Man Mi-100en En1 01

Burckhardt Compression AG
Im Link 5
P.O. Box 65
CH-8404 Winterthur
Switzerland
Tel. +41 (0) 52 262 55 00
Fax +41 (0) 52 262 00 53
www.burckhardtcompression.com
Instruction for Field

Service Engineers
MI-100en
for
Laby® Compressors
Type K/D/E
Original instructions
Table of Contents
Table of Contents
1 Components of Laby® Type D + E with Bolted

Connections Crosshead – Piston Rod
2 Components of Laby® Type D + E with

Wedges Type Crosshead – Piston Rod
3 Components of Laby® Type K
4 Dismantle Crankshaft sidewards of Laby®

Type K and small Type D
5 Earlier Laby® Compressors with Thick

Bearing Shells
6 Appendix
7 Index
02.12.2011 Rev. 002/kneubuehler_e MI 100en

Table of Contents
MI 100en Rev. 002/kneubuehler_e 02.12.2011

Components of Laby® Type D + E with Bolted Connections Crosshead
– Piston Rod

Bolted Connections Crosshead – Piston
Rod
1.1 Dismantling and Assembling Overview . . . . . . . . . . . . . . . 3

1.1.1 Marking of Compressor Components. . . . . . . . . . 4
1.2 Switch Off Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Switch Off Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Non-Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Suction Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Controlled Suction Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.7 Suction Valves and Discharge Valves. . . . . . . . . . . . . . . . . 27
1.8 Cylinder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.9 Frame Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.10 Drain Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.11 Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.12 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.13 Piston and Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.13.1 SUPERBOLT® Tensioner . . . . . . . . . . . . . . . . . . . 67
1.13.2 Tightening Torques and Method . . . . . . . . . . . . . 72
1.13.3 Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . 74
1.14 Internal Gas Leakage Pipes . . . . . . . . . . . . . . . . . . . . . . . . 75
1.15 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.16 External Gas Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.17 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.18 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.19 Guide Bearing Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.20 Guide Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.21 Connecting Rod Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.22 Crosshead and Connecting Rod. . . . . . . . . . . . . . . . . . . . . 95
1.23 Crosshead Pin Bearing (with Cylinder Removal) . . . . . . . . 97
1.24 Crosshead Pin Bearing (without Cylinder Removal). . . . . . 98
1.25 Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.26 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.27 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.28 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.29 Oil Trap and Crankshaft Seal . . . . . . . . . . . . . . . . . . . . . . . 107
1.30 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.31 Crankshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.32 Axial Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.33 Dismantle Crankshaft Upwards . . . . . . . . . . . . . . . . . . . . . 120
02.12.2011 Rev. 002/kneubuehler_e MI 100en 1–1

– Piston Rod
1–2 MI 100en Rev. 002/kneubuehler_e 02.12.2011

– Piston Rod
Dismantling and Assembling Overview
1.1 Dismantling and Assembling Overview

Dismantling Overview This chapter follows a step by step philosophy to explain the complete dis-
mantling or assembling, respectively. It starts with the procedure to switch
off the compressor and ends up with the dismantling of the crankshaft as
the last unit.
Prerequisites before Before you start any inspection or repair activity take all safety measures
Dismantling according to plant operator.
DANGER
Unintended start-up of compressor is possible!
 Before beginning any inspection or repair, switch off the power at the
switch box and padlock the switch in the OFF position.
Prerequisites before
Assembly
CAUTION
Contamination of process gas!
All components coming in contact with process gas must be checked for
cleanliness prior to their installation.
 When performing overhauls or exchanging spare parts, make sure that
all significant surfaces have been cleaned according to the cleaning
specification prior to assembly or installation.
 If in doubt about cleanliness, repeat cleaning procedure.
Important Markings
Compressor parts which must always be fitted in the same position are
numbered. Please refer to section 1.1.1 Marking of Compressor Compo-
nents.
Lubricants, Tightening
Torques and Methods
For applicable lubricants, mandatory tightening torques as well as appro-

priate tightening methods: refer to the relevant Instruction Manual.

– Piston Rod
1.1.1 Marking of Compressor Components
numbered.
On the assembled compressor, these markings must lie on the right hand
side when looking from the non-drive end towards the drive end.
The numbering of the individual parts starts with a V1 from the non-drive
end and ascends to V2, V3 etc. towards the drive end. Furthermore, the se-
rial no. is marked on important compressor components.
Some parts are only marked with a matching number, like the following:
• Connecting rod – connecting rod bearing shells
• Crankshaft main bearing – bearing cover
• Connecting rod – connecting rod bolts

– Piston Rod
10
11
12
13
14
LD_XX_0008b_01
Fig. 1-1 Important markings on a Laby® compressor type D
1 Cylinder cover 8 Crosshead

2 Upper piston crown 9 Lower piston rod nut
3 Gland flange 10 Crosshead pin
4 Cylinder (serial no. only) 11 Frame (serial no. only)
5 Guide bearing 12 Base plate (serial no. only)
6 Name plate 13 Connecting rod
7 Upper piston rod nut 14 Connecting rod cover

– Piston Rod
Switch Off Compressor
1.2 Switch Off Compressor

Status Completed activities: none
Special Tools none
Switch Off 1. Switch off the compressor.

2. Before you start any maintenance or trouble shooting activity take all
safety measures according to the relevant Instruction Manual.
Required Checks Make sure, that:

• the compressor and the surrounding plant components are in good
condition,
• all compressor parts are fixed correctly and
• no personnel is staying within danger zones.
Switch On 1. Re-insert the safety switch.

2. Start the compressor according to Control Description.
Final Checks See “Control Description” in the relevant Instruction Manual.
1.3 Switch Off Cooling System

Status Completed activities:
• 1.2 Switch Off Compressor
Special Tools none
Switch Off 1. Switch off the cooling system by turning the main switch to off position.
 The compressor is now switched off and ready for maintenance
2. If the dismantling of the coolant pipes is required, then drain the
coolant.
Please remember to collect the glycol mixture if used in your cooling
system!
Switch On and Final Please refer to the relevant Instruction Manual.

Checks

– Piston Rod
Non-Return Valve
1.4 Non-Return Valve

Special Tools none
Dismantle Non-Return Dismantle the non-return valve according to following figure:

Valve Variant A
2 3 4 5 6 7 8
XA_L2_0003b_01
Fig. 1-2 Non-return valve (Variant A)
1 Flow direction 5 Ring

2 Threaded bolt 6 Housing
3 Flange 7 Non-return valve
4 Gasket 8 Nut
Contrary to the assembly of plate valves installed in the compressor, the

non-return valve is assembled without springs (elimination of whistling
noises).

– Piston Rod
Non-Return Valve
Dismantle Non-Return Dismantle the non-return valve according to following figure:

Valve Variant B (especially
for O2 Applications) 2 3 4 5 6 7
XA_L2_0002b_01
Fig. 1-3 Non-return valve (Variant B)
1 Flow direction 5 Housing

2 Threaded bolt 6 Non-return valve
3 Flange 7 Nut
4 Gasket
Required Checks Check the marking “X5”:
1 Valve guard
1
2 Damper disc
3 Valve disc
HS 1
4 Valve seat
2 5 Marking X5
HS 2
HS 3 HS Distance discs
3
4
XA_CX_0027b_01
HS
Fig. 1-4 X5 Marking

– Piston Rod
Non-Return Valve
Assemble New or Used

Parts 1 Correct position
1 2
2 Incorrect position
XA_CX_0030b_01
Fig. 1-5 Positioning of damper disc
and valve disc
6
XA_L2_0006b_01
Fig. 1-6 Components of non-return valve
1 Nut 5 Valve disc

2 Washer 6 Valve seat
3 Valve guard 7 Center bolt
4 Damper disc 8 Distance disc

– Piston Rod
Non-Return Valve
Thread diameter Ma [Nm]
mm min max
12 36 45
16 90 110
20 180 220
24 300 350
Tab. 1-1 Tightening torques, only valid if Burckhardt Lubrication Grease BLG05 is
used
1 – 10 MI 100en Rev. 002/kneubuehler_e 02.12.2011

– Piston Rod
Suction Valve Actuator
1.5 Suction Valve Actuator

Special Tools Small hook or prepared screw driver as shown in Fig. 1-7.
XA_C3_0011a_01
Fig. 1-7 Special tool
1 2
XA_T9_0030b_01
Fig. 1-8 Assembling device for TURCITE step seal
1 Bar
2 Bush
T97182 (can be ordered at Burckhardt Compression AG)
02.12.2011 Rev. 002/kneubuehler_e MI 100en 1 – 11

– Piston Rod
Dismantle
Option (18)
19 1
2 (C) 17
2 (D) 16
15
Mode A 3
14
3
Mode A
4
13
12
Option 6
9 11
10
XA_C3_0030b_02
Fig. 1-9 Suction valve actuator for low temperature application
1 Bonnet 12 Guiding band

2 Spring 13 USIT ring
3 Piston ring GLYD 14 Actuator piston (Mode A)
4 Housing 15 O-Ring
5 Vent valve 16 Screw
6 Turcite Stepseal 17 Vent
7 Circlip (Option) 18 Position indicator (Option)
8 Scraper ring (Option) 19 Plug
9 O-Ring C Inner spring
10 Nipple (guiding piece) D Outer spring
11 Pressure pin

– Piston Rod
Variant without
Intermediate Piece Option (18) 19 1
2 (C) 17
2 (D) 16
15
Mode A 3
14
3
Mode A
4
13
12
Option 6
11
9
10
XA_C3_0042b_02
Fig. 1-10 Suction valve actuator

4 Housing 15 O-Ring
9 O-Ring C Inner spring
10 Nipple (guiding piece) D Outer spring
11 Pressure pin

– Piston Rod
Variant with Intermediate

Piece Option (18)
19 1
2 (C) 17
2 (D) 16
15
Mode A 3
14
3
Mode A
4
13
12
Option 6
9 11
10 20
XA_C3_0073b_01
Fig. 1-11 Suction valve actuator

4 Housing 15 O-Ring
9 O-Ring 20 Intermediate piece
10 Nipple (guiding piece) C Inner spring
11 Pressure pin D Outer spring

– Piston Rod
Dismantle 1. Disconnect piping of control medium.

2. Remove actuator from valve cover.
3. Mark position of bonnet (1) against housing (to remount the cover in the
right position afterwards).
4. Remove 2 diametrically located screws (16) of bonnet (1).
5. Fit screws of extended length to handle the actuator spring(s) (2) being
under tension.
6. Remove all screws (except the two long ones).
7. To release the tension of the spring(s), loosen the two long screws
crosswise.
8. Mark/record position of piston (14) assembly, i.e. the assembly mode
(A/B).
9. Record position of springs (C and D).
10. Dismount piston (14) with pressure pin (11).
11. Dismount the upper Turcite Stepseal (6) as shown in (see Fig. 1-12). To
remove the Turcite Stepseals use a small hook or a prepared screw
driver (see Fig. 1-7).
XA_C3_0012a_01
Fig. 1-12 Dismount Turcite Stepseal
12. Dismount the lower Turcite Stepseal (6) after you have removed the
nipple (10) as shown in Fig. 1-12.
Do not reuse the dismantled notched ring, mount a new one.
13. If necessary: remove guiding band (12).
Required Checks Check for correct dimensions and number of springs “C”, “D” and for cor-
rect assembly mode of actuator piston as follows:

– Piston Rod
For LT, KS, KVG refer to the relavant Instruction Manual.
LT Total length of pressure pin (pin dismantled)

KS Reference dimension of actuator when actuator is dismantled
KVG Clearance between edge of valve cover and pressure sleeve for con-
trolled suction valve
For definitions of LT, KS and KVG see Fig. 1-14, Fig. 1-15 and Fig. 1-16.

Parts
Prior to assembly, slightly lubricate all parts exposed to friction.
1. Check all seals/O-rings and replace them if necessary.

2. If the piston ring GLYD (3) is worn, the complete piston (14) must be
replaced. During loosening of the piston nut, do not damage pressure
pin surface (11).
3. If the pressure pin (11) shows corrosion spots, polish or replace it.
4. Install new USIT ring (13) and piston (14) according to marked surface.
5. Consider correct mounting of Turcite Stepseal by using the special
mounting device (see Fig. 1-13).
Do not reuse a dismantled Turcite Stepseal, mount a new one.
XA_T9_0030c_02
Fig. 1-13 Mounting device for Turcite Stepseals

– Piston Rod
6. Install spring (2) and disk (if applicable) at its correct position.
7. Fit bonnet (1) by means of the screws with extended length.
Required Checks 1. Determine the clearance KVG (see Fig. 1-14 and Fig. 1-15 and
Fig. 1-16) by using a depth gauge and compare value with reference to
the relevant Instruction Manual.
2. Determine the reference dimension KS (see Fig. 1-14 and Fig. 1-15
and Fig. 1-16) and compare value with reference to the relevant In-
struction Manual.
Note: The actuator must be in the released state during this measure-
ment.
Install Suction Valve 1. Fit and tighten all screws.

Actuator
2. Replace both long screws by the original ones.
3. Attach actuator to valve cover.
4. Connect the piping.

– Piston Rod
Suction Valve Actuator for

Low Temperature
1
LT
KS 7
KVG 9
10
11
12
XA_C3_0027d_01
Fig. 1-14 Controlled suction valve with actuator for low temperature (typical view)
LT Total length of pressure pin 6 PTFE bush

KS Reference dimension actuator 7 Threaded bolt
KVGClearance valve cover–pressure 8 Pressure screw
sleeve 9 Valve cover
1 Bonnet 10 Lantern
2 – 11 Cylinder
3 Housing 12 Controlled suction valve
4 Pressure pin
5 Intermediate piece with isolating
bush and gasket

– Piston Rod
Suction Valve Actuator for (Variant without Intermediate Piece)

Normal Temperature
LT
4
KS 6
KVG 8
10
11
XA_C3_0028e_01
Fig. 1-15 Controlled suction valve with actuator (typical view)
LT Total length of pressure pin 5 –

KS Reference dimension actuator 6 Threaded bolt
KVG Clearance valve cover–pressure 7 Pressure screw
sleeve 8 Valve cover
1 Bonnet 9 Lantern
2 – 10 Cylinder
3 Housing 11 Controlled suction valve
4 Pressure pin

– Piston Rod
Suction Valve Actuator for (Variant with Intermediate Piece)

Normal Temperature
LT
4
KS 7
KVG 9
10
11
12
XA_C3_0072c_01
Fig. 1-16 Controlled suction valve with actuator (typical view)
LT Total length of pressure pin 5 Intermediate piece

KS Reference dimension actuator 6 –
KVGClearance valve cover–pressure 7 Threaded bolt
sleeve 8 Pressure screw
1 Bonnet 9 Valve cover
2 – 10 Lantern
3 Housing 11 Cylinder
4 Pressure pin 12 Controlled suction valve

– Piston Rod
Required Checks 1. Check connections for leakages.
3
4
LA_C3_0004b_01
Fig. 1-17 Water drain
1 Cylinder
2 Actuator
3 Plug with vent
4 Vent installed looking downwards: water can drain off
2. Close unused connection for control medium pressure with plug. Mount
actuator in a manner, that water cannot enter, respectively condensa-
tion water can drain off (downward, see Fig. 1-17).
3. Check differential control medium pressure – between above and
below the actuator piston(s) – using a pressure gauge.
The differential control medium pressure must reach at least the specified
control pressure.
4. Check during released state: the differential control medium pressure

must be zero.

– Piston Rod
XA_C3_0071b_01
2 1 2
Fig. 1-18 Connecting arrangement for one piston actuator operated by spring
1 Control medium line

2 Equalizing line
Variant with Diaphragm for Low Temperature

Actuator Piston
Special Tools none
Dismantle 1. Disconnect piping of control medium and leak gas.

2. Remove valve actuator from cylinder.
3. Remove cover for actuator piston (2) from valve cover (6).
4. Dismount diaphragm actuator piston (4).

– Piston Rod
1 2 3 4 5
7
14
13 8
LT
12 KS
KLG
9
10
11
LA_C3_0000d_01
Fig. 1-19 Controlled suction valve with actuator (leak gas outlet to safe location)
LT Total length of pressure pin 6 Valve cover

KS Reference dimension actuator 7 Leak gas outlet to safe location
KLG Clearance lantern–pressure sleeve 8 Pressure pin
1 Threaded bolt 9 Lantern
2 Cover for actuator piston 10 Controlled suction valve
3 Spring F 11 Cylinder
4 Diaphragm actuator piston 12 Gasket
5 Control medium inlet 13 Gasket
14 Gasket
Required Checks 1. Check for correct dimension of spring F (3) in the relevant Instruction
Manual.
2. Check gaskets and replace them if necessary.
3. Check diaphragm actuator piston for damage.
4. Check pressure pin protrusion, see in the relevant Instruction Manual.

– Piston Rod
For LT, LS, KLG refer to the relevant Instruction Manual.
LT Total length of pressure pin (pin dismantled).

LS Reference dimension of actuator; spring(s) according to the relevant In-
struction Manual.
KLG Clearance between edge of lantern and pressure sleeve for controlled
suction valve (see Fig. 1-19).
Assemble New
or Used Parts
CAUTION
Lubricants solidify when in contact with low temperature.
Pressure pin gets jammed.
 Do not use any lubricant on components of the suction valve actuator!
1. Fit spring F.
2. Fit diaphragm actuator piston with flat copper gaskets.
3. Fit cover for actuator piston to valve cover.
Required Checks 1. Determine the clearance KLG (see Fig. 1-19) by using a depth gauge
and compare value with reference to the relevant Instruction Manual.
2. Determine the reference dimension KS (see Fig. 1-19) and compare

value with reference to the relevant Instruction Manual.
Note: The actuator must be in the released state during this measure-
ment.
Install Suction Valve 1. Install assembled valve cover to corresponding controlled suction
Actuator valve.
2. Connect piping of control medium and leak gas.

– Piston Rod
Controlled Suction Valve
1.6 Controlled Suction Valve

• 1.5 Suction Valve Actuator
Special Tools none
X
3 1
LA_C3_0018b_02
A B
Fig. 1-20 Tolerances and clearances of controlled suction valve (typical view)
A Detail of valve with metal valve disc X Clearance

B Detail of valve with synthetic valve Y Clearance
disc Z Clearance
1 Valve disc synthetic
2 Damper plate
3 Valve disc metal

– Piston Rod
Controlled Suction Valve
Stage [mm]
Range
Clearance X for Burckhardt Plate ValveTM 1.2–2.2
®
Clearance X for Manley Valve 1.1–2.17
TM
Clearance X for Burckhardt Poppet Valve 1.4–2.1
Clearance Z 1.0–6.0
Clearance Y 0.3–0.8
Tab. 1-2 Valve clearances
For detailed information about controlled suction valves refer to the rele-
vant instruction for field engineers:
• MI91en Uncontrolled and Controlled Manley® Valve
• MI96en Controlled Burckhardt Poppet ValveTM

– Piston Rod
Suction Valves and Discharge Valves
1.7 Suction Valves and Discharge Valves

• 1.6 Controlled Suction Valve
For detailed information about suction valves and discharge valves refer to
the relevant instruction for field engineers:
• MI87en Burckhardt Plate ValveTM, Type BC-Special
• MI88en Burckhardt Poppet ValveTM, Type K-CP
• MI90en Burckhardt Plate ValveTM, Type HB
• MI91en Uncontrolled and Controlled Manley® Valves
• MI92en Burckhardt Poppet ValveTM, Type CP-Special
• MI93en Burckhardt Plate ValveTM with Synthetic Valve Disc
Fit Valves into Cylinder The sealing surfaces between the valves and the cylinders are lapped in.
Avoid damages of the sealing surfaces during installation of valves. The
lanterns on the suction side are shorter than those on the discharge side.
Variant without Pressure

Screws 0–0.1 mm
LA_CX_0011a_01
Fig. 1-21 Overlap
1. Insert valves with their lanterns into the correct valve cavities (use eye
bolts). Valves and lanterns must show an overlap at the cylinder of 0–
0.1 mm in the fitted position (Fig. 1-21). The inserted lantern must fit
properly.

– Piston Rod
CAUTION
Lantern too short
A difference of only 0.1 mm in length is sufficient to cause the affected lan-
tern to shift axially.This will successively increase the axial clearance and
leads to damage to the valves and especially the valve guards.
Lanterns which are too short can be rectified by welding-up or by fitting thin
rings of non ferrous metal or stainless steel disc.
STOP
XA_CX_0031a_01
2. Lubricate bolts and nuts with an admitted lubricant. Use Burckhardt Lu-
brication Grease BLG05 for oxygen compressors.
3. Put valve cover and gasket on cylinder and tighten the nuts slightly.
4. Tighten the nuts diagonally, applying specified torque. For mandatory
tightening torques: refer to the relevant Instruction Manual.

