Ariel JGW Series User manual

ARIEL
Heavy Duty
Balanced Opposed
Compressors
TECHNICAL MANUAL
For Models:
JGW, JGR and JGJ
ARIEL CORPORATION
35 BLACKJACK ROAD, MOUNT VERNON, OHIO 43050
TELEPHONE: [phone] FAX: [phone]
VISIT OUR WEB SITE: www.arielcorp.com
EMAIL: [email protected] REV: 1/01

CAUTION
GAS COMPRESSOR UNITS ARE COMPLICATED AND DANGEROUS
PIECES OF EQUIPMENT, IF YOU ARE NOT FULLY TRAINED AND
FAMILIAR WITH THEIR OPERATION.
BEFORE STARTING THIS UNIT:
FAMILIARIZE YOURSELF WITH THE UNIT.
READ AND STUDY START-UP AND SHUT-DOWN INFORMATION FOR
BOTH PACKAGE AND COMPRESSOR CAREFULLY!
A GAS/AIR MIXTURE UNDER PRESSURE CAN EXPLODE! YOU CAN BE
SEVERELY INJURED OR KILLED. MAKE SURE THE COMPRESSOR IS
SUFFICIENTLY PURGED OF ANY EXPLOSIVE MIXTURE BEFORE
LOADING.
AFTER COMPLETING THE ABOVE, BEGIN PROPER STARTING
PROCEDURE.
CAUTION
DO NOT ATTEMPT TO START-UP UNIT WITHOUT REFER-
RING TO THIS MANUAL SECTION 3: START-UP. IT IS ALSO
ESSENTIAL TO REFER TO THE PACKAGER’S OPERATING
MANUAL.
CAUTION
THIS MANUAL EDITION IS BASED ON THE CURRENT DESIGN, BUILD
AND PRACTICES. THIS MANUAL MAY NOT BE APPLICABLE TO
EQUIPMENT BUILT PRIOR TO THE DATE ON FRONT COVER AND IS
SUBJECT TO CHANGE WITHOUT NOTICE. CONTACT ARIEL WITH ANY
QUESTIONS (REFER TO “Ariel Telephone and Fax Numbers” on
page 7-9).
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FOR MODELS: JGW,JGR AND JGJ TABLE OFCONTENTS
1/01 i
TABLE OFCONTENTS
Design Specifications & Data ............................................................. 1 - 1
General................................................................................................................. 1 - 1
Specifications ....................................................................................................... 1 - 2
Product Information and Safety Plates................................................................. 1 - 4
Important Safety Information........................................................................... 1 - 5
Clearances ........................................................................................................... 1 - 9
Piston Ring and Packing Ring Side Clearance, Inches (mm) ....................... 1 - 10
Fastener Tightening Torque ............................................................................... 1 - 15
Tightening Torque Procedures...................................................................... 1 - 19
Ariel Bolting ........................................................................................................ 1 - 21
Optional Main Bearing Temperature Instrumentation - Alarm & Shutdown........ 1 - 23
Amot 4103 Temperature Valve ..................................................................... 1 - 23
Electrical Instrumentation Setting.................................................................. 1 - 23
Installation ............................................................................................ 2 - 1
General................................................................................................................. 2 - 1
Procedure For Setting and Aligning...................................................................... 2 - 1
Setting............................................................................................................. 2 - 2
Alignment ........................................................................................................ 2 - 2
Vents and Drains.................................................................................................. 2 - 3
Start Up ................................................................................................. 3 - 1
General................................................................................................................. 3 - 1
Start-Up Check List .............................................................................................. 3 - 2
Maximum Allowable Working Pressure ................................................................ 3 - 6
Relief Valve Settings ............................................................................................ 3 - 7
Filling Sump & Priming a Main Oil Lube Oil System - Before Starting ................. 3 - 8
Filling The Sump ............................................................................................. 3 - 8
Priming - Main Lube Oil System...................................................................... 3 - 8
Force Feed Lubricator Adjustment ....................................................................... 3 - 8
Compressor Re-Application.................................................................................. 3 - 9
Lubrication and Venting...................................................................... 4 - 1
General................................................................................................................. 4 - 1
Oil Cooler ........................................................................................................ 4 - 1
Cold Starting ................................................................................................... 4 - 2
Compressor Prelube Pump............................................................................. 4 - 2
Petroleum Based Oils - also referred to as mineral oils: ................................. 4 - 2
Compounded Cylinder Oil Additives ............................................................... 4 - 2
Animal Fats ..................................................................................................... 4 - 3
Vegetable Oils................................................................................................. 4 - 3
Synthetic Lubricants........................................................................................ 4 - 3

FOR MODELS: JGW, JGR AND JGJ TABLE OFCONTENTS
ii 1/01
Compressor Frame Lubricants ............................................................................. 4 - 4
Cylinder And Packing Lubrication Requirements.................................................. 4 - 5
Force Feed Lubrication System - Description..................................................... 4 - 11
Force Feed Lubricator Adjustment ................................................................ 4 - 11
Blow-Out Fittings and Rupture Disks............................................................. 4 - 12
Divider Valves ..................................................................................................... 4 - 13
Description..................................................................................................... 4 - 14
Standard Electronic-Lubricator Digital No-Flow Timer Switch - DNFT .......... 4 - 14
Assembly Instructions For Divider Valves ..................................................... 4 - 15
Operation....................................................................................................... 4 - 15
Force Feed Lubrication System and Running Conditions................................... 4 - 18
Force Feed Lubrication System..................................................................... 4 - 18
Running Conditions ....................................................................................... 4 - 18
System Design Considerations and Operating Parameters .......................... 4 - 18
Force Feed Balance Valves................................................................................ 4 - 19
Setting and Maintaining Balance Valves ....................................................... 4 - 20
Checking/Adjusting Balance Valves on Subsequent Start-up ....................... 4 - 21
Frame Lubricating System - Description............................................................. 4 - 21
Lube Oil Strainer, Filter & Filter Installation Instructions ..................................... 4 - 24
Lube Oil Strainer............................................................................................ 4 - 24
Lube Oil Filter ................................................................................................ 4 - 24
Filter Element Installation Instructions........................................................... 4 - 24
Lube Oil Pump & Lube Oil Pressure ................................................................... 4 - 25
Description & Adjustment .............................................................................. 4 - 25
Lube Oil Pressure.......................................................................................... 4 - 25
Low Oil Pressure Shutdown................................................................................ 4 - 25
Maintenance......................................................................................... 5 - 1
General Introduction ............................................................................................. 5 - 1
Connecting Rod - Removal................................................................................... 5 - 2
Crank Pin Bearing & Connecting Rod Bushing Removal & Installation................ 5 - 3
Crank Pin Bearing ........................................................................................... 5 - 3
Connecting Rod Bushing................................................................................. 5 - 3
Connecting Rod - Installation................................................................................ 5 - 4
Crosshead - Removal ........................................................................................... 5 - 5
Crosshead - Installation ........................................................................................ 5 - 7
Crankshaft - Removal ........................................................................................... 5 - 8
Crankshaft - Oil Slinger....................................................................................... 5 - 10
Removal ........................................................................................................ 5 - 10
