BLACKMER LB161B Guide

2003/06 588/A
COMPRESSORS

INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
LB161B LB361B LB601B
MODELS LB162B LB362C LB602B
TABLE OF CONTENTS
SAFETY DATA ..........................................................1
GENERAL INFORMATION
Compressor Data .................................................2
Nameplate Data ...................................................3
Maximizing Compressor Life................................4
INSTALLATION
Location and Piping..............................................5
Mounting the Compressor Unit ............................5
Stationary Compressors....................................... 5
Truck Mounted Compressors ..............................5
Compressor Flywheel ..........................................6
V-Belt Drive...........................................................6
PTO Drive .............................................................6
Liquefied Gas Transfer Piping Schematic ........... 7
Typical Transfer Compressor, Drawing ...............7
Relief Valves.........................................................8
4-Way Valves .......................................................8
Liquid Traps..........................................................8
Temperature and Pressure Switches ........... 8 & 9
Pressure Gauges .................................................9
OPERATION
Pre-Start up Check List .......................................... 9
Start Up Procedure ............................................... 10
MAINTENANCE
Service Schedule .................................................. 11
Tool List................................................................. 11
Bolt Torque Table ................................................. 12
Crankcase Lubrication.......................................... 12
Setting the Oil Pressure........................................ 12
COMPRESSOR DISASSEMBLY.............................. 13
COMPRESSOR ASSEMBLY.................................... 14
VALVE REPLACEMENT........................................... 16
SEAL (PACKING) REPLACEMENT ........................ 18
BEARING REPLACEMENT...................................... 19
OIL PUMP REPLACEMENT ..................................... 20
EXTENDED STORAGE............................................. 20
TROUBLESHOOTING............................................... 21
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.

SAFETY DATA
588/A page 2/24
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 DISCONNNECT 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 DISCONNNECT 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
The models listed are single-stage, vertical, air-cooled reciprocating style compressors with single acting cylinders.
Single-Seal Models
Double-Seal Models
LB161B
LB162B
LB361B
LB362C
LB601B
LB602B
Minimum / Maximum RPM * 350 / 825 350 / 825 350 / 790
Reduce maximum speeds by 9% for continuous duty operation.
Displacement
@ min rpm - CFM (m3/hr)
@ max rpm - CFM (m3/hr)
7.16 (12.2)
16.9 (28.7)
15.3 (26.0)
36.0 (61.2)
27.2 (46.3)
61.5 (104.5)
Max. BHP (kw) 10 (7.5) 15 (11) 40 (30)
MAWP - psia (kPa) 350 (2,413)
Maximum Discharge Temperature 350°F (176°C)
Rotation Direction Bi-Directional
Table 1 - Compressor Data

GENERAL INFORMATION
588/A page 3/24
MODEL: LB 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
Figure 1 - Typical Compressor

GENERAL INFORMATION
588/A page 4/24
An 11 character "I.D. No." identifies the construction of the compressor.
BABAC1TA4AA
VALVES Code Fields
Steel,w/LiquidRelief BA 1&2
O-RINGS Field3
Buna-N B
GASKETS Field4
Aluminum A
PISTONRINGS Field5
Carbon Filled Teflon C
SEAL (PACKING) ORIENTATION Field 6
AllLipsup 1
SEAL MATERIAL Field 7
Teflon T
CYLINDER&HEAD Field8
DuctileIron A
GGG40.3 Ductile Iron D
PISTONRODS Field9
BlackSurfaceSteel 4
CRANKSHAFT&OILFILTER Field10
Standard A
ExtendedCrankshaft B
Spin-onOilFilter C
Ext.Crank/OilFilter D
OTHER A Field11
Note: A 'Z' in any field indicates a non-standard option. No model is available with all shown options.
Table 2 - ID Number Key
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
Table 3 - Year of Manufacture
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:
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.
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.

GENERAL INFORMATION
588/A page 5/24
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
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°C).
TEMPERATURES SHOULD BE
MONITORED AND ADEQUATE
WARNINGS POSTED.
MOUNTING THE COMPRESSOR UNIT
Stationary Compressors
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.
Truck Mounted Compressors
Blackmer compressors may be mounted to the frame
rails of a truck/transport and driven by either a V-belt or
PTO drive.
The compressor should be solidly mounted and care
should be taken to ensure that the dipstick and
inspections plates are readily accessible.
Check compressor mounting bolts and baseplate
anchor bolts regularly.

