BLACKMER LB COMPRESSORS
Installation, Operation, and Maintenance Instructions
960474
INSTRUCTIONS CB5A-021
Section
Effective
Replaces
502
Mar 2013
Feb 2010
MODELS: LB161B, LB361B, LB601B,
LB162B, LB362C, LB602C,
& Discontinued LB602B
r130716
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 ................................................................. 12
Bolt Torque Table ................................................. 12
Crankcase Lubrication .......................................... 13
Setting the Oil Pressure........................................ 13
Compressor Disassembly ....................................... 14
Compressor Assembly ............................................ 15
Valve Replacement................................................... 17
Seal (Packing) Replacement ................................... 19
S3R Seal Replacement ............................................ 20
Bearing Replacement .............................................. 21
Oil Pump Replacement ............................................ 22
Extended Storage ..................................................... 22
Troubleshooting ....................................................... 23
SAFETY DATA
NOTICE
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.
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
Flammable gas can
cause death, serious
personal injury or
property damage
Hazardous
machinery can
cause serious
personal injury.
Hazardous or toxic
fluids can cause
serious injury.
Flammable gas and/or liquid can form
explosive mixtures with air causing
property damage, serious personal injury
or death
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
Hazardous pressure
can cause serious
personal injury or
property damage
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.
If handling hazardous or toxic fluids,
system must be flushed and
decontaminated, inside and out, prior to
performing service or maintenance
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns or
death
Disconnecting fluid or pressure
containment components during
compressor operation can cause
serious personal injury, death or major
property damage
Hazardous pressure
can cause serious
personal injury or
property damage
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
Hazardous gases
can cause property
damage, personal
injury or death
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
Minimum / Maximum RPM *
Displacement
@ min rpm - CFM (m3/hr)
@ max rpm - CFM (m3/hr)
Max. BHP (kw)
MAWP - psia (kPa)
Maximum Discharge Temperature
LB161B
LB361B
LB601B
LB162B
LB362C
LB602C, LB602B
350 / 825
350 / 825
350 / 790
Reduce maximum speeds by 9% for continuous duty operation.
7.16 (12.2)
16.9 (28.7)
10 (7.5)
15.3 (26.0)
36.0 (61.2)
15 (11)
350 (2,413)
350F (176C)
Bi-Directional
See Document CB240
Rotation Direction
Critical Dimensions
Table 1 - Compressor Data
CB5A-021
page 2/24
27.2 (46.3)
61.5 (104.5)
40 (30)
GENERAL INFORMATION
Figure 1 - Typical Compressor (LB361 shown)
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 by 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.
Figure 2 - Compressor Nameplate
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.
CB5A-021
page 3/24
GENERAL INFORMATION
An 11 character "I.D. No." identifies the construction of the compressor.
B
VALVES
Code Fields
Steel, w/ Liquid Relief
BA
1&2
O-RINGS
Field 3
Buna-N
B
GASKETS
Field 4
Aluminum
A
PISTON RINGS
Field 5
Carbon Filled PTFE
C
SEAL (PACKING) ORIENTATION
Field 6
All Lips up
1
SEAL MATERIAL
Field 7
PTFE
T
CYLINDER & HEAD
Field 8
Ductile Iron
A
GGG40.3 Ductile Iron
D
PISTON RODS
Field 9
Black Surface Steel
4
CRANKSHAFT & OIL FILTER
Field 10
No Oil Filter
A
Extended Crankshaft / No Oil Filter
B
Spin-on Oil Filter (std)
C
Ext. Crank / Oil Filter
D
OTHER
A
Field 11
Note: A 'Z' in any field indicates a non-standard option.
A
B
A
C
1
T
A
4
C
A
No model is available with all shown options.
Table 2 - ID Number Key
Table 3 - Year of Manufacture *
Suffix
P
Q
R
Year
1994
1995
1996
Serial Number: 6 digits and a suffix letter indicating the year of manufacture.
S
T
U
V
W
X
Y
Z
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
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.
CB5A-021
Hazardous gases
can cause property
damage, personal
injury or death
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.
page 4/24
GENERAL INFORMATION
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
NOTICE:
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
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.