– Piston Rod
S D
ø> ø<
3
LA_CX_0018b_01
G G
Fig. 1-22 Suction valve diameter > discharge valve diameter
S Installed suction valve 2 Gasket

D Installed discharge valve 3 Lantern
G Gas flow 4 Suction valve
Ø Valve diameter 5 Discharge valve
1 Valve cover
Variant with Pressure Installed valves and their lanterns are pressed to their seating surfaces by
Screws pressure screws (1). There is a gap between valve covers and installed lan-
terns/valves.
1 Pressure screw
2 Cap nut
1 3 Valve cover
4 Cap nut gasket
2 5 Nut
6 Cover gasket
3
4
XA_CX_0032b_01
6
10 mm
Fig. 1-23 Valve cover
1. Insert valves with their lanterns into the correct valve cavities (use eye
bolts). The inserted lantern must fit properly. The inserted lanterns must
stand approx. 10 mm back from the cylinder face.

– Piston Rod
CAUTION
Wrongly installed valves can lead to compressor damage.
 see Fig. 1-24
STOP
XA_CX_0031a_01
Fig. 1-24 Prevent compressor from damage
Observe the following information to install the valves on the correct side of
the compressor:
• A suction valve cannot be inserted in a valve cavities on the discharge
side because its diameter is larger than the diameter of a valve cavity
on the discharge side.
• A discharge valve, however, can be inserted into a valve cavity on the
suction side because its diameter is smaller than the diameter of a
valve cavity on the suction side.
A discharge valve that has been inserted into a valve cavity on the suc-
tion side can nonetheless not be properly installed because its lantern
can then not be moved into its correct position.
• In suction valves, the center bolt is threaded in the guard.

• In discharge valves, the center bolt is threaded in the seat.
• Due to valve design, the lanterns for the suction side are shorter than
those for the discharge side.
2. Turn back pressure screws (1) of valve covers until they no longer pro-
trude from the inner surface of the valve cover. Lubricate all parts to
avoid fretting of bolts and sealing surface of cap nut with an admitted
lubricant. Use Burckhardt Lubrication Grease BLG05 for oxygen com-
pressors.
3. Put gasket (6) and valve cover (3) on cylinder and tighten the nuts (5)
slightly.
4. Tighten the nuts diagonally, applying specified torque.
5. Tighten pressure screws (1), applying specified torque.

– Piston Rod
6. Fit gaskets for cap nuts.

7. Fit cap nuts (2) and tighten them firmly.
For mandatory tightening torques: refer to the relevant Instruction Manual.
S D
1
ø> ø<
5
LA_CX_0002b_01
G G
Fig. 1-25 Suction valve diameter > discharge valve diameter
S Installed suction valve 3 Pressure screw

D Installed discharge valve 4 Gasket
G Gas flow 5 Lantern
Ø Valve diameter 6 Suction valve
1 Cap nut for pressure screw 7 Discharge valve
2 Valve cover

– Piston Rod
Cylinder Cover
1.8 Cylinder Cover

• 1.3 Switch Off Cooling System
Special Tools
LA_T9_0009a_01
Fig. 1-26 Eye bolt
Dismantle and Checks 1. Dismantle one of the upper and one of the lower valves.
 The cylinder clearance is now accessible
2. Check the Bottom Dead Center (BDC) cylinder clearance with a feeler
gauge through the valve openings (see Fig. 1-27).
Repeat this procedure in the Top Dead Center (TDC).
A
• a min. = X mm
a
• a max. = X mm
• b min. = X mm
• b max. = X mm
LA_C0_0002b_01
Measurements and tolerances re-

fer to the relevant Instruction Man-
b
ual.
Fig. 1-27 Measure cylinder clearance
A Piston diameter
a Top Dead Center (TDC)
b Bottom Dead Center (BDC)

– Piston Rod
Cylinder Cover
CAUTION
Use of wrong lead wire
Wrongly measured or adjusted cylinder clearances can cause major com-
pressor failure.
 Use lead wire of appropriate thickness or use a feeler gauge.
 Using too thick lead wire can lead to wrong measurement of cylinder
clearance.
3. Remove all nuts of the cylinder cover.

4. Fit eye bolts to cylinder cover.
5. Remove cylinder cover.
Required Checks 1. Check cylinder cover surface for cleanliness.

2. Check if the O-ring is in perfect condition.
Assemble New or Used 1. Replace O-ring if required.

Parts
Installation takes place in reverse order to dismantling.

– Piston Rod
Cylinder Cover
Variant HD Laby® Piston, 1. Remove all nuts of the cylinder cover.

Dismantle and Checks
2. Fit attachment gear to the lifting rings (refer to the relevant Instruction
Manual).
DANGER
Suspended loads!
Falling loads can cause serious injury or death.
 Lift cylinder cover only in the correct manner as described and illus-
trated in this Instruction Manual.
 Check correct tightening torque for attachment gear.
 Make sure that the carrying capacity of the hoist corresponds to the
weight of the cylinder cover.
 Protect carrying ropes/straps against sharp edges.
 Do not stand beneath suspended loads.
3. Remove cylinder cover.
4. Check the Top Dead Center (TDC) cylinder clearance with a lead wire
that covers approx. half the radius on both sides (see Fig. 1-28 and
Fig. 1-29). Remove the copper flat gasket at the top of the cylinder liner.
Re-install cylinder cover. Tighten cylinder bolt nuts manually. Turn the
flywheel several times by hand – using the bar – in running direction.
Take off cylinder cover and check clearance by measuring the thick-
ness of the lead wire.
2
LA_C0_0019b_01
Fig. 1-28 Measure cylinder clearance with lead wire
1 Guide ring 4 Part of radius

2 Piston rod 5 Lead wire
3 Head section

– Piston Rod
Cylinder Cover
A
• a min. = X mm
• a max. = X mm
a
ual.
LA_C0_0016b_01
A Piston diameter
a Top dead center (TDC)
CAUTION
pressor failure.
clearance.
Required Checks 1. Check cylinder cover surface for cleanliness.
Assemble New or Used 1. Replace copper flat gasket each time the cylinder cover is removed.
Parts
Installation takes place in reverse order to dismantling.

– Piston Rod
Frame Covers
1.9 Frame Covers

Special Tools none
Dismantle and Assemble 1. Remove all screws at the margin of the covers.
2. Lift off the covers according to following figure and stow them away.
Fig. 1-30 Frame cover removal LD_M0_0013a_02

– Piston Rod
Drain Lubricating Oil
1.10 Drain Lubricating Oil

• 1.9 Frame Covers
Special Tools none
Drain 1. Drain the oil from the oil sump.

2. Drain the piping of the lubrication system.
3. Remove oil heater.
4. Remove and clean the oil strainer of the compressor (see section 1.12
Oil Strainer).
5. Clean the crankgear with a sponge (do not use fibrous textile).
6. Clean the duplex oil filter in accordance with the manufacturer’s in-
structions (see Technical Documentation).
8 2
7 4
LD_M2_0002b_01
Fig. 1-31 Gear oil pump
1 Gauge for lubricating oil pressure 5 Oil drain

2 Gauge for crankgear pressure 6 Connection for oil level switch
3 Gear oil pump 7 Oil sight glass
4 Oil strainer (and heater, if appli- 8 Temperature indicator
cable)
Refill Information about required lubricating oil quantity for the compressor
crankgear refer to the relevant Instruction Manual.
Additional oil for associated pipes, oil cooler and filters is required.
The oil filling of the compressor is contained in the crankgear. The level
may be checked at the oil sight glass. When the compressor is at standstill,
3/4 of the oil sight glass must be covered.

– Piston Rod
3/4
LA_M2_0008b_01
2
Fig. 1-32 Check oil level
1 Oil sight glass

2 Lubricating oil
3 Crankgear
Refill as follows:
1. Shut oil outlets.
2. Refit oil strainer, filter, etc.
3. Fill the compressor with fresh oil.
4. Use the prelubrication pump to fill the complete oil system.

– Piston Rod
Oil Heater
1.11 Oil Heater

• 1.10 Drain Lubricating Oil
Special Tools none
Dismantle and Assemble The oil heater is located in the crankgear:
LD_M1_0018c_02
1 2 3 4 5
Fig. 1-33 Dismantle oil heater and strainer
1 Cover
2 O-ring
3 Oil strainer
4 Crankgear
5 Oil heater

– Piston Rod
Oil Strainer
1.12 Oil Strainer

Special Tools none
Dismantle and Assemble The oil strainer is located in the crankgear:
LD_M1_0018b_01
1 2 3 4
Fig. 1-34 Dismantle oil strainer
1 Cover
2 O-ring
3 Oil strainer
4 Crankgear

– Piston Rod
Piston and Piston Rod
1.13 Piston and Piston Rod

• 1.7 Suction Valves and Discharge Valves
• 1.8 Cylinder Cover
Special Tools
XA_T9_0024a_01
Fig. 1-35 Spanner for piston rod nut
LA_T9_0009a_01
Fig. 1-36 Eye bolt
Dismantle Measure Piston Clearance
Prior to measuring, clean all measuring tools, according to the relevant In-
struction Manual.
1. The piston clearance of each individual stage must be measured in the

Top Dead Center (TDC) as well as in the Bottom Dead Center (BDC)
position.
Always measure simultaneously with two opposite feeler gauges (see
Fig. 1-37).
Record measured values in the compressor check list.
The clearance measured at the same place in the BDC and TDC must
be practically the same. Should doubts arise concerning measurement,
please contact our Technical Service Support.

– Piston Rod
1 2 3 4
7 6 5
A E
D C H G
LA_C1_0006b_03
B F
Fig. 1-37 Measure piston clearance
1 Feeler gauge no. 1 5 Measuring points BDC (E with F, G

2 Feeler gauge no. 2 with H)
3 Piston 6 Piston rod
4 Cylinder 7 Measuring points TDC (A with B,C
with D)
2. Check cylinder clearances and record them.

– Piston Rod
A
• a min. = X mm
a
• a max. = X mm
• b min. = X mm
• b max. = X mm
LA_C0_0002b_01
b
ual.
A Piston diameter
CAUTION
pressor failure.
clearance.
4. Check clearance between guide bearing bush and piston rod (see sec-
tion 1.19 Guide Bearing Bush).
Variant HD Laby® Piston Measure Cylinder Clearance
5. Check the Top Dead Center (TDC) cylinder clearance with a lead wire
that covers approx. half the radius on both sides (see Fig. 1-39 and
Fig. 1-40). Remove the copper flat gasket at the top of the cylinder liner.
Re-install cylinder cover. Tighten cylinder bolt nuts manually. Turn the
flywheel several times by hand – using the bar – in running direction.
Take off cylinder cover and check clearance by measuring the thick-
ness of the lead wire.

– Piston Rod
LA_C0_0019b_01
1
Fig. 1-39 Measure cylinder clearance with lead wire
1 Guide ring 4 Part of radius

2 Piston rod 5 Lead wire
3 Head section
A
• a min. = X mm
• a max. = X mm
a

ual.
LA_C0_0016b_01
A Piston diameter
a Top dead center (TDC)
CAUTION
pressor failure.
clearance.

– Piston Rod
Variant A Dismantling Procedure with 1-piece Oil Scraper Rings
15
14
13
2
12
3
5
11
6
10
LA_C1_0024b_01
Fig. 1-41 Components to dismantle (typical view)
1 Oil shield 9 Lower piston rod nut

2 Guide bearing cover 10 Set screw
3 Spring plate 11 Piston rod
4 Oil scraper rings 12 Guide bearing
5 Shoulder 13 Piston rod gland
6 Upper piston rod nut 14 Piston
7 Locking plate 15 Cylinder
8 Key
7. Loosen and remove the toothed locking plate (7).

8. Unscrew the set screw (10).
9. Loosen the upper piston rod nut (6).

– Piston Rod
10. Loosen the lower piston rod nut (9) while simultaneously raising the rod
with the hoist till the lower piston rod nut is fully unscrewed.
11. Unscrew the upper piston rod nut.
12. Lift piston (14) and piston rod (11) carefully.
13. Make sure that the gland rings, the oil scraper rings and the guide
bearing bush are not damaged by the thread of the piston rod.
14. Loosen the guide bearing cover (2), the spring plate (3) and remove the
oil scraper rings (4).
Details regarding oil scraper rings, see section 1.18 Oil Scraper.
Required Checks Observe numbering of individual parts (see section 1.1.1 Marking of Com-
pressor Components).
1. Check all items to be fitted for possible damage.

2. Check if the piston rod surface is in perfect condition. Should a piston
rod be damaged, contact our Technical Service Support.
3. Check pretension of piston crowns according to section “Check the

Pretension of Piston Crowns”.
4. The oil scraper rings shall not show any sign of damage and must lie
snug against the piston rod on their whole circumference. The height of
the ring surface on the piston rod (running surface) should be 1.5 mm
to max. 2 mm. The scraping edge must be as sharp as possible and
must end in a pointed angle.The rings must have a slight pretension
when pushed onto the piston rod, even without the garter spring. With
the garter spring fitted, they must not slide off the piston rod when in a
vertical position.

– Piston Rod
LA_M5_0037b_01
8
Fig. 1-42 Oil scraper with 1-piece oil scraper rings (set)
1 Oil scraper ring 5 Scraping edge

2 Garter spring 6 Marking (line-up when fitting)
3 Brad 7 Top
4 Running surface 8 Bottom

Parts
If you insert a new piston rod, please note the last part in this section: “Fur-
ther Steps for Piston Rod Replacement”.
Preparations
1. Bring crosshead to TDC (Top Dead Centre).

2. Fit eye bolt into the piston rod. Lift piston rod and piston with the hoist.

– Piston Rod
CAUTION
3. Fasten a protection sheet around the lower piston rod thread (strong
paper or plastic).
Install Oil Scraper
4. Lower the oil-free and dry piston rod through the gland to approxi-
mately 50 mm above the guide bearing housing.
5. Using the correct sequence, slide the following parts on the dry piston
rod:
• Oil shield (1)
• Guide bearing cover with O-ring installed (2)
• Spring plate (3)

– Piston Rod
6
LA_M5_0038b_01
Fig. 1-43 Install oil scraper
1 Oil shield (without garter spring) 4 Piston rod

2 Guide bearing cover 5 Oil scraper rings
3 Spring plate 6 Guide bearing
6. Hold these parts in the uppermost possible position and oil the piston
rod (4) underneath.

– Piston Rod
7. Mount the scraper rings in the correct order: top, middle and bottom
ring. Make sure that the diagonal cuts of the scraper rings are offset
120° to each other (they must form a triangle when viewed from above
(see figures below).
 Another indication of proper assembly are the positioning marks
(black vertical notch on each scraper ring). They line up, one on top
of the other. Bottom, middle and top oil scraper rings have different
code numbers.
 The two upper oil scraper rings have one brad each. The brads prevent
the rings to rotate against each other.
Never tilt the oil scraper rings on the piston rod.
2 1 2 3 2
LA_M5_0011b_01
Fig. 1-44 Oil scraper rings without garter spring
1 Brad (upper rings)

2 Diagonal cut: 120° staggered
3 Marking

– Piston Rod
2 1 2 3
LA_M5_0006b_01
2
Fig. 1-45 Oil scraper rings with garter spring

3 Marking
8. Oil the oil scraper rings with compressor lubricating oil on the inside
and slide them with fitted garter springs onto the piston rod.
9. Put the spring plate and the guide bearing cover with the O-ring on top
of the scraper rings.
Install Oil Shield
10. While lowering the piston rod through the oiled guide bearing, move the
dry oil shield up along the piston rod. Make sure that the portion of the
piston rod below the oil shield always gets some oil before it moves
through the scraper rings.
11. As soon as the piston rod is positioned in the guide bearing, tighten the
guide bearing cover by hand.
12. Lower the piston rod and continue to move up the oil shield on the
piston rod until it sits in its groove on the piston rod. At the same time
clean off excess oil on the piston rod taper and crosshead.
13. Install the garter spring on the oil shield.

– Piston Rod
Connecting Crosshead to Piston Rod
11 5
6
7
8
9
10
LA_M3_0012b_02
Fig. 1-46 Crosshead-piston rod connection
5 Shoulder 9 Lower piston rod nut

6 Upper piston rod nut 10 Set screw
7 Locking plate 11 Piston rod
8 Key
14. Remove the protection sheet from the piston rod (11) and generously
lubricate the thread of the piston rod with compressor lubricating oil.
15. Screw the upper piston rod nut with toothing (6) on the piston rod till it
covers about half of the shoulder (5) of the piston rod.
16. Line up the key way on the piston rod to the key (8) in the crosshead.
17. Lower the piston rod carefully into the crosshead till the lower piston rod
nut (9) can be screwed on.
18. Continue lowering slowly while screwing the lower piston rod nut (9) up-
wards till the upper piston rod nut (6) touches the crosshead.
19. Line up the lower piston rod nut (9) so that set screw (10) can be
screwed in.
20. Tighten the upper piston rod nut (6) with the spanner by hand and mark
the position. Then finally tighten up to required torque referring to the
relevant Instruction Manual. Always tighten the piston rod nut from the
side of the name plate of the compressor. Lock the upper piston rod nut
(6) with locking plate (7).
Check Cylinder Clearances
21. Check cylinder clearances and record it.

– Piston Rod
Variant B Dismantling Procedure with 3-piece Oil Scraper Rings
15
14
13
2
12
3
5
11
6
10
LA_C1_0024b_01
1 Oil shield 9 Lower piston rod nut

2 Guide bearing cover 10 Set screw
4 Oil scraper rings 12 Guide bearing
5 Shoulder 13 Piston rod gland
6 Upper piston rod nut 14 Piston
7 Locking plate 15 Cylinder
8 Key
1. Loosen and remove the toothed locking plate (7).

2. Unscrew the set screw (10).
3. Loosen the upper piston rod nut (6).

– Piston Rod
4. Loosen the lower piston rod nut (9) while simultaneously raising the rod
with the hoist till the lower piston rod nut is fully unscrewed.
5. Unscrew the upper piston rod nut.
6. Lift piston (14) and piston rod (11) carefully.
bearing bush are not damaged by the thread of the piston rod.
8. Loosen the guide bearing cover (2), the spring plate (3) and remove the
oil scraper rings (4).

rod be damaged, contact our Technicel Service Support.

snug against the piston rod on their whole circumference when assem-
bled. The scraping edges must be as sharp as possible.
With the garter spring fitted, they must not slide off the piston rod when
in a vertical position.
2
LA_M5_0015c_01
1 Supporting ring 4 Garter spring

2 Oil scraper ring 5 Seal ring
3 Scraping edges

– Piston Rod
The segments of an oil scraper ring are precisely matched; do not intermix
segments of different oil scraper rings.
The segments of a seal ring are precisely matched; do not intermix seg-
ments of different seal rings.

Parts
Preparations

CAUTION
3. Fasten a protection sheet around the lower piston rod thread (strong
paper or plastic).
Install Oil Shield
rod:
• Oil shield (1)
• Supporting ring (7)

– Piston Rod
6
LA_M5_0038e_01
1 Oil shield (without garter spring) 5 –

2 Guide bearing cover with O-ring 6 Guide bearing
3 Spring plate 7 Supporting ring
4 Piston rod
rod underneath.

– Piston Rod
7. While lowering the piston rod through the guide bearing, move the dry
oil shield up along the piston rod.
8. Prior to futher lowering the piston rod, lubricate it in the area of the
guide bearing.
10. Lower the supporting ring (7) onto the crown ring.
Connecting Crosshead to Piston Rod
11 5
6
7
8
9
10
LA_M3_0012b_02
5 Shoulder 9 Lower piston rod nut

6 Upper piston rod nut 10 Set screw
7 Locking plate 11 Piston rod
8 Key
12. Remove the protection sheet from the piston rod (11) and generously
lubricate the thread of the piston rod with compressor lubricating oil.
13. Screw the upper piston rod nut with toothing (6) on the piston rod till it
covers about half of the shoulder (5) of the piston rod.
14. Line up the key way on the piston rod to the key (8) in the crosshead.
15. Lower the piston rod carefully into the crosshead till the lower piston rod
nut (9) can be screwed on.
16. Continue lowering slowly while screwing the lower piston rod nut (9) up-
wards till the upper piston rod nut (6) touches the crosshead.