INSTALLATION
588/A page 6/24
COMPRESSOR FLYWHEEL
Blackmer compressors are fitted with flywheels which
MUST be used regardless of the type of drive system
employed.
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
FAILURE TO DISCONNNECT AND
LOCKOUT ELECTRICAL POWER OR
ENGINE DRIVE BEFORE ATTEMPTING
MAINTENANCE CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
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.
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
V-BELT DRIVES
Most Blackmer compressors are driven via V-belts
which must be properly aligned and tensioned.
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
FAILURE TO DISCONNNECT AND
LOCKOUT ELECTRICAL POWER OR
ENGINE DRIVE BEFORE ATTEMPTING
MAINTENANCE CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
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.
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.
PTO DRIVES
Truck mounted Compressors may be driven by the
power take-off through a jackshaft connected by
universal joints. The compressor must be fitted with an
optional extended crankshaft to use a PTO drive without
removing the flywheel. Proper PTO installation is
essential:
1. Compressor shaft and PTO shaft must be parallel.
2. The yokes at the end of the jackshaft must be
parallel and in phase.
3. The angle between two shafts must not exceed 15°.
4. An EVEN number of U-joints must be used.

INSTALLATION
588/A page 7/24
Figure 4 -
Liquid Transfer
Flow Schematic
Figure 5 -
Vapor Recovery
Flow Schematic
Figure 6 - Typical Liquefied Gas Transfer Compressor

INSTALLATION
588/A page 8/24
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
COMPRESOR 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.
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
Should the Relief Valve actuate, the cause MUST be
determined and corrected before continuing operations.
See the 'Troubleshooting' section.
Blackmer offers various relief valves for gas
compatibility:
•Brass for LP-Gas service
•Aluminum for anhydrous ammonia
•Steel, A.S.M.E. code stamped for both services,
and other applications.
LIQUID TRAPS
Compressors handling gasses that contain
condensates or other liquids MUST be protected from
entry of the liquid. While the use of liquid traps is
recommended, many operators of transports do not use
them. 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.
Blackmer offers a variety of liquid traps. The most
common variations include:
1. A non-code vessel fitted with a stainless steel float
which will shut off the intake line to the compressor
in the event of an excessive liquid level. A vacuum
breaking valve is provided on the liquid trap head in
case the trap closes and a vacuum develops
between the compressor and the trap. A manual
drain valve is provided.
2. The above trap is fitted with an port allowing the
use of an electric float switch which protects the
compressor by stopping the compressor when a
high liquid level is present in the liquid trap. The
electric float switch may be used with or without the
mechanical float described above.
3. For additional protection, a larger ASME code
stamped vessel is available. This liquid trap is
typically fitted with one or two electric float switches
for both a high liquid level shut down and alarm
signal, a relief valve, and a manual drain valve.
Level gauges and automatic drain systems are
available options.
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.
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.
Figure 7 - Typical Liquid Trap

INSTALLATION
588/A page 9/24
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.
PRESSURE GAUGES
Install pressure gauges in the discharge and inlet lines
to verify actual suction and discharge pressures.
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
PRE-STARTUP CHECK LIST
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
FAILURE TO DISCONNNECT 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

OPERATION
588/A page 10/24
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 (172 kPa) 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, 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 Table 7 - "Bolt Torque."
MAINTENANCE
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 DISCONNNECT 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 DISCONNNECT 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

MAINTENANCE
588/A page 11/24
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.
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 (Double-Seal Models) 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 unusually dirty,
change oil and external filter as often as needed to maintain clean oil.
Table 5 - Service Schedule
TOOL LIST
Description Used For:
Blackmer Wrench 790535 Valve Hold-down screw
Blackmer Packing Installation Tool
790536 for 160 and 360 Series Compressors
790538 for 600 Series Compressors
Rod-packing protection during installation.
3" Adjustable Spanner with 1/4" pins
(Blackmer PN 790316)
Piston Nut, Piston, Packing Box Hold-down Ring
9/16", 5/8" or 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, 0 to 45 lb-ft range Various
Hoist (useful) Cylinder and Crosshead Guide
Table 6 - TOOL LIST

