Transcript LB161 Teardown

LB161 LPG / NH3 Compressor
This presentation is a simplified
description of the disassembly of a
Blackmer LB161.
The current production model is
the LB161B (August 1997). The
largest difference affecting
disassembly is in the oil pump.
The current oil pump is self
reversing and is not shown in this
presentation
Select one of the following:
Hilites Only
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Detailed Text
LB161 LPG / NH3 Compressor
LB161
LPG / NH3
Compressor
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The LB161 compressor is
suitable for many applications,
but the most common is the
transfer and vapor recovery of
liquefied gases such as
propane, butane, and
anhydrous ammonia. The
non-lubricated cylinder design
of the LB161 allows the
transfer of these products
without contamination of the
products and is capable of
transferring up to 90 gallons
per minute (340 lpm).
Typically the LB161 is driven
by a 5 or 7.5 HP driver in the
650 to 800 rpm range.
LITERATURE
Be sure you have the proper
literature before starting work
on the compressor. Locate
the parts list and Installation,
Operation and Maintenance
instructions. In addition, you
may have received additional
instruction sheets with your
machine that further describe
such items as valves and
packing.
Literature is available on the
web at:
blackmercompressor.com
or from your Blackmer
distributor.
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Tools
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The tools normally required for
small machine service will be
adequate. A small strap wrench is
useful as well as a good spanner.
The Blackmer spanner p/n 790316
has 1/4” pins and is used for piston
removal. Blackmer wrench p/n
790535 may be used for the valve
hold down screws. A flat scraper and
inside snap ring pliers are also
needed.
Blackmer offers a complete tool kit
which has all of the hand tools
necessary to dismantle the machine.
On larger machines a small hoist
might be needed for one man to do
the job, depending on the
environment. Generally, two men can
handle the disassembly of any
Blackmer machine.
Nameplate
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On the side of every Blackmer
compressor is a nameplate
which doubles as an access
opening for inspecting the
piston rod.
The nameplate will show the
compressor’s model number,
serial number, ID number, and
oil capacity.
The compressor ID is a coded
number that fully describes the
compressor’s construction.
Make certain that you have
these identifying numbers when
you call your Blackmer
distributor for parts or service
assistance.
LB161
Compressor
Blackmer offers a variety of
LPG transfer compressors.
The LB162 is similar to the
LB161 shown in this presentation
but has two seals separated by a
distance piece on each piston
rod.
Larger models are:
LB361 / LB362
[15 bhp (11 kw)]
LB601 / LB602
[40 bhp (30 kw)]
LB942
[50 bhp (37 kw)]
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Pressure
Gauges
Blackmer compressors are
typically fitted with a pressure
gauge on both the suction and
discharge. The gauges are fitted
with a pulsation dampener to
eliminate much of the vibration of
the gauge needle making it
easier to read and extending the
life of the pressure gauge.
Both suction and discharge
pressure gauges should be
installed on every compressor.
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Valve Caps and
Hold Down
Screws
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Remove the valve caps to
access the valves.
After the valve caps have been
removed, the valve hold down
screws can be removed with a
spanner wrench (such as a
Blackmer p/n 790316 or 790535).
Note the O-ring under each
cap; these should be replaced
rather than reused. Older models
will have a metal gasket instead
of an O-ring under the valve cap.
Valves
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With the hold down screws
removed, the valve post, valve
and gasket may be taken out.
A liquid relief device in the
suction valve post helps protect
the compressor in case liquid
enters the cylinder area. It
consists of a ball and spring
relief valve which will allow liquid
to be returned to the suction
piping if necessary.
The discharge valve is held in
place by a solid post.
Make certain the valve
gaskets are removed with each
valve as they may be difficult to
see in the head. The valve
gaskets are normally aluminum
and must be replaced when the
valves are removed.
Cylinder Head
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To remove the cylinder head,
unbolt the two center head bolts
from the top of the head and the
four head bolts from the corners
of the head. The two center
head bolts have metal gaskets
which are normally not reusable.
After the cylinder head bolts
have been removed, the head
may be lifted from the cylinder.
Head O-rings
and Piston Nut
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The head is sealed to the
cylinder with four O-rings
(usually Buna-N). O-rings seal
each cylinder and both center
head bolts and are not normally
reusable.
The piston nut is removed with
an adjustable spanner. This
spanner has two 1/4” pins which
fit into holes in the top of the
piston nut. Note the nylon locking
device on the piston nut.
Piston Removal
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Once the piston nut has been
removed, the spanner is used to
unscrew the piston from the rod.
Under each piston is a thick washer
and one, or more, shims. These shims
adjust the height of the piston in the
cylinder. This is referred to as the
“deck height”. Unless a major part has
been changed, the deck height should
not need adjustment. Changing the
piston, crosshead assembly, cylinder
body, main bearings or crankshaft may
require adjustment of the deck height.
Rotate the crankshaft to bring the
other piston to top-dead-center for
removal. Each piston is fitted with
three piston rings. Each ring has a
stainless steel expander between it
and the piston. Install each piston ring
with the bevel on the inside facing up.
