BLACKMER HD942A Manual

BLACKMER HD COMPRESSORS 960478
INSTRUCTIONS CB9A-030
Installation, Operation, and Maintenance Instructions Section
Effective
Replaces
901
Jan 2007
Oct 2006
DISCONTINUED MODELS HD942A and HDL942A
TABLE OF CONTENTS
SAFETY DATA..........................................................1
GENERAL INFORMATION
Compressor Data.................................................2
Nameplate Data ...................................................3
INSTALLATION
Location and Piping..............................................5
Mounting the Compressor Unit............................5
Compressor Flywheel ..........................................6
V-Belt Drive...........................................................6
Suction Valve Unloaders......................................7
Maximizing Compressor Life................................7
Seal Arrangements...............................................8
Typical Compressor, Drawing..............................9
Relief Valves.........................................................9
4-Way Valves .......................................................9
Liquid Traps..........................................................9
Temperature and Pressure Switches..................9
Pressure Gauges .................................................9
OPERATION
Pre-Start up Check List ........................................10
Start Up Procedure...............................................10
MAINTENANCE
Service Schedule..................................................11
Tool List.................................................................12
Bolt Torque Table .................................................12
Crankcase Lubrication..........................................13
Setting the Oil Pressure........................................13
COMPRESSOR DISASSEMBLY..............................14
COMPRESSOR ASSEMBLY....................................16
UNLOADER SEAL REPLACEMENT.......................18
VALVE REPLACEMENT...........................................18
SEAL (PACKING) REPLACEMENT ........................20
BEARING REPLACEMENT......................................23
OIL PUMP REPLACEMENT.....................................24
EXTENDED STORAGE.............................................24
TROUBLESHOOTING...............................................25
SAFETY DATA
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the product, or in the
manual, look for one of the following signal words and
be alert to the potential for personal injury or property
damage.
Warns of hazards that WILL cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury, or
property damage.
NOTICE
Indicates special instructions which are very important
and must be followed.
NOTICE
Blackmer compressors MUST only be installed in
systems which have been designed by qualified
engineering personnel. The system MUST conform to
all applicable local and national regulations and safety
standards.
These instructions are intended to assist in the
installation and operation of Blackmer compressors
and MUST be kept with the compressor.
Blackmer compressor service and maintenance shall
be performed by qualified technicians ONLY. Service
and maintenance shall conform to all applicable local
and national regulations and safety standards.
Thoroughly review this manual, all instructions and
hazard warnings, BEFORE performing any work on
the compressor.
Maintain ALL system and compressor operation and
hazard warning decals.
For handling liquefied gas, NFPA Pamphlet 58 should
be consulted.
r2010feb

SAFETY DATA
CB9A-030 page 2/28
Flammable gas can
cause death, serious
personal injury or
property damage
Flammable gas and/or liquid can form
explosive mixtures with air causing
property damage, serious personal injury
or death Hazardous pressure
can cause serious
personal injury or
property damage
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
Hazardous
machinery can
cause serious
p
ersonal in
j
ur
y
.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death Hazardous voltage.
Can shock, burn or
cause death.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Hazardous or toxic
fluids can cause
serious injury.
If handling hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance Hazardous pressure
can cause serious
personal injury or
property damage
Disconnecting fluid or pressure
containment components during
compressor operation can cause
serious personal injury, death or major
property damage
Hazardous gases
can cause property
damage, personal
in
j
ur
y
or death
Explosive gas can cause property
damage, personal injury, or death.
Extreme Heat can
cause personal injury
or property damage
Extreme heat can cause personal injury
or property damage
GENERAL INFORMATION
COMPRESSOR DATA
TABLE 1 - COMPRESSOR DATA Air-Cooled
Water-Cooled HD942A
HDL942A
MAWP - psia (Bar) 350 (24.1)
Displacement CFM (m3/hr)
@ 350 rpm (Minimum Speed)
@ 835 rpm (Maximum Speed) *
52.5 (89.1)
125.1 (213)
Max. BHP (kw) 50 (37)
Maximum Discharge Temperature 350°F (176°C)
Rotation Direction Either Direction
Bore x Stroke, Two Double-Acting Cylinders in. (mm) 4.625 x 4 (117 x 102)
Type: Single-stage, vertical, air-cooled, non-lubricated, reciprocating compressor.
* NOTE: Reduce maximum speeds by 9% for continuous duty operation.

GENERAL INFORMATION
CB9A-030 page 3/28
Figure 1 – Air-Cooled HD942A Compressor (Type 'B' Packing shown)
MODEL: HD ID#: SERIAL NO:
Before proceeding:
1. Note the nameplate data in the space provided above.
2. Obtain the appropriate parts lists for the model in question.
Manuals and Parts Lists for Blackmer products may be obtained from
Blackmer's website (www.blackmer.com) or be contacting Blackmer's Customer Service.
NAMEPLATE DATA
A nameplate is attached to the side of
all Blackmer compressors showing the
Model No., I.D. No., and Serial No.
These numbers should be available
when information or parts are needed
for a particular unit.
The basic size and type of the
compressor is indicated by "Model No." A suffix letter is used on most models to indicate the version.
Figure 2 - Compressor Nameplate

