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1 0997 CB259

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Earlier models were fitted with the finned tube intercooler as shown on the right. ... Connecting rod has cast-in lube channels, big end to small end ... – PowerPoint PPT presentation

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Title: 1 0997 CB259


1
HD372 Compressor
This presentation is a simplified description of
the disassembly of a Blackmer HD372A. The
current production model is the HD372C (March
1997). Significant changes are needle bearings
at the wrist pin, a larger wrist pin 1 instead
of 7/8 and a full-flow, spin-on, oil filter as
standard equipment. With some minor differences,
this presentation is also appropriate for the
other Blackmer 1 and 2-stage models, with the
exception of the HD942, double-acting
compressor. Select one of the following
Hilites Only
Detailed Text
2
HD372 Industrial Compressor
3
LITERATURE
  • Have the literature for your machine at hand
  • Parts lists
  • Installation, Operation and Maintenance manual
  • Call your Blackmer distributor for literature

4
LITERATURE
  • Be sure that you have the literature you require
    before starting to work on the compressor.
    Locate the parts list and Installation, Operation
    and Maintenance instructions. In addition, you
    may have received additional instruction sheets
    with your machine that further describe such
    items as valves and packing.
  • If you do not have all of the necessary
    information, call your Blackmer distributor.

5
Tools
  • Use standard tools for small machines
  • Blackmer spanner (p/n 790535) for valve hold down
    screws
  • Blackmer adjustable spanner with 1/4 pins (p/n
    790316)
  • Inside snap ring pliers

6
Tools
  • Blackmer offers a complete tool kit which has all
    of the hand tools necessary to dismantle the
    machine.
  • The tools normally required for small machine
    service will be adequate for the work on an HD
    compressor. A small strap wrench is useful and a
    good spanner. The Blackmer p/n 790535 spanner is
    used for valve hold down screws. The Blackmer
    spanner p/n 790316 has 1/4 pins and is used for
    piston removal. A flat scraper and inside snap
    ring pliers are also needed.
  • On larger machines a small hoist might be needed
    for one man to do the job, depending on the
    environment. Generally, two men can handle the
    disassembly of any Blackmer machine.

7
Nameplate
  • Model number
  • Serial number
  • I.D. number
  • Defines construction
  • Oil capacity
  • Rod inspection access

8
Nameplate
  • On the side of every Blackmer compressor is a
    nameplate which doubles as an access opening for
    inspecting the piston rod.
  • The nameplate will show the compressors model
    number, serial number, ID number, and oil
    capacity.
  • The compressor ID is a coded number that fully
    describes the compressors construction.
  • Make certain that you have these identifying
    numbers when you call your Blackmer distributor
    for parts or service assistance.

9
HD372 Flywheel Side
  • Two-stage 20 bhp (11 kw )
  • Non-lubricated 400-825 rpm
  • Reciprocating air-cooled
  • Single-acting various gases

10
HD372 Flywheel Side
  • The HD372A is a two-stage, non-lubricated,
    reciprocating compressor designed to handle many
    different gasses. It is rated for up to 20 bhp
    (15kw) and operates generally between 400-825
    rpm.
  • The HD372A is an air-cooled machine and is
    normally fitted with an air-cooled intercooler
    for the compressed gas. The intercooler shroud
    was removed for these photos.
  • Some process application will require engineered
    intercooling systems with heat exchanger and
    liquid separation equipment. These are provided
    by the equipment packager as part of an
    integrated system.

11
HD372 Oilpump Side
  • Other Models Available
  • Liquid-cooled HDL372
  • Smaller HD17210 bhp (7.5 kw)
  • Larger HD612 and HDL61240 bhp (30 kw)

12
HD372 Oilpump Side
  • Blackmer offers a variety of two-stage
    compressors.
  • The HDL372 is similar to the HD372 shown in this
    presentation but is liquid cooled. It has a
    water cooled head and cylinder for lower metal
    temperatures and longer life of wearing parts. It
    is also fitted with a water cooled intercooler to
    keep gas temperatures at acceptable levels for
    continuous duty.
  • The smaller HD172 air-cooled model is rated for
    10 bhp (7.5 kw).
  • The larger HD612 (air-cooled) and HDL612 (liquid
    cooled) models are rated for 40 bhp (30 kw).