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.
NOTICE:
This compressor shall be installed in accordance with
the requirements of NFPA 58 and all applicable local,
state and national regulations.
Install, ground and wire to local and
National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Hazardous voltage.
Can shock, burn or
cause death.
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.
CB5A-021
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.
page 5/24
INSTALLATION
COMPRESSOR FLYWHEEL
V-BELT DRIVES
Blackmer compressors are fitted with flywheels which
MUST be used regardless of the type of drive system
employed.
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
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
Capscrew
Torque
Size
Size
ft-lbs. (Nm)
3/8 – 16
30 (40.7)
SF
1/2 - 13
60 (81)
E
9/16 – 12
75 (101)
F
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
injury or death
Flywheel guard contact with moving
parts may be a source
of ignition in explosive atmospheres
causing severe personal injury or death
CB5A-021
Most Blackmer compressors are driven via V-belts
which must be properly aligned and tensioned.
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
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.
Operation without guards in place can
cause serious personal injury, major
property damage or death.
Hazardous
machinery can
cause serious
personal injury.
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.
5. PTO shafts MUST have guards installed.
page 6/24
INSTALLATION
Figure 4 Liquid Transfer
Flow Schematic
Figure 5 Vapor Recovery
Flow Schematic
Figure 6 - Typical Liquefied Gas Transfer Compressor
CB5A-021
page 7/24
INSTALLATION
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.
Hazardous gases
can cause property
damage, personal
injury or death
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 and
application compatibility:
 Brass for LP-Gas service
 Aluminum for anhydrous ammonia
 Steel, A.S.M.E. code stamped for both services,
and other applications.
Figure 7 –
Typical Liquid Trap
2. The above trap is fitted with a 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.
This type trap is needed if level gauges or automatic
drain systems are to be used.
4-WAY VALVES
Many liquefied gas compressors are used for both liquid
transfer and vapor recovery operations. An optional 4way valve is used to reverse the direction of flow
through the system when changing from liquid transfer
to vapor recovery. Both lubricated and non-lubricated
models are available. Lubricated models should be
lubricated every 6 months.
TEMPERATURE SWITCHES
LIQUID TRAPS
Compressors handling gasses containing 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.
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.
CB5A-021
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.
page 8/24
INSTALLATION
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
injury or death
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
personal injury.
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
injury or death
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.
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
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 via the
compressor nameplate opening. See "Crankcase
Lubrication" in this manual.
Discharge piping surface temperatures
may be hot during operation (over
158°F, 70°C). Temperatures should be
monitored and adequate warnings
posted.
Operation without guards in place can
cause serious personal injury, major
property damage or death.
Hazardous
machinery can
cause serious
personal injury.
Hazardous gases
can cause property
damage, personal
injury or death
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.
CB5A-021
page 9/24
Flywheel guard contact with moving
parts may be a source
of ignition in explosive atmospheres
causing severe personal injury or death
OPERATION
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".
Hazardous gases
can cause property
damage, personal
injury or death
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 Table 7 - "Bolt Torque."
CB5A-021
page 10/24
MAINTENANCE
Flammable gas can
cause death, serious
personal injury or
property damage
Hazardous
machinery can
cause serious
personal injury.
Hazardous or toxic
fluids can cause
serious injury.
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 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.
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
Explosive gas can cause property
damage, personal injury, or death.
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
Failure to disconnect and lockout
electrical power before attempting
maintenance can cause shock, burns
or death
Disconnecting fluid or pressure
containment components during
compressor operation can cause
serious personal injury, death or major
property damage
Extreme heat can cause personal
injury or property damage
Extreme Heat can
cause personal injury
or property damage
Hazardous gases
can cause property
damage, personal
injury or death
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
Overall Visual Check
Check Crankcase Oil Pressure
Check Suction and Discharge Pressures
Drain Distance Piece (Double-Seal Models)
Drain Liquid From Accumulation Points
Clean Compressor Cooling Fins
Check Crankcase Oil Level *
Check Mounting and Anchor Bolts
Check V-Belt Tension
Change Oil and External Oil Filter *
Check Inlet Filter/Strainer Element
Inspect Valves
Lubricate 4-way Valve (if equipped)
Lubricate Motor Bearings per Manufacturer's Suggestions
Inspect Motor Starter Contact Points
Daily
X
X
X
Weekly
X
X
X
Monthly
X*
X
X
6 Months
X*
X
X
X
X
Yearly
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.