– Piston Rod
17. Line up the lower piston rod nut (9) so that set screw (10) can be
screwed in.
18. Tighten the upper piston rod nut (6) with the spanner by hand and mark
the position. Then finally tighten up to required torque referring to the
relevant Instruction Manual. Always tighten the piston rod nut from the
side of the name plate of the compressor. Lock the upper piston rod nut
(6) with locking plate (7).
Install Oil Scraper
The segments of an oil scraper ring are precisely matched; do not intermix
segments of different oil scraper rings.
The segments of a seal ring are precisely matched; do not intermix seg-
ments of different seal rings.
19. Attach the magnetic tapered sleeve halves (1) to the piston rod (3)
below the cover and spring plate such that tapering faces downwards.
5
LA_M5_0045c_01
Fig. 1-51 Install tapered sleeve
1 Tapered sleeve 4 Bearing bush

2 – 5 Crown ring
3 Piston rod 6 Supporting ring
20. Place 2-piece seal ring (11) on top of tapered sleeve. Pay attention to
the following (Fig. 1-52).
• Mount seal ring without garter spring (2).

– Piston Rod
• Positioning bore (10) faces downwards.

• Both ring segments carry the same identification number.
11
10 1
LA_M5_0046c_01
4
Fig. 1-52 Install seal ring
1 Tapered sleeve 7 –
2 Garter spring 8 –
3 Piston rod 9 –
4 Bearing bush 10 Bore
5 Crown ring 11 Seal ring
6 Supporting ring
21. Place garter spring around piston rod below tapered sleeve.
22. Join together both spring ends.
23. Slide garter spring upwards along tapered sleeve until engaging into
groove of seal ring.
24. Move mounted seal ring upwards along piston rod.
25. Place the first 3-piece oil scraper ring (8) onto tapered sleeve
(Fig. 1-53). Pay attention to the following:
• Mount oil scraper without garter spring.

– Piston Rod
• Positioning pin (9) faces upwards such to fit into corresponding

bore (10) of seal ring.
• Check that the identification numbers of all three ring segments are
identical.
11
10
9
8
LA_M5_0047c_01
5
Fig. 1-53 Install oil scraper ring
1 Tapered sleeve 7 –
2 Garter spring 8 3-piece oil scraper
3 Piston rod 9 Positioning pin
4 Bearing bush 10 Bore
6 Supporting ring
26. Place garter spring around piston rod below tapered sleeve.
27. Join together both spring ends.
28. Slide garter spring upwards along tapered sleeve until engaging into
groove of oil scraper.
29. Slide assembled oil scraper ring up to seal ring such that positioning pin
of the oil scraper ring fits into corresponding bore of seal ring.
30. For assembly of second oil scraper ring, apply same procedure.

– Piston Rod
31. Remove tapered sleeve (Fig. 1-54).
11
1
8
3
7
LA_M5_0048c_02
5
Fig. 1-54 Remove tapered sleeve
1 Tapered sleeve 7 Pin

2 – 8 3-piece oil scraper
3 Piston rod 9 –
4 Bearing bush 10 –
6 –
32. Lubricate piston rod below assembled seal ring and oil scraper
rings.
33. Carefully slide down assembled seal ring and oil scraper rings onto the
supporting ring.
Pay attention that oil scraper set does not tilt.
34. Align pin (7) with corresponding bore of bottom oil scraper ring.
35. Slide spring plate on top of seal ring.

– Piston Rod
36. Check that between spring plate and supporting area of guide bearing
a clearance (1) approx. 0.2 mm exists (Fig. 1-55).
1 2
LA_M5_0049b_01
Fig. 1-55 Check clearance
X Clearance = 0.2 mm
1 Clearance
2 Spring plate
37. Insert O-ring into groove of guide bearing cover.
38. Place guide bearing cover on spring plate.
39. Install all screws together with washers.
For removal of piston rod during revisions and/or malfunctions: First re-
move complete oil scraper set!

– Piston Rod
Dismantle and Assemble Dismantle and assemble the piston according to Fig. 1-56.
3-Piece Piston
1 2 3 4 5
LA_C1_0018b_01
Fig. 1-56 Dismantled 3-piece piston
1 Piston rod
2 Lower piston crown
3 Piston skirt
4 Upper piston crown
5 Piston nut SUPERBOLT®
Solid Piston
1 2 3
LA_C1_0019b_01
Fig. 1-57 Dismantled solid piston
1 Piston rod
2 Solid piston
For detailed information about piston nut SUPERBOLT® see section 1.13.1
SUPERBOLT® Tensioner.
Dismantle and Assemble

HD Laby® Piston
If dismantling or assembling of a HD Laby® piston should become neces-

sary, please contact our Technical Service Support (refer to the relevant In-
struction Manual).
Continue with installing the piston rod as mentioned within this section in
part “Assemble New or Used Parts”.

– Piston Rod
Check the Pretension of 1. The pretension of the piston crowns to the piston skirt is measured
Piston Crowns when a piston part is replaced or after the interval indicated on the
maintenance schedule. This applies also, if a piston nut came loose.
Pretension is the value by which the piston crowns are bent inwards
when the piston nut is tightened, thereby clamping the piston skirt.
Measure distance “A” as shown in Fig. 1-58 with the piston crowns
clamped together without the piston skirt.
Pretension = Dimension B - Dimension A
1 2 3 4
A B
LA_C1_0004b_01
5
Fig. 1-58 Check pretension of piston crowns
1 Piston crown
2 Piston nut
3 Key
4 Piston skirt
5 Piston rod
Information about pretension measurements refer to the relevant Instruc-

tion Manual.
WARNING
Risk of piston seizure or loose piston skirt!
 The measured values must be within the tolerances given above.
 Tighten piston nut in accordance with section 1.13.2 Tightening
Torques and Method.
2. When installing a new piston skirt, it must be match-marked with the top
piston crown. It is important to define the position of the piston parts by
reference marking during assembly. This also applies to inspections,
whether parts are replaced or not (i.e. when checking the piston preten-
sion). During reassembly of the parts, these markings will help to re-
cover the correct position of the piston skirt in relation to the cylinder.
The marking should be stamped or engraved only. When assembled
and installed the piston markings should always be on the “V”-side
(name plate side) of the compressor (see Fig. 1-59).

– Piston Rod
1 2
xx*
: *xx
S/NoV *x*
V *x*
LA_C1_0005b_01
Fig. 1-59 Marking of piston crown and skirt

2 Piston skirt
3. Measure piston clearance (refer to the relevant Instruction Manual).
Re-machining of Piston Piston crowns which have to be re-machined because of pretension loss
Crowns must not be reduced more than 1.5 mm in height. Face runout must not ex-
ceed 0.02 mm.
LA_C1_0008b_01
h
Fig. 1-60 Overview
hmin = h - 1.5 mm
After facing the outer contact surface (1) and the inner contact surface (2)
of the upper and lower piston crown proceed as follows:
LA_C1_0008c_01
1 2
Fig. 1-61 Contact surfaces to be faced
1 Outer contact surface

2 Inner contact surface
1. Clamp the piston crowns together without the piston skirt, see
Fig. 1-58.
2. Compare the measured pretension with the values specified in the rel-
evant Instruction Manual.
3. Re-machine the pretension by facing the outer contact surface (1) and
the inner contact surface (2).
If the values are not within the given tolerances there might be a mix-up of
parts (e.g. piston rod nuts, piston rods or crosshead).
In case the piston must be removed, mark skirt, upper and lower crown.

– Piston Rod
Further Steps for Piston Principally, proceed as mentioned within this section in part “Assemble
Rod Replacement New or Used Parts”, if a piston rod has to be replaced. The piston dead
clearance must be adjusted first as follows:
1. Screw up or down the lower piston rod nut (Fig. 1-50, 9) until the mea-
sured values correspond to the values given in the the relevant Instruc-
tion Manual.
2. Mark the new position for the bore of the set screw (Fig. 1-50, 10) on
the lower piston rod nut.
3. Remove the lower nut (Fig. 1-50, 9) for drilling the new bore. If neces-
sary the piston rod must be slightly lifted therefore.
4. Plug the previous bore on the lower piston rod nut.
5. Refit the lower piston rod nut and continue, according to instructions in
the former part of this section.

– Piston Rod
1.13.1 SUPERBOLT® Tensioner

(Tightening Method V)
XA_M0_0006a_01
Fig. 1-62 SUPERBOLT® Tensioner
Description This section of the Instruction Manual gives directions for the use of SU-
PERBOLT® tensioners at the exterior and in the crankgear of compressors.
The nut must be tightened carefully with the supplied tools (see following
section “Tightening Procedure”).
The tensioner is prelubricated with the lubricant MOLYKOTE® G-N Plus
(except piston nuts). The marked tightening torque applies for this lubricant
only.
CAUTION
Please contact our Technical Service Support in case:
• a unlubricated connection is required,
• the admitted lubricant MOLYKOTE® G-N Plus is not available.
WARNING
Never use MOLYKOTE® G-N Plus for the lubrication of SUPERBOLT® ten-
sioners that are used as piston nut! For further instructions about piston
nuts, refer to the relevant Instruction Manual.
Maintenance and SUPERBOLT® tensioners do not loose their preload force even after sev-
Revisions eral years in service providing that they are correctly tightened. Neverthe-
less, we recommend to check the preload force during each revision. Use
a torque wrench adjusted to 100 % of the permitted tightening torque.
Should some pressure screws unexpectedly have lost some of the preload
force the following procedure is recommended:

– Piston Rod
1. Relieve tension of the tensioner slightly by loosening the pressure

screws (1/4 turn only) according to following section “Loosening Proce-
dure”. Thus, the tensioner remains tensioned.
2. Now tense according to following section “Tightening Procedure”, i.e.
tighten in circular sequence with full tightening torque, until all pressure
screws are tightened.
Preventive Maintenance i.e. removal for maintenance purposes:
1. Relieve according to following section “Loosening Procedure”.

2. Treat thread and end of pressure screws with admitted lubricant.
3. Hardened washer may be reused despite indentations, simply by
turning over. Depressions of a few 1/100 mm are normal.
4. Tighten again according to following section “Tightening Procedure”.
Loosening Procedure Loosening requires an exact procedure. The pressure screws must be re-
lieved stepwise!
Under no circumstances relieve single screws completely. The remaining
screws would have to carry the entire load and, a fact that makes it difficult
to loosen them. In extreme cases the pressure screws could jolt and make
loosening impossible!
1. Starting with No. 1 loosen every

1/4 pressure screw in circular se-
quence maximal 1/4 turn. Do
not loosen beyond break loose
point. After the first round, pres-
1 sure screw No. 1 will again be
8 2
tightened, however, on a lower
level of loading.
2. In a 2nd round, repeat step 1.
7 3 3. In a 3rd round, repeat step 1.
XA_T9_0023a_01
4. Relieve pressure screws com-

pletely. Now the tensioner can
6 4 be removed by hand.
5
Fig. 1-63 Loosening of pressure

screws
CAUTION
Follow previous section “Preventive Maintenance” respectively following
section “Trouble Shooting” before reusing the pressure screws!

– Piston Rod
Tightening Procedure
Required Tools
• Torque wrench
• Socket
• Lubricant MOLYKOTE® G-N
Plus
XA_T9_0016a_01
Fig. 1-64 Required tools
The marked tightening torque is the maximum permitted value.

For applicable tightening torques: refer to the relevant Instruction Manual.
Preparation
Make sure that:
• pressure screws do not protrude from the nut.
• pressure screws are well lubricated.
Procedure
1 Hardened washer
1 2 3 4
2 Pressure screw
3 Bolt
4 SUPERBOLT® tensioner
X Gap approx. 1–3 mm
XA_T9_0017b_02
X
Fig. 1-65 Gap “X”
1. Clean main thread and contact areas.

2. Lubricate main thread and contact areas with admitted lubricant.
3. Firmly tighten the tensioner by hand.
4. Afterwards turn back approx. 1/4 turn. Depending on size the gap will
be approx. 1–3 mm.

– Piston Rod
Tightening of Nuts Having The tightening must take place gradually:

8 (Eight) Pressure Screws
1 1
8 2
3 4 7 3
XA_T9_0019a_01
XA_T9_0020a_01
6 4
2 5
Fig. 1-66 Tighten 4 pressure screws Fig. 1-67 Tighten all pressure screws
1. Tighten 4 pressure screws crosswise with 50 % of the recommended

tightening torque.
2. Tighten the same 4 pressure screws crosswise with 100 %.
3. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.
Tightening of Nuts Having The tightening must take place gradually:

6 (Six) Pressure Screws
1 1
6 2
XA_T9_0021a_01
XA_T9_0022a_01
3 2 5 3
Fig. 1-68 Tighten 3 pressure screws Fig. 1-69 Tighten all pressure screws
1. Tighten 3 pressure screws with 50 % of the recommended tightening

torque.
2. Tighten the same 3 pressure screws with 100 %.
3. Now change to circular tightening and tighten all pressure screws with
100 % until all pressure screws are equally tightened.
Trouble Shooting Pressure Screws Cannot Be Loosened
1. Try to free at least one pressure screw.

2. Remove pressure screw, lubricate with admitted lubricant and tighten
with 110 % of the permitted tightening torque.

– Piston Rod
3. The two neighboring pressure screws should become free. Remove

these two pressure screws, lubricate and tighten with 110 %.
4. The next two pressure screws should become free.
5. And so on.
6. Afterwards relieve all pressure screws according to previous section
“Loosening Procedure”.
Hardened Washers Are Damaged, i.e. after a Long Time in Service

Exchange against original (OEM) hardened washers SUPERBOLT®.
Pressure Screws Are Damaged or Missing

Exchange against original (OEM) pressure screws SUPERBOLT®.
CAUTION
Do not use commercial screws because they are not suitable for such high
loads!
Other Problems?
Please contact our Technical Service Support.

– Piston Rod
1.13.2 Tightening Torques and Method

For specific tightening methods for the compressor please see section
1.13.3 Tightening Methods and a comprehensive table with tightening
torques can be found in the relevant Instruction Manual.
Tightening Method I Bolted Connections of Secondary Level

• This category includes all bolts not being particularly stressed during
operation.
• Tightening is usually done using a standard-sized wrench without ex-
tension.
• Tightening torques depend on bolt size and material.
• Torque values are listed in the following table.
Bolt quality class and bolt material are marked on the head of a bolt (see
Fig. 1-70).
Should questions arise, please contact our Technical Service Support.
1
XA_XX_0111b_01
Fig. 1-70 Marking on bolts
1 Marking (quality class and material)
Data only applicable if no other tightening methods or torque values are

specified.
CAUTION
If gaskets are used, attentively follow the specifications of the gasket man-
ufacturer!
Tightening Method • Clean areas of support (connecting parts) free of grease

• Apply lubricant to gliding surfaces of bolt (thread, head support and nut
support)
• Tighten screw at least twice using torque wrench (tightening torque ac-
cording to table)

– Piston Rod
Lubricant • MOLYKOTE® G-N Plus

• Other suitable lubricants
Tightening Torques
Bolt quality standard Bolt quality heat-treated
4.6-2, 5.6, G, YK 6.9, 8.8, VCN 35
Thread Nm mkp ft-lbs Nm mkp ft-lbs

M12 25 2.5 18.4 39 4 28.8
M14 39 4 28.8 64 6.5 47.2
M16 59 6 43.5 93 9.5 68.6
M18 83 8.5 61.2 132 13.5 97.4
M20 113 11.5 83.3 177 18 130.6
M22 147 15 108.4 245 25 180.7
M24 186 19 137.2 324 33 239
M27 265 27 195.5 461 47 340
M30 343 35 253 638 65.1 470.6
M33 422 43 311.3 834 85 615.2
M36 530 54 390.9 1080 110.1 796.6
M39 667 68 492 1373 140 1012.7
M42 – – – 1766 180.1 1302.6
M45 – – – 2256 230 1664
Data valid only using MOLYKOTE® G-N Plus!

– Piston Rod
1.13.3 Tightening Methods

Please note that just a few methods mentioned here are used on your com-
pressor.
Tightening Method II Bolted Connections with Specified Torque Values

• Tightening is done using a torque wrench.
• If required, use a multiplier with the torque wrench.
• Torque wrenches are to be calibrated periodically.
Tightening Method III Bolted Connections with Specified Torsion Angle

• Without using force, manually tighten nut several times until the con-
nection is well set.
• To be able to tighten nut up to specified angle, use wrench extension.
For higher values, use extension or multiplier.
Tightening Method IV Bolted Connections with Specified Bolt Elongation

• Check length of bolt before tightening.
• Tighten nut until the bolt elongation is as specified.
Tightening Method V SUPERBOLT®

• For tightening of SUPERBOLT® tensioner on crankgear and/or frame
see section 1.13.1 SUPERBOLT® Tensioner.
• For tightening of piston nut SUPERBOLT® refer to the relevant Instruc-
tion Manual.
Tightening Method VI Bolted Connections with Specified Hydraulic Pressure

• Tighten nut according to specified hydraulic pressure.
For mandatory tightening torques, appropriate tightening methods and ap-

plicable lubricants: refer to the relevant Instruction Manual.

– Piston Rod
Internal Gas Leakage Pipes
1.14 Internal Gas Leakage Pipes

Special Tools none
Dismantle and Assemble Dismantle and assemble the internal gas leakage pipes according to
Fig. 1-72.
1 2
LA_C5_0025b_01
Fig. 1-71 Piston rod gland gas leakage pipes
1 Piston rod gland

2 Gas leakage pipes
1.15 Piston Rod Gland

• 1.13 Piston and Piston Rod
• 1.14 Internal Gas Leakage Pipes

– Piston Rod
Piston Rod Gland
Special Tools
LA_T9_0001c_01
3
Fig. 1-72 Piston rod gland dismantling and assembling device
1 Cylinder
2 Piston rod gland dismantling and assembling device
3 Piston rod gland
4 Bottom disc of dismantling and assembling device
Dismantle 1. Mount dismantling and assembling device (2). (see Fig. 1-72).
2. Unfasten gland flange and carefully lower the complete piston rod
gland.
3. Dismantle piston rod gland and clean individual parts.
Required Checks 1. Inspect individual parts for possible damage. Grooves and front faces
must not be damaged.
2. Measure the radial clearance of the one-piece rings on the piston rod
(on oil scraper area).
Minimum measured gland ring clearance with new gland rings refer to rel-
evant Instruction Manual.

Parts
CAUTION

– Piston Rod
Piston Rod Gland
The gland rings with gland chambers are fitted with the special tool (see
Fig. 1-72).
LD_C5_0002b_01
Fig. 1-73 Piston rod gland (typical view)
1 Gland chamber (top) 4 Gland chamber (middle)

2 Spring 5 Intermediate ring
3 Gland ring 6 Gland flange (with 2 connections
for gas leakage pipes)
Procedure:
1. Place bottom disc of dismantling and assembling device on top of
guide bearing.
2. Place gland flange (6) with bottom gland ring (3) and springs (2) on
bottom disc.
3. Place intermediate ring (5) on top of the gland flange.
4. Build a stack with following sequence:

– Piston Rod
External Gas Pipes
• 4 gland chambers (4) with gland rings and springs

• 1 gland chamber (1) with gland ring and springs
5. Mount dismantling and assembling device.
6. Lift the whole piston rod gland into the cylinder.
7. Tighten flange slightly.

 With flange tightened, the gland rings must be movable radially.
8. Install piston, see section 1.13 Piston and Piston Rod.
9. Turn the flywheel several times manually in running direction.Verify that
everything is in proper mechanical condition.
10. Tighten flange with the mandatory tightening torque.
11. Fit the gas leakage lines.
1.16 External Gas Pipes

Special Tools none
Dismantle and Assemble For details concerning external gas pipes please see “General Arrange-
ment” of the relevant Instruction Manual.

– Piston Rod
Cylinder
1.17 Cylinder
• 1.16 External Gas Pipes
Special Tools
XA_T9_0007a_01
Fig. 1-74 Flogging spanner
Dismantle 1. Remove coolant pipes from cylinder.

2. Loosen the nuts of the threaded bolts.
DANGER
Suspended loads!
 Lift cylinder only in the correct manner as described and illustrated in
this Instruction Manual.
 Make sure that the carrying capacity of the hoist corresponds at least
to the heaviest individual component weight.
3. Attach carrying ropes in the safe manner, described and illustrated in

4. Lift off the cylinder. Be careful that the threaded bolts do not touch the
bores in the frame.

– Piston Rod
Cylinder

Parts
CAUTION
All components coming into contact with process gas must be clean (oil-
free and free of grease).
When using solvents, observe the safety precautions of the manufacturer.
1. Degrease gas leakage pipes of piston rod glands referring to the rele-
vant Instruction Manual.
2. Place them on the frame inside the distance piece.
DANGER
Suspended loads!
3. Attach carrying ropes in the safe manner, referring to the relevant In-
struction Manual.
4. When lowering the cylinder onto the frame, be careful that the threaded
bolts do not touch the bores in the frame.
5. Pay attention that the centering pins fit properly into the corresponding
bores in the cylinder.

