3. Segmented packing:
NOTE: The instructions below are for packing
specification “J”. Depending on the packing
specification used in your compressor, the order of
assembly for the segmented packing arrangement
(radial or tangent) will vary. Refer to Appendix E
to view the segmented packing arrangements. If
you do not know the packing arrangement used
in your compressor, refer to the model number
identification codes listed in Appendix A.
a. Clean the segmented packing cups and the area
inside the packing barrel.
b. Insert the segmented packing cups, segmented
packing pairs and backup rings one at a time in
the order shown in Appendix E.
c. Reattach the packing box cartridge to the packing
barrel using the four socket head screws.
4. Install three O-rings on the packing barrel and packing
box cartridge as shown in the D-Style Crosshead
Guide Details in Appendix E.
5. Install packing installation cone (part number 3905)
over the threaded end of the piston rod.
6. Carefully install barrel/cartridge assemblies over the
piston rods, noting the alignment of the barrels as
they sit on the crosshead guide. The valve scallops
on the barrels must align properly with the valves in
the cylinder.
7. Remove packing installation cone.
8. Replace pistons, cylinders, heads and cylinder cap.
See details in Section 5.3 for proper assembly of
pistons.
9. Rotate unit by hand to ensure proper assembly.
5.7 Bearing Replacement for
Crankcase and Connecting Rod
1. To replace the crankcase roller bearings, wrist pin
bushing and connecting rod bearings, begin by
removing the head, cylinder, piston, crosshead guide
and crosshead assembly.
2. Drain the crankcase and remove the inspection plate(s).
3. Before disassembly, choose and mark one connecting
rod and the corresponding connecting rod cap. DO
NOT MIX CONNECTING RODS AND CAPS. Loosen
and remove the connecting rod bolts in order to
remove the crosshead and connecting rod assembly.
5.7.1 Wrist Pin Bushing Replacement
1. To replace the wrist pin bushing, remove the retainer
rings that position the wrist pin in the crosshead.
2. Press out the wrist pin so the crosshead and
connecting rod may be separated. Inspect the wrist
pin for wear and damage and replace if necessary.
3. Press out the old wrist pin bushing and press a
new bushing into the connecting rod. DO NOT
MACHINE THE O.D. OR I.D. OF THE BUSHING
BEFORE PRESSING INTO CONNECTING ROD.
4. Make sure the lubrication hole in the bushing
matches the oil passage in the connecting rod. If
the holes do not align, press out and insert a new
one. Bore the wrist pin bushing I.D. as indicated
on the respective connecting rod assembly details.
These pages are located in Appendix E. Over boring
the bushing can lead to premature failure of the wrist
pin bushing.
5. Inspect the oil passage for debris and clean thoroughly
before proceeding.
6. Press the wrist pin back into the crosshead and
wrist pin and reinstall retainer rings. NOTE: The
fit between the wrist pin and bushing is tighter
than ordinary lubricated air compressors and
combustion engines.
5.7.2 Replacing Connecting Rod Bearings
Connecting rod bearings are easily replaced by removing
the semicircular bearings. Make sure the indentations
in the connecting rod bearing and connecting rod line
up when installing the new bearings. MAKE SURE
THE ARROW AND/OR ALIGNMENT NOTCH ON
CONNECTING ROD AND CAP ARE ALIGNED.
Before reinstalling the crosshead/connecting rod
assembly, make sure the crankshaft throw and bearing
surface are clean and lubricated. Tighten the connecting
rod bolts to the torques listed in Appendix B.
5.7.3 Replacing Crankcase Roller Bearings
To inspect the roller bearings, remove the flywheel from
the crankshaft and then remove the bearing carrier and
crankshaft from the crankcase. If corrosion or pitting is
present, the roller bearings should be replaced. When
replacing roller bearings, always replace the entire
bearing, not just the cup or the cone.
1. To replace the bearings, press the cups out of the
crankcase and bearing carrier and press the cones off
the crankshaft.
2. Press the new bearings into position and reassemble
the crankshaft and bearing carrier to the crankcase.
When reinstalling the bearing carrier, make sure the oil
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