MAINTENANCE
588/A page 12/24
BOLT TORQUES FOR BLACKMER COMPRESSORS LBS-FT (Nm)
Size Connecting
Rod Bolt
Bearing
Carrier
Bearing
Cover
Plate
Crankcase
Inspection
Plate
Crosshead
Guide Cylinder Head Piston Nut
Valve
Cover
Plate
Valve
Hold Down
Screw
Valve
Cap
160 30
(40.7)
30
(40.7)
35
(47.5)
7
(9.5)
25
(33.9)
25
(33.9)
20
(27.1)
40
(54) -- 120
(163)
80
(108)
360 35
(47.5)
30
(40.7)
35
(47.5)
7
(9.5)
35
(47.5)
35
(47.5)
40
(54))
40
(54)
35
(47.5)
80
(108)
80
(108)
600 45
(61)
30
(40.7)
40
(54)
7
(9.5)
40
(54)
40
(54)
40
(54)
60
(81)
35
(47.5)
80
(108)
80
(108)
Table 7 - Bolt Torque
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.
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 8.
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 8)
1. The oil pressure should be about 25 psig
(173 KPa).
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.
Models Quarts
LB161B, LB162B
LB361B, LB362C
LB601B, LB602B
2
3
7
Table 8 - Oil Capacity
Air Temperature Oil Viscosity
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
SAE 5W
SAE 10W
SAE 20W
SAE 30W
Table 9 - Oil Viscosity
Figure 8 - Compressor Lubrication System

COMPRESSOR DISASSEMBLY
588/A page 13/24
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
ju
r
y
.
FAILURE TO DISCONNNECT 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 center head capscrews from the
cylinder head. Remove the outer cylinder head
capscrews.
2. Remove the cylinder head assembly and cylinder
head O-rings from the cylinder. The suction and
discharge valve assemblies will come off with the
cylinder head. For valve replacement instructions,
refer to the "Valve Replacement" section of this
manual.
3. Removal of the piston requires a 3" adjustable
spanner wrench with 1/4" pins, such as Blackmer
PN 790316.
a. Rotate the flywheel by hand to bring a piston to
top dead center of the cylinder.
b. Remove the piston nut by turning the nut
counterclockwise. (The nylon locking insert in
the piston nut must be replaced during
reassembly.)
c. To remove the piston from the cylinder, turn it
counterclockwise with the use of the adjustable
spanner wrench. For removal and replacement
of the piston rings, refer to the "Compressor
Assembly" section.
d. Remove the thrust washer and any shims.
Keep the shims and piston together.
e. Repeat these steps for the other piston.
4. Remove the cylinder capscrews.
5. Lift the cylinder and cylinder O-rings from the
crosshead guide (or distance piece).
6. Packing Box Removal
a. Using an adjustable spanner wrench, remove
the packing box hold-down rings. (Replace the
nylon locking inserts in the hold-down rings
during reassembly.)
b. Remove the packing box and packing box O-
ring from each piston rod. Double-Seal models
will have a spacer ring and a second packing
box O-ring to remove from each piston rod.
c. For disassembly of the packing boxes, refer to
the "Seal (Packing) Replacement" section of
this manual.
7. Remove the crosshead guide capscrews, and lift
the crosshead guide and gasket off.
8. To remove the connecting rod assemblies, with the
crossheads attached, it may be necessary to drain
the oil from the crankcase. The piston rod is
permanently attached to the crosshead to form a
single assembly. Do not attempt disassembly.
a. Remove the inspection plate from the
crankcase.
b. Remove the locknuts from the 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 properly aligned when reassembling.
c. Lift the crosshead assembly and connecting
rod off the top of the crankcase.
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 in the same manner as
outlined in step 8.
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. New bushings
must be honed to the proper size after installation.