– Piston Rod
Cylinder
1 2 3 4 5
LA_C0_0003b_01
Fig. 1-75 Centering pin
1 Plug 4 Epoxy resin

2 Cylinder 5 Frame
3 Centering pin
6. Tighten the nuts of the threaded bolts with the mandatory tightening
torque.

– Piston Rod
Oil Scraper
1.18 Oil Scraper

Special Tools none
Dismantle and Assemble A detailed description of assembling the oil scraper see section 1.13 Piston
1-piece Oil Scraper Rings and Piston Rod.
Dismantle and Assemble 1. Remove covers and spring plate from guide bearing.
3-piece Oil Scraper Rings
2. Remove oil scraper set (see Fig. 1-76) from guide bearing.
Please note that the piston rod needs not to be taken out for disman-
tling the 3-piece oil scrapers.
LA_M5_0015d_01
For a detailed description of assembling the oil scraper set, see section
1.13 Piston and Piston Rod.
Please note that the piston rod needs not to be taken out for assembling
the 3-piece oil scrapers.

– Piston Rod
Guide Bearing Bush
1.19 Guide Bearing Bush

• 1.18 Oil Scraper
Special Tools Dismounting device for bush (see Fig. 1-77)
Dismantle If the diametrical clearance between bush and piston rod exceed the Dia.
“B” (for applicable clearances refer to the relevant Instruction Manual), re-
place the bush with the device to be made on site as shown in Fig. 1-77.

– Piston Rod
Guide Bearing Bush
LA_M5_0002b_02
Fig. 1-77 Dismantle guide bearing bush
1 Guide bearing
2 Bearing bush
3 Dismounting device
4 Crosshead

– Piston Rod
Guide Bearing Bush
LA_M5_0041b_01
Fig. 1-78 Guide bearing details
1 Hexagonal screw 5 Bearing housing

2 Usit ring 6 Spring plate
3 Crown ring 7 O-ring
4 Bearing bush 8 Guide bearing cover

– Piston Rod
Guide Bearing
Required Checks Before fitting the new bush, check the clearance between bush and piston
rod (refer to the relevant Instruction Manual).
1.20 Guide Bearing

Special Tools none
Dismantle Before removal and inspection, the guide bearing clearance must be mea-
sured.
Measure the clearance with a feeler gauge.
For applicable clearances see Table of Clearances of the relevant Instruc-

tion Manual.
Should doubts arise about acceptance of measured clearance, contact our

Technical Service Support that will gladly assist you.
1. Remove all coolant pipes.

If a guide bearing must be replaced, e.g. after a damage by freezing,
the coolant pipes of guide bearings must be blown out first from outlet
side. Then the guide bearing can be removed through the lateral
opening in the frame.
2. Loosen the screws and remove the guide bearing according to

Fig. 1-79

– Piston Rod
Guide Bearing
1 2 3 4
LA_M5_0028b_01
9 8
Fig. 1-79 Typical view of a guide bearing with cooling and open design
1 Bearing housing 6 Crown ring

2 Piston rod 7 Bearing bush
3 Oil shield 8 Adjustable elbow union
4 Guide bearing cover 9 Oil syphon
5 Oil scraper rings (according to appli-
cation: 2 or 3 pieces)

– Piston Rod
Connecting Rod Bearing
1.21 Connecting Rod Bearing

• 1.20 Guide Bearing
Special Tools
LA_T9_0019a_01
Fig. 1-80 Support for dismantling and assembling of connecting rod bearing
1
LA_T9_0002b_01
Fig. 1-81 Hydraulic tightening device
1 High-pressure hose
2 Pressure head
3 Pump
General Remarks for Hydraulic Tightening Device

General instructions for hydraulic tightening device, used on connecting
rod bearings:

– Piston Rod
Important notes for tightening device and hand pump:

1. The vent valve of the hand pump must always be open when the pump
is in use.
2. For transport or refilling the hand pump, the vent valve as well as the
relief valve must be closed.
3. Use hydraulic oil ISO VG5 only.
4. Vent the hydraulic tightening device before initial use or reuse after
storage of more than 3 months.
• Assemble all parts of the hydraulic tightening device.
• Open the vent valve and relief valve of the hand pump and tighten
the threaded sleeves to push back oil or air from the hydraulic head
through the hoses into the pump cylinder.
• Disconnect all hoses from the hydraulic heads, close the relief
valve, vent all the hoses by opening the check valve in the con-
necting piece with a pin or screw driver and pump until oil flows out
without air. Make sure that no oil pressure remains. Oil pressure
cannot increase with an open check valve.
• Repeat this procedure for all hydraulic hoses.
• When all hydraulic heads and hoses are properly vented, the hy-
draulic device is ready to be used.

– Piston Rod
Typical Arrangement of Hydraulic Tightening Device
LA_M4_0006b_01
Fig. 1-82 Arrangement for connecting rod
1 High pressure hose

2 Pressure head
3 Connecting rod bolt
4 Connecting rod
5 Pump
Dismantle For the tightening and unfastening of the nuts a hydraulic tightening device
is required, which is supplied with the compressor, shown on Fig. 1-83.

– Piston Rod
WARNING
Pressurized hydraulic tightening device
Improper use or loose parts of the hydraulic tightening device in conjunc-
tion with high oil pressure may cause injuries.
 Prior to any use check hoses and connections of pump and tightening
device for mechanical damages.
 Before assembling make sure that the system is not pressurized.
 Do not exceed the maximum pressure indicated.
 Check the oil pressure gauge periodically.
 Take into account that the pressure gauge indicates the oil pressure in
bar.
8 9 10
12
7
6
4
5
1
3
LA_T9_0008b_01
1 Cylinder 7 Supporting ring

2 Piston 8 Nipple
3 Supporting sleeve 9 Adapter
4 Gasket 10 Swivel elbow
5 Supporting ring 11 -
6 Gasket 12 Stroke indicator
Required checks
Turn crank to BDC and measure clearance between crankshaft journal and
connecting rod lower bearing shell with a feeler gauge.
For applicable clearances refer to the relevant Instruction Manual.

– Piston Rod
1 Connecting rod
1
2 Crosshead pin bearing
2 3 Connecting rod bolt
4 Nut
5 Connecting rod bearing
6 Connecting rod cover
LA_M4_0007b_01
Fig. 1-84 Connecting rod bearing
Dismantle the connecting rod bearing as follows:

1. Measure bearing clearance and record it (see section required
checks).
2. Turn respective crank to BDC (Bottom Dead Centre).
3. Set up the tightening devices as shown on Fig. 1-82/Fig. 1-83.
4. Fit high pressure hoses and connect pump correctly.
5. Make sure that the pistons (2) are at zero position! Then turn back 1/2
a turn.
6. Use pump, to vent tightening device the first time after long storage, by
unscrewing vent screw.
7. Center tightening devices and ensure proper setup.
8. Raise oil pressure to a value as indicated in the relevant Instruction
Manual until the nuts come loose, make sure that the allowable piston
stroke of the device is not exceeded.
9. Unscrew connecting rod nuts by several turns.
10. Lower pump pressure to 0 bar.
11. Open the pump relief valve and set the pistons (2) down at zero posi-
tion.
12. Remove all components of the tightening devices.
13. Turn respective crank to TDC (Top Dead Centre).

– Piston Rod
14. Set support (Fig. 1-80) into the base plate.

15. Lower connecting rod cover to the support.
Assemble After removal for inspection, refitting of bearing is generally carried out in
reverse sequence to removal.
1. Turn respective crank to TDC.

2. Fit connecting rod cover with bearing shell, using the support.
3. Set connecting rod nut with a mandril.
4. Turn crank to BDC.
5. Set up the tightening devices according to Fig. 1-82 and Fig. 1-85.
Make sure that the pistons (2) are at zero position!
1 Cylinder
8 9 10
2 Piston
3 Supporting sleeve
4 Gasket
2 5 Supporting ring
6 Gasket
12 7 Supporting ring
8 Nipple
7 9 Adapter
6 10 Swivel elbow
11 Mandril
4
5 12 Stroke indicator
1
3
LA_M4_0009b_01
11
6. Raise pump pressure to the maximum value as indicated in the rele-

vant Instruction Manual and make sure that the admissible piston
stroke of the device is not exceeded.
7. Firmly set connecting rod nut. Line-up the punch mark on the nut with
its corresponding mark on the connecting rod. If the nut needs to be
turned by more than one increment to line-up the punch marks (V),
elongation of the connecting rod bolts must be checked. (Turning back
necessarily, the first appearing punch mark must be the V one).
8. Lower pump pressure to 0 bar.

– Piston Rod
9. Open pump relief valve and set pistons down to zero position.
11. Check elongation “L1” of connecting rod bolts according to Fig. 1-86
L
L1
LA_M4_0008b_01
2
Fig. 1-86 Instructions for fitting of connecting rod bolts.

2 Nut
3 Bearing shell
“L”: Length of bolt before tightening

“L1”: Length of bolt when tightened
The bolt is properly tightened when:

“L1” – “L” = refer to relevant Instruction Manual
12. Measure bearing clearance.

13. Only if necessary, re-punch marks on the connecting rod.

– Piston Rod
Crosshead and Connecting Rod
1.22 Crosshead and Connecting Rod

• 1.21 Connecting Rod Bearing
Special Tools
1 2 3
LA_T9_0017b_01
Fig. 1-87 Pull-off device for removing crosshead pin
1 Crosshead pin
2 Crosshead
3 Pull-of device

– Piston Rod
LA_T9_0018b_01
Fig. 1-88 Support (not supplied by Burckhardt Compression AG)
1 Crosshead
2 Support
3 Connecting rod
XA_T9_0003a_01
XA_T9_0004a_01
Fig. 1-89 Circlip pliers
Dismantle The crosshead may be removed through the bore of the guide bearing.
1. Lift crosshead with hoist.Take care that the connecting rod is hanging
freely, i.e. not damaging the crosshead guide while lifting.
2. Remove crosshead pin.
Assemble New or Used Installation takes place in reverse order to dismantling.

Parts

– Piston Rod
Crosshead Pin Bearing (with Cylinder Removal)
1.23 Crosshead Pin Bearing (with Cylinder Removal)

• 1.17 Cylinder
• 1.22 Crosshead and Connecting Rod
Special Tools Press, Freezer, Oven
Dismantle Push the used crosshead pin bearing out of the connecting rod bore with a
press.
Assemble New or Used 1. Clean the connecting rod bore and the crosshead pin.
Parts
2. Check the crosshead pin and the crosshead pin bearing diameter. The
diameter of the crosshead pin and the crosshead pin bearing must cor-
respond to the set values given in the table of clearancesof the relevant
Instruction Manual.
3. The crosshead pin bearing must be cooled down to approximately
-20°C before it can be installed. Therefore, cool it in a freezer for about
12 hours.
4. The connecting rod must be heated-up evenly to 60°C–80°C (e.g. in
hot oil). Never use a burner or a blower for heating-up. Risk of con-
necting rod deformation!
5. Insert the new crosshead pin bearing quickly. Make sure that the posi-
tioning pin in the bearing and the groove of the connecting rod are in
line.
Due to thermal expansion of the crosshead pin bearing, thermal
shrinkage of the connecting rod the position of the crosshead pin
bearing cannot be corrected anymore after a few seconds!
Final Checks Check the diameter of the crosshead pin bearing when the crosshead pin
bearing and the connecting rod have reached ambient temperature. Table
of clearances, refer to the relevant Instruction Manual.

– Piston Rod
Crosshead Pin Bearing (without Cylinder Removal)
1.24 Crosshead Pin Bearing (without Cylinder Re-

moval)
3
LA_T9_0018b_01
1 Crosshead
2 Support
3 Connecting rod

– Piston Rod
1 2 3
LA_T9_0017b_01
Fig. 1-91 Pull-off device for removing crosshead pin
1 Crosshead pin
2 Crosshead
3 Pull-of device
Dismantle 1. Lift crosshead with hoist and fixate connecting rod with locating device
(support) according to Fig. 1-90.
2. Turn the crosshead secured with the hoist. Remove crosshead pin with
pull-off device, see Fig. 1-87.
3. Remove crosshead through frame opening.
4. Remove connecting rod through frame opening.
5. Push the used crosshead pin bearing out of the connecting rod bore
with a press.
Parts
respond to the set values given in the table of clearances, refer to the
relevant Instruction Manual.
12 hours.
line.

– Piston Rod
Gear Oil Pump
1.25 Gear Oil Pump

Special Tools
LA_T9_0009a_01
Fig. 1-92 Eye bolt
Dismantle 1. Remove external oil pipes.

2. Dismantle the oil pump according to figure Fig. 1-93 and Fig. 1-94.
LD_M0_0012a_02
Fig. 1-93 Dismantled gear oil pump (typical view)

– Piston Rod
Gear Oil Pump
14
11 12 13
10
LD_M1_0008c_01
5 4 3 2 1
Fig. 1-94 Typical view of crankshaft-driven gear oil pump
1 Crankshaft 8 Throttling valve

2 Gasket 9 Relief valve
3 O-ring 10 Pressure gauge
4 Bearing bracket 11 Temperature indicator
5 Housing 12 Driving flange
6 Driven gearwheel 13 Nylon bush
7 Driving gearwheel 14 Frame
The gear oil pump is fitted to the frame (14) at the non-drive end of the com-
pressor. The bearing bracket (4) is sealed against oil leakage by a gasket
(2). The housing (5) is fitted to the bearing bracket and sealed by an O-ring
(3).
The gear oil pump consists of a driven gearwheel (6) and a driving gear-
wheel (7) attached to the driving flange (12), which is driven by the crank-
shaft (1). The two gearwheels are of the same diameter and fit snugly in the
pump body. The lubricating oil is carried from the inlet to the delivery side
of the pump by both gearwheels.

– Piston Rod
Gear Oil Pump
LD_M2_0022a_01
Fig. 1-95 Typical view of dismantled gear oil pump
Assemble New or Used Assemble the gear oil pump in reverse order of dismantling procedure.
Parts

– Piston Rod
Electric Motor
1.26 Electric Motor

Special Tools none
Dismantle 1. Remove flywheel guard.

2. Release electric motor from coupling.
Assemble New or Used For detailed assembly instructions refer to the relevant Instruction Manual.
Parts
1.27 Coupling
Special Tools none
Dismantle Dismantle coupling according to manufacturer’s instructions (refer to the

relevant Instruction Manual).
Assemble New or Used For assembly of the coupling, refer to the relevant Instruction Manual.
Parts

– Piston Rod
Flywheel
1.28 Flywheel
• 1.27 Coupling
Transport and Lifting of For transport and lifting of flywheel, take care to avoid any damage; please
Flywheel refer to the relevant Instruction Manual.
DANGER
Suspended loads!
 Lift flywheel only in the correct manner as described and illustrated in
 Do not stand underneath suspended loads.
LA_XX_0044c_01
Fig. 1-96 Transport and lifting of flywheel
Dismantle 1. Dismount coupling.

2. Attach flywheel in the safe manner as described and illustrated in this
Instruction Manual to a lifting device, strapping carefully the ropes.

– Piston Rod
Flywheel
3. Take off flange (Fig. 1-97).
1 2 3 4 5 6 1 2 3 4 6
LA_L1_0018b_01
LA_L1_0017b_01
Fig. 1-97 Pulling-off flywheel
1 Crankshaft 4 Threaded bolt

2 Key 5 Bolt
3 Flywheel 6 Flange
4. Turn over flange (6), attach on crankshaft such that bossed side of
flange faces towards crankshaft (1).
5. Tighten outer bolts until flywheel is pulled off from taper (Fig. 1-97).
6. Drain the lube oil from the seal housing through the drain plug before
opening the bearing bracket.
Parts
Final Checks 1. Check radial and face runout as illustrated in Fig. 1-98.

– Piston Rod
Flywheel
1 2 3 4 5 6
LA_L1_0009b_01
Fig. 1-98 Radial and face runout
1 Crankshaft 4 Outer bolt

2 Flywheel 5 Measuring head
3 Inner bolt 6 Dial gauge
Tolerance of radial and face runout must not exceed 0.05 mm.
When checking the face runout, push the crankshaft to one side up to its
stop. The axial clearance of the crankshaft must be eliminated.

– Piston Rod
Oil Trap and Crankshaft Seal
1.29 Oil Trap and Crankshaft Seal

• 1.27 Coupling
• 1.28 Flywheel
Special Tools none
Variant A: Dismantle and Dismantle the crankshaft seal according to Fig. 1-99.
Assemble Non-gastight
For mandatory tightening torques refer to the relevant Instruction Manual.
Crankshaft Seals
1 2 3
LD_M1_0002c_01
Fig. 1-99 Pulling-off oil trap and crankshaft seal
1 Bearing cover 4 Lip-seals

2 Crankshaft 5 Gasket
3 Oil trap

– Piston Rod
Variant B: Dismantle and Dismantle or assemble the oil trap and crankshaft seal according to
Assemble Gastight Fig. 1-100.
Crankshaft Seals
1 2 5 1 6
LA_M1_0013b_02
8 7 3 4 7 8
Fig. 1-100 Components of gastight crankshaft seal
1 Running ring 5 Spring

2 O-ring 6 Lip-seal
3 Spring guide ring with cylindrical pin 7 Sealing ring
4 Spring guide ring 8 Flat gasket (rubber)
Required Checks 1. Check the diametrical clearance between running rings (1) and shaft.
 Required clearance: 0.4–0.5mm
2. Check the diametrical clearance between spring guide rings (3, 4) and
running rings.
3. Check the crankshaft surface.
 The surface must be in perfect condition in the area where the
crankshaft seal is fitted.
4. Check the distance between the two spring guide rings.
We recommend to apply some hard plaster at three points between the
two spring guide rings and mount the crankshaft seal completely (see
Fig. 1-101). Let the hard plaster dry up and dismantle the crankshaft
seal again. The thickness of the hard plaster matches the distance be-
tween the rings.

– Piston Rod
LA_M1_0023a_01
Fig. 1-101 Apply hard plaster between the spring guide rings
 The distance must be at least 1.5mm.

5. Check the oil leakage while compressor is running.
 Oil leakage should no exceed 3–5 drops per minute.

– Piston Rod
Frame
1.30 Frame
• 1.17 Cylinder
• 1.25 Gear Oil Pump
• 1.26 Electric Motor
• 1.27 Coupling
• 1.28 Flywheel
• 1.29 Oil Trap and Crankshaft Seal
Special Tools none
Dismantle and Assemble Dismantle the frame according to Fig. 1-102. Please note the special nuts
SUPERBOLT® inside the frame.

– Piston Rod
Frame
LD_M0_0011a_01
Fig. 1-102 Dismantled frame (typical view)

– Piston Rod
Crankshaft Bearing
1.31 Crankshaft Bearing

Special Tools
6 5
LA_T9_0021b_01
Fig. 1-103 Lifting device for main bearing cover
1 Frame 4 Main bearing cover

2 Lifting device 5 Crankshaft
3 Bolt 6 Base plate

– Piston Rod
Crankshaft Bearing
LA_T9_0002b_01
3
1 High-pressure hose
2 Pressure head
3 Pump
General Remarks for Hydraulic Tightening Device

General instructions for hydraulic tightening device, used on main bear-
ings:
Important notes for tightening device and hand pump:

1. The vent valve of the hand pump must always be open when the pump
is in use.
2. For transport or refilling the hand pump, the vent valve as well as the
relief valve must be closed.
3. Use hydraulic oil ISO VG5 only.
4. Vent the hydraulic tightening device before initial use or reuse after
storage of more than 3 months.
• Assemble all parts of the hydraulic tightening device.
• Open the vent valve and relief valve of the hand pump and tighten
the threaded sleeves to push back oil or air from the hydraulic head
through the hoses into the pump cylinder.
• Disconnect all hoses from the hydraulic heads, close the relief
valve, vent all the hoses by opening the check valve in the con-
necting piece with a pin or screw driver and pump until oil flows out
without air. Make sure that no oil pressure remains. Oil pressure
cannot increase with an open check valve.
• Repeat this procedure for all hydraulic hoses.
• When all hydraulic heads and hoses are properly vented, the hy-
draulic device is ready to be used.

– Piston Rod
Crankshaft Bearing
Dismantle The crankshaft main bearing may be removed without removing the frame.
For unfastening and tightening, the specially-supplied tool must be used as
follows:
WARNING
Pressurized hydraulic tightening device
Improper use or loose parts of the hydraulic tightening device in conjunc-
tion with high oil pressure may cause injuries.
 Prior to any use check hoses and connections of pump and tightening
device for mechanical damages.
 Before assembling make sure that the system is not pressurized.
 Do not exceed the maximum pressure indicated.
 Check the oil pressure gauge periodically.
 Take into account that the pressure gauge indicates the oil pressure in
bar.
8 9 10
12
7
6
4
5
1
3
LA_T9_0008b_01
1 Cylinder 7 Supporting ring

2 Piston 8 Nipple
3 Supporting sleeve 9 Adapter
4 Gasket 10 Swivel elbow
5 Supporting ring 11 -
6 Gasket 12 Stroke indicator
1. Set up the tightening devices as shown in Fig. 1-105.