13
Head with Standard Suction Valves
The HD372 is a two cylinder compressor. Each
cylinder has a suction and discharge valve. These
operate automatically and independently for each
cylinder.
14
Head with Suction Valve Unloaders
  • Loadless starting
  • Constant speed operation

15
Head with Suction Valve Unloaders
  • Optional suction valve unloaders allow the
    compressor to be deactivated in service. That
    is, gas that is drawn into the cylinder during
    the suction stroke is expelled through the
    suction valve on the discharge stroke and does
    not pas through the machine into the discharge
    line. This is accomplished by holding the
    compressor suction valve plates open throughout
    the full cycle. The unloader mechanism does this
    mechanically and can be powered by compressed gas
    from the discharge storage or an independent
    source, as required.
  • The suction valves can be unloaded to produce
    no-load starts or reduced capacity operation on
    demand.

16
Removing Standard Valves
  • Cap O-ring
  • Remove hold down screw from valve cap

17
Removing Standard Valves
  • Remove the valve caps to access the valves.
  • After the valve caps have been removed, the
    valve hold down screws can be removed with a
    spanner wrench (such as a Blackmer p/n 790535).
  • To prevent possible damage to the valves during
    reassembly, the hold down screws must be
    completely removed from the valve cover plates.
  • Note the O-ring under each cap these should be
    replaced rather than reused. The compressor I.D.
    number on the nameplate contains a code for the
    O-ring material used.

18
Valve Cover Plates
  • Replace O-rings
  • Reassemble covers before installing
  • the hold down screws

19
Valve Cover Plates
  • Once the valve caps and hold down screws have
    been removed, the cover plates can be removed.
  • Note the O-ring under the valve cover plate.
    Typically, O-rings are not reusable and should be
    replaced any time the cover plates are remove.
  • During reassembly the valve cover plates must be
    reinstalled first, before the hold down screws
    are installed.

20
Valves
  • Valve cages
  • Valves
  • Always replace gaskets

21
Valves
  • Once the cover plates removed, the valve cage,
    valve and gasket may be taken out.
  • Make certain the valve gaskets are removed with
    each valve. When they are left in the head they
    may be difficult to see. The valve gaskets are
    normally iron although other materials are used
    as required. Valve gaskets should be replaced
    when the valves are removed.

22
Removing Suction Valves with Unloaders
  • O-ring
  • Remove hold down screw from valve cap

23
Removing Suction Valves with Unloaders
  • Use a strap wrench to remove the unloader
    assembly and its O-ring. Alternately, a bar can
    be levered against a pair of unloader cap screws.
  • Once the unloader assembly is removed, the valve
    hold down screw can be removed.
  • When assembling, make sure the cover plate is
    firmly secured before reinstalling the hold down
    screw.

24
Suction Valve Removal
  • Valve cage
  • Unloader plunger
  • Valve with actuator
  • Always replace gasket

25
Suction Valve Removal
  • Once the hold down screw is removed, the cover
    plate and its O-ring can be removed. Under the
    cover plate is the valve cage, unloader plunger,
    suction valve with unloader actuator, and a valve
    gasket.

26
Suction Valve Unloaders
  • PTFE Unloader piston seals
  • All Stainless Steel Parts

27
Suction Valve Unloaders
  • The unloader assembly consists of a cap, body
    with O-ring, and a piston with two spring loaded
    PTFE seals. The open side of the seals should
    face outward. The unloader actuator and spring
    are held to the valve with a snap ring.
  • The unloader cap, body piston, actuator and
    spring are all stainless steel.

28
Disassembled Valves
  • Valve components
  • seat
  • bumper
  • springs
  • plate
  • post
  • nut
  • lock washers

29
Disassembled Valves
  • A disassembled suction valve is shown on the
    left, a discharge valve on the right.
  • Each valve consists of a seat, stop ( bumper ),
    springs, plate, threaded post, nut and locking
    washers.

30
Standard Intercooler
  • Radiator or Finned tube types
  • All steel construction

31
Standard Intercooler
  • The intercooler is readily unbolted from the
    cylinder head at two locations. Note the PTFE
    intercooler flange O-rings.
  • Earlier models were fitted with the finned tube
    intercooler as shown on the right. Standard
    intercoolers are all steel construction and rated
    for the first stage discharge pressure.

32
Cylinder Head
  • O-ring head - to - cylinder seals

33
Cylinder Head
  • To remove the cylinder head, unbolt the two
    center head bolts from the top of the head and
    the eight head bolts from the bottom of the head.
    After the cylinder head bolts have been removed,
    the head may be lifted from the cylinder. Note
    that the head is sealed to the cylinder by an
    O-ring at each cylinder bore.