Table 5 - Service Schedule
CB5A-021
page 11/24
MAINTENANCE
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.
Blackmer Torque Wrench Adaptors
798003 for LB160 Series Compressors
798004 for LB360 Series Compressors
798007 for LB600 Series Compressors
Piston
Piston
Piston
798010 for LB160 and LB360 Series Compressors
798011 for LB600 Series Compressors
Piston Nut
Piston Nut
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
Various
Hoist (useful)
Cylinder and Crosshead Guide
Table 6 - TOOL LIST
BOLT TORQUES FOR BLACKMER COMPRESSORS LBS-FT (Nm)
CrankBearing
Bearing
case
Cover
Carrier
Inspec.
Plate
Plate
Oil
Pump
Cover
Cross
Head
Guide
Piston
Cylinder Head
&
Nut
Valve
Cover
Plate
Valve
Hold
Down
Screw
Valve
Cap
Packing
Box
Hold
Down
Ring
Size
Con.
Rod
Bolt
160
30
(40.7)
30
(40.7)
35
(47.5)
7
(9.5)
12
(16.3)
25
(33.9)
25
(33.9)
20
(27.1)
40
(54)
--
120
(163)
80
(108)
75
(102)
360
35
(47.5)
30
(40.7)
35
(47.5)
7
(9.5)
12
(16.3)
35
(47.5)
35
(47.5)
40
(54))
40
(54)
35
(47.5)
80
(108)
80
(108)
75
(102)
600
45
(61)
30
(40.7)
40
(54)
7
(9.5)
12
(16.3)
40
(54)
40
(54)
40
(54)
60
(81)
35
(47.5)
80
(108)
80
(108)
75
(102)
Table 7 - Bolt Torque
CB5A-021
page 12/24
MAINTENANCE
Models
Quarts
Liters
LB161B, LB162B
LB361B, LB362C
LB601B, LB602B, LB602C
2
3
7
1.89
2.84
6.62
Table 8 - Oil Capacity
Mineral Based Oil - API Grade SN, SM, SL, SJ
ISO
Ambient
SAE
Product
Grade
Temperature
Figure 8 - Compressor Lubrication System
CRANKCASE LUBRICATION
Change the crankcase oil every 1,000 hours or 180
days, whichever is shorter. Under severe dusty, sandy
or wet operating conditions, the oil should be changed
every 500 hours or every 90 days.
If the crankcase oil becomes contaminated or diluted
due to gas leakage past the packing seals, the oil must
be changed more frequently. In such cases, change
the packing seals as soon as possible.
Non-detergent oils are recommended. Detergent oils
can be used providing the gas being handled does not
react with the detergent in the oil. If using a detergent
oil, be sure there is not a compatibility problem.
Ammonia, amine and imine gases are known to react
with many of the detergents in oil.
The oil used, detergent or non-detergent, should
be of high quality such as API grade SJ, SL, SM,
SN or similar.
API grade SA, SB, SC or similar oils should never
be used. Recycled oils should never be used.
Synthetic oils are acceptable; use the same guidelines
as mineral based lubricants. Consult factory for special
lubricating requirements.
100
30
80°F (27°C)
and above
46
20
32 to 80°F
(0 to 27°C)
32
10
0 to 32°F
(-18 to 0°C)
22 - 15
5-0
Below 0°F
(-18°C)
ISO
Grade
68
20+
Full Range
Table 10 - Oil Viscosity
Product
Mobil®
Rarus SHC
1026
or
equivalent
SETTING THE OIL PRESSURE (see Figure 8)
1. The oil pressure should be about 25 psig
(1.73 Barg).
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.
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 or nameplate
opening. DO NOT OVERFILL THE CRANKCASE!
The oil pump on these models will operate in either
direction of crankshaft rotation.