GENERAL INFORMATION
CB9A-030 page 4/28
An 11 character "I.D. No." identifies the construction of the compressor.
TABLE 2 - COMPRESSOR ID NUMBER KEY PBBFM1TA4CA
VALVES Code Fields
Ductile Iron / PEEK PB
DI/PEEK w/ Unloaders PC
TNT-12DI/PEEK PE
TNT-12DI/PEEKw/Unloaders PF
StainlessSteel SB
SSw/Unloaders SC
O-RINGS Field3
Buna-N B
Neoprene N
PTFE T
FKM V
Ethylene-Propylene E
GASKETS Field4
Aluminum A
Iron F
Copper C
PISTONRINGS Field5
Glass & Moly Filled M
PolyFilledPTFE A
SEAL (PACKING) ORIENTATION Field 6
3-ringSegmented A
5-ringSegmented B
Vent,Segmented D
SEAL MATERIAL Field 7
PTFE T
CYLINDER&HEAD Field8
DuctileIron A
TNT-12 DI Cylinder B
TNT-12 DI Cyl. & Head C
PISTONRODS Field9
CrO2CoatedSteel 3
BlackSurfaceSteel 4
CRANKSHAFT&OILFILTER Field10
Spin-onOilFilter C
OTHER A Field11
Notes: A 'Z' in any field indicates a non-standard option.
Serial Number *: 6 digits and a suffix letter indicating the year of manufacture.
Suffix P Q R S T U V W X Y Z
Year 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
*Starting in 2005, the suffix letter is no longer used; the year & month of construction is indicated on the nameplate.
Table 3 - Year of Manufacture

INSTALLATION
CB9A-030 page 5/28
NOTICE:
Blackmer compressors must only be installed in
systems designed by qualified engineering personnel.
System design must conform with all applicable
regulations and codes and provide warning of all
system hazards.
NOTICE:
This compressor shall be installed in accordance with
the requirements of NFPA 58 and all applicable local,
state and national regulations.
Hazardous voltage.
Can shock, burn or
cause death.
Install, ground and wire to local and
National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Disconnect and lockout electrical power
before installation or service
Electrical supply MUST match motor nameplate
specifications.
Motors equipped with thermal protection automatically
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
LOCATION AND PIPING
Compressor life and performance can be significantly
reduced when installed in an improperly designed
system. Before starting layout and installation of the
piping system, consider the following:
1. All piping must be leak free to a pressure of 1.5
times the maximum system pressure.
NOTICE: If the system is to be hydro-statically
tested, the compressor MUST be isolated.
Liquid entering the compressor will cause
damage and void the warranty.
2. A strainer should be installed in the inlet line to
protect the compressor from foreign matter. A #30
mesh screen or finer is recommended. Strainers
must be cleaned every 180 days, or more
frequently if the system requires.
3. Expansion joints, placed within 36" (0.9 m) of the
compressor, will compensate for expansion and
contraction of the pipes. Contact the flexible
connector/hose manufacturer for required
maintenance/care and design assistance in their
use.
4. Piping must be adequately supported to ensure
that no piping loads are placed upon the
compressor.
5. Both suction and discharge piping should slope
down from the compressor. The compressor
should not be placed at a low point in the piping
system.
Extreme Heat can
cause personal injury
or property damage
Discharge piping surface temperatures
may be hot during operation (over
158°F, 70°). Temperatures should be
monitored and adequate warnings
posted.
MOUNTING THE COMPRESSOR UNIT
A solid foundation reduces noise and vibration, and will
improve compressor performance. On permanent
installations, it is recommended the compressor be
secured by anchor bolts as shown. This arrangement
allows for slight shifting of position to accommodate
alignment with the mounting holes in the base plate.
Figure 3 - Anchor Bolt
Set the anchor bolts in concrete for new foundations.
When compressors are to be located on existing
concrete floors, holes should be drilled into the concrete
to hold the anchor bolts.
To keep vibration at a minimum, in addition to a solid
concrete foundation, it is important that the concrete be
located on a stable soil foundation. The base must
have complete contact along its entire length with the
foundation. Visible separations will result in vibrations
which are magnified in the upper part of the unit.
Check compressor mounting bolts and baseplate
anchor bolts regularly.
See CB220 “Compressor Bases, Skids and
Foundations” for additional information.

INSTALLATION
CB9A-030 page 6/28
COMPRESSOR DRIVE SYSTEMS
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Flywheel guard contact with moving
parts may be a source of ignition in
explosive atmospheres causing severe
personal injury or death
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
j
u
r
y
.
Operation without guards in place can
cause serious personal injury, major
property damage or death.
FLYWHEEL
Blackmer compressors are fitted with flywheels which
MUST be used regardless of the type of drive system
employed.
Flywheels must be properly installed and aligned:
1. Ensure that the mating surface between the hub
and flywheel are clean and dry – do not use a
lubricant.
2. Install the hub and key on clean compressor shaft,
flange end first.
3. Tighten the hub setscrew just enough to prevent it
from sliding on the shaft – do not overtighten.
4. Place the flywheel on the hub and loosely thread
the capscrews with lockwashers into the assembly.
Do not use lubricant on the capscrews.
5. Tighten all capscrews evenly and progressively in
rotation to the torque value in Table 4. There must
be a gap between the hub flange and the flywheel
with installation is complete. Do not over-torque.
Do not attempt to close gap between hub flange
and flywheel.
Hub
Size Capscrew Size Torque ft-lbs. (Nm)
SF 3/8 – 16 30 (40.7)
E 1/2 - 13 60 (81)
F 9/16 – 12 110 (149)
Table 4 – Flywheel Hub Torque Values
6. Ensure that the radial and axial runout values at the
rim do not exceed the following values:
Radial O.D. Runout: 0.016 in. (0.4046 mm)
Axial Rim Runout: 0.021 in. (0.5334 mm)
7. Ensure that the compressor flywheel guard is
properly installed before operation. The guard must
not contact moving parts.
V-BELT DRIVES
Most Blackmer compressors are driven via V-belts
which must be properly aligned and tensioned.
1. Lay a straight edge along the face of the motor
sheave and compressor flywheel.
2. Adjust either as needed to provide alignment.
3. Tighten the V-belts such that they are taut, but not
overly tight. Moderate thumb pressure should
deflect each belt about 1/4 – 3/8 in. (6 – 10 mm).
Consult your V-belt supplier for specific values.
4. Check the belt tension after 24 - 48 hours run-in.
Recheck the tension periodically, and tighten the
belts as required.
Caution should be used to avoid overtightening belts,
which can shorten bearing and belt life. Belts should
be inspected periodically for signs of excessive wear
and replaced if necessary.