The ring and expander gaps should be
staggered at 180° intervals during
installation.
Cylinder
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With the pistons removed, the
cylinder can be unbolted and
removed to gain access to the
packing boxes. Two O-rings seal
the bottom of the cylinder.
Notice the passage in the
bottom of the cylinder between
the bores. This allows gas to
move from one cylinder to the
other as the pistons move up
and down.
Packing Box
Removal
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The packing boxes are
secured by a hold down screw
which is removed with the same
adjustable spanner that was
used on the piston nut and
piston. Note that the hold down
screw also has a nylon insert
that keeps it in place.
The packing boxes may now
be lifted off the rod. O-rings seal
the bottom side of the packing
boxes.
Packing Box
disassembly
To remove the seals (packing)
from the box:
Remove the top snap ring
with a pair of inside snap ring
pliers. Depress the spring with
a screwdriver handle to make
this operation easier.
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Rod Seals
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With the snap ring removed, the
top washer, spring, middle
washer, seal rings, bottom washer
and retainer ring can all be
removed.
The seal consists of three types
of rings. One ring is a male ring,
next a series of V-rings, then a
female ring.
On LB161 compressors, the
spring and male ring will be at the
top and the female ring will be at
the bottom.
Piston Rod
Inspection
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The piston rods and the top
on the crossheads are visible
through the opening when
the nameplate is removed.
The crosshead guide is
secured to the crankcase by
six bolts.
Crankcase and
Crosshead
With the crosshead guide
removed, the crosshead / piston
rods are visible. The flat gasket
on top of the crankcase may
require the use of a flat scraper
to remove completely.
The oil dipstick is located in
the access cover. On current
models, it is located adjacent
to the access cover. The oil
viscosity and capacity are
found in the Instruction
Manual.
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Crosshead &
Connecting Rod
Removal
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Removal of the crankcase
access cover and gasket
permits access to the
connecting rods. After the
bottom cap of the connecting
rod has been removed, the
piston rod / crosshead and
the top half of the connecting
rod may be lifted off from
above.
Crosshead and
Connecting
Rod
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The connecting rod and
crosshead assembly are separated
by removing the wrist pin in a bench
press. Note that the wrist pin has a
plastic retainer plug on each end.
The piston rod is permanently
secured to the crosshead at the
factory and no attempt should be
made to separate them. Final
machining is done to the assembled
crosshead / rod which precludes
their reassembly once separated.
The grooves in the crosshead are
lubrication channels.
The small end of the connecting
rod has a bronze bushing and is
lubricated via and internal port
running the length of the connecting
rod.
Crosshead and
Connecting Rod
(cont’d)
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A precision insert split shell bearing
is located at the big [journal] end.
Tabs on the bearing shells fit into slots
in the rod and bearing cap. These
retain the shells and align the oil feed
holes.
The LB161 uses a bronze bushing
on a steel wrist pin at the small end of
the conrod. The oil admission hole in
the bearing or bushing must align with
the oil supply hole in the connecting
rod small end. When the bronze
wrist pin bushing is replaced, it must
be honed to final dimension after
being pressed into the connecting rod
The rod and cap are matched sets,
do not mix. Match marks must align
when assembling bearing cap to
connecting rod.
Oil Pressure
adjustment,
Strainer
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The oil pressure adjustment
screw includes an O-ring, lock
nut, spring and ball. Turn the
screw inward (clockwise) to
increase the oil pressure setting.
The oil pickup tube with
washers, O-ring and strainer fits
in the crankcase under the
bearing carrier. If any foreign
material is noticed in the
strainer, its source should be
quickly identified to prevent
reoccurrence of the problem.
The pipe plug next to the oil
pickup tube opening is the
crankcase oil drain.
Some units will be fitted with
an external oil filter (not shown).
Oil Pump
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This photo shows the oil pump
used in the LB161. The LB161B
uses a different pump.
Remove the oil pump cover
and O-ring to withdraw the oil
pump. Notice the small O-ring
on the pump shaft and the
bronze bushing in the bearing
carrier.
The oil pump cover can be
installed with either left or right
rotation arrow visible. When
installing the cover, make sure
that the arrow at the TOP of the
cover indicates the desired
rotation direction.
Bearing Carrier
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The photo shows the
bearing carrier / oil pump
used in the LB161. The
LB161B uses a different
style.
The entire bearing carrier /
oil pump assembly, with
gasket, can be removed
intact. This allows the
crankshaft to be removed.
Note the slot in the end of
the oil pump drive shaft. This
slot must align with the drive
tang in the end of the
crankshaft during installation.
Crankshaft
Removal
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Remove the crosshead and
connecting rod assemblies to
proceed with the crankshaft
removal. Notice the lubrication
holes on the bearing journals.
Also note the spray nozzles on
the crankshaft. The spray
nozzles lubricate the crosshead
guide and the main [ roller ]
bearings.
The top of the crankcase is
fitted with a breather which
prevents entry of foreign
material into the crankcase but
allows the release of crankcase
pressure.