2. Firmly tighten pistons (see Fig. 1-105, Pos. 2). Then turn back the pis-
tons by one half of a turn (180°).

– Piston Rod
Crankshaft Bearing
3. Increase the hydraulic oil pressure carefully to the value as indicated in

the relevant Instruction Manual and make sure that the allowable piston
stroke (see Fig. 1-105, Pos.12) of the device is not exceeded.
4. Loosen the nuts using a mandril. Make sure that the nuts are not
touching the pistons. Lower pressure to 0 bar.
5. Open the pump relief valve and firmly tighten the pistons so that the oil
can flow back into the pump tank.
7. Lift the bearing cover with the lifting device (see Fig. 1-106).
6 5
LA_T9_0021b_01
Fig. 1-106 Lifting device
1 Frame 4 Main bearing cover

2 Lifting device 5 Crankshaft
3 Bolt 6 Base plate
Required Checks When assembling the main bearing, make sure that the bearing halves re-
main at its previous position. Do not swap used bearing halves. New ones
may be used either on top or on bottom. Verify the markings on the bearing
covers. They must match with the markings on the base plate.
Assemble Used Parts 1. Set up the tightening devices as shown in Fig. 1-107 and Fig. 1-108.

– Piston Rod
Crankshaft Bearing
1 Cylinder
8 9 10
2 Piston
3 Supporting sleeve
4 Gasket
2
5 Supporting ring
6 Gasket
12 7 Supporting ring
8 Nipple
7 9 Adapter
6
10 Swivel elbow
4 11 Mandril
5 12 Stroke indicator
1
3
LA_M1_0008b_01
11
Fig. 1-107
X
XLA_M1_0006c_02
Fig. 1-108 Arrangement for main bearing

– Piston Rod
Crankshaft Bearing
2. Firmly tighten pistons (see Fig. 1-107 Pos. 2).

3. Firmly set the nuts with a mandril (11).
4. Increase the hydraulic pressure referring to the relevant Instruction
Manual.
5. Firmly tighten the nuts with a mandril. Lower the oil pressure to 0 bar.
6. Check by means of a feeler gauge if gap “X” = 0 mm.
7. Increase the hydraulic pressure referring to the relevant Instruction
Manual. Make sure that the allowable piston stroke (12) of the device
is not exceeded.
8. Firmly tighten the nuts with a mandril. Then lower the oil pressure to 0
bar.
9. Check if the punch marks of the nuts line up with their corresponding
mark on the bearing cover. If the marks do not line up, unfasten the nut
and repeat steps 1 to 9.
10. Open the pump relief valve and firmly tighten the pistons (2) so that the
oil can flow back into the pump tank.
Assemble New Parts With the installation of a new bearing half, the projection “X” must be
checked as follows (see Fig. 1-109):
1. Install new bearing halves according to previous section for used parts,
steps 1 to 9.
2. Open the pump relief valve and firmly tighten the pistons (2) so that the
oil can flow back into the pump tank.
3. Remove one pressure head with high pressure hose (see Fig. 1-109).

– Piston Rod
Crankshaft Bearing
LA_M1_0006b_03
Fig. 1-109 Check of projection “X”
4. Turn back the piston (2) by one half of a turn (180°).

5. Increase the hydraulic oil pressure referring to the relevant Instruction
Manual. Make sure that the allowable piston stroke (12) of the device
is not exceeded.
6. Turn back the nut using a mandril. Make sure that the nut is not
touching the piston (2). Lower pressure to 0 bar.
7. Compare projection “X” with the values indicated in following table. If
the projection is not within these limits, the bearing halves must be re-
jected.
Compressor Type Bearing Dia. Projection “X”

4D225B 170 mm 0.20 – 0.45 mm
4D250B 200 mm 0.20 – 0.45 mm
4D250EK 240 mm 0.30 – 0.65 mm
2D250B 240 mm 0.30 – 0.65 mm
4D300B 240 mm 0.30 – 0.65 mm
4D375B 280 mm 0.30 – 0.70 mm
8. Tighten the loosened nut according to previous section for used parts,
step 1 to 11.

– Piston Rod
Axial Bearing
1.32 Axial Bearing

Special Tools none
Dismantle 1. Lift bearing cover.

2. Roll up the segments on top of the crankshaft.
3. Take the segments out.
1 2 3 4 5
LD_M0_0002b_01
Fig. 1-110 Typical view of main bearing drive end and axial bearing
1 Crankshaft
2 Connecting rod
3 Bearing cover
4 Main bearing drive end
5 Flywheel
6 Axial bearing

– Piston Rod
Dismantle Crankshaft Upwards
1.33 Dismantle Crankshaft Upwards

Completed activities:
• 1.17 Cylinder
• 1.27 Coupling
• 1.28 Flywheel
• 1.30 Frame
• 1.31 Crankshaft Bearing
• 1.32 Axial Bearing
Special Tools Spirit-level, lifting device

– Piston Rod
Dismantle Dismantle crankshaft according to following figures.
LD_M1_0012b_01
Fig. 1-111 Removal of axial bearing half
1 Bearing half
2 Crankshaft
WARNING
Crankshaft attached not exactly horizontal!
Damage of bearings and bearing shells, respectively.
 Make shure the crankshaft is in exact horizontal attitude: Check contin-
uously with spirit-level.

– Piston Rod
5
LD_M1_0011b_01
Fig. 1-112 Lifting of crankshaft
1 Spirit-level
2 Crankshaft
3 Base Plate
4 Bearing shell
5 Engraved markings

– Piston Rod
Assemble Assemble crankshaft according to following figures.
WARNING
Crankshaft attached not exactly horizontal!
Damage of bearings and bearing shells, respectively.
 Make sure the crankshaft is in exact horizontal attitude: Check contin-
uously with spirit-level.

– Piston Rod
5
LD_M1_0011b_01
Fig. 1-113 Installation of crankshaft in crankgear
1 Spirit-level
2 Crankshaft
3 Base Plate
4 Bearing shell
5 Engraved markings
1. Check engraved markings (see Fig. 1-113, Pos. 5) on bearing shells (4)
and base plate (3) for accordance.

– Piston Rod
2. Lower crankshaft (2) into the bearing shells (4).

3. Insert and roll down the axial bearing half (see Fig. 1-114, Pos. 1)
4. Fit bearing covers according to section 1.31 Crankshaft Bearing “As-
semble New Parts” or “Assemble Used Parts”.
LD_M1_0012b_01
Fig. 1-114 Insert axial bearing half
1 Bearing half
2 Crankshaft
Final Checks Bearing clearance: refer to the relevant Instruction Manual

Crankshaft deflection: refer to the relevant Instruction Manual

– Piston Rod

Components of Laby® Type D + E with Wedges Type Crosshead –
Piston Rod

Wedges Type Crosshead – Piston Rod

2.5 Crosshead Pin Bearing (without Cylinder Removal). . . . . . 27
2.6 Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.9 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.12 Bearing Bracket and Main Bearing . . . . . . . . . . . . . . . . . . . 39
2.13 Dismantle Crankshaft Sidewards . . . . . . . . . . . . . . . . . . . . 40
2.14 Crankshaft Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 40

Piston Rod

Piston Rod

• Switch Off Compressor
• Switch Off Colant System
• Suction Valves and Discharge Valves
• Cylinder Cover
• Frame Covers
Special Tools
1 2 3
LA_T9_0022b_01
Fig. 2-1 Cotter key in 3 pieces
1 Crosshead
2 Piston rod
3 Cotter key
LA_T9_0009a_01
Fig. 2-2 Eye bolt
Prior to measuring, clean all measuring tools, referring to the relevant In-
struction Manual.

Piston Rod

position.
Fig. 2-3).
1 2 3 4
7 6 5
A E
D C H G
LA_C1_0006b_03
B F

with D)

Piston Rod
Measure Cylinder Clearances
A
• a min. = X mm
a
• a max. = X mm
• b min. = X mm
• b max. = X mm
LA_C0_0002b_01
b
ual.
A Piston diameter
CAUTION
pressor failure.
clearance.
Measure Guide Bearing Clearances

Piston Rod
Dismantling Procedure
12
11
10
9 2
8 3
5
7
6
LA_C1_0023b_01
1 Guide bearing cover 7 Safety device

3 Oil scraper rings 9 Oil shield
4 Guide bearing 10 Piston rod gland
5 Wedge 11 Cylinder
6 Crosshead 12 Piston
5. Disconnect the piston rod (8) from the crosshead, proceeding as fol-
lows:
• Bring crosshead to TDC (Top Dead Centre).
• Loosen safety device (7) and knockout wedges (5).

Piston Rod
• Apply lube oil to the sliding faces and insert the cotter key (see
Fig. 2-6 Cotter key T97010).
• Drive in the middle wedge until the piston rod is forced out, a dull
sound can be heard.
1 2 3
LA_T9_0022b_01
Fig. 2-6 Cotter key T97010
1 Crosshead
2 Piston rod
3 Cotter key
Confirm that the two rounded parts of the cotter key are inserted as shown
in the figure above.
Make sure to allow the tapered centre wedge to work properly (tapered
opening between rounded pieces). Working order is correct, when the
stamped-on numbers of the three parts are facing to the same side.
6. Remove cotter key.

7. Lift piston and piston rod carefully.
bearing bush are not damaged.
9. Loosen guide bearing cover, the spring plate and remove the oil
scraper rings.

Piston Rod


vertical position.
1
LA_M5_0037b_01

3 Brad 7 Top

Piston Rod

Parts
Preparations

CAUTION
Install Oil Scraper
rod:
• Oil shield (1)

Piston Rod
6
LA_M5_0039b_01

rod (4) underneath.

Piston Rod
code numbers.
2 1 2 3 2
LA_M5_0011b_01

3 Marking

Piston Rod
2 1 2 3
LA_M5_0006b_01
2

3 Marking
Install Oil Shield

Piston Rod
Connecting Piston Rod to Crosshead
X
5 4
LA_M3_0003b_01
1 Piston rod
2 Wedges for piston rod
3 X = Minimum clearance 0.5 mm
4 Crosshead
5 Hexagonal screw
13. Make sure the number on the wedges corresponds with the crosshead
and piston rod.
14. Lower the piston rod completely. Apply some compressor lubricating oil
to all sliding surfaces and fit the wedges according to Fig. 2-11. Force
the wedges (2) firmly into its slot by hand, now use a copper punch and
a hammer and knock in the lower wedge approx. 15 mm from this po-
sition (see Fig. 2-11).
15. Secure the wedges with the hexagonal screw (5).

Piston Rod
3-piece Piston
1 2 3 4 5
LA_C1_0018c_01
6
Fig. 2-12 Dismantled piston
1 Piston rod
3 Piston skirt
6 Washer 0.5mm (one or several pieces)
Solid Piston
1 2 3
LA_C1_0019c_01
Fig. 2-13 Solid piston
1 Piston rod
2 Solid piston

Piston Rod
1 2 3 4
A B
LA_C1_0004b_01
5
1 Piston crown
2 Piston nut
3 Key
4 Piston skirt
5 Piston rod
Information about pretension measurements refer to the relevant Instruc-

tion Manual.
WARNING
Torques and Method.
reference marking during assembly. This also applies to inspections,
whether parts are replaced or not (i.e. when checking the piston preten-
sion). During reassembly of the parts, these markings will help to re-
cover the correct position of the piston skirt in relation to the cylinder.
The marking should be stamped or engraved only. When assembled
and installed the piston markings should always be on the “V”-side
(name plate side) of the compressor (see Fig. 2-15).

Piston Rod
1 2
xx*
: *xx
S/NoV *x*
V *x*
LA_C1_0005b_01
Fig. 2-15 Marking of piston crown and skirt

2 Piston skirt
ceed 0.02 mm.
LA_C1_0008b_01
h
Fig. 2-16 Overview
hmin = h - 1.5 mm
LA_C1_0008c_01
1 2

Fig. 2-14.
2. Compare the measured pretension with the values in the relevant In-
struction Manual.

Check cylinder clearances and record them:

Piston Rod
Cylinder Clearance with Spacer Ring

The cylinder cover of the 3rd stage is equipped with a spacer ring. The
value for clearance “a” – stated in the “Table of clearances” of the relevant
Instruction Manual – is specified with spacer ring.
Admissible Tolerances not Achieved?

If the values are not within the given tolerances, there might be a mix-up of
parts (e.g. wedges, piston rods or crosshead).
If there is no mix-up with the assembly, the cylinder clearance must be ad-
justed with distance washers of 0.5 mm thickness between the lower piston
crown and piston rod (Fig. 2-18).
1 2 3
5
LA_C0_0008b_01
Fig. 2-18 3-piece piston
1 Piston skirt
2 Piston rod
5 Washer 0.5 mm
1 2 3
LA_C0_0009b_01
1 Solid piston
2 Piston rod
3 Washer 0.5 mm

Piston Rod
Further Steps for Piston In general, proceed as mentioned within this section in part “Assemble New
Rod Replacement or Used Parts”, sequence 1 through 10.
Because new parts have to be fitted, the contact pattern of the tapered seat
(piston rod and crosshead) and of the wedges must be checked. The posi-
tion of the piston in the cylinder must also be checked. Proceed as follows:
clean off any oil on the piston rod taper and cross head seat with a sol-
vent. Apply some blue ink for a dye check.
2. Lower the piston rod and check the blue pattern, the cone should be
matching at its whole surface area (check contact pattern and run-out).
3. Apply some oil to the contact faces, between the wedges only, apply
blue ink to the outside (rounded side) and firmly force wedges by hand
into crosshead slot, now use a copper punch to hammer the lower
wedge in approx. 10 mm from this position. Check the clearances of the
piston to the cylinder. (Compare clearances with the piston clearances
taken with the old piston rod. Clearances should not change.
4. Remove the wedges and compare the contact faces to its counter part,
i.e. the top wedge to the corresponding part of the crosshead and the
lower wedge to the corresponding part of the piston rod. File off the high
points on the wedges only, with a fine file. Repeat this procedure 3 and
4 until the wedges get contact along the entire seat-engaging surface.
5. Finally force wedges by hand firmly into crosshead slot, now use a
copper punch to hammer the lower wedge in approx. 15 mm from this
position. The piston rod must drop about 0.4 mm into the tapered bore
during this procedure. The piston rod has to have a min. of 0.5 mm
clearance measured between the lower wedge and the lowest point of
the crosshead slot. Mark the position for the locking device hole. Dis-
mantle the wedges and drill the holes for the applicable locking device
(probably the old hole has to be closed first). Fit the wedges securely
with the safety device according to the drawing (Fig. 2-11).
6. Check piston clearances and compare them with the previous mea-
surements and record them as described in this section at the begin-
ning.
7. Verify the proper tightening torque of the piston nut. Install the cylinder
cover and tighten the nuts (see part “Final Checks” in this section).
8. Check cylinder clearance according to previous instructions and adjust
if necessary with washers (Fig. 2-18).
Adjusting of Asymmetric Crosshead Wedges

Piston rod (3) and crosshead (1) are connected with two asymmetric
wedges (2). Cotter keys allow to loose the wedging. After mounting of
piston rod and crosshead, the crossheads run-out with reference to the
piston rod has to be minimal. The contact patterns at the taper part of the
piston rod and at the back of the wedges (4) have to be even.

Piston Rod
4
3
LA_M3_0007b_01
5 4
Fig. 2-20 Adjustment of wedges
1 Crosshead
2 Wedges
3 Piston rod
4 Back of wedges
5 Sliding faces
Assembly of Crosshead and Piston Rod
1. Fit the taper part of the piston rod (3) into the tapered bore of the cross-
head (1) (check the contact pattern and run-out, touch up by blue ink).
2. Fit the wedges (2) into the slot (make it move freely).
3. Knock the large wedge in slightly, check run-out of crosshead, adjust
rounded backs of wedges.
4. Apply lube oil to the sliding faces (5) and force the wedge by hand
firmly into its slot and knock it in approx. 10 mm from this position.
Check the run-out.
5. Knock out lower wedge (2) with a mandrel, disassemble wedges and
adjust backs of wedges.

Piston Rod
6. Place cotter keys according to following figure in the way, that the flat
key (7) lays between the two rounded ones (6 and 8):
6
1
LA_T9_0022c_01
8
Fig. 2-21 Cotter keys
1 Crosshead
3 Piston rod
6 Upper cotter key
7 Middle cotter key
8 Lower cotter key
The cotter keys are placed in correct order, when the stamped-on numbers
are facing to the same side
Force out piston rod (3) from crosshead (1) by driving in the middle
cotter key (7); a dull sound can be heard. Remove cotter keys.

Piston Rod
7. Apply lube oil to the sliding faces (5). Force the wedges (2) again by
hand firmly into its slot and knock it in 15 mm from this position. The
piston rod must consequently enter into the tapered bore by approx.
0.4mm.
15 mm
0.4 mm
11
10
5
9
LA_M3_0003c_01
Fig. 2-22 Position of wedges
2 Wedges
5 Sliding faces
9 Locking plates
10 Hexagonal screw
11 Overlapping end
8. Check contact pattern of the wedges back and run-out of crosshead.

9. Dismantle the piston rod again, adjust the contact patterns of the taper
end and the wedges back.
10. Repeat points 7 to 9 until run-out and contact patterns are in order.
11. Short the large wedge on the two ends (11) in case it overlaps the
crosshead.
Make sure that the wedge is forced into the slot by 15 mm and the piston
rod has entered the tapered bore by at least 0.4 mm.
12. Drill the bore for the hexagonal screw (10) in the wedge in closest po-
sition to the crosshead neck when positioning the locking plates (9).
The bore in the locking plates are excentric in order to allow 4 different
positions for clearance-free adjustment.

Piston Rod

• Cylinder Cover
• Drain Lubricating Oil
• Guide Bearing
Special Tools none
Dismantle Required checks

Turn crank to BDC and measure clearance between crankshaft journal and
1 Connecting rod
1 2 Crosshead pin bearing
3 Crosshead pin
2
4 Circlip for crosshead pin bearing
4 8 Locking plate
6
LA_M4_0004b_01
Dismantle the connecting rod bearing as follows:

1. Measure bearing clearance and record it (see section Required
Checks).
2. Remove bolt locking device.
3. Slacken bolts.

Piston Rod

5. Lower connecting rod cover by unscrewing the bolts.

2. Fit connecting rod cover with bearing shell.
3. Tighten bolts according to the following instruction.
LA_M4_0005b_01
4

2 Locking plate
3 Bearing shell


“L1” – “L” = refer to the relevant Instruction Manual
 For applicable clearances refer to the relevant Instruction Manual.
6. Fit locking plate (2).

Piston Rod

• Switch Off Coolant System
• Cylinder Cover
• Frame Cover
• Guide Bearing
Special Tools
3
LA_T9_0018b_01
1 Crosshead
2 Support
3 Connecting rod

Piston Rod
XA_T9_0003a_01
XA_T9_0004a_01

Parts

Piston Rod

• Cylinder Cover
• Frame Covers
• Internal Gas Leakage Pipes
• Cylinder
• Guide Bearing
Special Tools • Press, freezer, oven
press.
Parts
respond to the set values given in the table of clearances of the rele-
3. The crosshead pin bearing must be cooled down to approximately–
20°C before it can be installed. Therefore, cool it in a freezer for about
12 hours.
line.

Piston Rod
2.5 Crosshead Pin Bearing (without Cylinder Re-

moval)
• Cylinder Cover
• Frame Cover
• Guide Bearing
Special Tools • Press, freezer, oven

• Support according to Fig. 2-27.
3
LA_T9_0018b_01
1 Crosshead
2 Support
3 Connecting rod
Dismantle 1. Lift crosshead with hoist and fixate connecting rod with locating device
(support) according to Fig. 2-27.
2. Turn the crosshead secured with the hoist. Remove crosshead pin with
pull-off device, see .
3. Remove crosshead through frame opening.
4. Remove connecting rod through frame opening.
5. Push the used crosshead pin bearing out of the connecting rod bore
with a press.
Parts

Piston Rod
Gear Oil Pump
respond to the set values given in the table of clearances, refer to the
relevant Instruction Manual.
3. The crosshead pin bearing must be cooled down to approximately–
20°C before it can be installed. Therefore, cool it in a freezer for about
12 hours.
line.
2.6 Gear Oil Pump

Special Tools
LA_T9_0009a_01
Fig. 2-28 Eye bolt

2. Dismantle the oil pump according to figure Fig. 2-29 and Fig. 2-30.

Piston Rod
Gear Oil Pump
1 2 3 4 5
LD_M2_0025b_01
7 6
1 Housing 5 O-ring
2 O-ring 6 Main bearing non-drive end
3 Bearing bracket 7 Crankshaft
4 O-ring

Piston Rod
Gear Oil Pump
12
11
10
9
13
8
LD_M2_0028b_01
4
3 2 1
Fig. 2-30 Crankshaft driven gear oil pump
1 Crankshaft 8 Driving flange

2 Bearing bracket 9 Nylon bush
3 O-ring 10 Oil temperature element
4 Housing 11 Oil pressure
5 Driven gearwheel 12 Frame
6 Driving gearwheel 13 Relief valve
7 Throttle valve
pressor. Bearing bracket (2) and housing (4) are sealed with O-rings (3).
shaft (1). The two gearwheels are of the same size and fit snugly in the
Assemble New or Used Assemble the gear oil pump in reverse order of dismanting procedure.
Parts

Piston Rod
Electric Motor
2.7 Electric Motor

Special Tools none

Parts
2.8 Coupling
Special Tools none

Assemble New or Used For assembly of the coupling, follow the instructions referring to the rele-
Parts vant Instruction Manual.