INSTALLATION
CB9A-030 page 7/28
SUCTION VALVE UNLOADERS
Compressors may be fitted with suction valve unloaders
to provide loadless start or capacity control functions.
Blackmer unloaders are basically a piston and a plunger
atop the suction valve. When pressure is applied to the
top of the unloader piston, it and the plunger move
downward, pushing the suction valve off its seat and
unloading the compressor. When the pressure signal is
removed, the unloader spring pushes the piston and
plunger back up and the suction valve will resume
normal operation.
1. In order for the unloaders to function, the unloader
pressure must be at least 30 psi (2.1 Bar) above
suction pressure.
2. Do not operate unloaders for longer than 10
minutes as gas recirculation through the suction
valves will cause overheating.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Excessive gas recirculation using
suction valve unloaders can be a source
of ignition in explosive atmospheres
causing severe personal injury or death
3. Do not place a restrictive device such as a back
check valve in the suction line near the compressor.
If such a device must be installed, the volume in the
piping between the device and the compressor
must be at least 10 times the cylinder swept
volume.
WATER-COOLED COMPRESSORS
NOTICE:
DO NOT OPERATE WATER-COOLED UNITS
WITHOUT WATER FLOW!
Cooling water should be clean and at not more than
100 psig (6.90 Bar-g). A flow of 1 gpm (4 lpm) is
normally adequate. In general, cooler water
temperatures are preferable. However, care must be
taken as condensation may occur inside the
compressor if the water is too cold. Such condensation
can cause corrosion or even destroy the compressor.
Figure 4 - HDL942 Water Conntections
MAXIMIZING COMPRESSOR LIFE
Life of critical compressor components such as piston
rings, valves and packing will vary considerably with
each application, installation, and operating procedures.
Premature failure of wear parts can often be attributed
to one of the following causes:
1. Excessive Temperatures
Primary causes are:
•Operating at pressures other than those originally
specified.
•Handling a different gas than originally specified.
•Clogged strainer or filter elements.
•Line sizes too small, or other flow restrictions.
•Excessive ambient temperature or suction gas
temperature.
•Valve problems. (See Foreign Material.)
•Badly worn piston rings. (See Foreign Material.)
Lower operating temperatures will increase valve
and piston ring life significantly.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Extreme temperatures caused by
abnormally high discharge pressure or
valve problems can be a source of
ignition in explosive atmospheres
causing severe personal injury or death.
2. Foreign Material
Solid particles in the gas stream will:
•Rapidly wear the piston rings and score the
cylinder wall.
•Destroy the rod packing causing excessive
leakage and score the piston rods.
•Lodge in the valves causing loss of capacity and
broken valve plates and springs.
Liquid in the gas stream will:
•Cause broken valve plates and springs.
•Destroy the compressor if present in sufficient
quantity.
On new installations, it is suggested that the valves
and piston rings be inspected after the first few
hundred hours of operation. This will give an early
indication of any abnormal problems and allow for
corrective action to be taken before a costly failure
results. Although piston ring life will vary from
application to application, wear will be fairly
consistent on subsequent sets of rings.

INSTALLATION
CB9A-030 page 8/28
SEAL ARRANGEMENTS
These compressors are furnished with three types
of piston rod seals. The type used is noted by the 6th
digit of the compressor's ID Number on the nameplate.
Refer to the section 'SEAL REPLACEMENT' for
drawings of the three seal types.
Hazardous gases
can cause property
damage, personal
injury or death
Improper seal installation could release
explosive gas to the atmosphere
creating an explosion hazard, possibly
causing severe personal injury or death.
Seal Types A and B
These two seal types are the same except for the
number of packing sets used. The 1/8" and 1/4" seal
openings in the cylinder should be plugged as they
serve no function with these seal arrangements.
The crosshead guide casting includes four 1/4" NPT
openings into the distance piece area. This is the area
separating the upper and lower sets of packing. If
desired, the upper openings may be connected to a
vent line. Such a vent should be at a pressure lower
than suction pressure.
The lower distance piece openings are typically used
to drain any oil that might accumulate in the distance
piece. Only one opening need be used.
Seal Type D
This seal arrangement is designed to allow the
packing to be vented if desired. Vent openings to
each rod's packing are located in the cylinder casting
below the valves. The 1/8" openings should remain
plugged as they serve no function with this packing
arrangement. The 1/4" openings may be plugged or
vented as desired. If vented, the vent line should be at
a pressure lower than the suction pressure to the
compressor. Note that each rod packing will need a
vent line.
The crosshead guide casting includes four 1/4" NPT
openings into the distance piece area. This is the area
separating the upper and lower sets of packing. If
desired, the upper openings may be connected to a
vent, pad or purge line:
Vent - The distance piece vent should be at a
pressure lower than suction pressure.
Pad - The distance piece may be padded with an
inert gas at most any desired pressure. A
pad pressure above suction pressure
combined with a packing vent mentioned
above would be typical.
Purge - Similar to the inert gas pad, except that a
continuous flow of padding gas is
maintained in the distance piece area.
Both of the upper openings would be used:
one for purge gas IN and one for purge gas
OUT.
The lower distance piece openings are typically used
to drain any oil that might accumulate in the distance
piece. Only one opening need be used.