COMPRESSOR DISASSEMBLY
588/A page 14/24
12. To replace the crankshaft bearings, the crankcase
must be disassembled, and the crankshaft
removed. Refer to the "Bearing Replacement"
section of this manual.
Compressor
Model
Bushing I.D.
Inches (mm)
LB161B, LB162B
LB361B, LB362C
0.8753 to 0.8756
(22.233 to 22.240)
LB601B, LB602B 1.2511 to 1.2514
(31.778 to 31.786)
Table 10 - Wrist Pin Bushing Dimensions
COMPRESSOR ASSEMBLY
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 bores of the crosshead guide 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
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. Do not damage the packing when
starting it over the rod. Use of a Blackmer
packing installation tool is recommended.
Single-Seal Models
a. Insert the packing box O-ring into the
crosshead guide.
b. Start the packing box assembly, short end
down, over the piston rod and into the counter-
bored hole of the crosshead guide.
c. Install the packing box retainer ring, with new
nylon locking inserts, and tighten securely.
d. Repeat the above steps for the remaining
packing box.
Double-Seal Models
a. Insert the lower packing box O-ring into the
crosshead guide.
b. Start the packing box assembly, short end
down, over the piston rod and into the
crosshead guide.

COMPRESSOR ASSEMBLY
588/A page 15/24
c. After the lower set of packing is started over the
piston rod, make sure the oil deflector ring is
properly aligned (with the flat side down) over
the piston rod. Use the hole in the side of the
packing box to center the deflector ring. Once
the deflector ring is over the rod, the packing
box can be fully inserted.
d. Install the upper packing box O-ring on the end
of the packing box.
e. Place the packing box spacer ring over the
O-ring.
f. Install the packing box retainer ring, with new
nylon locking inserts, and tighten securely.
g. Repeat the above steps for the remaining
packing box.
6. Rotate the crankshaft by hand a few times, then
uniformly tighten the crosshead guide capscrews
per Table 7 - "Bolt Torque."
7. Break in new packing per the "Seal (Packing)
Replacement" section of this manual.
8. CYLINDER ASSEMBLY
a. Install new O-rings in the bottom of the cylinder.
A small amount of grease may be used to hold
the O-rings in place during assembly.
b. Set the cylinder over the piston rods and
against the crosshead guide.
c. Install the cylinder capscrews. DO NOT
tighten.
9. PISTON RINGS
a. Place an expander in the top groove of the
piston. Place an expander in the second
groove with the break in this expander 180
degrees from the break of the top expander.
Place the third expander in the bottom groove
with its break in the same position as the top
expander.
b. Place piston rings in all three grooves of the
piston. Align the breaks in the piston rings
directly opposite the breaks in the
corresponding expanders.
10. PISTONS
a. Rotate the flywheel by hand to bring one piston
rod to top dead center of the cylinder assembly.
b. Set the thrust washer and one shim on the
shoulder of the piston rod.
c. With light pressure, squeeze the piston rings
inward while threading the piston clockwise
onto the rod. Tighten with the 3" adjustable
spanner wrench.
d. Follow this same procedure for the second
piston.
e. Rotate the crankshaft by hand a number of
times to verify that the pistons are centered in
the cylinder bores. Adjust the cylinder so that
the pistons DO NOT touch the cylinder walls.
f. Using an alternating pattern, torque the cylinder
capscrews per Table 7 - "Bolt Torque."
11. PISTON CLEARANCE
a. Rotate the flywheel by hand to bring one piston
to the top.
b. Measure the distance from the top of the piston
to the top of the cylinder.
LB161B .010" to .025"
(.254 to .635 mm
LB162B .015" to .030"
(.381 to .762 mm)
LB361B .020" to .035"
(.508 to .889 mm)
LB362C .025" to .040"
(.635 to 1.016 mm)
LB601B .020" to .035"
(.508 to .889 mm)
LB602B .030" to .045"
(.762 to 1.143 mm)
Table 11 - Piston Clearance
c. If necessary, remove the piston and add or
subtract shims accordingly.
d. Install new nylon locking inserts in the piston
retainer nuts.
e. Thread the piston nut onto the piston rod and
tighten securely with the spanner wrench.
f. Follow this same procedure for the second
piston.
12. CYLINDER HEAD ASSEMBLY
If the valve assemblies have been removed from
the cylinder head, refer to the "Valve Replacement"
section of this manual.
a. Place the cylinder head O-rings in the grooves
located on top of the cylinder.
b. Place the cylinder head assembly on top of the
cylinder.
c. Hand tighten the outer capscrews and center
capscrews into the cylinder head.
d. Gaskets MUST be used on the center
capscrews of the LB161 and LB162 models.
e. Uniformly torque the cylinder head capscrews
per Table 7 - "Bolt Torque."
13. Rotate the compressor by hand to verify that it turns
freely. Ensure that the pistons are not hitting the
cylinder head assembly.
14. Follow all procedures listed in the "Pre-Startup
Check List" and "Startup Procedure" sections of this
manual.
15. Start the compressor and bring to normal operating
temperature. Stop the compressor, allow it to cool
and retorque the valve hold down screws per Table
7 -"Bolt Torque."