Piston Rod
Flywheel
2.9 Flywheel
• 2.8 Coupling
Special Tools
1 2 3
LA_T9_0023b_01
Fig. 2-31 Pull-off device for dismantling of flywheel (complete with threaded rod
and nut)
1 Crankshaft
2 Flywheel
3 Pull-off device
DANGER
Suspended loads!

Piston Rod
Flywheel
LA_XX_0044c_01


Piston Rod
Flywheel
3. Unfasten crankshaft nut (Fig. 2-33).
1 2
LA_L1_0022b_01
1 Crankshaft 5 Washer
2 Flywheel 6 Castellated nut for crankshaft
3 Key 7 Split pin
4 Feeler gauge
4. Remove crankshaft nut (6) and washer (5).

Piston Rod
Flywheel
5. Remove the flywheel, using the pull-off device (Fig. 2-34).
1 2 3
LA_T9_0023b_01
1 Crankshaft
2 Flywheel
3 Pull-off device
Parts
1 2 3 4 5 6
LA_L1_0001b_01
1 Crankshaft 4 Dial gauge

2 Flywheel 5 Washer
3 Measuring head 6 Castellated nut for crankshaft

Piston Rod

• 2.8 Coupling
• 2.9 Flywheel
Special Tools none
Dismantle and Assemble Dismantle or assemble the oil trap and crankshaft seal according to
Fig. 2-36.
1 2 5 1 6
LA_M1_0013b_02
8 7 3 4 7 8

2 O-ring 6 Lip-seal

Piston Rod
running rings.
two spring guide rings and mount the crankshaft seal completly (see
Fig. 2-37). Let the hard plaster dry up and dismantle the crankshaft seal
again. The thickness of the hard plaster matches the distance between
the rings.
LA_M1_0023a_01


Piston Rod

• 2.8 Coupling
• 2.9 Flywheel
Special Tools none
Dismantle and Assemble Dismantle the crankshaft seal according to Fig. 2-38.
2 3 4 5 6 7 8 9 10
11
LD_M1_0022b_01
Fig. 2-38 Pulling-off oil trap and crankshaft seal
1 Crankcase 7 Slinger
2 Crankshaft 8 O-ring
3 Sunk key 9 Pressure ring
4 Main bearing 10 Gasket
5 O-ring 11 Oil trap
6 Bearing bracket

Piston Rod
Bearing Bracket and Main Bearing
2.12 Bearing Bracket and Main Bearing

• Frame Covers
• 2.8 Coupling
• 2.9 Flywheel
Special Tools none
Dismantle and Assemble Dismantle or assemble the bearing bracket and main bearing according to
Fig. 2-39.
1 2 3 4 5
LA_M1_0019b_01
Fig. 2-39 Removal of bearing bracket and main bearing
1 Crankgear
2 Crankshaft
3 Main bearing
4 Bearing bracket
5 Oil trap
CAUTION
Risk of crankshaft drop!
Damage on crankshaft and bearings.
 Dismantle only the respective bearing bracket, never both sides!
Required Checks Measure clearance with feeler gauge at the upper circumference between
crankshaft and main bearing.

Piston Rod
Dismantle Crankshaft Sidewards
For applicable clearances: refer to the relevant Instruction Manual.
2.13 Dismantle Crankshaft Sidewards

Please refer to chapter 4 Dismantle Crankshaft sidewards of Laby® Type
K and small Type D.
2.14 Crankshaft Center Bearing

• Cylinder Cover
• Frame Covers
• Oil Heater
• Oil Strainer
• Guide Bearing
• 2.8 Coupling
• 2.9 Flywheel
• 2.12 Bearing Bracket and Main Bearing
• 2.13 Dismantle Crankshaft Sidewards
Special Tools none
Dismantle and Assemble Dismantle or assemble the center bearing according to figure Fig. 2-40.

Piston Rod
Crankshaft Center Bearing
Center Bearing
A-A 1
A 4 2
LA_M1_0012b_01
9 8 7 6 5
Fig. 2-40 Typical view of a center bearing
1 Frame 6 Crankshaft
2 Bearing housing 7 Set screw
3 Positioning pin 8 Shims
4 Center bearing 9 Threaded bolt
5 Fastening bolt
Required Checks 1. Do not exchange the shells!

 They are not identical.
2. Adjust clearance with shims (8).

Piston Rod

Components of Laby® Type K
3 Components of Laby® Type K
3.1 Frame Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.2 Drain Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5.1 Marking of Compressor Components. . . . . . . . . . 28
3.6 Internal Gas Leakage Pipes . . . . . . . . . . . . . . . . . . . . . . . . 30
3.7 Piston Rod Gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.8 External Gas Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.10 Oil Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.11 Guide Bearing Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.12 Guide Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.16 Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.17 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.18 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.19 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.21 Bearing Bracket and Main Bearing . . . . . . . . . . . . . . . . . . . 55
3.23 Crankshaft Center Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 56


Frame Covers
3.1 Frame Covers

Special Tools none
Variant A: Dismantle and 1. Remove all screws at the margin of the covers.
Assemble
LK_M0_0009a_01
Fig. 3-1 Frame cover removal (Variant A)

Frame Covers
Variant B: Dismantle and 1. Remove all screws at the margin of the covers.
Assemble
LK_M0_0020a_01
Fig. 3-2 Frame cover removal (Variant B)

3.2 Drain Lubricating Oil

Special Tools none
Drain 1. Drain the oil from the oil sump.

2. Drain the piping of the lubrication system.
3. Remove oil heater.
4. Remove and clean the oil strainer of the compressor (see section 3.4
Oil Strainer).
5. Clean the crankgear with a sponge (do not use fibrous textile).
6. Clean the duplex oil filter in accordance with the manufacturer’s in-
structions (see Technical Documentation).
7
LK_M2_0004b_01
Fig. 3-3 Gear oil pump
1 Gauge for crankgear pressure 5 Oil sight glass

2 Gauge for lubricating oil pressure 6 Oil drain
3 Gear oil pump 7 Connection for oil level switch
4 Oil strainer (and heater, if appli-
cable)
Refill The required lubricating oil quantity for the compressor crankgear is indi-
cated in the relevant Instruction Manual.
Additional oil for associated pipes, oil cooler and filters is required. Refer to
The oil filling of the compressor is contained in the crankgear. The level
may be checked at the oil sight glass. When the compressor is at standstill,
3/4 of the oil sight glass must be covered.

3/4
LA_M2_0008b_01
2
Fig. 3-4 Check oil level
1 Oil sight glass

2 Lubricating oil
3 Crankgear
Refill as follows:
1. Shut oil outlets.
2. Refit oil strainer, filter, etc.
3. Fill the compressor with fresh oil.
4. Use the prelubrication pump to fill the complete oil system.

Oil Heater
3.3 Oil Heater

Special Tools none
Dismantle and Assemble The oil heater is located in the crankgear:
LK_M1_0016c_02
1 2 3 4 5
1 Cover
2 O-ring
3 Oil strainer
4 Crankgear
5 Oil heater

Oil Strainer
3.4 Oil Strainer

• 3.3 Oil Heater
Special Tools none
Dismantle and Assemble The oil strainer is located in the crankgear:
LK_M1_0016c_02
1 2 3 4 5
1 Cover
2 O-ring
3 Oil strainer
4 Crankgear
5 Oil heater


• Suction Valves and Discharge Valoves
• Cylinder Cover
Special Tools
1 2 3
LA_T9_0022b_01
Fig. 3-7 Cotter key in 3 pieces
1 Crosshead
2 Piston rod
3 Cotter key
LA_T9_0009a_01
Fig. 3-8 Eye bolt
Prior to measuring, clean all measuring tools, referring to the relevant In-
struction Manual.


position.
Fig. 3-9).

1 2 3 4
7 6 5
A E
D C H G
LA_C1_0006b_03
B F

with D)

A
• a min. = X mm
a
• a max. = X mm
• b min. = X mm
• b max. = X mm
LA_C0_0002b_01
b
ual.
A Piston diameter
CAUTION
pressor failure.
clearance.
5. Disconnect the piston rod from the crosshead, proceeding as follows:

• Bring crosshead to TDC (Top Dead Centre).
• Loosen safety device and knockout wedges.
• Apply lube oil to the sliding faces and insert the cotter key.
• Drive in the middle wedge until the piston rod is forced out, a dull
sound can be heard.

1 2 3
LA_T9_0022b_01
Fig. 3-11 Cotter key T97010
1 Crosshead
2 Piston rod
3 Cotter key
Confirm that the two rounded parts of the cotter key are inserted as shown
in the figure above.
Make sure to allow the tapered centre wedge to work properly (tapered
opening between rounded pieces). Working order is correct, when the
stamped-on numbers of the three parts are facing to the same side.
6. Remove cotter key.

7. Lift piston and piston rod carefully.
bearing bush are not damaged.
9. Loosen guide bearing cover, the spring plate and remove the oil
scraper rings.


vertical position.
LA_M5_0037b_01
8
Fig. 3-12 Oil scraper rings (packing)

3 Brad 7 Top


Parts
Preparations

CAUTION
specification prior to assembling or installation.
Install Oil Scraper
3. Lower the oil-free piston rod through the gland to approximately 50 mm

above the guide bearing housing.
4. Using the correct sequence, fit the following parts onto the dry piston
rod:
• Oil shield (1) without garter spring
• Guide bearing cover (2)

6
LA_M5_0039b_01

rod (4) underneath.

code numbers.
2 1 2 3 2
LA_M5_0011b_01

3 Marking

2 1 2 3
LA_M5_0006b_01
2

3 Marking
Install Oil Shield

Crosshead – Piston Rod Connection
X
5 4
LA_M3_0003b_01
1 Piston rod
2 Wedges for piston rod
3 X = Minimum clearance 0.5 mm
4 Crosshead
5 Hexagonal screw
13. Make sure the number on the wedges corresponds with the crosshead
and piston rod.
14. Lower the piston rod completely. Apply some compressor lubricating oil
to all sliding surfaces and fit the wedges according to Fig. 3-16. Force
the wedges (2) firmly into its slot by hand, now use a copper punch and
a hammer and knock in the lower wedge approx. 15 mm from this po-
sition (see Fig. 3-16).
15. Secure the wedges with the hexagonal screw (5).
16. Before tightening the screws of the guide bearing cover, turn the fly-
wheel manually for at least 1 full turn.

Dismantle and Assemble Dismantle and assemble the piston according to Fig. 3-17 .
3-piece Piston
1 2 3 4 5
LA_C1_0018c_01
6
Fig. 3-17 Dismantled piston
1 Piston rod
3 Piston skirt
Solid Piston
1 2 3
LA_C1_0019c_01
1 Piston rod
2 Solid piston

1 2 3 4
A B
LA_C1_0004b_01
5
1 Piston crown
2 Piston nut
3 Key
4 Piston skirt
5 Piston rod
For information about pretension measurements refer to the relevant In-

struction Manual.
WARNING
Torques and Method.
reference marking during assembly. In case a piston is disassembled
for inspection purposes, with or without replacing parts (i.e. checking of
piston pretension). During reassembly of the parts, these markings will
facilitate to have the identical position of the piston skirt in relation to
the cylinder.
Such marking shall be stamped or engraved only. In the assembled
and installed position of a piston, the marking shall always be on the
“V”-side (name plate side) of the compressor (see Fig. 3-20).


1 2
2 Piston skirt
xx*
: *xx
S/NoV *x*
V *x*
LA_C1_0005b_01
Fig. 3-20 Marking of piston crown and
skirt
ceed 0.02 mm.
LA_C1_0008b_01
h
Fig. 3-21 Overview
hmin = h - 1.5 mm
LA_C1_0008c_01
1 2

Fig. 3-19.
2. Compare the measured pretension with the values in the relvant In-
struction Manual.
Admissible Tolerances not Achieved?

If the values are not within the given tolerances, there might be a mix-up of
parts (e.g. wedges, piston rods or crosshead).

If there is no mix-up with the assembly, the cylinder clearance must be ad-
justed with distance washers of 0.5 mm thickness between the lower piston
crown and piston rod (Fig. 3-23 and Fig. 3-24).
1 Piston skirt
1 2 3
2 Piston rod
5 Washer 0.5 mm
4
LA_C0_0008b_01
Fig. 3-23 3-piece piston
1 Solid piston
1 2 3
2 Piston rod
3 Washer 0.5 mm
LA_C0_0009b_01
Further Steps for Piston In general, proceed as mentioned within this section in part “Assemble New
Rod Replacement or Used Parts”, sequence 1 through 10.
Because new parts have to be fitted, the contact pattern of the tapered seat
(piston rod and crosshead) and of the wedges must be checked. The posi-
tion of the piston in the cylinder must also be checked. Proceed as follows:
clean off any oil on the piston rod taper and cross head seat with a sol-
vent. Apply some blue ink for a dye check.
2. Lower the piston rod and check the blue pattern, the cone should be
matching at its whole surface area (check contact pattern and run-out).
3. Apply some oil to the contact faces, between the wedges only, apply
blue ink to the outside (rounded side) and firmly force wedges by hand
into crosshead slot, now use a copper punch to hammer the lower

wedge in approx. 10 mm from this position. Check the clearances of the

piston to the cylinder. (Compare clearances with the piston clearances
taken with the old piston rod. Clearances should not change.
4. Remove the wedges and compare the contact faces to its counter part,
i.e. the top wedge to the corresponding part of the crosshead and the
lower wedge to the corresponding part of the piston rod. File off the high
points on the wedges only, with a fine file. Repeat this procedure 3 and
4 until the wedges get contact along the entire seat-engaging surface.
5. Finally force wedges by hand firmly into crosshead slot, now use a
copper punch to hammer the lower wedge in approx. 15 mm from this
position. The piston rod must drop about 0.4 mm into the tapered bore
during this procedure. The piston rod has to have a min. of 0.5 mm
clearance measured between the lower wedge and the lowest point of
the crosshead slot. Mark the position for the locking device hole. Dis-
mantle the wedges and drill the holes for the applicable locking device
(probably the old hole has to be closed first). Fit the wedges securely
with the safety device according to the drawing (Fig. 3-16).
6. Check piston clearances and compare them with the previous mea-
surements and record them as described in this section at the begin-
ning.
7. Verify the proper tightening torque of the piston nut. Install the cylinder
cover and tighten the nuts (see part “Final Checks” in this section).
8. Check cylinder clearance clearances according to previous instructions
and adjust if necessary with washers (Fig. 3-23 and Fig. 3-24).
Adjusting of Asymmetric Crosshead Wedges

Piston rod (3) and crosshead (1) are connected with two asymmetric
wedges (2). Cotter keys allow to loose the wedging. After mounting of
piston rod and crosshead, the crossheads run-out with reference to the
piston rod has to be minimal. The contact patterns at the taper part of the
piston rod and at the back of the wedges (4) have to be even.

4
3
LA_M3_0007b_01
5 4
Fig. 3-25 Adjustment of wedges
1 Crosshead
2 Wedges
3 Piston rod
4 Back of wedges
5 Sliding faces
Assembly of Crosshead and Piston Rod
1. Fit the taper part of the piston rod (3) into the tapered bore of the cross-
head (1) (check the contact pattern and run-out, touch up by blue ink).
2. Fit the wedges (2) into the slot (make it move freely).
3. Knock the large wedge in slightly, check run-out of crosshead, adjust
rounded backs of wedges.
4. Apply lube oil to the sliding faces (5) and force the wedge by hand
firmly into its slot and knock it in approx. 10 mm from this position.
Check the run-out.
5. Knock out lower wedge (2) with a mandrel, disassemble wedges and
adjust backs of wedges.

6. Place cotter keys according to following figure in the way, that the flat
key (7) lays between the two rounded ones (6 and 8):
6
1
LA_T9_0022c_01
8
Fig. 3-26 Cotter keys
1 Crosshead
3 Piston rod
6 Upper cotter key
7 Middle cotter key
8 Lower cotter key
The cotter keys are placed in correct order, when the stamped-on numbers
are facing to the same side
Force out piston rod (3) from crosshead (1) by driving in the middle
cotter key (7); a dull sound can be heard. Remove cotter keys.

7. Apply lube oil to the sliding faces (5). Force the wedges (2) again by
hand firmly into its slot and knock it in 15 mm from this position. The
piston rod must consequently enter into the tapered bore by approx.
0.4mm.
15 mm
0.4 mm
11
10
5
9
LA_M3_0003c_01
Fig. 3-27 Position of wedges
2 Wedges
5 Sliding faces
9 Locking plates
10 Hexagonal screw
11 Overlapping end
8. Check contact pattern of the wedges back and run-out of crosshead.

9. Dismantle the piston rod again, adjust the contact patterns of the taper
end and the wedges back.
10. Repeat points 7 to 9 until run-out and contact patterns are in order.
11. Short the large wedge on the two ends (11) in case it overlaps the
crosshead.
Make sure that the wedge is forced into the slot by 15 mm and the piston
rod has entered the tapered bore by at least 0.4 mm.
12. Drill the bore for the hexagonal screw (10) in the wedge in closest po-
sition to the crosshead neck when positioning the locking plates (9).
The bore in the locking plates are excentric in order to allow 4 different
positions for clearance-free adjustment.

3.5.1 Marking of Compressor Components
numbered.
On the assembled compressor, these markings must lie on the right hand
side when looking from the non-drive end towards the drive end.
The numbering of the individual parts starts with a V1 from the non-drive
end and ascends to V2, V3 etc. towards the drive end. Furthermore, the se-
rial no. is marked on important compressor components.
Some parts are only marked with a matching number, like the following:
• Connecting rod – connecting rod bearing shells
• Crankshaft main bearing – bearing cover
• Connecting rod – connecting rod bolts

10
11
12
LK_XX_0031b_01
Fig. 3-28 Important markings on a Laby® compressor type K
1 Cylinder cover 7 Wedge (V1/V2 etc. only)

2 Upper piston crown 8 Crosshead
3 Gland flange 9 Crosshead pin
4 Guide bearing 10 Name plate
5 Cylinder (serial no. only) 11 Connecting rod
6 Frame (serial no. only) 12 Connecting rod cover

Internal Gas Leakage Pipes
3.6 Internal Gas Leakage Pipes

Special Tools none
Dismantle and Assemble Dismantle and assemble the internal gas leakage pipes according to
Fig. 3-29.
B A
LA_C5_0022b_01
1 2
Fig. 3-29 Piston rod gland gas leakage pipes (typical view)
A Cylinder 1st stage

B Cylinder 2nd stage
1 Piston rod gland
2 Gas leakage pipes

Piston Rod Gland
3.7 Piston Rod Gland

• Cylinder Cover
Special Tools none
Dismantle 1. Unfasten gland flange and carefully lower the complete piston rod
gland.
The gland flange cannot be taken out through the lower ports of the cyl-
inder. Whenever a gland flange must be replaced, removal of cylinder
is required.
2. Dismantle piston rod gland and clean individual parts.
Required Checks 1. Inspect individual parts for possible damage. Grooves and front faces
must not be damaged.
2. Measure the radial clearance of the one-piece rings on the piston rod
(on oil scraper area).
Measured gland ring clearance with new gland rings refer to the relevant
Instruction Manual.

Parts
All components coming into contact with process gas must be clean and
free of grease and oil.
When using solvents, observe manufacturer’s safety precautions.