Installation ..................................................................................................... 5 - 10
Crankshaft - Chain Sprocket............................................................................... 5 - 10
Removal ........................................................................................................ 5 - 10
Installation ..................................................................................................... 5 - 11
Main Bearings - Removal and Installation .......................................................... 5 - 11
Crankshaft - Installation ...................................................................................... 5 - 12
Chain Drive System ............................................................................................ 5 - 12
Description..................................................................................................... 5 - 12
Chain Adjustment .......................................................................................... 5 - 13

FOR MODELS: JGW,JGR AND JGJ TABLE OFCONTENTS
1/01 iii
Chain and Sprocket Replacement ................................................................ 5 - 14
Eccentric Vernier - Chain Idler Sprocket Replacement (Self-Align Sprocket) 5 - 14
Lube Oil Pump Chain Sprocket Replacement............................................... 5 - 15
Force Feed Lubricator Chain Sprocket Replacement ................................... 5 - 16
Piston and Rod - Removal.................................................................................. 5 - 18
Piston and Rod - Disassembly and Reassembly................................................ 5 - 19
Disassembly.................................................................................................. 5 - 19
Reassembly .................................................................................................. 5 - 20
Piston and Rod - Installation............................................................................... 5 - 21
Piston Rod Run Out............................................................................................ 5 - 22
Piston Rings ....................................................................................................... 5 - 23
Determining Ring Wear:................................................................................ 5 - 24
Removal:....................................................................................................... 5 - 24
Wear Bands........................................................................................................ 5 - 24
Determining Wear Band Wear: ..................................................................... 5 - 24
Piston Rings - Installation ................................................................................... 5 - 24
Wear Band - Installation ..................................................................................... 5 - 24
Piston Rod Pressure Packing - Removal ........................................................... 5 - 24
Piston Rod Packing - Reassembly ..................................................................... 5 - 25
Types of Piston Rod Packing Rings ................................................................... 5 - 27
Type "P" Pressure Breaker ........................................................................... 5 - 27
Type "BTR" Single Acting Seal Set............................................................... 5 - 28
Type "BD" Double Acting Seal Set................................................................ 5 - 29
Type "3RWS" Oil Wiper Set .......................................................................... 5 - 30
Type “AL” Double Acting Seal Set ................................................................ 5 - 31
Typical Arrangement of Piston Rod Packing Rings............................................ 5 - 31
Piston Rod Packing Ring Material ...................................................................... 5 - 32
Valves................................................................................................................. 5 - 32
Valves - Removal .......................................................................................... 5 - 32
Valves - Maintenance.................................................................................... 5 - 33
Valves - Reassembly .................................................................................... 5 - 33
Bolt Tightening for Valve Caps........................................................................... 5 - 34
VVCP - Variable Volume Clearance Pocket Head End Unloader ...................... 5 - 36
Removal ........................................................................................................ 5 - 36
Disassembly.................................................................................................. 5 - 36
Maintenance.................................................................................................. 5 - 37
Adjustment .................................................................................................... 5 - 37
Water-Cooled Compressor Rod Packing ........................................................... 5 - 39
Re-assembly ................................................................................................. 5 - 39
Testing .......................................................................................................... 5 - 39
Ethylene Glycol Contamination .......................................................................... 5 - 40
Cleaning Non-Lube Compressor Cylinder Components .................................... 5 - 40
Technical Assistance .......................................................................... 6 - 1
Recommended Maintenance Intervals ................................................................. 6 - 1
Daily ................................................................................................................ 6 - 1
Monthly (in addition to Daily Requirements) ................................................... 6 - 2
Every 6 Months or 4,000 Hours (plus Daily/Monthly)...................................... 6 - 2

FOR MODELS: JGW, JGR AND JGJ TABLE OFCONTENTS
iv 1/01
Yearly or 8,000 Hours (plus Daily/Monthly/6 Months) ..................................... 6 - 2
Every 2 Years or 16,000 Hours (plus Daily/Monthly/6 months/yearly) ............ 6 - 3
Every 4 Years or 32,000 Hours (plus Daily/Monthly/6 Months/1/2 Years) ...... 6 - 3
Every 6 Years or 48,000 Hours (plus Daily/Monthly/6 Months/1/2/4 Years..... 6 - 4
Trouble Shooting................................................................................................... 6 - 4
Appendices .......................................................................................... 7 - 1
Ariel Tools............................................................................................................. 7 - 1
Ariel Furnished Tools....................................................................................... 7 - 1
Ariel Optional Tools ......................................................................................... 7 - 1
Minimum Hand Tools Required ............................................................................ 7 - 2
Terms, Abbreviations and Conversion to SI Metric............................................... 7 - 3
Area................................................................................................................. 7 - 3
Flow - Gas ....................................................................................................... 7 - 3
Flow - Liquid .................................................................................................... 7 - 4
Force ............................................................................................................... 7 - 4
Heat................................................................................................................. 7 - 4
Length.............................................................................................................. 7 - 4
Mass................................................................................................................ 7 - 4
Moment or Torque........................................................................................... 7 - 4
Power .............................................................................................................. 7 - 4
Pressure or Stress........................................................................................... 7 - 4
Speed .............................................................................................................. 7 - 5
Temperature.................................................................................................... 7 - 5
Time................................................................................................................. 7 - 5
Viscosity .......................................................................................................... 7 - 5
Volume ............................................................................................................ 7 - 5
Other Abbreviations .............................................................................................. 7 - 5
Gas Analysis Common Abbreviations................................................................... 7 - 7
Technical and Service Schools on Ariel Compressors ......................................... 7 - 8
Ariel Customer Technical Bulletins (Formerly Ariel Newsletters).......................... 7 - 8
Ariel Telephone and Fax Numbers ....................................................................... 7 - 9

FOR MODELS: JGW, JGR AND JGJ
1/01 PAGE 1 - 1
SECTION 1 - DESIGN SPECIFICATIONS & DATA
General
Ariel compressors are designed for ease of operation and maintenance. Experience has
shown that an Ariel compressor will normally provide years of satisfactory performance with
minimal maintenance.