CB5A-021
SAE
Synthetic Oil
Ambient
Temperature
Mobil®
Rarus 427
or
equivalent
page 13/24
COMPRESSOR DISASSEMBLY
Hazardous
machinery can
cause serious
personal injury.
Hazardous pressure
can cause serious
personal injury or
property damage
Hazardous gases
can cause property
damage, personal
injury or death
Failure to disconnect and lockout
electrical power or engine drive before
attempting maintenance can cause
severe personal injury or death
Failure to relieve system pressure prior
to performing compressor service or
maintenance can cause serious
personal injury or property damage.
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.
CB5A-021
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 Oring 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.
See Table 10 - Wrist Pin Bushing Dimensions.
page 14/24
COMPRESSOR DISASSEMBLY
Compressor
Model
Bushing I.D.
Inches (mm)
LB161B, LB162B
LB361B, LB362C
0.8753 to 0.8756
(22.233 to 22.240)
LB601B, LB602C,
LB602B
1.2511 to 1.2514
(31.778 to 31.786)
12. To replace the crankshaft bearings, the crankcase
must be disassembled, and the crankshaft
removed. Refer to the "Bearing Replacement"
section of this manual.
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 until the pin begins to project through
to the inside of the crosshead assembly. (Use
an arbor press if available.)
c. Slide the connecting rod up inside of the
crosshead assembly and align the bushing with
the wrist pin.
d. Install 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.
CB5A-021
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 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, and
MUST be used on the LB602C. (see ‘Tool List’
table).
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 counterbored 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.
page 15/24
COMPRESSOR ASSEMBLY
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.
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.
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."
CB5A-021
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)
LB602C
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."
page 16/24
VALVE REPLACEMENT
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.
Failure to install compressor valves
properly can lead to component failure,
personal injury or property damage.
Hazardous pressure
can cause serious
personal injury or
property damage
Hazardous gases
can cause property
damage, personal
injury or death
Hazardous gases
can cause property
damage, personal
injury 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.
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.
CB5A-021
Figure 10 - LB161 or LB162 Valves
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.
page 17/24
VALVE REPLACEMENT
MODELS LB361B, LB362C, LB601B, LB602C or
LB602B
Figure 11 LB361, LB362, LB601 & LB602 Valves
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.
CB5A-021
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 re-torque the hold down screw. Replace
the valve cap and gasket.
page 18/24
SEAL (PACKING) REPLACEMENT
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.
5. S3R Seal Cup (LB602C only)
Disassembly
a. Remove the seal cup from the packing box by
removing the eight socket head capscrews.
b. Remove the retainer ring, spring, packing and
washers.
c. Remove the remaining two socket head
capscrews to remove the seal cup cover.
d. Remove the S3R seal from the seal cup.
Figure 12 - Typical Seal Assembly
Figure 13 - TYPE 1 Seal Orientation
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 Box Assembly
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.
CB5A-021
Fig. 13c – LB602C Packing Box Assembly
page 19/24
SEAL (PACKING) REPLACEMENT
Assembly
e. Clean the seal cup in a suitable solvent.
Inspect the bore for wear, roughness, or
corrosion.
f. Refer to the sketch of the lower packing box for
the proper location and orientation of the
packing components, then install the packing
rings, washers, and spring. Install the retainer
ring while using the handle end of a screwdriver
to compress the packing spring.
g. Install the S3R seal in the seal cup as shown
in figure 14a. Place the S3R seal on the
packing installation tool in the order shown in
figure 14b, with the upper segment toward the
tapered end of the installation tool. Insert the
installation tool, with the S3R seal, into the
seal cup, with the tapered end toward the
packing rings. Place seal cup cover on seal
cup and secure with two capscrews
h. Install the O-ring on the seal cup. Secure the
seal cup to the packing box with eight
capscrews.
6. Two-Seal Packing Box Assembly
a. Install the inner retainer ring of the lower
packing.
b. LB162B, LB362C, LB602B – 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.
LB602C –Attach the S3R seal cup assembly to
the bottom of the packing box.
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.
7. Packing Break-in
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. If possible, perform the packing break-in
at a lower speed – 400-500 rpm.
To lubricate the packing:
a. Remove the inspection plate from the
crosshead guide.
b. Run the compressor for 5 minutes then stop
the compressor for 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.