Piston Rod Gland
Variant A
8 1
2
7
4
6
LK_C5_0002b_01
Fig. 3-30 Piston rod gland
1 Gland chamber (top) 5 Nipple

2 Gland chamber (middle) 6 Gasket
3 Intermediate ring 7 Gland ring
4 Gland flange 8 Spring
Procedure:
1. Place bottom disc of dismantling and assembling device on top of
guide bearing.
2. Place gland flange (4) with bottom gland ring (7) on bottom disc.
• 2 gland chambers (2) with gland rings and springs

6. Tighten flange slightly. With flange tightened, the gland rings must be
movable radially.

Piston Rod Gland
Variant B
9 1
2
8
7 4
LK_C5_0001b_01
Fig. 3-31 Piston rod gland
1 Gland chamber (top) 6 Gland flange

2 Gland chamber (middle) 7 O-ring
3 Intermediate ring 8 Gland ring
4 Gasket 9 Spring
5 Nipple
Procedure:
1. Place gland flange (6) with bottom gland ring (8) and springs (9) on top
of guide bearing.
4. Place this stack on top of the intermediate ring.

6. Tighten flange slightly. With flange tightened, the gland rings must be
movable radially.

External Gas Pipes
3.8 External Gas Pipes

Special Tools none
Dismantle and Assemble For details concerning external gas pipes please refer to “General Arrange-
ment” in the relevant Instruction Manual.

Cylinder
3.9 Cylinder
• Cylinder Cover
Special Tools
XA_T9_0007a_01
Fig. 3-32 Flogging spanner
Dismantle 1. Remove coolant pipes from cylinder.

2. Loosen the nuts of the threaded bolts.
DANGER
Suspended loads!

4. Lift off the cylinder. Be careful that the threaded bolts do not touch the
bores in the frame.

Cylinder

Parts
CAUTION
All components coming into contact with process gas must be clean (oil-
free and free of grease).
When using solvents, observe the safety precautions of the manufacturer.
1. Degrease gas leakage pipes of piston rod glands referring to the rele-
2. Place them on the frame inside the distance piece.
DANGER
Suspended loads!

4. When lowering the cylinder onto the frame, be careful that the threaded
bolts do not touch the bores in the frame.
5. Pay attention that the centering pins fit properly into the corresponding
bores in the cylinder.

Oil Scraper
1 Plug
1 2 3 4 5
2 Cylinder
3 Centering pin
4 Epoxy resin
5 Frame
LA_C0_0003b_01
Fig. 3-33 Centering pin
6. Tighten the nuts of the threaded bolts with the mandatory tightening
torque.
3.10 Oil Scraper

• Cylinder Cover
Special Tools none
Dismantle and Assemble A detailed description of assembling the oil scraper see section 3.5 Piston
and Piston Rod.

Guide Bearing Bush
3.11 Guide Bearing Bush

• Cylinder Cover
• 3.10 Oil Scraper
Special Tools Dismouting device for bush (see Fig. 3-34)
Dismantle If the diametrical clearance between bush and piston rod exceed the Dia.
“B” (for applicable clearances refer to the relevant Instruction Manual), re-
place the bush with the device to be made at site as shown in Fig. 3-34.
1 2 3 4
LA_M5_0026b_01
Fig. 3-34 Dismantle guide bearing bush
1 Guide bearing
2 Bearing bush
3 Dismounting device
4 Crosshead

Guide Bearing Bush
8 1
7 2
LA_M5_0032b_01
Fig. 3-35 Guide bearing details
1 Hexagonal nut 5 Bearing housing

2 Usit ring 6 Spring plate
3 Crown ring 7 O-ring
4 Bearing bush 8 Guide bearing cover
Required Checks Before fitting the new bush, check the clearance between bush and piston
rod (refer to the relevant Instruction Manual).

Guide Bearing
3.12 Guide Bearing

• Cylinder Cover
• 3.9 Cylinder
Special Tools none
Dismantle Before removal and inspection, the guide bearing clearance must be mea-
sured.
Measure the clearance with a feeler gauge.
For applicable clearances see Table of Clearances in the relevant Instruc-

tion Manual.
Should doubts arise about acceptance of measured clearance, contact our

Technical Service Support that will gladly assist you.
1. Loosen the screws and remove the guide bearing according to

Fig. 3-36

Guide Bearing
1 2 3 4
LK_M5_0003b_01
Fig. 3-36 Typical view of a guide bearing without cooling and with open design
1 Bearing housing 5 Oil scraper rings (according to

2 Piston rod application: 2 or 3 pieces)
3 Oil shield 6 Crown ring
4 Guide bearing cover 7 Bearing bush


• Cylinder Cover
Special Tools none
Dismantle
1 Connecting rod
1 2 Crosshead pin bearing
3 Crosshead pin
2
4 Circlip for crosshead pin bearing
4 8 Locking plate
6
LA_M4_0004b_01
1. Measure bearing clearance and record it (see section Required

Checks).
2. Remove bolt locking device.
3. Slacken bolts.
5. Lower connecting rod cover by unscrewing the bolts.
Required Checks Turn crank to BDC and measure clearance between crankshaft journal and


2. Fit connecting rod cover with bearing shell.
3. Tighten bolts according to the following instruction.
LA_M4_0005b_01
4

2 Locking plate
3 Bearing shell


“L1” – “L” = refer to the relevant Instruction Manual

6. Fit locking plate (2).


Status • Switch Off Compressor
• Cylinder Cover
• 3.9 Cylinder
Special Tools
XA_T9_0003a_01
XA_T9_0004a_01

Parts


• Cylinder Cover
• 3.9 Cylinder
press.
Parts
respond to the set values given in the table of clearances of the rele-
12 hours.
line.

Gear Oil Pump
3.16 Gear Oil Pump

Special Tools
LA_T9_0009a_01
Fig. 3-40 Eye bolt

2. Dismantle the oil pump according to figure Fig. 3-41 and Fig. 3-42
LK_M2_0008a_01

Gear Oil Pump
12
11
10
LK_M2_0005b_01
3 2 1
Fig. 3-42 Typical view of crankshaft driven gear oil pump
1 Crankshaft 7 Throttle valve

2 Bearing bracket 8 Driving flange
3 O-ring 9 Nylon bush
4 Housing 10 Crankgear pressure
5 Driven gearwheel 11 Gear oil pump outlet pressure
6 Driving gearwheel 12 Frame
pressor. Bearing bracket (2) and housing (4) are sealed with O-rings (3).
shaft (1). The two gearwheels are of the same size and fit snugly in the
Assemble New or Used Assemble the gear oil pump in reverse order of dismanting procedure.
Parts

Electric Motor
3.17 Electric Motor

Special Tools none

Parts
3.18 Coupling
Special Tools none

Assemble New or Used For assembly of the coupling, refer to the relevant Instruction Manual.
Parts

Flywheel
3.19 Flywheel
• 3.18 Coupling
Special Tools
1 2 3
LA_T9_0023b_01
Fig. 3-43 Pull-off device for dismantling of flywheel (complete with threaded rod
and nut)
1 Crankshaft
2 Flywheel
3 Pull-off device
DANGER
Suspended loads!

Flywheel
LA_XX_0044c_01


Flywheel
3. Unfasten crankshaft nut (Fig. 3-45).
1 2
LA_L1_0022b_01
1 Crankshaft 5 Washer
2 Flywheel 6 Castellated nut for crankshaft
3 Key 7 Split pin
4 Feeler gauge
4. Remove crankshaft nut (6) and washer (5).

Flywheel
5. Remove the flywheel, using the pull-off device (Fig. 3-46).
1 2 3
LA_T9_0023b_01
1 Crankshaft
2 Flywheel
3 Pull-off device
Parts
1 2 3 4 5 6
LA_L1_0001b_01
1 Crankshaft 4 Dial gauge

2 Flywheel 5 Washer
3 Measuring head 6 Castellated nut for crankshaft


• 3.18 Coupling
• 3.19 Flywheel
Special Tools none
Dismantle and Assemble Dismantle or assemble the oil trap and crankshaft seal according to
Fig. 3-48.
1 2 5 1 6
LA_M1_0013b_02
8 7 3 4 7 8

2 O-ring 6 Lip-seal

running rings.
two spring guide rings and mount the crankshaft seal completly (see
Fig. 3-49). Let the hard plaster dry up and dismantle the crankshaft seal
again. The thickness of the hard plaster matches the distance between
the rings.
LA_M1_0023a_01


Bearing Bracket and Main Bearing
3.21 Bearing Bracket and Main Bearing

• 3.18 Coupling
• 3.19 Flywheel
Special Tools none
Dismantle and Assemble Dismantle or assemble the bearing bracket and main bearing according to
Fig. 3-50.
1 2 3 4 5
LA_M1_0019b_01
Fig. 3-50 Removal of bearing bracket and main bearing
1 Crankgear
2 Crankshaft
3 Main bearing
4 Bearing bracket
5 Oil trap
CAUTION
Risk of crankshaft drop!
Damage on crankshaft and bearings.
 Dismantle only the respective bearing bracket, never ever both sides!
Required Checks Measure clearance with feeler gauge at the upper circumference between
crankshaft and main bearing.

For applicable clearances: refer to the relevant Instruction Manual.

Please refer to chapter 4 Dismantle Crankshaft sidewards of Laby® Type
K and small Type D.
3.23 Crankshaft Center Bearing

• Cylinder Cover
• 3.3 Oil Heater
• 3.4 Oil Strainer
• 3.18 Coupling
• 3.19 Flywheel
• 3.21 Bearing Bracket and Main Bearing
• 3.22 Dismantle Crankshaft Sidewards
Special Tools none
Dismantle and Assemble Dismantle or assemble the center bearing according to figure Fig. 3-51.

Center Bearing
A-A 1
A 4 2
LA_M1_0012b_01
9 8 7 6 5
Fig. 3-51 Typical view of a center bearing
1 Frame 6 Crankshaft
2 Bearing housing 7 Set screw
3 Positioning pin 8 Shims
4 Center bearing 9 Threaded bolt
5 Fastening bolt
Required Checks 1. Do not exchange the shells!

 They are not identical.
2. Adjust clearance with shims (8).


Dismantle Crankshaft sidewards of Laby® Type K and small Type D
4 Dismantle Crankshaft sidewards of Laby®

Type K and small Type D



• Cylinder Cover
• Frame Covers
• Oil Strainer
• Gas Leakage Pipes
• Electric Motor
• Coupling
• Flywheel
• Oil Trap and Crankshaft Seal
Special Tools Lifting/balancing device
Dismantle 1. Dismantle connecting rod bearing covers and bearings according to

section 1.21 Connecting Rod Bearing.
2. Lift and secure pistons according to Fig. 4-1.

LK_M1_0009a_01
Fig. 4-1 Lifting of pistons (typical view)
3. Dismantle gear oil pump according to section 1.25 Gear Oil Pump.
4. Fix bearing bracket non-drive end according to Fig. 4-2.

LK_M1_0006a_01
Fig. 4-2 Fixation of bearing bracket non-drive end
5. Dismantle bearing bracket and main bearing according to section 2.12

Bearing Bracket and Main Bearing.
6. Attach a rope to the crankshaft.
7. Attach a lifting/balancing device to the crankshaft, see Fig. 4-3. LK_M1_0007a_01
Fig. 4-3 Attach lifting/balancing device

8. Loosen set screw of center bearing (if applicable).

9. Dismantle crankshaft sidewards according to Fig. 4-4.
LK_M1_0008a_01
Fig. 4-4 Dismantle crankshaft sidewards
Required Checks 1. Measure the clearance between the bearing and bearing journal.
 Replace bearing if clearance is out of tolerance.
2. Check crankshaft for any damage on bearing journal surface.
 Sometimes it is possible to overhaul crankshafts in case of dam-
aged bearing journal surface.
3. Check counterweights (if applicable) for perfect seating and fixation.
 Retighten nuts if required.
Assemble Newor Used Installation takes place in reverse order to dismantling.

Parts

Earlier Laby® Compressors with Thick Bearing Shells
5 Earlier Laby® Compressors with Thick

Bearing Shells
5.1 Assemble the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5.2 Assemble the Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Assemble the Gear Oil Pump to the Compressor. . . . . . . . 10
5.4 Assemble the Oil Trap at Flywheel Side . . . . . . . . . . . . . . . 11
5.5 Assemble the Flywheel (and Barring Gear for large Com-
pressor Types) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


Assemble the Crankshaft
5.1 Assemble the Crankshaft

Clean the crankshaft bearing, the crankshaft and the bearing saddles in the
base plate (5). Before assembling the lower bearing shells (4) into the
bearing saddles, the white metal in the gliding surfaces of the bearing shell
must be scraped. Thereby, the possible deposits of dust which may accu-
mulate on the white metal, will be definitively removed. Furthermore, the
blue spotted points at the scraped bearings are also more visible. The
lower bearing shells are now clamped dry – without oil – into the bearing
saddles. This is most suitably done with hard wood (3), which is placed on
both sides of the stud bolts and clamped by the nuts. This also prevents the
bearing shell from turning while applying the blue ink onto the crankshaft.
1 2 3
LA_M1_0029b_01
5 4
Fig. 5-1 Assemble the crankshaft
1 Tension bolt 3 Hard wood

2 Bearings equally protruding on both 4 Bearing shell
sides 5 Base plate
Use steel wire ropes for lifting the crankshaft. The supporting points at the
crankshaft must be protected to prevent damage by the steel wire ropes.
For a evenly lowering of the crankshaft into the bearings, the crankshaft
must hang as horizontally as possible (check by using a spirit level).
Slightly color the relevant areas of the crankshaft surface with blue ink to
make the contact points of the crankshaft in the bearings visible. The blue
ink also serves as a lubricant when turning the crankshaft.
Utmost caution is called for that the crankshaft front face is not damaged
when lowering the crankshaft into the axial bearing. The best way to turn
the crankshaft is to attach 2 bolts into the coupling bolt holes and use a
round wood bar as a lever. Crankshafts with a conical end are turned by a
key and a screwed-on nut. While turning the crankshaft when applying the
blue ink, measure the crankshaft deflection simultaneously.

The dial indicator (1) must be placed outermost between the crankweb ac-
cording to Fig. 5-2. At one turn of the crank the maximum deflection of the
dial indicator must not exceed 0.01 mm. This procedure has to be done for
all cranks. The level of the crankshaft is checked by using a spirit level (4).
This must correspond with the base plate.
LA_M1_0030b_01
1 2 3
Fig. 5-2 Checking the crankshaft deflection at the crankshaft
1 Dial indicator 3 Bearings

2 Crankshaft 4 Spirit level
Lift the crankshaft to check the blue inked contact areas of the bearings.
Please note, that the crankshaft must be lifted as horizontally as possible.
Given that the crankshaft has been scraped in our shop, significant devia-
tions should not occur. Application of blue ink on the crankshaft is only
meant as a check.
Experience has shown, that the crankshaft is correctly supported in a once
scraped bearing. The bearings should only bear 2/3 of the whole bearing
surface according to Fig. 5-3. The transition of oil pocket to oil wedge sur-
face and bearing surface must be carried out steadily.

LA_M1_0031b_01
4
Fig. 5-3 Bearing surface
X Total bearing surface 2 Oil wedge surface

Y approx. 2/3 supporting surface of 3/ 3 Oil groove
3 bearing surface 4 Bearing shell
1 Oil pocket
The white metal of the bearings must only be machine finished by using a
scraping tool. It is strictly prohibited to use emery cloth.
After positioning the crankshaft into the lower bearing shells, the upper
bearing shells with bearing covers will be assembled. It is advisable to
scrape the white metal of the upper bearing shells (4) as well. To prevent
oil loss, the shims, which are screwed onto the lower bearing shell, may not
overlap the crankshaft too much. The clearance between crankshaft and
shim must not exceed 0.1 mm and must be adjusted by using a feeler
gauge (see Fig. 5-4). When assembling the bearing covers, be sure that
they are tightened evenly. With a completely tightened cover, the clearance
between base plate and cover must be equally distributed in all 4 corners.
The bearing clearance is measured by a feeler gauge and should match
the relevant technical specification (see attached graphic no. 4-
106.033.294 in chapter 6 Appendix concerning adjustment of 2-piece
crankshafts and connecting rod bearings).

1 2 3 4
LA_M1_0032b_01
5 6
Fig. 5-4 Check clearance adjustment
X Clearance S 3 Bearing cover

X Clearance X 4 Bearing
1 Feeler gauge 5 Crankshaft
2 Shim 6 Base plate
Slightly loosen the screws, place feeler gauge 0.1 mm between crankshaft
(5) and shims (2), press shims against crankshaft and tighten the screws.
Adjust the clearance X equally in all 4 corners (tolerance: +/-0.2 mm).
Clearance S must match the grafik 4-106.033.29 for 2-piece bearings with
tightened bearing cover (3) of crankshaft bearings and connecting rod
bearings.
The bearing cover nuts must be tightened thoroughly.
The axial clearance of the axial bearing measures between approx. 0.10
and 0.25 mm depending on the compressor type.
Check the crankshaft deflection once more after assembly of the bearing
covers.
For cleaning purposes, the bearings (4) and the crankshaft must be disas-
sembled afterwards. It is advisable to mark the nuts and bolts of the bearing
covers and ensure that they are tightened with the same torque at final as-
sembly.
Carefully wash the oil groove in the base plate and the oil pipes with crude
oil or petroleum and blow out with compressed air. Tighten the fittings of oil
piping thoroughly and secure by a locking wire. Afterwards slightly oil the
bearing saddles and the lower bearing shells and clamp the bearing shells
together with the hard wood into the bearing saddle (see Fig. 5-1). The
crankshaft and its oil grooves must be cleaned as well. After oiling of bear-
ings and bearing surfaces at the crankshaft, the crankshaft is lowered into
the bearings. For oiling the bearings use the same oil as will be used later
for operating the compressor. The upper bearing halves are also oiled and

the bearing covers tightened. Secure the crown nut with a split pin. As a
final check, the bearing clearances are measured by using a feeler gauge
and the crankshaft deflection is checked. We advise you to note the mea-
sured values on a control sheet.
For assembly, it is well understood that the surrounding area of the com-
pressor should be as dust-free as possible. During interruption of as-
sembly, cover the compressor with a plastic cover.

Assemble the Frame
5.2 Assemble the Frame

Lifting specification for frame (3) on a crane (mainly for frames with weights
exceeding 4 tons).
1 2 3
LA_T9_0044b_01
Fig. 5-5 Assemble the frame
1 Steel wire ropes

2 Round wood, pressure pipe or round steel bar
3 Frame
The blank parts, which do not get in contact with the process gas, are pro-
tected by a rust preventative. This protection film will be removed with
crude oil or petroleum before placing the frame onto the base plate. Con-
taminants, residues and possible scratches on the supporting surface of
the frame and base plate must be removed (by using a fine file and fine
emery cloth). In the meantime, the crosshead bores must also be cleaned.
The bores for bolts at the frame foot and the 2 conical bores for the posi-
tioning pins must be perfectly clean.
The separation planes (base plate/frame) must be washed with Acetone for
better adhesion of the provided sealing compound when assembling the
two parts.
The application of a sealing compound can be done in two different man-
ners:
1. By pressing the sealing compound out of the tube and placing a line of
approx. 4–5mm thickness onto the base plate surface, outside of the
oil groove and between the stud bolts.
2. Same procedure as described above, but the line is evenly distributed
on the surface of the base plate by a scraper.
In case of cold atmospheric conditions, preheat the sealing compound
in a tube for easier distribution.
When placing the frame onto the base plate, take care that the frame is
hanging absolutely horizontal to avoid differences or errors when placing
the positioning pins. It is advisable to first put the frame onto the base plate

Assemble the Frame
without sealing compound. Afterwards lift the frame again to applicate the
sealing compound. Please be careful not to fill the oil groove. The posi-
tioning pin holes must also remain uncovered by sealing compound.
The frame is now slowly lowered and put into correct position referring to
the base plate by constantly pressing the positioning pins. Then the posi-
tioning pins are stamped by using a hammer.
Afterwards tighten the nuts in alternating and crosswise manner, starting
with the nuts next to the positioning pins and then including all nuts. Lock
the internal screws with a circlip.

Assemble the Gear Oil Pump to the Compressor
5.3 Assemble the Gear Oil Pump to the Compressor

It is not necessary to disassemble the gear oil pump for cleaning purposes.
The gearwheels are oiled in our shop and finally assembled. Only the
blank, rust preventative parts need to be cleaned. The two positioning pin
holes in the gear oil pump housing and in the frame must also be cleaned.
Put the recess in the crankshaft and the corresponding driving tag at the
driving gear wheel of the gear oil pump in 12 o'clock position before assem-
bling. Afterwards, the pump is attached to the frame together with a gasket,
the positioning pins are stamped and finally the screws are tightened.

