight of the input shaft
assembly (120) near the bearing being
removed. Otherwise the bearing will not
be able to be rotated, and the bearing may
be damaged.
5a) Rotate the bearing in the bore until the
the halves together are accessible.
5b) Remove the 2 recessed socket head cap
5c) The bearing halves are pinned together,
to make the separation easier. Use an
allen wrench, ground down to a flat
“screw-driver” tip at the end.
Section C, Page 40
5d) The top half of the bearing may be lifted
off of the lower half of the bearing and the
input shaft (120).
5e) In order to remove/replace an entire
bearing with the input shaft (120) in place,
one half of a bearing must always be
supporting the shaft. Therefore, after
removing the top half, a new top half must
be assembled to the old bottom half, then
the assembly must be rotated to remove
the old bottom half. Then finally the new
bottom half may be assembled to the new
top half, and the bearing assembly may be
rotated into position.
6) Remove/Replace the Output Bearings (151A & B, or C & D).
Be extremely careful with the temperature element and vibration probe leads extending
from the bearings, especially when rotating. When the bearing is rotated with probes
mounted in brackets, the lube supply pipe to the bearing will be very close to the probes
6a) Orient the bearing with the holes for the
socket head cap screws facing upwards.
This may require rotating the bearing in the
bore. Remove the 2 recessed socket
halves together.
To rotate the bearing it may be
necessary to support the weight of the
shaft (130 or 140) by hand.
Be careful of the probe wires when
rotating the bearing, especially when
passing near the lube piping below.
(Pictures show assembly without output shaft,
but instructions explain bearing removal with
shaft in place)
Section C, Page 41
6b) The bearing halves are pinned together,
to make the separation easier. Use an allen
wrench, ground down to a flat “screw-driver”
tip at the end.
6c) The top half of the bearing may be lifted
off of the lower half of the bearing and the
output shaft (130 or 140).
6d) In order to remove/replace an entire
bearing with the output shaft in place, one
half of a bearing must always be
supporting the shaft. Therefore, after
removing the top half, a new top half must
be assembled to the old bottom half, then
rotate the assembly to remove the old
bottom half. Then finally the new bottom
half may be assembled to the new top half,
and the bearing assembly may be rotated
into position.
6e) For units with two output shafts (130 and
140), repeat all of the steps of this section
for the second set of bearings.
6f) Be sure to verify the shaft endplay by
repeating Step 5 in the Gearbox Assembly
instructions found above.

Pinnacle LF-2230 Compressor

Transcription

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