Bearing Cover
Plate
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The bearing cover plate is on
the flywheel side of the
crankcase. Behind this plate
are a series of shims which
adjust the preload on the main
bearings. These shims are
normally reusable and the shim
thickness will not have to be
adjusted unless the crankshaft
and / or main bearings are
replaced. The bearing cover
plate also contains a crankshaft
oil seal.
End
of
Presentation
1809 Century Avenue
Grand Rapids, MI, USA 49503
Ph: 616-241-1611
Fax: 616-241-3752
www.blackmer.com
LB161 LPG / NH3 Compressor
LB161
LPG / NH3
Compressor
• Liquid transfer /
vapor recovery of:
propane
butane
anhydrous ammonia
• Transfer without
contamination
• Up to 90 GPM
(340 lpm)
• Usually driven by 5
or 7.5 HP driver at
650 to 800 rpm
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LITERATURE
Have the proper
literature at hand
• Parts lists
• Installation,
Operation and
Maintenance manual
For literature:
• blackmercompressor.com
• Call your Blackmer
distributor
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Tools
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• Use standard tools
for small machines
• Blackmer adjustable
spanner with 1/4”
pins (p/n 790316)
• Blackmer valve hold
down screw wrench
(790535)
• Inside snap ring
pliers
• Blackmer tool kit
available
Nameplate
• Model number
• Serial number
• I.D. number
Defines construction
• Oil capacity
• Rod inspection
access
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LB161
Compressor
Other Models Available:
LB162 double-seal
LB361 / LB362
[15 bhp (11 kw)]
LB601 / LB602
[40 bhp (30 kw)]
LB942
[50 bhp (37 kw)]
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Pressure
Gauges
• Always install!
• Suction & Discharge
• Pulsation
dampener- extends
gauge life & makes
it easier to read.
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Valve Caps and
Hold Down
Screws
• Cap O-ring
(or metal gasket)
• Screws are
removed with
spanner
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Valves
• Liquid relief device ball & spring
• Post
• Valves
• Valve gaskets usually aluminum
• Always replace
gaskets
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Cylinder Head
• Two center head
bolts have metal
gaskets
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Head O-rings
and Piston Nut
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• Head O-rings - not
normally reusable
• Remove piston nut
with 1/4” pin
spanner
• Piston nut has nylon
locking insert
Piston Removal
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• Use spanner to
unscrew piston
• Washer and shims
adjust piston deck
height
• Piston rings have
expanders
• Bevel on inside of
the ring faces up
• Install rings and
expanders with
staggered gaps
Cylinder
• Two O-rings seal
the cylinder to the
crankcase
• Under-piston
channel between
bores
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Packing Box
Removal
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• Remove hold down
screw with spanner
• Hold down screw
has nylon locking
insert
• O-rings seal bottom
of packing box
Packing Box
disassembly
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• Depress spring with
screwdriver
• Remove retainer
ring with inside snap
ring pliers
Rod Seals
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• Female packing ring
on bottom
• “V” - ring type
• Male packing ring
on top
• Spring is on top of
the packing
Piston Rod
Inspection
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• Piston rods and
tops of the
crossheads are
visible through the
nameplate opening
Crankcase and
Crossheads
• Gasket between
crankcase and
guide
• Oil level dipstick
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Crosshead &
Connecting Rod
Removal
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• Access cover and
gasket
• Remove lower
bearing caps, lift
crosshead and
connecting rod
assembly
Crosshead and
Connecting
Rod
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• Plastic retainer plugs
• Connecting rod has
cast-in oil channel,
big end to small end
• Connecting rod is
Ductile Iron
• Cast iron crosshead
• Don’t remove piston
rod from crosshead
Crosshead and
Connecting Rod
(cont’d)
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• Wrist pin is pressed
into the crosshead
• Wrist pin bushing is
pressed in and honed
to the proper bore
• Bushing oil hole must
align with connecting
rod feed hole
• Split bearings on the
crankend
• Keep rod caps on the
correct rod - use
match marks
Oil Pressure
adjustment,
Strainer
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• Oil pressure
adjustment screw
and lock nut
• Clean the oil
strainer
• Oil drain plug
• External oil filter on
some units
Oil Pump
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• May be installed for
either rotation
direction
• The top arrow
indicates rotation
direction
• Rotate cover 180°
for opposite rotation
direction
Bearing Carrier
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• Carrier and oil pump
are removed as an
assembly
• Slot in carrier fits
into tang at
crankshaft end
Crankshaft
Removal
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• Pressure lubrication
holes at the journal
bearings
• Oil spray nozzles on
the crankshaft for
the crossheads
• Crankcase breather
vent
Bearing Cover
Plate
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• Located at flywheel
end
• Shims adjust main
bearing preload
• Cover contains
crankshaft oil seal
End
of
Presentation
1809 Century Avenue
Grand Rapids, MI, USA 49503
Ph: 616-241-1611
Fax: 616-241-3752
www.blackmer.com