While Ariel compressors share many similarities, each model has aspects that are unique to
the particular type. If you as an operator are familiar with Ariel compressors, it is still impor-
tant to review this manual to determine the differences. If you are new to Ariel compressors
it is critical that you become very familiar with this manual prior to operating the compressor.
This manual is designed to provide information on installation, start up, operation and main-
tenance of a JGW, JGR or JGJ compressor. If you have any questions please contact your
packager. If they are unable to provide resolution, they will refer your concerns to Ariel Cor-
poration. If you prefer, you may always contact Ariel directly.
This manual provides design specifications for standard current production equipment at
publication date. Do not exceed information plate ratings for a particular compressor.
The location of the throws and the data shown on the Information Plates is very important
when communicating questions concerning an Ariel compressor.
FIGURE 1-1: TYPICAL COMPRESSOR THROW NUMBERING AND INFORMATION PLATE LOCATION
Engine/Motor
#2
#1
#4
#3
#6
#5
Information Plate
Auxiliary End

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 2 1/01
Specifications
FIGURE 1-2: AUXILIARY END VIEW
TABLE 1-1: JGW/JGR FRAME SPECIFICATIONS
MODEL JGW/2 JGW/4 JGR/2 JGR/4
Stroke, inches (mm) 4-1/4 (108) 4-1/4 (108) 4-1/4 (108) 4-1/4 (108)
Speed, RPM 600 to 1200 600 to 1200 600 to 1200 600 to 1200
Piston Speed, FPM (m/s) To 850 (4.32) To 850 (4.32) To 850 (4.32) To 850 (4.32)
Number of Throws 2 4 2 4
Horsepower (kW) To 325 (242) To 650 (485) To 430 (321) To 860 (641)
Height - Bottom to Crankshaft Centerline,
in. (mm)
12 (305) 12 (305) 12 (305) 12 (305)
Connecting Rod Centerline To Centerline,
in. (mm)
10.250 (260.35) 10.250 (260.35) 10.250 (260.35) 10.250 (260.35)
Maximum Width, in. (m) 103 (2.62) 103 (2.62) 103 (2.62) 103 (2.62)
Maximum Length, in. (m) 41 (1.04) 77 (1.96) 41 (1.04) 77 (1.96)
Approximate Weight with Cylinders, lb. (kg) 4000 (1814) 7000 (3175) 4200 (1905) 8200 (3720)
Oil Pump Capacity, GPM (L/s) 8 (0.50) 14 (0.88) 8 (0.50) 14 (0.88)
Oil Heat Rejection, BTU/hr. (J/s) 7000 (2065) 12,000 (3540) 8000 (2360) 14,000 (4130)
Sump Capacity, US gallons (L) 6 (23) 15 (57) 6 (23) 15 (57)
Piston Rod Diameter, in. (mm) 1.500 (38.1) 1.500 (38.1) 1.500 (38.1) 1.500 (38.1)
Internal Rod Load - Double Acting:
Compression + Tension, lbf. (kN) 24,000 (107) 24,000 (107) 32,000 (142) 32,000 (142)
Tension, lbf. (kN) 12,000 (53) 12,000 (53) 16,000 (71) 16,000 (71)
Compression, lbf. (kN) 15,000 (67) 15,000 (67) 20,000 (89) 20,000 (89)
Internal Rod Load - Single Acting:
Tension, lbf. (kN) 12,000 (53) 12,000 (53) 16,000 (71) 16,000 (71)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
1/01 PAGE 1 - 3
TABLE 1-2: JGJ FRAME SPECIFICATIONS
MODEL JGJ/2 JGJ/4 JGJ/6
Stroke, inches (mm) 3-1/2 (88.9) 3-1/2 (88.9) 3-1/2 (88.9)
Speed, RPM 900 to 1800 900 to 1800 900 to 1800
Piston Speed, FPM (m/s) To 1050 (5.33) To 1050 (5.33) To 1050 (5.33)
Number of Throws 2 4 6
Horsepower (kW) To 620 (460) To 1240 (920) To 1860 (1380)
Height - Bottom to Crankshaft Centerline, in.