Do not insert objects or fingers in
inspection cavity. Can cause severe
personal injury
Figure 14a – Seal Cup Assembly
Hazardous
machinery can
cause serious
personal injury.
Hazardous gases
can cause property
damage, personal
injury or death
Figure 14b - S3R Oil Seal Installation
CB5A-021
Improper seal installation could release
explosive gas to the atmosphere
creating an explosion hazard, possibly
causing severe personal injury or death.
8. Proceed according to steps 5 through 15 of the
"Compressor Assembly" section.
page 20/24
BEARING REPLACEMENT
NOTICE: When replacing the bearings, the entire
bearing assembly, including the bearing cup and
the bearing cone, must be replaced and the
crankshaft endplay must be readjusted.
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:
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:
End Play at Room Temperature
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.
Figure 14 - Bearing Locations
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.
CB5A-021
13. Reassemble the compressor according to the
"Compressor Assembly" section.
page 21/24
OIL PUMP REPLACEMENT
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, care must be taken to protect the
compressor. The following steps must be taken for both
bare compressors and those already piped into a
system.
If proper storage procedures are not followed,
damage to the compressor may occur. Complete
compressor disassembly and replacement of rod
packing, bearings and other parts may be required.
1. Keep a written record storage procedures
performed – preferably on the unit itself.
2. Fill the crankcase with rust inhibiting oil. (New
compressors leave 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.
3. 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.
Check the unit monthly and add additional purge
gas as needed.
NOTICE: Tag the unit with a warning that it is
pressurized.
CB5A-021
4. 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.
5. Turn the flywheel by hand a few revolutions
once a month to distribute the oil.
6. 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.
7. Placing the Compressor back in service.
When the compressor is to be put in service, vent
the remaining purge gas and change the crankcase
oil. Follow the "Pre-Startup Checklist" and "Startup
Procedure" sections in this manual.
Hazardous pressure can
cause property damage,
serious personal injury
or death.

Compressor is pressurized with inert gas.
CAREFULLY bleed off gas BEFORE
attempting any service.
Figure 16 – Pressurized Compressor Tag
page 22/24
TROUBLESHOOTING
PROBLEM
Low
Transfer
Rate
No
Flow
Knocks or
Other
Noises
No Oil
Pressure
STEP PROBABLE CAUSE
WHAT TO CHECK
IF PROBLEM
STILL EXISTS
GO TO STEP ...
1
4-Way Valve Leaking
(when equipped)
Lubricate with a stick lubricant compatible with
material being transferred.
2
2
Worn or Broken Piston Rings
Check condition of rings by restricting discharge
line. If pressure increases slowly, rings are
probably faulty.
3
3
Plugged Strainer
Clean screen as necessary.
4
4
Compressor Valve Faulty
Remove and inspect for broken or worn springs,
discs, or bodies.
5
5
Liquid Relief Valves Need
Adjusting
Adjust per instructions in "Valve Replacement."
6
6
Compressor Drive Slipping
Tighten belts, check for sheared keys, loose keys
or loose flywheel.
7
7
Piping Improperly Designed or
Installed
Use proper pipe sizes.
8
8
Liquid Trap Full
Drain liquid trap through drain valve. Relieve
vacuum through bleeder valve on top of liquid trap.
9
9
Excess Flow Valves Slugged
Stop the compressor to let the excess flow open.
Installation of a valved bypass line between the
suction and discharge lines my be necessary.
10
Loose Valves
Tighten valve hold-down screws.
11
11
Worn Internal Parts
Inspect through inspection plates and repair as
necessary.
4
12
Oil Pump Relief Valve Not Properly
Set oil pump relief valve.
Set.
13
Oil Pump Not Working
Check the Oil Pump drive tab or stop pin for
damage.
14
14
Low Oil Level
Check and fill as necessary
15
Clean Inlet Strainer
6&7
13
15
Dirty Inlet Strainer
Gas
Leaking
from
Crankcase
Breather
16
Faulty/Worn Packing
Replace Packing.
17
17
Piston Rod Scored
Replace crosshead assemblies and packing.