34
Piston Removal
  • Remove piston nut with 1/4 pin spanner
  • Piston nut has nylon locking insert
  • Use spanner to unscrew piston
  • Washer and shims adjust piston end travel
  • Piston rings have expanders

35
Piston Removal
  • The piston nut is removed with an adjustable
    spanner. This spanner has two 1/4 pins which
    fit into holes in the top of the piston nut. Note
    the nylon locking device on the piston nut.
  • Once the piston nut has been removed, the same
    spanner can be used to unscrew the piston from
    the rod. There is a thick washer under each
    piston and one, or more, shims. These shims
    adjust the height of the piston in the cylinder.
    This is referred to as the deck height. Unless
    a major part has been changed, the deck height
    should not need adjustment. Change of the piston,
    crosshead assembly, cylinder body, main bearings
    or crankshaft may require adjustment of the deck
    height.
  • Rotate the crankshaft to bring the other piston
    to top-dead-center for removal. Each piston is
    fitted with three piston rings. Each ring has a
    stainless steel expander between it and the
    piston.

36
Piston and Cylinder
  • Ring gap is 180o from expander gap
  • Stagger ring gaps around piston
  • Two O-rings cylinder-to-crankcase
  • Under-piston channel between bores

37
Piston and Cylinder
  • When installing he piston rings and expanders
    make sure that each piston ring is installed with
    its gap 1800 from the expander gap. Also, the
    piston ring gaps should be staggered around the
    piston.
  • With the pistons removed, the cylinder can be
    unbolted and removed to gain access to the
    packing boxes. Two O-rings seal the bottom of the
    cylinder.
  • Notice the passage in the bottom of the cylinder
    between the bores. This allows gas to move from
    one cylinder to the other as the pistons move up
    and down.

38
Packing Box Removal
  • Remove hold down screw with spanner
  • Hold down screw has nylon locking insert
  • O-rings seal packing box at each end

39
Packing Box Removal
  • The packing boxes are secured by a hold down
    screw which is removed with the same adjustable
    spanner that was used on the piston nut and
    piston. Note that the hold down screw also has a
    nylon insert that keeps it in place.
  • The packing boxes may now be lifted off the rod.
    O-rings seal the top and bottom side of the
    packing boxes.

40
Packing Box disassembly
  • Depress spring with screwdriver while removing
    retainer ring

41
Packing Box disassembly
  • Remove the seals (packing) from the box as
    follows
  • Use a pair of inside snap ring pliers to remove
    the top snap ring. A screwdriver handle can be
    used to depress the spring to make this operation
    easier.
  • Turn the packing box over to remove the bottom
    seal.

42
Rod Seals
  • V - ring type
  • Spring is next to the convex surface
  • Oil deflector ring between seals

43
Rod Seals
  • With the snap ring removed, the top washer,
    spring, middle washer, seal rings, bottom washer
    and retainer ring can all be removed.
  • The seal consists of three types of rings. One
    ring is a male ring, next a series of V-rings,
    then a female ring.
  • The upper and lower seals are the same. The seal
    orientation will depend on the operating
    pressures. The spring and washer, however, always
    press against the male ring.
  • The red oil deflector ring fits on the piston rod
    between the two seals. The holes in the side of
    the packing box allow the oil deflector ring to
    be guided onto the rod as the box is installed.

44
Piston Rod Inspection
  • Piston rods and tops of the crossheads are
    visible through the nameplate opening

45
Piston Rod Inspection
  • The piston rods and the top on the crossheads are
    visible through the opening when the nameplate is
    removed.

46
Crankcase and Crosshead
  • Gasket between crankcase and guide

47
Crankcase and Crosshead
  • By removing the crosshead guide, access is given
    to the crosshead / piston rods.
  • The flat gasket that fits on top of the crankcase
    may require the use of a flat scraper to remove
    completely.

48
Oil Pressure adjustment, Strainer
  • Oil pressure adjustment screw and lock nut
  • Clean the oil strainer
  • Oil drain plug
  • Oil filter now standard

49
Oil Pressure adjustment, Strainer
  • The oil pressure adjustment screw complete with
    O-ring, lock nut, spring and ball fits into the
    bearing carrier. Turning the screw inward
    (clockwise) increases the oil pressure setting.
  • The oil pickup tube with washers, O-ring and
    strainer fits in the crankcase under the bearing
    carrier. If any foreign material is noticed in
    the strainer, its source should be quickly
    identified to prevent reoccurrence of the
    problem.
  • The pipe plug next to the oil pickup tube opening
    is the crankcase oil drain.

50
Crankcase Access
  • Access cover and gasket
  • Dipstick
  • Remove lower bearing caps, lift crosshead and
    connecting rod assembly

51
Crankcase Access
  • The oil dipstick is located adjacent to the
    access cover. In earlier models, it was located
    in the access cover. The oil viscosity and
    capacity are found in the Instruction Manual.
  • Removal of the crankcase access cover and gasket
    permits access to the connecting rods. After the
    bottom cap of the connecting rod has been
    removed, the piston rod / crosshead and the top
    half of the connecting rod may be lifted off from
    above.