(mm)
12 (305) 12 (305) 12 (305)
Connecting Rod Centerline To Centerline,
in. (mm)
10.250 (260.35) 10.250 (260.35) 10.250 (260.35)
Maximum Width, in. (m) 103 (2.62) 103 (2.62) 103 (2.62)
Maximum Length, in. (m) 41 (1.04) 77 (1.96) 113 (2.87)
Approximate Weight with Cylinders, lb. (kg) 4200 (1905) 8200 (3720) 12,000 (5445)
Oil Pump Capacity, GPM (L/s) 8 (0.50) 14 (0.88) 20 (1.26)
Oil Heat Rejection, BTU/hr. (J/s) 10,000 (2940) 16,000 (4700) 21,000 (6170)
Sump Capacity, US gallons (L) 6 (23) 15 (57) 24 (91)
Piston Rod Diameter, in. (mm) 1.500 (38.10) 1.500 (38.10) 1.500 (38.10)
Internal Rod Load - Double Acting:
Compression + Tension, lbf. (kN) 42,000 (187) 42,000 (187) 42,000 (187)
Tension, lbf. (kN) 21,000 (93) 21,000 (93) 21,000 (93)
Compression, lbf. (kN) 23,000 (102) 23,000 (102) 23,000 (102)
Internal Rod Load - Single Acting:
Tension, lbf. (kN) 21,000 (93) 21,000 (93) 21,000 (93)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 4 1/01
Product Information and Safety Plates
FIGURE 1-3: TOP COVER
Oil Filter Plate with installa-
tion instructions. (See Page
4-24)
IMPORTANT SAFETY INFOR-
MATION PLATES
See Page 1-5
Information plate: Model,
Frame serial number, Stroke,
Maximum and minimum speed,
Maximum rod load, Ariel ship-
ping date, Normal lube oil
pressure, Low oil pressure
shutdown and Maximum lube
oil temperature.
ARIEL LOGO NAME
PLATE AND ADDRESS
Top Cover
Direction of Rotation
plate, located at the
drive end

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
1/01 PAGE 1 - 5
Important Safety Information
CAUTION
SEVERE PERSONAL INJURY AND PROPERTY DAMAGE
CAN RESULT IF PRESSURE SYSTEM IS NOT
COMPLETELY VENTED BEFORE LOOSENING THE
BOLTS ON FLANGES, HEADS, VALVE CAPS, OR
PACKING. CONSULT ARIEL TECHNICAL MANUAL
BEFORE PERFORMING ANY MAINTENANCE.
CAUTION
SEVERE PERSONAL INJURY AND PROPERTY DAMAGE
WILL RESULT IF SUCTION AND DISCHARGE VALVES
ARE NOT INSTALLED IN THEIR PROPER LOCATION.
CAUTION
NOISE GENERATED BY RECIPROCATING MACHINERY
CAN BE A SOURCE FOR HEARING INJURY. SEE
PACKAGER’S INFORMATION FOR ANY SPECIFIC
RECOMMENDATIONS. WEAR HEARING PROTECTION
WHEN UNIT IS RUNNING.
CAUTION
HOT GAS TEMPERATURES ESPECIALLY THE CYLINDER
DISCHARGE AREAS, 190°F (88°C) OIL AND HIGH
FRICTION AREAS CAN BE A SOURCE FOR BURNS.
WEAR PROPER INSULATION WHEN WORKING AROUND
THESE AREAS. SHUT DOWN UNIT AND ALLOW TO COOL
BEFORE DOING MAINTENANCE IN THESE AREAS.
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FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 6 1/01
The Force Feed Lubricator provides oil to the piston rod packing and the compressor pis-
tons. The Lubricator Plate gives directions for adjusting the flow of oil. If this plate is missing,
please contact Ariel Corporation, Mount Vernon, Ohio for a replacement or directions.
NOTE: THE FORCE FEED LUBRICATOR BOX CONTAINS APPROXIMATELY 1/3 GAL-
LONS (1 L) OF LUBRICANT.
FIGURE 1-4: FORCE FEED LUBRICATOR PUMP - TYPICAL
FIGURE 1-5: FORCE FEED LUBRICATOR DATA PLATES
Data Plate
Distribution
Block Part
Number
Force Feed Lubricator
Data Plate for Twin
Pumps - Indicator Cycle
Time:
Force Feed Lubricator
Data Plate for Single
Pump - Indicator Cycle
Time:
Normal
(Seconds/cycle)
Break In
(Seconds/cycle)
Throw
Number
Increase
Pump
Stroke
Increase
Pump
Stroke
Distribution Block
Part Number
Indicator Pin
Cycle Time
Seconds/
cycle
Normal
Break In

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
1/01 PAGE 1 - 7
Cylinder Identification Plates appear on each cylinder. The serial number is also stamped on
the end of each cylinder. If any plate is missing, please contact Ariel Corporation, Mount
Vernon, Ohio for a replacement or specific directions.
NOTE: USE THE CYLINDER AND FRAME SERIAL NUMBERS IN ALL CORRESPON-
DENCE.
FIGURE 1-6: IDENTIFICATION PLATES - TYPICAL
Serial Number, MAWP, Part
Number, Work Order Number,
Hydrostatic Test Pressure, Test
Date and Tester’s Personal
Stamp are stamped on the end
of each cylinder
Discharge Valve
Pocket Identifica-
tion plate
Suction Valve
Pocket Identifica-
tion Plate
Unloader Identification Plate:
Customer Work Order Number,
Hydrotest Pressure and Tester’s
Personal Stamp are stamped
near this plate on top of the
Unloader body.
Frame Serial Number:
stamped on machined sur-
face above the Mechanical
Inspector’s Plate. On drive
end throw #2 side.