INSTALLATION
CB9A-030 page 9/28
RELIEF VALVES
A relief valve of a type, material and pressure rating
suitable to the installation, MUST be installed. The
relief valve shall be installed in the discharge line
between the compressor head and the first block valve.
Hazardous pressure
can cause serious
personal injury or
property damage
Compressor operating against closed
valve can cause system component
failure, personal injury or property
damage.
Since all systems differ in design, care must be taken to
ensure the relief valve is installed to safely vent away
from sources of ignition and personnel. This can be
accomplished by either orientation or a pipe away,
consult the Relief Valve manufacture for assistance.
Should the Relief Valve actuate, the cause MUST be
determined and corrected before continuing operations.
See the 'Troubleshooting' section.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Operation of the relief valve can release
explosive gas to the atmosphere
creating an explosion hazard, possibly
causing personal injury or death
Blackmer offers various relief valves for gas and
application compatibility.
PRESSURE GAUGES
Install pressure gauges in the discharge and inlet lines
to verify actual suction and discharge pressures.
LIQUID TRAPS
Compressors handling gasses that contain
condensates or other liquids MUST be protected from
entry of the liquid. Liquid can also enter the compressor
from the discharge piping, particularly if the piping
slopes down toward the compressor. To prevent liquid
from entering the compressor and causing major
damage, it is necessary to carefully consider the system
design and have strict procedures for operation.
NOTICE: Liquid in the compressor cylinder can
cause destruction of the compressor.
Suction liquid traps collect liquid entrained in the suction
gas stream, preventing it from entering the compressor.
The most common liquid trap is an ASME code vessel
(approx. 12" diameter X 50" tall) fitted with an internal
stainless steel mist pad, a relief valve, a manual drain
valve, and one or two electric float switches. Level
gauges and automatic drain systems are also available.
If the liquid level rises too high in the trap, a float switch
is tripped, sending a signal to stop the compressor or
sound an alarm. The trap must then be drained before
the compressor can be restarted. The cause of the high
liquid level must be found and the problem corrected.
Figure 5 – Typical HD942 Compressor Package
4-WAY VALVES
Many liquefied gas compressors are used for both liquid
transfer and vapor recovery operations. An optional 4-
way valve is used to reverse the direction of flow
through the system when changing from liquid transfer
to vapor recovery. Both lubricated and nonlubricated
models are available. Lubricated models should be
lubricated every 6 months.
TEMPERATURE SWITCHES
Excessive discharge temperature is a leading cause of
premature component failure and is often an early
warning sign of impending problems.
Optional temperature switches should be installed with
a thermowell as close to the compressor discharge as
possible. The switch should be set to actuate at a
temperature just above the maximum operating
temperature of the compressor.
ATEX compliant compressors must have a temperature
switch installed.
LOW OIL PRESSURE SWITCHES
Loss of crankcase oil pressure is a rare occurrence, but
can result in costly damage. An optional low oil
pressure switch set at about 15 psig (1 bar-g) may be
installed to shut down the compressor in the event of a
lubrication failure. A 10 second delay timer should be
used to lock the low oil pressure switch out during
compressor startup.
PRESSURE SWITCHES
Pressure switches may be installed in the suction or
discharge gas stream as protective devices, for
compressor control, or for other uses varying with each
application and system design.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Optional liquid trap level switches,
temperature switches, pressure
switches or other electrical devices
must be properly specified for
applications using explosive gases.

OPERATION
CB9A-030 page 10/28
PRE-STARTUP CHECK LIST
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
1. After the compressor is installed in the system, a
complete leak test MUST be performed on both the
compressor and the piping.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Failure to properly leak test the
compressor installation may result in
leakage of explosive gas to the
atmosphere creating an explosion
hazard, possibly causing severe
personal injury or death.
2. Re-check the system piping and the piping supports
to ensure that no piping loads are being placed on
the compressor.
Extreme Heat can
cause personal injury
or property damage
Discharge piping surface temperatures
may be hot during operation (over
158°F, 70°C). Temperatures should be
monitored and adequate warnings
posted.
3. If V-belt driven, check the alignment of the motor
and the compressor sheaves. The faces of the
sheaves must be parallel.
4. Ensure that pressure gauges are installed on both
inlet and discharge of the compressor.
5. Blackmer compressors are shipped from the factory
without oil in the crankcase. Fill with a high quality
non-detergent oil of the proper viscosity. See
"Crankcase Lubrication" in this manual.
6. Check the electrical connections for proper wiring,
grounding, etc.
7. With the power disconnected, remove the
compressor nameplate. Squirt oil onto each
crosshead while rotating the compressor by hand to
verify smooth operation.
8. Ensure that all guarding is properly installed.
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
Operation without guards in place can
cause serious personal injury, major
property damage or death.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Flywheel guard contact with moving
parts may be a source of ignition in
explosive atmospheres causing severe
personal injury or death
STARTUP PROCEDURE
NOTICE:
Consult the 'troubleshooting' section of this manual if
difficulties during startup are experienced.
1. Start the compressor. Oil pressure should register
25 psig (1.7 bar-g) within 10 seconds.
If proper oil pressure is not present, stop the
compressor and correct the problem.
Operating the compressor with low oil pressure will
cause severe damage to the unit. Adjust if
necessary. See "Setting the Oil Pressure" in this
manual.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Operation of the compressor with low or
no oil may result in extreme
temperature in the crankcase. This
could be an ignition source in the
presence of explosive gas and could
lead to severe personal injury or death.
The oil pump on these models will operate in either
direction of crankshaft rotation.
2. Verify that the suction and discharge pressures are
within the expected ranges.
Operating limits listed in the "Compressor Data"
section must not be exceeded.
3. Check for leakage from the piping and equipment,
and repair as necessary.
4. If the seals (packing) have just been replaced, or if
the compressor has been out of service for over 6
months, the lower seal MUST be manually
lubricated during the first 60 minutes of operation.
See "Seal (Packing) Replacement" section. New
compressors have had the packing broken in at the
factory.
5. On newly rebuilt units, the valve hold down screws,
valve cover plate bolts and cylinder head bolts
MUST have their torque checked after 60 minutes
running time. Also re-tighten all hold down bolts,
flywheel bolts, etc. after 60 minutes running time.
See the "Bolt Torque." table.