18
18
Improper Seal Arrangement
See "Seal Arrangements."
---
Relief
Valve
Actuates
19
Valve Closed Downstream of the
Compressor
Open Valve
20
20
Line Blockage Downstream of the
Compressor
Locate Blockage and Correct
---
21
Loose/Broken Mounting or Anchor
Bolts
See “Mounting the Compressor Unit“
22
22
Improper Mounting
Ensure base is supported full length. See
"Mounting the Compressor."
23
23
Improperly Aligned V-belt Sheaves See "V-Belt Drives"
24
24
Improperly Installed Flywheel
See "Compressor Flywheel"
25
25
Nonfunctioning Valves
Replace or repair valves.
---
Shake
or Vibration
CB5A-021
page 23/24
ATEX Declarations
Compressors
Page Number
Form 576
Effective
February
2012
Replaces
Section
June 2010
Forms
Blackmer, A Dover Company,
1809 Century Avenue S.W., Grand Rapids, Michigan 49503-1530, United States of America
DECLARATION OF
CONFORMITY
As defined by the ATEX directive 94/9/EC
Herewith we declare that all Blackmer LB and HD
compressor product lines to which this declaration relates
are in conformity with the provisions of the ATEX
Directive 94/9/EC as of 01 July 2003. This equipment is a
reciprocating compressor for liquefied gas transfer or gas
compression applications. This device is not intended to act
as a safety accessory.
Applied Harmonized Standards:
EN1127-1, EN13463-1
DECLARATION OF CONFORMITY
As defined by the Machinery Directive 2006/42/EC
Herewith we declare that all Blackmer LB and HD
compressor product lines to which this declaration relates
are in conformity with the provisions of the Machinery
Directive, 2006/42/EC Annex IIA as of 17 May 2006. The
above equipment is a reciprocating compressor designed for
liquefied gas transfer or gas compression applications. This
device is not intended to act as a safety accessory.
This component must not be operated until the machine into
which it is incorporated has been declared in conformity
with the provision of the directive.
Applied Harmonized Standards:
EN1012-1, EN292
Date:
29 February 2012
Thomas Madden.
Vice President and General Manager
Date:
29 February 2012
Thomas Madden.
Vice President and General Manager
ATEX/ Machinery Directive Notifications:
Maximum Surface Temperature: An ATEX compliant temperature switch must be installed if the compressor is
used in an ATEX zone. It is the end users responsibility to ensure the compressor does not exceed the
temperature limits for the relevant ATEX zone. Closed inlet or outlet valves can result in excess compressor
surface temperature conditions.
Intended Use: Blackmer compressors are intended for use in liquefied gas transfer or gas compression
applications. The compressor must be operated in systems, with gasses and at conditions for which it is
specifically designed and sized.
Possible Misuse Warning: The compressor must only be installed in systems designed for its intended use.
Mechanical Ignition Sources: Guards, intended to protect from personal injury from rotating components, must
be fabricated from ATEX compliant materials to prevent a potential ignition source. The compressor and its drive
system must be properly grounded to prevent electrostatic discharge. The compressor has internal parts that rub
together. These parts require proper viscosity lubricant to lubricate the rubbing surfaces. Compressor must be
properly maintained and lubricated, see IOM (Installation, Operation, & Maintenance Instructions) for service
information.
Sound Measurements: Sound Levels for gas compression equipment vary greatly, depending on operating
conditions, piping system design, foundation design, etc. You can expect the following sound levels when
operating a Blackmer compressor at its’ maximum rated speed and discharge pressure. Sound levels are
measured at 1 meter from the compressor and 1.6 meters from the foundation per European Machinery Directive
2006/42/EC. Maximum Noise Level: 85 dba
Equipment Marking: All compressor models are classified Group II category 2, Gas Group IIB and have a
temperature limit of 176 C. Compressors are marked “Ex II 2 G IIB 176 C MAX ”
Compressor Models Covered: LB, HD
Technical file is archived with LCIE notified body number 0081, file no. LCIE 60052731-553645.
Telephone: (616) 241-1611 / Fax: (616) 241-3752 / E-Mail: blackmer@blackmer.com
www.blackmer.com