Cylinder Identification Plate

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 8 1/01
FIGURE 1-7: CYLINDER AND UNLOADER IDENTIFICATION PLATES
CYLINDER IDENTIFICATION
PLATE:
Nominal Bore Diameter
Inches
Stroke Inches
Class
Rated Revolutions
per Minute
Crank End
Head End
Piston End Clearance
Inches:
Cylinder Serial Number
Minimum Volumetric Clearance
Percentage:
Unloader Serial
Number
UNLOADER IDENTIFICATION
PLATE:
Thread Lead -
Threads Per Inch
Travel Inches
Cubic Inches Per Inch
Volume
Nominal Unloader Bore
Diameter Inches
Nominal Cylinder Bore
Diameter Inches
Maximum Allowable
Working Pressure (Max-
imum Relief Valve Set-
ting PSIG - Pounds per
Square Inch Gauge)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
1/01 PAGE 1 - 9
Clearances
NOTE: MEASURED CLEARANCES WILL NOT NECESSARILY AGREE BECAUSE OF
OIL FILMS, ASSEMBLY TOLERANCES, WEAR, ETC. PLASTIGAGES, SOL-
DER, ETC. ARE NOT TO BE USED.
TABLE 1-3: CLEARANCES
DESCRIPTION CLEARANCE, IN. (CLEARANCE, mm)
Crankshaft Dust Seal (Feeler Gauge - Centered) 0.008 to 0.010 (0.20 to 0.25)
Crankshaft Thrust (End) 0.0085 to 0.019 (0.215 to 0.48)
Crankshaft Journal Bearing (Jack) 0.001 to 0.004 (0.025 to 0.10)
Crankshaft Pin to Connecting Rod Bearing (Jack) 0.002 to 0.005 (0.05 to 0.125)
Connecting Rod Thrust (Side) 0.010 to 0.021 (0.25 to 0.53)
Connecting Rod Bushing to Crosshead Pin 0.0015 to 0.0035 (0.038 to 0.089)
Crosshead Bushing to Crosshead Pin - JGJ/JGR 0.0015 to 0.0035 (0.038 to 0.089)
Crosshead (Bronze) to Crosshead Pin 0.0015 to 0.0028 (0.038 to 0.071)
Crosshead (Gray Iron) to Crosshead Pin - JGW 0.0015 to 0.0028 (0.038 to 0.071)
Crosshead (Babbitted Ductile Iron) to Guide - JGJ/JGR (Feeler Gaugea)
a. Crosshead guide to crosshead clearance at the top is to be checked by inserting a standard 0.5 inch (13
mm) wide feeler stock from one side edge of the crosshead across to the opposite side. This is to be done
at both ends. The bottom clearance is to be checked with 0.0015 inch (0.038 mm) feeler stock at the 4
corners. If the feeler can be inserted more than 0.5 inches (13 mm), the assembly is not acceptable.
0.0060 to 0.0095 (0.152 to 0.241)
Crosshead (Babbitted Bronze) to Guide (Feeler Gaugea)0.0080 to 0.0115 (0.203 to 0.292)
Crosshead (Gray Iron) to Guide - JGW (Feeler Gaugea)0.0090 to 0.0125 (0.229 to 0.318)
Total Piston End Clearance - Double Actingb
b. If piston end clearance is not within table tolerance, crank end + head end, contact Packager or Ariel.
0.110 to 0.170 (2.79 to 4.32)
Piston End Clearance - Crank End - Double Actingb0.040 (1.02)
Piston End Clearance - Head End - Double Actingb0.070 to 0.130 (1.78 to 3.30)
Total Piston End Clearance - Tandemb0.200 to 0.260 (5.08 to 6.60)
Piston End Clearance - Crank End Tandemb0.040 (1.02)
Piston End Clearance - Head End Tandemb0.160 to 0.220 (4.06 to 5.59)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 10 1/01
Piston Ring and Packing Ring Side Clearance, Inches (mm)
The standard side clearance in inches (mm) for JGW, JGR and JGJ compressor piston rings
and packing rings when new are as follows:
TABLE 1-4: NEW PISTON RING SIDE CLEARANCE, INCHES (mm)
NOMINAL WIDTH ACTUAL GROOVE WIDTH TEFLON ONE-PIECE BRONZE
3/16 (4.76) 0.187 to 0.189 (4.75 to 4.80) 0.0035 to 0.0075 (0.09 to 0.19) 0.004 to 0.008 (0.10 to 0.20)
1/4 (6.35) 0.250 to 0.252 (6.35 to 6.40) 0.005 to 0.009 (0.13 to0.23) 0.004 to 0.008 (0.10 to 0.20)
5/16 (7.94) 0.312 to 0.314 (7.92 to 7.98) 0.006 to 0.010 (0.15 to 0.25) 0.004 to 0.008 (0.10 to 0.20)
3/8 (9.53) 0.375 to 0.377 (9.53 to 9.58) 0.008 to 0.012 (0.20 to 0.30) 0.004 to 0.008 (0.10 to 0.20)
3/4 (19.05) 0.750 to 0.752 (19.05 to 19.10) 0.016 to 0.022 (0.41 to 0.56) 0.006 to 0.010 (0.15 to 0.25)
TABLE 1-5: RIDER RING SIDE CLEARANCE, INCHES (mm)
ACTUAL GROOVE WIDTH CLEARANCE
1.000 0.012 to 0.018 (0.30 to 0.46)
2.000 0.024 to 0.030 (0.61 to 0.76)
3.000 0.036 to 0.042 (0.91 to 1.07)
4.000 0.048 to 0.054 (1.22 to 1.37)
TABLE 1-6: PACKING RING SIDE CLEARANCE
RING TYPE OR
MATERIAL SIDE CLEARANCE, INCHES (mm)
Bronze 0.006 to 0.008 (0.15 to 0.20)
Teflon One-Piece 0.010 to 0.012 (0.25 to 0.30)
P (PEEK) 0.010 to 0.015 (0.25 to 0.38)
BTR (TFE/CI) 0.012 to 0.018 (0.30 to 0.46)
AL (TFE) 0
BD (TFE) 0.010 to 0.015 (0.25 to 0.38)
3RWS (CI) 0.006 to 0.012 (0.15 to 0.30)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
1/01 PAGE 1 - 11
TABLE 1-7: PISTON TO BORE CLEARANCE AND CONVENTIONAL PISTON RING END GAP,
INCHES (mm) - W & R CLASS CYLINDERS
BORE
DIAMETER PISTON TO BORE CLEARANCE PISTON RING END GAPa
a. A piston/rider ring is optional for all W and R Class cylinders and is standard for R Class cylinders
with diameters of 13.5 to 19.5 inches (343 to 495 mm).