MAINTENANCE
CB9A-030 page 11/28
Flammable gas can
cause death, serious
personal injury or
property damage
Flammable gas and/or liquid can form
explosive mixtures with air causing
property damage, serious personal injury
or death Hazardous pressure
can cause serious
personal injury or
property damage
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
Hazardous
machinery can
cause serious
personal injury.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death Hazardous voltage.
Can shock, burn or
cause death.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Hazardous or toxic
fluids can cause
serious injury.
If handling hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance Hazardous pressure
can cause serious
personal injury or
property damage
Disconnecting fluid or pressure
containment components during
compressor operation can cause
serious personal injury, death or major
property damage
Hazardous gases
can cause property
damage, personal
injury or death
Explosive gas can cause property
damage, personal injury, or death.
Extreme Heat can
cause personal injury
or property damage
Extreme heat can cause personal
injury or property damage
NOTICE:
Blackmer compressor service and maintenance shall be performed by qualified technicians only. Service
and maintenance shall conform to all applicable local and national regulations and safety standards.
Table 5 – SERVICE SCHEDULE
Daily Weekly Monthly 6 Months Yearly
Overall Visual Check X
Check Crankcase Oil Pressure X
Check Suction Pressure X
Check Discharge Pressure X
Drain Distance Piece X
Drain Liquid From Accumulation Points X
Clean Compressor Cooling Fins X
Check Crankcase Oil Level * X*
Check Mounting and Anchor Bolts X
Check V-Belt Tension X
Change Oil and External Oil Filter * X*
Check Inlet Filter/Strainer Element X
Inspect Valves X
Lubricate 4-way Valve X
Lubricate Motor Bearings per Manufacturer's Suggestions X
Inspect Motor Starter Contact Points X
* Change oil every 1,000 hours of operation, or every 6 months which ever occurs first. If the oil becomes dirty or diluted,
change oil and external filter as often as needed to maintain clean oil.

MAINTENANCE
CB9A-030 page 12/28
TOOL LIST
Description Used For:
Blackmer Wrench 790535 Valve Hold-down screw
Blackmer Packing Installation Tool 790540 Rod-packing protection during installation.
3" Adjustable Spanner with 1/4" pins
(Blackmer PN 790316) Lower Packing Box Hold-down Ring
15/16" socket with 4" extension Piston Nut
3/4" End Wrench Cylinder and Crosshead Guide
1-1/16" Wrench or Socket Valve Caps
Allen Wrenches: 3/16", 1/4", 3/8" Valves
Sockets: 7/16", 1/2", 9/16", 5/8", 3/4", 7/8" Various
Internal Snap Ring Pliers Seal Replacement
Feeler gauges or Depth Micrometer Piston Clearance
Screwdriver, Flat Blade Nameplate screws, Packing Installation
Pliers
Rubber Mallet
Arbor Press Wrist Pin Removal
Bearing Puller Crankshaft Bearings
Torque Wrench Various
Hoist (useful) Cylinder and Crosshead Guide
Table 6 - TOOL LIST
BOLT TORQUE VALUES LBS-FT (Nm)
Connecting
Rod Bolt Bearing Carrier Bearing Cover Plate
Crankcase
Inspection
Cover
Crosshead
Guide Cylinder Head
45 (61.0) 30 (40.7) 40 (54.2) 7 (9.5) 40 (54.2) 40 (54.2) 40 (54.2)
Piston Nut Valve
Assembly Nut Valve Cover Plate Valve Hold Down Screw
Packing Box
Hold Down
Ring
Upper Packing
Box Screw Flywheel Hub Bolt
60 (81) 10 (13.6) 35 (47.5) 120 (163) 75 (102) 50 (68) 60 (81)
Table 7 - Bolt Torque