Assemble the Oil Trap at Flywheel Side
5.4 Assemble the Oil Trap at Flywheel Side

The 2-piece rings of the shaft seal and the oil trap housing must be disas-
sembled for cleaning and subsequent assembly. Clean the two positioning
pin holes in the oil trap and in the frame as well as the supporting surfaces
of the relevant parts.
The gasket is temporarily fixed to the upper part of the frame with 2 screws.
Afterwards, the lower part of the oil trap is slightly screwed to the base
plate. The separation plane of the lower oil trap part must be covered by
the provided sealing compound. Loosen the two temporary screws of the
gasket and screw the upper oil trap part to the lower part. The oil trap must
only be tightened to the base plate and to the frame after stamping of the
positioning pins.
Shaft seal
The self-lubricating seal ring must be cut to perfect length before assembly.
We advise you to grease the sealing ring with MOLYKOTE® G-N Plus be-
fore assembling into the oil trap. The sealing ring is placed with the diag-
onal cut on top (12 o'clock). To avoid an initial high contact pressure on the
crankshaft, the designated contact pressure can be adjusted by adding thin
fibre shims. The 2-piece flange is tightened with bolts, which are secured
with circlips.

Assemble the Flywheel (and Barring Gear for large Compressor Types)
5.5 Assemble the Flywheel (and Barring Gear for

large Compressor Types)
Check the supporting surface of the coupling flange at the crankshaft and
the supporting surfaces of the flywheel for damages. Damages of the con-
tact surfaces can be repaired with a fine file.
The flywheel (1) is tightened onto the the crankshaft coupling flange with 2
hexagonal screws. For perfect fitting of the bores adjust them by using an
adjustment spike. Radial and face runout must be checked according to
Fig. 5-6 and may not exceed a maximum deflection of 0.04 mm at the feeler
gauge. For control of face runout the crankshaft (2) must be moved to the
stop of one crankgear side to compensate the clearance in the axial
bearing (normally crankshaft bearing on drive side).
1 2 3 4
PA_L1_0001b_01
1 Flywheel
2 Crankshaft
3 Measuring head
4 Dial gauge
Assemble the barring gear to allow a turning of the crankgear for further as-
sembly of the compressor (concerning only compressors 4D300, 4D375
and 6D375).

1 2
XA_L1_0001b_01
4 3
Fig. 5-7 Manual barring device
1 Pawl
2 Lever
3 Grease cup
4 Flywheel
The barring device enables slow turning of the crankshaft during installa-
tion and for maintenance works. For this purpose, engage the pawl (2) with
the gear rim of the flywheel (4) and turn flywheel by means of the lever (2).


Appendix
6 Appendix
Technical Data
Title Drawing No. Sheet No.

Bearing Clearances of Crankshaft Bear- 4-106.033.294
ings and Connecting Rod Bearings
Technical information, Guide bearing 4-122497277
clearance
Mounting instruction for connecting rod 4-106.012.290
bearing
Mounting instruction for connecting rod 4-106.012.099
screws
Mounting instruction for thick connecting 4-106.107.823
rod bearing
Mounting Instruction for Thin Connecting 4-106.106.415
Rod Bearings
Mounting Instruction for Connecting Rod 6117072
Bearing
Mounting instruction for thin main bear- 4-122.803.361
ings

Mounting Instruction for Connecting Rod Bearing and Screws /
Montagevorschrift für Schubstangenlager und Schrauben
Diameter of Extension of
Clearance of
connecting rod connecting rod
connecting rod
Compressor bearing / screw at tightening /
bearing (scraped) /
types / Durchmesser Verländerung der
Spiel der
Kompressor der Schubstangen-
Schubstangenlager
Typen Schubstangen- Protrusion X per schrauben beim
(geschabt)
lager bearing half after Anziehen
[mm]
[mm] mechanic blue / [mm]
Überstand X pro
Lagerhälfte nach
eintouchieren und
abrichten [mm]
1D65 55 0.05 / 0.07 0.05 0.130 ± 0.04

1D85
K78 70 0.06 / 0.08 0.05 0.180 ± 0.04
K80
2E130
K90
80 0.06 / 0.08 0.05 0.220 ± 0.05
1D100
2D100
4D105
95 0.07 / 0.10 0.05 0.220 ± 0.05
K105
1D130
100 0.07 / 0.10 0.05 0.280 ± 0.05
3D130
4E150
4B 120 0.08 / 0.11 0.08 0.280 ± 0.05
2D150
1D150
4D150 120 0.08 / 0.11 0.08 0.300 ± 0.06
K140
K160 140 0.09 / 0.13 0.08 0.300 ± 0.06
2D200
2D195 150 0.09 / 0.13 0.08 0.300 ± 0.06
4D200
4D225 170 0.10 / 0.15 0.08 0.320 ± 0.06
K165 180 0.10 / 0.15 0.08 0.320 ± 0.06
4D250 200 0.11 / 0.16 0.08 0.360 ± 0.07
4D300 240 0.12 / 0.18 0.12 0.400 ± 0.07

4E300
240 0.12 / 0.18 0.12 0.420 ± 0.10
K250
6D375 280 0.13 / 0.20 0.12 0.420 ± 0.07
4D375 280 0.13 / 0.20 0.12 0.420 ± 0.10
4-106.012.290 Rev. 01, 07/2010

Length of untightened Screw / Länge der ungespannten Schraube = L
Length of tightened Screw / Länge der angezogenen Schraube = L1
Stress in cross
section after L
Extensible Total Extension at
Compressor Drawing Extension max./min. /
cross section / length / tightening /
types / No. / length / Beanspruchung
Dehnquer- Totale Verlängerung
Kompressor Zeichnungs Dehnlänge im Dehnquer-
schnitt Länge beim Anziehen
Typen Nr. L = l1+l2;[mm] schnitt nach
[f in cm2] [L in mm] [mm]
L max./min.
[kg/mm2]
1D65 6303571 59 1.13 130 0.13 ± 0.04 60.6 / 32.1

1D85
K80 6303503 76 1.77 162 0.18 ± 0.04 60.8 / 38.8
K78
2E130 2302518 94 2.27 192 0.22 ± 0.05 60.4 / 38.0
K90 6000514 95 2.27 180 0.22 ± 0.05 59.6 / 37.6

1D100
6303504 99 2.84 192 0.22 ± 0.05 57.4 / 36.1
2D100
4D105
6003589 106 3.14 213 0.22 ± 0.05 53.5 / 33.7
K105
4E150 - 4B 2301655 133 3.14 238 0.28 ± 0.05 52.1 / 36.3
2D150 6303125 128 3.8 230 0.28 ± 0.05 54.1 / 37.7

1D130
6303211 125 4.53 232 0.28 ± 0.05 55.1 / 38.6
3D130
1D150
5D150 6303212 141 5.3 270 0.30 ± 0.06 53.66 35.8
K140
2D200
K160
2302836 144 7.08 295 0.30 ± 0.06 52.5 / 35.0
4D200
2D195
4D225
6302665 165 8.05 326 0.32 ± 0.06 48.4 / 33.1
K165
4D250 6301111 208 9.6 380 0.36 ± 0.07 43.4 / 29.3
4D300 6308103 255 12.56 433 0.40 ± 0.07 38.7 / 27.2
6D375 6309911 271 12.56 449 0.42 ± 0.07 38.0 / 27.1

4E300
4D375 6309974 282 25.52 505 0.42 ± 0.10 38.7 / 23.8
K250
4-106.012.099 Rev. 01, 07/2010
Mounting Instruction for Thick Connecting Rod Bearings
(with Shims) and Screws without Nuts /
Montagevorschrift für dickwandige Schubstangenlager

(mit Beilagen) und Schrauben ohne Muttern
Parallelity
respective to A /
Parallität
bezogen auf A
Vertical
Extension of [mm]
Diameter of clearance of
screw at
Compressor bearing bores / connecting
tightening /
Type / Durchmesser rod bearings /
Schraubenver-
Kompressor der Lager- Vertikalspiel
Overlap X of längerung beim
Typ bohrung der Schub-
bearing when Anziehen
[mm] stangenlager
tightened on one [mm]
[mm]
side / Überstand X
unter einseitiger
Klaffung;
X = X1 + X2 [mm]
2K90 80 0.06 – 0.08 0.10 – 0.18 0.17 – 0.22 B=4; 0 – 0.015
2K105 95 0.07 – 0.10 0.10 – 0.18 0.17 – 0.22 B=55; 0 – 0.015
2K140 120 0.08 – 0.11 0.15 – 0.28 0.24 – 0.29 B=75; 0 – 0.020
3K140
2K160
3K160 140 0.09 – 0.13 0.15 – 0.28 0.26 – 0.33 B=80; 0 – 0.020
2K150
2K158
Bemerkungen: - Das Horizontalspiel darf nicht kleiner als das Vertikale sein!
- siehe auch: 4-106.106.415 für Dünnwandlager
4-106.012.290 für Dickwandlager + Schrauben mit Muttern
Remarks: - The horizontal clearance must not be larger then the vertical clearance!
- see also: 4-106.106.415 for thin bearing shells
4.106.012.290 for thick bearing shells + screws and nuts
4-106.107.823 Rev. 01, 07/2010

Mounting Instruction for Thin Connecting Rod Bearings
(without Shims) and Screws /
Montagevorschrift für dünnwandige Schubstangenlager
(ohne Beilagen) und Schrauben
Parallelity
respective to A /
Parallität
Vertical bezogen auf A
Extension of
Diameter of clearance of [mm]
screw at
Compressor bearing bore / connecting rod
tightening /
type / Durchmesser bearings /
Schraubenver-
längerung
Typ bohrung der Schub-
beim Anziehen
[mm] stangenlager Overlap X of bearing
when tightened on [mm]
[mm]
one side / Überstand
X unter einseitiger
Klaffung [mm]
2K120 105 0.070 – 0.144 0.20 – 0.40 0.20 – 0.25 B=65; 0 – 0.020
2D160
110 0.077 – 0.151 0.15 – 0.40 0.25 – 0.30 B=65; 0 – 0.020
3D160
3K120 120 0.080 – 0.157 0.20 – 0.45 0.22 – 0.27 B=70; 0 – 0.020
2K140 120 0.080 – 0.156 0.20 – 0.45 0.26 – 0.31 B=75; 0 – 0.020
2K160
3K160
2K158 140 0.098 – 0.177 0.20 – 0.45 0.28 – 0.4 B=80; 0 – 0.020
2K150
3K140
3D200 150 0.090 – 0.170 0.20 – 0.55 0.24 – 0.30 B=80; 0 – 0.020
2D205 170 0.100 – 0.184 0.20 – 0.55 0.27 – 0.35 B=95; 0 – 0.025
4K165 180 0.126 – 0.208 0.20 – 0.45 0.39 – 0.45 B=80; 0 – 0.020
0.39 – 0.51
4D225 ** 170 0.119 – 0.202 0.20 – 0.45 B=85; 0 – 0.025
53.0 – 75.0
0.46 – 0.58
4D250 ** 200 0.140 – 0.227 0.20 – 0.45 B=95; 0 – 0.025
56.0 – 75.0
0.63 – 0.78
4EH250 ** 240 0.168 – 0.252 0.20 – 0.40 B=150; 0 – 0.040
109.0 – 134.0
0.54 – 0.65
4D300 ** 240 0.170 – 0.261 0.30 – 0.65 B=120; 0 – 0.030
79.5 – 94.0
0.61 – 0.73
6D375 ** 280 0.197 – 0.290 0.30 – 0.70 B=120; 0 – 0.035
71.5 – 84.0
0.59 – 0.75
4D375 ** 280 0.197 – 0.290 0.30 – 0.70 B=150; 0 – 0.040
75.0 – 93.0
Bemerkungen: - Die Schubstangen-Schrauben der Typen markiert mit ** werden hydaulisch vorgespannt
- Das Horizontalspiel darf nicht kleiner als das Vertikale sein!
- siehe auch: 4-106.012.290 für Dickwandlager + Schrauben mit Muttern
4-106.107.823 für Dickwandlager + Schrauben ohne Muttern
Remarks: - The connecting rod screws of the types marked with ** are pretightened hydraulic
- The horizontal clearance must not be larger then the vertical clearance!
- see also: 4.106.012.290 for thick bearing shells + screws with nuts
4-106.107.823 for thick bearing shells + screws without nuts
4-106.106.415 Rev. 01, 07/2010

Mounting Instruction for Connecting Rod Bearing /
Monteurinstruktion für Schubstangenlager
1. K-Kompressoren / K-Compressors:
Scraping of oil
Oil pocket, wedge surface Beilagen-
Bearing-Dia. / cutter dia. / Oil pocket / on dim. b/ Dim. / Dim. / Radius / dicke /
Type /
Lager-ø Oeltasche, Oeltasche Oelkeilfläche Mass c Mass e Radius r thickness
Typ Fräser-ø nachschaben
[mm] [mm] [mm] [mm] [mm] of shims
[mm] auf Breite b
[mm]
[mm]
K80 70-F8 +0.076/+0.030 55 2x14=28 8 0.1 1–2 6.6 5 +0/-0.05
K90 80-F8 +0.078/+0.030 60 2x16=32 8 0.1 1–2 6.6 5 +0/-0.05
K105 95-F8 +0.090/+0.036 80 2x18=36 10 0.1 1–2 8.6 5 +0/-0.05
K140 120-F8 +0.090/+0.038 100 2x22=44 12 0.1 1–2 10.8 5 +0/-0.05
K160 140-F8 +0.108/+0.043 120 2x25=50 15 0.1 1–2 10.8 5 +0/-0.05
2. Beilagen zu Schubstangenlager für K- und CV-Kompressoren:

Die Beilagen sind bis 0.05 mm an den Kurbelzapfen zu schieben. Dieses Mass ist vor allem über die Partie
"e" einzuhalten um den Oelverlust auf ein Minimum zu reduzieren.
3. CV-Kompressoren:
Bei Lagern für CV-Kompressoren sind die Oelkeilflächen gleich nachzuschaben, entsprechend den
ähnlichen Durchmesser wie bei den K-Kompressoren. Die Oelkeilflächen sind seitlich auf 1–3 mm an den
Radius hinauszuziehen (Siehe Mass "e")
Achtung! Die Radien, resp. die Gleitflächen "e", dürfen nicht verletzt werden wegen Oelverlust!
2. Shims for connecting rod bearings of K- and CV-Compressors:

The shims must be moved to the crankpin with a gap of 0.05 mm. This measurement must be kept over
area "e" to reduce the oil loss to a minimum.
3. CV-Compressors:
The surfaces of the oil wedges at bearings of CV-Compressors must be scraped in accordance to the
similar diameters of K-Compressor bearings. The lateral faces of the oil wedge surface should end 1–3 mm
before the radius (see dimension "e")
Caution! The radiuses, respectively the sliding surfaces "e", must not be damaged to avoid oil loss!
6117072 Rev. 01, 07/2010

Mounting Instruction for Thin Main Bearings
(without Shims) and Screws /
Montagevorschrift für dünnwandige Hauptlager
(ohne Beilagen) und Schrauben
Setting angle for

nut at final
tightening /
Hydr. pump Nachstell-Winkel
Vertical
pressure P1 to der Mutter beim
Diameter of clearance of
neutralize the Fertiganziehen
Compressor bearing bore / the main [°]
gap /
type / Durchmesser bearings /
Hydr. Pumpen-
druck P1 zur Pump pressure
Typ bohrung der
Aufhebung hydr. tightening /
[mm] Hauptlager
Overlap X of bearing der Klaffung Pumpendruck
[mm]
when tightened on one [M Pa] Hydr. Anziehen
side / Überstand X unter P2 [M Pa]
einseitiger Klaffung;
X = M + N [mm]
49°–54°
4EH250 ** 240 0.240 – 0.322 0.20 – 0.35 38.5
115
Bemerkungen: - Die Hauptlager-Schrauben der Typen markiert mit ** werden hydaulisch vorgespannt
- Anziehvorschrift auf Hauptlagerdeckel-Zeichnung beachten!
- Das Horizontalspiel darf nicht kleiner als das Vertikale sein!
Remarks: - The main bearing screws of the types marked with ** are hydraulic pretightened
- Consult the tightening instructions on the drawing of the main bearing cover!
- The horizontal clearance must not be larger then the vertical clearance!
4-122.803.361 Rev. 01, 07/2010

Index
7 Index
A P
Axial bearing 1-119 Piston 1-41, 2-3, 3-9
Piston rod 1-41, 2-3, 3-9
B
Piston rod gland 1-75, 3-31
Bearing bracket 2-39, 3-55
R
C
Refill lubricating oil 1-37, 3-5
Center bearing 2-41, 3-57
Connecting rod 1-95, 2-24, 3-44 S
Connecting rod bearing 1-88, 2-22, 3-42 Spacer ring 2-17
Controlled suction valve 1-25 Suction Valve Actuator 1-11
Coupling 1-103, 2-31, 3-48 Suction valves 1-27
Crankshaft bearing 1-112 SUPERBOLT®
Crankshaft center bearing 2-40, 3-56 loosening procedure 1-68
Crankshaft seal 1-107, 2-36, 2-38, 3-53 preventive maintenance 1-68
Crosshead 1-95, 2-24, 3-44 tightening procedure 1-69
Crosshead pin bearing 1-97, 1-98, 2-26, 2-27, 3- Switch off compressor 1-6
45 Switch off cooling system 1-6
Cylinder 1-79, 3-35
T
Cylinder cover 1-32 Tensioner SUPERBOLT® 1-67
D Tightening Methods 1-74
Discharge valves 1-27 Trouble shooting
Dismantle crankshaft sidewards 2-40, 3-56, 4-3, SUPERBOLT® 1-70
5-3
Dismantle crankshaft upwards 1-120
Drain lubricating oil 1-37, 3-5
E
Electric motor 1-103, 2-31, 3-48
External gas pipes 1-78, 3-34
F
Flywheel 1-104, 2-32, 3-49
Frame 1-110
Frame covers 1-36, 3-3
G
Gear oil pump 1-100, 2-28, 3-46
Guide bearing 1-86, 3-40
Guide bearing bush 1-83, 3-38
I
Internal gas leakage pipes 1-75, 3-30
M
Main bearing 2-39, 3-55
Marking of compressor components 1-4, 3-28
N
Non-return valve 1-7
O
Oil heater 1-39, 3-7
Oil scrapers 1-82, 3-37
Oil strainer 1-40, 3-8
Oil trap 1-107, 2-36, 2-38, 3-53

Index
7–2 MI100en Rev. 002/kneubuehler_e 02.12.2011

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Burckhardt Compression AG

Instruction for Field

1 Components of Laby® Type D + E with Bolted

2 Components of Laby® Type D + E with

3 Components of Laby® Type K

4 Dismantle Crankshaft sidewards of Laby®

5 Earlier Laby® Compressors with Thick

02.12.2011 Rev. 002/kneubuehler_e MI 100en

MI 100en Rev. 002/kneubuehler_e 02.12.2011

1 Components of Laby® Type D + E with

1.1 Dismantling and Assembling Overview . . . . . . . . . . . . . . . 3

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1–1

1–2 MI 100en Rev. 002/kneubuehler_e 02.12.2011

1.1 Dismantling and Assembling Overview

For applicable lubricants, mandatory tightening torques as well as appro-

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1–3

1.1.1 Marking of Compressor Components

1–4 MI 100en Rev. 002/kneubuehler_e 02.12.2011

Fig. 1-1 Important markings on a Laby® compressor type D

1 Cylinder cover 8 Crosshead

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1–5

1.2 Switch Off Compressor

Special Tools none

Switch Off 1. Switch off the compressor.

Required Checks Make sure, that:

Switch On 1. Re-insert the safety switch.

Final Checks See “Control Description” in the relevant Instruction Manual.

1.3 Switch Off Cooling System

Special Tools none

Switch On and Final Please refer to the relevant Instruction Manual.

1–6 MI 100en Rev. 002/kneubuehler_e 02.12.2011

1.4 Non-Return Valve

Special Tools none

Dismantle Non-Return Dismantle the non-return valve according to following figure:

1 Flow direction 5 Ring

Contrary to the assembly of plate valves installed in the compressor, the

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1–7

Dismantle Non-Return Dismantle the non-return valve according to following figure:

1 Flow direction 5 Housing

Required Checks Check the marking “X5”:

Fig. 1-4 X5 Marking

1–8 MI 100en Rev. 002/kneubuehler_e 02.12.2011

Assemble New or Used

Fig. 1-6 Components of non-return valve

1 Nut 5 Valve disc

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1–9

Thread diameter Ma [Nm]

1 – 10 MI 100en Rev. 002/kneubuehler_e 02.12.2011

1.5 Suction Valve Actuator

T97182 (can be ordered at Burckhardt Compression AG)

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1 – 11

Fig. 1-9 Suction valve actuator for low temperature application

1 Bonnet 12 Guiding band

1 – 12 MI 100en Rev. 002/kneubuehler_e 02.12.2011

Fig. 1-10 Suction valve actuator

1 Bonnet 12 Guiding band

02.12.2011 Rev. 002/kneubuehler_e MI 100en 1 – 13

Variant with Intermediate