NEW MAXIMUM
1.75 (44) Uses Wearbands, see Table 1-9 on page 1-13 and Table 1-10 on page 1-14
2 (51)
3.625 (92) 0.010 to 0.015 (0.25 to 0.38) 0.044 to 0.068 (1.12 to 1.73) 0.204 (5.18)
3.875 (98) 0.010 to 0.015 (0.25 to 0.38) 0.046 to 0.070 (1.17 to 1.78) 0.210 (5.33)
4.125 (105) 0.010 to 0.015 (0.25 to 0.38) 0.049 to 0.073 (1.24 to 1.85) 0.219 (5.56)
4.25 (108) 0.010 to 0.015 (0.25 to 0.38) 0.051 to 0.075 (1.30 to 1.91) 0.225 (5.72)
4.625 (117) 0.012 to 0.017 (0.30 to 0.43) 0.056 to 0.080 (1.42 to 2.03) 0.240 (6.19)
4.75 (121) 0.012 to 0.018 (0.30 to 0.46) 0.057 to 0.081 (1.45 to 2.06) 0.243 (6.17)
5.125 (130) 0.012 to 0.017 (0.30 to 0.43) 0.061 to 0.085 (1.55 to 2.16) 0.255 (6.48)
5.5 (140) 0.013 to 0.018 (0.33 to 0.46) 0.066 to 0.090 (1.68 to 2.29) 0.270 (6.86)
6 (152) 0.013 to 0.018 (0.33 to 0.46) 0.072 to 0.112 (1.83 to 2.84) 0.336 (8.53)
6.375 (162) 0.014 to 0.019 (0.36 to 0.48) 0.077 to 0.117 (1.96 to 2.97) 0.351 (8.92)
7 (178) 0.015 to 0.020 (0.38 to 0.51) 0.084 to 0.124 (2.13 to 3.15) 0.372 (9.45)
7.125 (181) 0.015 to 0.021 (0.38 to 0.53) 0.085 to 0.125 (2.16 to 3.18) 0.375 (9.53)
7.375 (187) 0.015 to 0.020 (0.38 to 0.51) 0.089 to 0.129 (2.26 to 3.28) 0.387 (9.83)
7.5 (191) 0.015 to 0.021 (0.38 to 0.53) 0.089 to 0.129 (2.26 to 3.28) 0.387 (9.83)
8 (203) 0.016 to 0.022 (0.41 to 0.56) 0.096 to 0.136 (2.45 to 3.45) 0.408 (10.36)
8.375 (213) 0.017 to 0.023 (0.43 to 0.58) 0.101 to 0.141 (2.57 to 3.58) 0.423 (10.74)
8.5 (216) 0.017 to 0.023 (0.43 to 0.58) 0.102 to 0.142 (2.59 to 3.61) 0.426 (10.82)
8.875 (225) 0.018 to 0.023 (0.46 to 0.58) 0.107 to 0.147 (2.72 to 3.73) 0.441 (11.20)
9.25 (235) 0.019 to 0.025 (0.48 to 0.64) 0.111 to 0.151 (2.82 to 3.84) 0.453 (11.51)
9.75 (248) 0.020 to 0.026 (0.51 to 0.66) 0.117 to 0.157 (2.97 to 3.99) 0.471 (11.96)
10.375 (264) 0.022 to 0.026 (0.56 to 0.66) 0.124 to 0.164 (3.15 to 4.17) 0.492 (12.50)
11 (279) 0.022 to 0.028 (0.56 to 0.71) 0.131 to 0.179 (3.33 to 4.55) 0.537 (13.64)
11.5 (292) 0.023 to 0.029 (0.58 to 0.74) 0.138 to 0.186 (3.51 to 4.72) 0.558 (14.17)
13 (330) 0.026 to 0.032 (0.66 to 0.81) 0.156 to 0.204 (3.96 to 5.18) 0.612 (15.54)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 12 1/01
TABLE 1-8: PISTON TO BORE CLEARANCE AND PISTON/ RIDER RING END GAP, INCHES (mm) -
W, R & J CLASS CYLINDERS.