MAINTENANCE
CB9A-030 page 13/28
CRANKCASE LUBRICATION
Change the crankcase oil every 1,000 hours or 180
days, whichever is shorter. Under severe dusty or
sandy operating conditions, the oil should be changed
every 500 hours or every 90 days
A high quality non-detergent oil is recommended. The
oil used should be of high quality such as API
grade SF, SG, SH or similar.
API grade SA, SB, SC or similar oils should never
be used. Recycled oils should never be used.
Consult factory for special lubricating requirements.
Models Quarts Liters
HD942A / HDL942A 7 6.62
Table 8 - Oil Capacity
Air Temperature SAE ISO Grade
Below 0°F (-18°C)
0 to 32°F (-18 to 0°C)
32 to 80°F (0 to 27°C)
80°F (27°C) and above
5W
10W
20W
30W
15
22
46
100
Table 9 - Oil Viscosity
Before changing the oil, bring the compressor up to
normal operating temperature. Remove the crankcase
drain plug and drain the oil into an adequately sized
container. Remove the oil pickup screen and clean in a
suitable solvent. When reinstalling the pickup screen,
inspect the metal gasket and the O-ring for damage,
replacing as necessary. If equipped, replace the
external oil filter. See Figure 6.
Refill the crankcase via the dipstick opening. DO NOT
OVERFILL THE CRANKCASE!
The oil pump on these models will operate in either
direction of crankshaft rotation.
SETTING THE OIL PRESSURE (see Figure 6)
1. The oil pressure should be about 25 psig
(1.73 Bar).
2. Loosen the locknut.
3. Increase the pressure setting by turning the
adjusting screw inward, CLOCKWISE.
Decrease the pressure setting by turning the
adjusting screw outward, COUNTER-CLOCKWISE.
4. Retighten the locknut.
Figure 6 - Compressor Lubrication System

COMPRESSOR DISASSEMBLY
CB9A-030 page 14/28
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Hazardous pressure
can cause serious
personal injury or
property damage
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Venting pressure from the compressor
piping could release explosive gas to
the atmosphere creating an explosion
hazard, possibly causing severe
personal injury or death.
NOTICE:
Before starting work on the compressor, make sure
all pressure is bled off on both the suction and
discharge.
1. Remove the head bolts from the head.
2. Remove the head and cylinder head O-rings from
the cylinder.
3. Remove the valves per the "Valve Replacement"
section.
4. PISTON REMOVAL
a. Rotate the crankshaft by hand to bring a piston
to the top dead center position.
b. Remove the piston nut.
c. Remove the piston cap using the two 1/4"
threaded puller holes. (If two 1/4" bolts are not
readily available, the oil pump cover bolts may
be used.)
d. Remove the upper shims, the piston and the
lower shims. Keep the upper and lower shim
sets together to simplify reassembly.
e. Repeat these steps for the other piston.
5. Remove the cylinder capscrews and lift cylinder
from the crosshead guide. Do not allow the upper
packing boxes to be lifted off with the cylinder as
the packing will be damaged.
Figure 7 - Cylinder and Piston
6. PACKING BOX REMOVAL
a. Remove nameplate from the crosshead guide.
b. Lift the upper packing box assembly and
O-rings off the rod.
c. Remove oil deflector ring from the piston rod.
d. Remove the lower packing box hold-down ring
using a 3" adjustable spanner with ¼" pins
(Blackmer PN 790316).
e. Place a wooden block (or the end of a mallet
handle) through the nameplate opening on top
of the crosshead. Rotate the crankshaft by
hand until the crosshead pushes the wooden
block against the lower packing box, unseating
it. DO NOT PLACE FINGERS INSIDE THE
NAMEPLATE OPENING!
f. Lift the lower packing box assembly and O-ring
off the piston rod.
g. Repeat the above steps for the packing boxes
on the other rod.
h. For disassembly of the packing boxes, refer to
"Seal (Packing) Replacement."
7. Remove the crosshead guide capscrews, and lift off
the crosshead guide and gasket.

COMPRESSOR DISASSEMBLY
CB9A-030 page 15/28
8. REMOVING THE CONNECTING ROD
ASSEMBLIES (with the crossheads attached).
The piston rod is permanently attached to the
crosshead to form a single assembly. Do not
attempt disassembly.
a. Drain the oil from the crankcase.
b. Remove the inspection plate from the
crankcase.
c. Remove the locknuts from the two connecting
rod bolts. This will release the connecting rod
cap (the lower half of the connecting rod) and
the two halves of the bearing insert. The
connecting rod and the connecting rod cap are
marked with a dot on one side so that they can
be matched properly when reassembling.
d. Lift the crosshead assembly and connecting
rod off the crankshaft.
NOTICE: The connecting rod parts are not
interchangeable and must be reassembled with
the same upper and lower halves. To avoid
confusion, work on one connecting rod at a
time, or mark the individual halves with
corresponding numbers.
9. Remove the opposite connecting rod and
crosshead assembly.
10. Rest the crosshead assembly on a bench.
Carefully drive the wrist pin and wrist pin plugs out
of the crosshead and connecting rod using a
suitable pin driver or an arbor press. Removal of
the pin releases the crosshead assembly from the
connecting rod.
11. If necessary, the wrist pin bushings can be replaced
after the crossheads are removed. Make sure the
oil hole in the new bushing aligns with the oil hole in
the connecting rod. New bushings must be honed
to the proper size after installation. Inner
Dimension = 1.2511" to 1.2514" (31.778 mm to
31.786 mm).
12. To replace the crankshaft bearings, the crankcase
must be disassembled, and the crankshaft
removed. Refer to "Bearing Replacement" for
disassembly instructions.
Figure 8 - Packing Boxes, Crosshead
and Connecting Rod Detail