52
Crosshead and Connecting Rod
  • Connecting rod has cast-in lube channels, big
    end to small end
  • Connecting rod is Ductile Iron
  • Crosshead is now cast iron
  • Dont remove piston rod from crosshead

53
Crosshead and Connecting Rod
  • The connecting rod and crosshead assembly are
    separated by removing the wrist pin in a bench
    press. Note that the wrist pin has a plastic
    retainer plug on each end.
  • The piston rod is permanently secured to the
    crosshead at the factory and no attempt should be
    made to separate them. Final machining is done to
    the assembled crosshead / rod which precludes
    their reassembly once separated. The grooves in
    the crosshead are lubrication channels.
  • The small end of the connecting rod shown here
    has a bronze bushing. This is used on some
    models. Current production for the HD362, 342 and
    372 incorporates a steel needle bearing in the
    connecting rod small end.

54
Crosshead and Connecting Rod (contd)
  • Wrist pin is pressed in or out of the crosshead
  • Wrist pin bushing is pressed in and honed to the
    proper bore
  • Bushing oil hole must align with connecting rod
    feed hole
  • Some models have needle wrist pin bearings

55
Crosshead and Connecting Rod (contd)
  • The ductile iron connecting rod has a cast in
    tube to route oil from the big end to the wrist
    pin.
  • A precision insert split shell bearing is located
    at the big journal end. Tabs on the bearing
    shells fit into slots in the rod and bearing cap.
    These retain the shells and align the oil feed
    holes.
  • The HD372A uses a bronze bushing on a steel wrist
    pin at the small end of the conrod. A steel
    needle bearing is used on some models. The oil
    admission hole in the bearing or bushing must
    align with the oil supply hole in the connecting
    rod small end. When the bronze wrist pin
    bushing is replaced, it must be honed to final
    dimension after being pressed into the connecting
    rod
  • The rod and cap are matched sets, do not mix.
    Match marks must align when assembling bearing
    cap to connecting rod.

56
Bearing Carrier
  • Carrier and oil pump are removed as an assembly
  • Slot in carrier fits into tang at crankshaft end

57
Bearing Carrier
  • The entire bearing carrier / oil pump assembly,
    with gasket, can be removed intact. This allows
    the crankshaft to be removed.
  • Note the slot in the end of the oil pump drive
    shaft. This slot must align with the drive tang
    in the end of the crankshaft during installation.

58
Oil Pump(HD372A)
  • May be installed for either rotation direction
  • Rotate cover 180 for opposite rotation direction

59
Oil Pump(HD372A)
  • This photo shows the oil pump used in the HD372A.
    Models HD372B and HD372C use a different pump.
  • Remove the oil pump cover and O-ring to withdraw
    the oil pump. Notice the small O-ring on the
    pump shaft and the bronze bushing in the bearing
    carrier.
  • The oil pump cover can be installed with either
    left or right rotation arrow visible. When
    installing the cover, make sure that the arrow at
    the TOP of the cover indicates the desired
    rotation direction.

60
Crankshaft Removal
  • Pressure lubrication holes at the journal
    bearings
  • Oil spray nozzles on the crankshaft for the
    crossheads
  • Crankcase breather vent

61
Crankshaft Removal
  • Remove the crosshead and connecting rod
    assemblies to proceed with the crankshaft
    removal. Notice the lubrication holes on the
    bearing journals. Also note the spray nozzles on
    the crankshaft. The spray nozzles lubricate the
    crosshead guide and the main roller bearings.
  • The top of the crankcase is fitted with a
    breather which prevents entry of foreign material
    into the crankcase but allows the release of
    crankcase pressure.

62
Bearing Cover Plate
  • Located at flywheel end
  • Shims adjust main bearing preload
  • Shims are reusable. Adjusted for new
  • main bearing or new crankshaft
  • Cover contains crankshaft oil seal

63
Bearing Cover Plate
  • Remove the crosshead and connecting rod
    assemblies to proceed with the crankshaft
    removal. Notice the lubrication holes on the
    bearing journals. Also note the spray nozzles on
    the crankshaft. The spray nozzles lubricate the
    crosshead guide and the main roller bearings.
  • The top of the crankcase is fitted with a
    breather which prevents entry of foreign material
    into the crankcase but allows the release of
    crankcase pressure.

64
End of Presentation
1809 Century Avenue Grand Rapids, MI, USA
49503 Ph 616-241-1611 Fax 616-241-3752 www.black
mer.com
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