BORE
DIAMETER PISTON TO BORE CLEARANCE PISTON RING END GAP
NEW MAXIMUM
1.75 (44) Uses Wearbands, see Table 1-9 on page 1-13 and Table 1-10 on page 1-14
2 (51)
3.625 (92) 0.090 to 0.096 (2.29 to 2.44) 0.044 to 0.060 (1.12 to 1.52) 0.180 (4.57)
3.875 (98) 0.090 to 0.096 (2.29 to 2.44) 0.045 to 0.061 (1.14 to 1.55) 0.183 (4.65)
4.125 (105) 0.090 to 0.096 (2.29 to 2.44) 0.049 to 0.065 (1.24 to 1.65) 0.195 (4.95)
4.25 (108) 0.090 to 0.096 (2.29 to 2.44) 0.050 to 0.066 (1.27 to 1.68) 0.198 (5.03)
4.625 (117) 0.090 to 0.096 (2.29 to 2.44) 0.056 to 0.072 (1.42 to 1.83) 0.216 (5.49)
4.75 (121) 0.090 to 0.096 (2.29 to 2.44) 0.057 to 0.073 (1.45 to 1.85) 0.219 (5.56)
5.125 (130) 0.090 to 0.096 (2.29 to 2.44) 0.062 to 0.078 (1.57 to 1.98) 0.234 (5.94)
5.5 (140) 0.090 to 0.096 (2.29 to 2.44) 0.068 to 0.084 (1.73 to 2.13) 0.252 (6.40)
6 (152) 0.090 to 0.096 (2.29 to 2.44) 0.074 to 0.090 (1.88 to 2.29) 0.270 (6.86)
6.125 (156) 0.090 to 0.096 (2.29 to 2.44) 0.069 to 0.099 (1.75 to 2.51) 0.297 (7.54)
6.375 (162) 0.090 to 0.096 (2.29 to 2.44) 0.073 to 0.103 (1.85 to 2.62) 0.309 (7.85)
6.5 (165) 0.090 to 0.096 (2.29 to 2.44) 0.074 to 0.104 (1.88 to 2.64) 0.312 (7.92)
7 (178) 0.090 to 0.096 (2.29 to 2.44) 0.091 to 0.121 (2.31 to 3.07) 0.363 (9.22)
7.125 (181) 0.090 to 0.096 (2.29 to 2.44) 0.083 to 0.113 (2.11 to 2.87) 0.339 (8.61)
7.375 (187) 0.090 to 0.096 (2.29 to 2.44) 0.097 to 0.127 (2.46 to 3.23) 0.381 (9.68)
7.5 (191) 0.090 to 0.096 (2.29 to 2.44) 0.088 to 0.118 (2.24 to 3.00) 0.354 (8.99)
8 (203) 0.090 to 0.096 (2.29 to 2.44) 0.106 to 0.136 (2.69 to 3.45) 0.408 (10.36)
8.375 (213) 0.090 to 0.096 (2.29 to 2.44) 0.112 to 0.142 (2.84 to 3.61) 0.426 (10.82)
8.5 (216) 0.090 to 0.096 (2.29 to 2.44) 0.114 to 0.144 (2.90 to 3.66) 0.432 (10.97)
8.875 (225) 0.090 to 0.096 (2.29 to 2.44) 0.120 to 0.150 (3.05 to 3.81) 0.450 (11.43)
9.25 (235) 0.090 to 0.096 (2.29 to 2.44) 0.125 to 0.155 (3.18 to 3.94) 0.465 (11.81)
9.75 (248) 0.090 to 0.096 (2.29 to 2.44) 0.133 to 0.163 (3.38 to 4.14) 0.489 (12.42)
10.375 (264) 0.090 to 0.096 (2.29 to 2.44) 0.142 to 0.172 (3.61 to 4.37) 0.516 (13.11)
10.5 (267) 0.090 to 0.096 (2.29 to 2.44) 0.144 to 0.174 (3.66 to 4.42) 0.522 (13.26)
11 (279) 0.090 to 0.096 (2.29 to 2.44) 0.152 to 0.182 (3.86 to 4.62) 0.546 (13.87)
11.5 (292) 0.090 to 0.096 (2.29 to 2.44) 0.160 to 0.190 (4.06 to 4.83) 0.570 (14.48)
13 (330) 0.090 to 0.096 (2.29 to 2.44) 0.182 to 0.212 (4.62 to 5.38) 0.636 (16.15)
13.5 (343) 0.090 to 0.096 (2.29 to 2.44) 0.190 to 0.220 (4.83 to 5.59) 0.660 (16.76)
15.25 (378) 0.090 to 0.096 (2.29 to 2.44) 0.216 to 0.246 (5.49 to 6.25) 0.738 (18.75)
15.75 (400) 0.090 to 0.096 (2.29 to 2.44) 0.224 to 0.254 (5.69 to 6.45) 0.762 (19.35)
16.75 (425) 0.090 to 0.096 (2.29 to 2.44) 0.239 to 0.269 (6.07 to 6.83) 0.807 (20.50)
17.25 (438) 0.090 to 0.096 (2.29 to 2.44) 0.247 to 0.277 (6.27 to 7.04) 0.831 (21.12)
19 (483) 0.090 to 0.096 (2.29 to 2.44) 0.273 to 0.303 (6.93 to 7.70) 0.909 (23.09)
19.5 (495) 0.090 to 0.096 (2.29 to 2.44) 0.281 to 0.311 (7.14 to 7.90) 0.933 (23.70)

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
1/01 PAGE 1 - 13
TABLE 1-9: PISTON TO BORE CLEARANCE, PISTON RING END GAP AND WEAR BAND END GAP AND
RADIAL PROJECTION, INCHES - RJ AND HJ CLASS CYLINDERS
BORE
DIAMETER
PISTON TO BORE
CLEARANCE
PISTON RING END GAPa
a. A piston/rider ring is optional for all W and R Class cylinders and is standard for R Class cylinders
with bore diameters of 13.5 to 19.5 inches (343 to 495 mm).