VALVE REPLACEMENT
588/A page 16/24
Figure 9 - Valve Location
Suction and discharge valves MUST be installed in the
correct cylinder head locations. See Figure 9.
The valves may be removed without removing the
cylinder head from the cylinder. Be sure to remove and
replace the valve gaskets.
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
j
ur
y
or death
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.
MODELS LB161B or LB162B - see Figure 10.
1. Remove the valve cap and O-ring from the valve
being serviced.
2. Remove the valve hold down screw with a spanner
wrench, such as Blackmer PN 790535.
3. Suction valve - Remove the liquid relief valve body,
valve assembly and gasket. DO NOT drop the
liquid relief ball and spring into the head interior.
4. Discharge valve - Remove the discharge valve
cage, valve assembly and gasket.
5. Inspect the valve for wear or breakage.
6. Ensure that the old gasket is removed, then install a
new valve gasket.
7. To reinstall the suction valves:
a. Install the valve assembly in the cylinder head.
Ensure the correct orientation and location of
the valve.
b. Center the liquid relief body on the valve
assembly.
c. Install the hold down screw and tighten per
Table 7 - "Bolt Torque."
d. Drop the liquid relief ball and the liquid relief
spring into the opening of the liquid relief body.
e. Insert the liquid relief adjusting screw and
adjust clockwise until the top of the screw is
approximately 3/8" (9.5 mm) above the top of
the liquid relief body. Add the locknut and
tighten securely.
8. To reinstall the discharge valves:
a. Install the valve assembly in the cylinder head.
Verify the correct valve orientation and location.
b. Center the valve cage on the valve assembly.
c. Install the hold down screw and tighten per
Table 7 - "Bolt Torque."
9. Install the valve cap and O-ring. A little oil or
grease on the O-ring will help hold it in place during
installation.
10. After replacing the valves, rotate the flywheel by
hand to check for interference between the pistons
and the valves.
11. After 60 minutes running time, remove the valve
cap and retorque the hold down screw. Replace
the valve cap and O-ring.
Figure 10 - LB161 or LB162 Valves

VALVE REPLACEMENT
588/A page 17/24
MODELS LB361B, LB362C, LB601B or LB602B
1. Remove the valve cap and gasket from the valve
being serviced.
2. Remove the valve hold down screw with an allen
wrench.
3. Remove the valve cover plate capscrews then lift
off the cover plate and O-ring.
4. Suction valves: remove the spacer, suction valve
assembly and valve gasket.
5. Discharge valves: remove the spacer, post,
discharge valve, and valve gasket.
6. Inspect the valve for wear or breakage. Repair or
replace as necessary.
7. To reinstall the suction valves:
a. Adjust the liquid relief valve adjusting screw
clockwise until the screw is flush with the top of
the liquid relief valve body, or no more than
1/16" (1.6 mm) above the top of the liquid relief
valve body.
b. Ensure that the old gasket is removed, then
install a new valve gasket.
c. Install the valve assembly with the liquid relief
valve upward. Verify the correct valve
orientation and location.
d. Install the valve spacer.
e. Ensure the valve hold down screw is removed
from the cover plate, then place the cover plate
and new O-ring in position.
f. Install the valve cover plate capscrews and
tighten per Table 7 - "Bolt Torque."
g. Install and tighten the hold down screw per
Table 7 - "Bolt Torque."
h. Install the valve cap with a new gasket.
8. To reinstall the discharge valves:
a. Ensure that the old gasket is removed, then
install a new valve gasket.
b. Install the valve assembly with the plug
downward. Verify the correct valve orientation
and location.
c. Install the valve post, small end first.
d. Install the valve spacer.
e. Ensure the valve hold down screw is removed
from the cover plate, then place the cover plate
and new O-ring in position.
f. Install the valve cover plate capscrews and
tighten per Table 7 - "Bolt Torque."
g. Install and tighten the hold down screw per
Table 7 - "Bolt Torque."
h. Install the valve cap with a new gasket.
9. After replacing the valves, rotate the flywheel by
hand to check for interference between the pistons
and the valves.
10. After 60 minutes running time, remove the valve
cap and retorque the hold down screw. Replace
the valve cap and gasket.
Figure 11 -
LB361, LB362, LB601 & LB602 Valves