COMPRESSOR ASSEMBLY
CB9A-030 page 16/28
Compressor assembly is generally the opposite of
compressor disassembly. Before reassembling, clean
each part thoroughly. Check all machined surfaces for
burrs or roughness, and file lightly if necessary.
Replace any O-rings or gaskets that are removed or
disturbed during service.
1. CRANKCASE ASSEMBLY
After replacing the crankshaft, bearing carrier, and
bearing cover plate, the connecting rod and
crosshead can be assembled in the crankcase. See
the "Bearing Replacement" section.
a. To attach the connecting rod to the crosshead
assembly, first coat the wrist pin, the wrist pin
bore in the crosshead assembly, and the wrist
pin bushing in the connecting rod with grease.
b. Start the wrist pin in the bore of the crosshead
assembly and tap lightly until the pin begins to
project through to the inside of the crosshead
assembly.
c. Slide the connecting rod up inside of the
crosshead assembly and align the bushing with
the wrist pin.
d. Lightly tap the wrist pin through the connecting
rod until it is centered in the crosshead
assembly. The wrist pin should be snug in the
crosshead assembly. The connecting rod
should rotate freely on the wrist pin, but should
not be loose.
e. Dip the wrist pin plugs in grease and press
them against the ends of the wrist pin.
f. Place the bearing halves into each half of the
connecting rod, aligning the bearing tangs with
the slots in the connecting rod. Coat the
bearing with grease.
g. Set the top of the connecting rod over the
crankshaft journal. Replace the connecting rod
cap with the dots on the connecting rod and
cap on the same side.
h. Start the nuts on the connecting rod bolts and
torque per Table 7 - "Bolt Torque."
i. Follow this same procedure for the opposite
connecting rod.
2. CROSSHEAD GUIDE
a. Place the crosshead guide gasket on top of the
crankcase.
b. Lubricate the inside bore of the crosshead
guide with light oil.
c. Set the crosshead guide over the piston rods
and the crossheads, and slowly lower it against
the crankcase. Make certain that the
crosshead assemblies are started straight in
the crosshead guide bores to prevent binding
when lowering the crosshead guide into
position.
d. Install the crosshead guide capscrews. DO
NOT tighten.
3. Fill the crankcase with oil. Refer to the "Crankcase
Lubrication" section. Squirt oil into the crankshaft,
roller bearings, crankshaft journals, and crosshead
assemblies to ensure proper lubrication at start up.
4. Attach the inspection plate and the inspection plate
gasket to the crankcase.
5. PACKING BOX ASSEMBLIES
Refer to the section 'SEAL REPLACEMENT' for
packing box assembly. Before installing the packing
boxes into the crosshead guide, inspect the piston
rods for scoring or roughness. Remove any burrs
or sharp edges. Lubricate the piston rods and
packing box O-rings with light oil. The packing
installation tool (Blackmer Part No. 795040)
must be used to avoid damaging the packing
when starting it over the rod.
a. Place the packing installation tool over the end
of the piston rod.
b. Install the O-ring on the lower packing box then
slide it onto the piston rod and down into the
crosshead guide.
c. Install the packing box retainer ring, with new
nylon locking inserts, and tighten.
d. Slide the oil deflector ring down over the piston
rod.
e. Place the two O-rings on the upper packing
box, then slide the box over the piston rod until
the upper packing box assembly rests on top of
the crosshead guide.
Figure 9 - Upper Packing Box Alignment
f. Note the orientation of the valve cutouts on the
packing box. The cutouts must align with the
valve pockets in the cylinder. Rotate the
packing box as needed for the proper
alignment.
g. Remove the packing installation tool from the
piston rod.
h. Repeat steps a - g for the other piston rod and
packing boxes.
6. Packing must be broken in. Finish compressor
assembly then refer to "Packing Lubrication."

COMPRESSOR ASSEMBLY
CB9A-030 page 17/28
7. CYLINDER ASSEMBLY
a. The cylinder should be installed with the valves
removed.
b. Set the cylinder on the crosshead guide over
the piston rods and packing boxes.
c. Ensure that the valve cutouts on the upper
packing boxes are aligned with the cylinder
valve pockets.
d. Place the pistons (without shims or rings) on
the rods. Rotate the compressor by hand and
verify that the pistons are centered in the
cylinder bores. The pistons must not touch the
cylinder walls. Adjust the cylinder as
necessary.
e. Install the cylinder capscrews and tighten
evenly per Table 7 - "Bolt Torque."
f. Remove the pistons.
8. Rotate the flywheel by hand to ensure the
compressor turns freely.
Figure 10 - Cylinder and Piston
9. PISTON INSTALLATION
a. To set the piston clearance, remove the valves
from one side of the cylinder.
b. Rotate the flywheel by hand to bring one piston
rod to top dead center.
c. Set the bottom shim washer(s) onto the piston
rod.
d. Place the piston (without rings and expanders)
on the piston rod.
e. Place the upper shim washer(s) over the rod
onto the piston.
f. Install the piston cap (without the O-ring).
g. Tighten the piston nut on securely.
h. Install the head (without the O-ring), and tighten
the head bolts securely.
i. Ensure that the piston is at top dead center.
Measure the clearance between the piston and
head through one of the upper valve pockets.
j. Rotate the crankshaft until the piston is at
bottom dead center. Measure the clearance
between the piston and packing box through a
lower valve pockets.
k. Compare the piston clearance values to those
in Table 10 - "Piston Clearance."
Upper Piston
Clearance 0.035" - 0.050"
(0.89 to 1.27 mm)
Lower Piston
Clearance 0.003" - 0.005"
(0.08 to 0.13 mm)
Table 10 - Piston Clearance
l. Remove the piston. Repeat steps b - k with
revised shimming until both clearances values
are satisfactory.
m. Once the proper shims are determined, remove
the piston again.
n. Install an expander and piston ring in each
groove in the piston. The gap in each
expander should be 180° from the gap in the
piston ring. In addition, each piston ring's gap
should be 180° from that of adjacent ring(s).
o. Squeeze the piston rings inward with light
pressure and work the piston into the cylinder
over the rod.
p. Place the upper shim washer(s) over the rod
onto the piston.
q. Install the piston cap and O-ring.
r. Tighten the piston nut per Table 7 - "Bolt
Torque."
s. Install the head with its O-ring, and evenly
tighten the head bolts per Table 7 - "Bolt
Torque."
t. Repeat same procedure for the second piston.
u. Verify the proper upper and lower piston
clearance before proceeding.
10. Install the valves per "Valve Replacement" Section.
11. Rotate the compressor by hand to verify that it turns
freely.
12. Refer to the "Pre-Startup Check List", and "Startup
Procedure."
13. After the compressor has run for a sufficient time to
reach operating temperature, allow to cool and
retighten the valve hold down screws.