WEAR BANDS - NEW
NEW MAXIMUM END GAP
MINIMUM
RADIAL
PROJECTION
1.75 0.030 to 0.037 0.025 to 0.035 0.105 0.058 0.0075 to 0.0145
2 0.030 to 0.037 0.028 to 0.038 0.114 0.065 0.0075 to 0.0145
3.625 0.069 to 0.077 0.044 to 0.068 0.204 0.116 0.023 to 0.031
3.875 0.069 to 0.077 0.047 to 0.071 0.213 0.124 0.023 to 0.031
4.25 0.070 to 0.078 0.051 to 0.075 0.225 0.136 0.023 to 0.031
4.625 0.070 to 0.078 0.056 to 0.080 0.240 0.148 0.023 to 0.031
5.125 0.073 to 0.081 0.061 to 0.085 0.255 0.164 0.023 to 0.031
5.5 0.073 to 0.081 0.065 to 0.089 0.267 0.176 0.023 to 0.031
6 0.079 to 0.087 0.072 to 0.112 0.336 0.192 0.025 to 0.033
6.375 0.079 to 0.087 0.077 to 0.117 0.351 0.204 0.025 to 0.033
7 0.085 to 0.093 0.084 to 0.124 0.372 0.224 0.028 to 0.036
7.375 0.085 to 0.093 0.089 to 0.129 0.387 0.236 0.028 to 0.036
8 0.090 to 0.099 0.096 to 0.136 0.408 0.256 0.030 to 0.038
8.375 0.090 to 0.099 0.101 to 0.141 0.423 0.268 0.030 to 0.038
9.25 0.094 to 0.103 0.111 to 0.151 0.453 0.296 0.032 to 0.040
9.75 0.094 to 0.103 0.117 to 0.157 0.471 0.312 0.032 to 0.040
10.375 0.097 to 0.106 0.124 to 0.164 0.492 0.332 0.032 to 0.042
11 0.100 to 0.109 0.131 to 0.179 0.537 0.352 0.032 to 0.042
11.5 0.100 to 0.109 0.138 to 0.186 0.558 0.368 0.032 to 0.042
13 0.108 to 0.117 0.155 to 0.203 0.609 0.415 0.034 to 0.044
13.5 0.108 to 0.117 0.162 to 0.210 0.630 0.432 0.034 to 0.044
15.25 0.115 to 0.126 0.183 to 0.231 0.693 0.488 0.036 to 0.046
15.75 0.115 to 0.126 0.189 to 0.237 0.711 0.504 0.036 to 0.046
16.75 0.123 to 0.134 0.201 to 0.251 0.753 0.536 0.038 to 0.048
17.25 0.123 to 0.134 0.207 to 0.259 0.777 0.552 0.038 to 0.048
19 0.131 to 0.142 0.228 to 0.292 0.876 0.608 0.037 to 0.049
19.5 0.131 to 0.142 0.234 to 0.298 0.894 0.624 0.037 to 0.049

FOR MODELS: JGW, JGR AND JGJ SECTION 1 - DESIGN SPECIFICATIONS & DATA
PAGE 1 - 14 1/01
TABLE 1-10: PISTON TO BORE CLEARANCE, PISTON RING END GAP AND WEAR BAND END GAP
AND RADIAL PROJECTION, (mm) INCHES - RJ AND HJ CLASS CYLINDERS
BORE
DIAMETER
(mm)
INCHES
PISTON TO BORE
CLEARANCE
PISTON RING END GAPa
a. A piston/rider ring is optional for all W and R Class cylinders and is standard for R Class cylinders
with bore diameters of 13.5 to 19.5 inches (343 to 495 mm).
WEAR BANDS - NEW
NEW MAXIMUM END GAP
MINIMUM
RADIAL
PROJECTION
(44) 1.75 (0.76 to 0.94) (0.64 to 0.89) (2.67) (1.47) (0.19 to 0.37)
(51) 2 (0.76 to 0.94) (0.71 to 0.97) (2.90) (1.65) (0.19 to 0.37)
(92) 3.625 (1.75 to 1.96) (1.12 to 1.73) (5.18) (2.95) (0.58 to 0.79)
(98) 3.875 (1.75 to 1.96) (1.19 to 1.80) (5.41) (3.15) (0.58 to 0.79)
(108) 4.25 (1.78 to 1.98) (1.30 to 1.91) (5.72) (3.45) (0.58 to 0.79)
(117) 4.625 (1.78 to 1.98) (1.42 to 2.03) (6.10) (3.76) (0.58 to 0.79)
(130) 5.125 (1.85 to 2.06) (1.55 to 2.16) (6.48) (4.17) (0.58 to 0.79)
(140) 5.5 (1.85 to 2.06) (1.65 to 2.26) (6.78) (4.47) (0.58 to 0.79)
(152) 6 (2.01 to 2.21) (1.83 to 2.84) (8.53) (4.88) (0.64 to 0.84)
(162) 6.375 (2.01 to 2.21) (1.96 to 2.97) (8.92) (5.18) (0.64 to 0.84)
(178) 7 (2.16 to 2.36) (2.13 to 3.15) (9.45) (5.69) (0.71 to 0.91)
(187) 7.375 (2.16 to 2.36) (2.26 to 3.28) (9.83) (5.99) (0.71 to 0.91)
(203) 8 (2.29 to 2.51) (2.44 to 3.45) (10.36) (6.48) (0.76 to 0.97)
(213) 8.375 (2.29 to 2.51) (2.57 to 3.58) (10.74) (6.81) (0.76 to 0.97)
(235) 9.25 (2.39 to 2.62) (2.82 to 3.84) (11.51) (7.52) (0.81 to 0.97)
(248) 9.75 (2.39 to 2.62) (2.97 to 3.99) (11.96) (7.92) (0.81 to 0.97)
(264) 10.375 (2.46 to 2.69) (3.15 to 4.17) (12.50) (8.43) (0.81 to 1.07)
(279) 11 (2.54 to 2.77) (3.33 to 4.55) (13.64) (8.94) (0.81 to 1.07)
(292) 11.5 (2.54 to 2.77) (3.51 to 4.72) (14.17) (9.35) (0.81 to 1.07)
(330) 13 (2.74 to 2.97) (3.94 to 5.16) (15.47) (10.54) (0.86 to 1.12)
(343) 13.5 (2.74 to 2.97) (4.11 to 5.33) (16.00) (10.97) (0.86 to 1.12)
(387) 15.25 (2.92 to 3.20) (4.65 to 5.87) (17.60) (12.40) (0.91 to 1.17)
(400) 15.75 (2.92 to 3.20) (4.80 to 6.02) (18.06) (12.80) (0.91 to 1.17)
(425) 16.75 (3.12 to 3.40) (5.11 to 6.38) (19.13) (13.61) (0.97 to 1.22)
(438) 17.25 (3.12 to 3.40) (5.26 to 6.58) (19.74) (14.02) (0.97 to 1.22)
(483) 19 (3.33 to 3.61) (5.79 to 7.42) (22.25) (15.44) (0.94 to 1.24)
(495)19.5 (3.33 to 3.61) (5.94 to 7.57) (22.71) (15.85) (0.94 to 1.24)