SEAL (PACKING) REPLACEMENT
588/A page 18/24
Follow steps 1 through 6 of the "Compressor
Disassembly" section of this manual.
1. Remove the upper and lower retainer ring from the
packing box being serviced. Disassemble the
packing box and discard the old packing sets and
packing springs.
2. Clean the packing box in a suitable solvent. Inspect
the bore for wear, roughness, or corrosion. Clean
or replace as necessary.
3. Ensure that the 6th digit of the Compressor ID
number is a "1", indicating a TYPE 1 packing
arrangement. See "Nameplate Data" in this
manual. Refer to Figures 12 and 13 for proper
TYPE 1 component location and orientation.
4. Single-Seal Packing Boxes
a. Install the lower retainer ring.
b. Install the packing rings, spring, washers, and
the upper retainer ring. To ease installation on
the second retainer ring, use a screwdriver
handle and press on the last washer to
compress the seal spring slightly.
5. Two-Seal Packing Boxes
a. Install the inner retainer ring of the lower
packing.
b. Install the packing rings, spring, washers, and
the second retainer ring. To ease installation
on the second retainer ring, use a screwdriver
handle and press on the last washer to
compress the seal spring slightly.
c. Insert the oil deflector ring through the top of
the packing box, flat side down, into the cavity
between the upper and lower packing. The oil
deflector ring will be positioned between the
two sets of packing.
d. Install the upper packing set starting with the
inner retainer ring.
6. The lower packing MUST be manually lubricated
with oil several times during the first 60 minutes of
compressor operation to prevent overheating of the
piston rods and potential damage to the packing
material.
To lubricate the packing:
a. Remove the inspection plate from the
crosshead guide.
b. Stop the compressor approximately every 5
minutes to allow adequate cooling of the piston
rods.
c. Using a small oil can, lubricate the piston rods
each time the compressor is stopped.
Hazardous
machinery can
cause serious
pe
r
so
n
a
l in
j
u
r
y
.
DO NOT INSERT OBJECTS OR
FINGERS IN INSPECTION CAVITY.
CAN CAUSE SEVERE PERSONAL
INJURY
Hazardous gases
can cause property
damage, personal
in
ju
r
y
o
r
dea
th
IMPROPER SEAL INSTALLATION
COULD RELEASE EXPLOSIVE GAS TO
THE ATMOSPHERE CREATING AN
EXPLOSION HAZARD, POSSIBLY
CAUSING SEVERE PERSONAL INJURY
OR DEATH.
7. Proceed according to steps 5 through 15 of the
"Compressor Assembly" section.
Figure 13 - TYPE 1 Seal Orientation
Figure 12 - Typical Seal Assembly