UNLOADER SEAL REPLACEMENT
CB9A-030 page 18/28
1. Remove the unloader cap and O-ring.
2. Remove the unloader body from the cylinder head
(a strap wrench is helpful).
3. Push the unloader piston out the top of the
unloader body.
4. Inspect and replace the seals as needed - note the
seal orientation!
5. Inspect the unloader body bore - it must be clean
and smooth.
6. Reassemble in the reverse order.
VALVE REPLACEMENT
Fig. 11 –
Valve Installation
Fig. 12 –
Valve Installation
(with Suction Valve Unloaders)

VALVE REPLACEMENT
CB9A-030 page 19/28
Suction and discharge valves MUST be installed in the
correct cylinder head locations. See Figures 11 & 12.
Hazardous pressure
can cause serious
personal injury or
property damage
Failure to install compressor valves
properly can lead to component failure,
personal injury or property damage.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Failure to install compressor valves
properly can result in leakage of
explosive gas creating an explosion
hazard, possibly causing severe
personal injury or death.
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
Failure to install compressor valves
properly can result in extreme
discharge temperatures. This could be
an ignition source in the presence of
explosive gas possibly causing severe
personal injury or death.
1. Remove the valve cap and O-ring from each valve.
2. Remove the valve hold down screw with a spanner
wrench (Blackmer PN 790535).
3. VALVE REMOVAL
a. Remove the valve cover plate capscrews then
lift off the cover plate and O-ring.
b. Remove the cage, (and unloader plunger) valve
assembly and valve gasket.
c. Inspect the valve for wear or breakage.
4. VALVE REPAIR
a. Remove hex nut from valve (after removing the
unloader actuator, retaining ring, actuator,
spring, and post).
b. Separate the valve halves and remove springs
and plate.
c. Inspect and replace worn components.
d. Reassemble valves as shown in the drawings
and tighten the valve assembly nut per Table 7
- "Bolt Torque."
5. VALVE INSTALLATION
The pistons should be installed and the proper
piston clearance set before the valves are installed.
a. Remove the old gasket and install a new valve
gasket into the cylinder head.
b. Install the valve assembly in the cylinder head.
Make sure the valve's orientation and location
are correct.
c. Hold the valve in place with a socket and
extension for steps d - f.
d. Center the valve cage on the valve assembly.
e. Remove the valve hold down screw from the
cover plate, then install the valve cover plate
with a new O-ring. Tighten the cover plate
capscrews according to Table 7 - "Bolt Torque."
f. Install the hold down screw and tighten
according to Table 7 - "Bolt Torque."
g. If suction valve unloaders are used: Install the
unloader plunger through the hold down screw.
h. Install the valve cap and O-ring.
6. After replacing the valves, rotate the flywheel by
hand to check for interference between the pistons
and the valves.
7. After 60 minutes of running time, remove the valve
cap and retorque the hold down screw. Replace
the valve cap and O-ring.
Figure 13 – Ductile Iron / PEEK Valve Detail
Figure 14 – Stainless Steel Valve Detail

SEAL (PACKING) REPLACEMENT
CB9A-030 page 20/28
Two seals separated by a distance piece seal the gas in
the cylinder and prevent contamination by the
crankcase oil. The upper seal consists of pairs of
segmented packing rings, while the lower seal utilizes a
number of PTFE V-rings.
Before starting work on the compressor, note the seal
orientation indicated by the 6th digit of the Compressor
ID # shown on the compressor's nameplate. Also note
any tubing connections in the seal area. 1/4" NPT ports
are provided between each pair of seals to allow
venting or pressurization of the seal areas.
1. Follow steps 1 - 6 of "Compressor Disassembly."
2. UPPER PACKING BOX
a. Remove the bolts from the bottom of the
packing box then remove the packing gland
and packing spacer.
b. Remove the packing cups with packing ring
pairs and O-rings. If the packing cups are
difficult to remove, place a screwdriver blade in
the groove in each packing cup and tap lightly
with a rubber mallet. Do not deform the
packing cups or scratch their sealing surfaces.
c. Remove the packing cup gasket.
d.
Clean and inspect all parts, replacing as
needed.
e. Refer to the appropriate drawing for the proper
orientation of the packing cups and rings. Note:
the bottom ring set differs from the upper pairs.
f. Install the gasket packing cups, packing ring
sets and O-rings per the appropriate drawing.
g. Install the packing spacer and gland, then
secure by tightening the bolts evenly.
Figure 15 Packing Ring Detail
Figure 16 - Type 'A' Packing Detail