BEARING REPLACEMENT
588/A page 19/24
NOTICE: When replacing the bearings, the entire
bearing assembly, including the bearing cup and
the bearing cone, must be replaced.
1. Follow steps 1 through 12 of the "Compressor
Disassembly" section.
2. Remove the Oil Pump per the section titled "Oil
Pump Replacement."
3. Remove the flywheel.
4. Remove the bearing carrier and gasket from the
outboard end of the crankcase. The outboard
bearing cup will come off with the bearing carrier
and will need to be removed with a bearing removal
tool.
5. Remove the key from the crankshaft and slide the
crankshaft through the outboard end of the
crankcase. The bearing cones can then be
removed with a bearing puller.
6. Remove the bearing cover plate from the inboard
end of the crankcase. The inboard bearing cup is
pressed into the crankcase and can be removed
with the use of a bearing removal tool.
7. To install the bearings:
a. Grease the outer edges of the bearing cups.
b. Referring to Figure 14 for the proper
orientation, carefully press the inboard bearing
cup into the crankcase until it is flush with the
outer surface of the crankcase.
c. Note the proper orientation and carefully press
the outboard bearing cup into the bearing
carrier assembly.
d. Press a bearing cone onto each end of the
crankshaft with the tapered end outward. The
bearing race should rest against the shoulder
on the crankshaft.
e. Lubricate the bearings with grease.
8. Install the crankshaft through the outboard end of
the crankcase.
9. With the oil pump assembly removed, install the
bearing carrier and new gasket. The bolt hole
positions ensure proper orientation. Tighten the
bolts evenly per Table 7 - Bolt Torque."
10. If the bearings have not been replaced, reinstall the
inboard bearing cover plate using the existing shim
set. If the bearings have been replaced, use a
thicker set of shims.
11. Rotate the crankshaft by hand to verify free
movement of the shaft.
a. If the crankshaft has an excessive amount of
end play, too many shims have been used.
Lateral crankshaft movement (end play)
between the bearings should be 0.0015 to
0.0030" (0.038 to 0.076 mm) . If necessary,
remove shims until the end play is within
tolerance.
b. If the crankshaft binds, or will not turn, not
enough shims have been used pushing the
bearing cup too tight against the bearing cone.
Remove the crankshaft from the crankcase and
drive the inboard bearing cup out toward the
inboard side of the crankcase. Reinstall the
crankshaft and the bearing cover plate using
additional shims as required.
12. Install the oil pump per the "Oil Pump Replacement"
section of this manual.
13. Reassemble the compressor according to the
"Compressor Assembly" section.
Figure 14 - Bearing Locations

OIL PUMP REPLACEMENT
588/A page 20/24
Figure 15 – Oil Pump
1. Remove the oil pump cover bolts and oil pump
cover.
2. Remove the oil pump assembly, drive cone and
spring.
3. Clean and inspect parts for wear or damage,
replace as necessary.
4. Place the spring and the drive cone in the end of
the crankshaft.
5. Note the slot in the end of the crankshaft and the
drive tab on the back of the oil pump assembly.
Install the oil pump assembly into the bearing
carrier with the tab and slot aligned.
6. Note the groove around outer edge of the oil pump
assembly and the stop pin in the oil pump cover.
Position the oil pump cover and new gasket with
the pin in the oil pump groove, rotating the oil pump
as needed. The bolt hole positions ensure proper
orientation of the oil pump cover.
7. BY HAND, tighten the oil pump cover bolts while
the pump cover is held flush with the bearing
carrier.
NOTICE: If by hand tightening, the oil pump
cover cannot be drawn flush with the bearing
carrier, the drive tab or the stop pin are
improperly aligned. DO NOT WRENCH
TIGHTEN OR THE OIL PUMP WILL BE
DAMAGED.
8. Once the oil pump cover is secured by hand, the
bolts may be evenly tightened per Table 7 - "Bolt
Torque."
EXTENDED STORAGE PROCEDURES
If a compressor is not to be put into service for some
time, or if a compressor is to be taken out of service for
an extended period, the following procedures should be
taken.
1. Fill the crankcase with rust inhibiting oil. (New
compressors are shipped from the factory without
oil.) Squirt oil on the piston rods and crossheads
through the nameplate opening. Loosen the V-
belts to relieve the load on the bearings. Rotate the
compressor by hand a few times to distribute the
oil.
2. Plug all openings and purge the compressor with
an inert gas such as nitrogen or dry air at about 50
psig (3.5 bar-g). This may be done at the factory if
requested. Leave the compressor pressurized to
prevent air or moisture from entering the unit.
NOTICE: Tag the unit with a warning that it is
pressurized.
3. If a purge gas is not available, fog oil into the
compressor suction while rotating the unit. Then
plug all openings to keep out moisture, insects, etc.
4. Turn the flywheel by hand a few revolutions once a
month to distribute the oil.
5. Store the unit under a plastic wrap on its wooden
shipping base up off the ground. If the unit was
boxed for export shipment, leave it in its box. An
indoor or covered storage area is preferable.
6. When the compressor is to be put in service, vent
the remaining purge gas and change the crankcase
oil. See the "Pre-Startup Checklist" and "Startup
Procedure" sections in this manual.
Figure 16 – Pressurized Compressor Tag
•
Compressor is pressurized with inert gas.
CAREFULLY bleed off gas BEFORE
attempting any service.
Hazardous pressure can
cause property damage,
serious personal injury
or death.