Attachment 2 - Maintenance Requirement Card.pdf

AHP-R-2

Maintenance Requirement Card

MRC AHP-R-2

Rev. 0, June 2024

AHP-R-2 Maintenance Requirement Card

SYSTEM: High Pressure Air (AHP) System

EQUIPMENT: AHP Compressor (HPAC)

MRC DESCRIPTION: To be completed every 8,000 run hours on each HPAC -OR- performed by OEM vendor under contract

1. Replace Compressor Stage Check Valves

2. Replace Piston Rings

3. Replace Piston Pins & Piston Pin Bearings

4. Measure Piston and Cylinder Wear

5. Rebuild Drain Solenoids & Pneumatic Drain Valves

6. Replace Coupling Insert

7. Check/ Tighten Cooler Tube Clamps

CONDITIONS/REMARKS: Compressor Shutdown

SAFETY PRECAUTIONS

1. Naval Nuclear Power Training Unit (NPTU)/Moored Training Ship (MTS) personnel comply with NPTUCHASNINST (NPTU Charleston Instruction), Occupational Safety and Health Manual (OSHMAN).

2. NPTU Charleston Instruction (NPTUCHASNINST), Occupational Safety and Health Manual (OSHMAN) and the applicable Safety Data Sheets (SDS) provide additional control measures, precautions, Personnel Protective Equipment (PPE), and spill controls for the hazardous materials.

3. Disposal of all hazardous material shall be in accordance with Hazardous Material Users Guide (HMUG), S9086-WK-STM-020, NSTM 670 Vol II and manufacturer’s SDS.

4. To prevent personnel injury, Tag-Out procedures shall be in accordance with S0400-AD-URM- 010 the Tag-out Users Manual (TUM), and/or local tag-out instruction.

PARTS

NOTE: 8000 Hour Maintenance Kit; [P/N WP4351-8KA, Manufacturer: Sauer] can be ordered which includes items 1 through 14, 16 through 29 and P/N: 039 548; Air Filter Insert.

1. Head Gasket, 1st Stage; [P/N: 056 237, Manufacture: Sauer] (quantity: 2)

2. Head Gasket, 2nd Stage; [P/N: 060 266, Manufacture: Sauer, NSN 5330-12-327-1792]

3. Head Gasket, 3rd Stage; [P/N: 065 666, Manufacture: Sauer] (quantity: 2)

4. Low Tolerance Gasket, 1st Stage; [P/N: 056 239, Manufacture: Sauer, NSN 5330-12-320-0405]

5. Low Tolerance Gasket, 3rd Stage; [P/N: 065 665, Manufacture: Sauer]

6. Low Tolerance Gasket, 4th Stage; [P/N: 066 186, Manufacture: Sauer]

7. Low Tolerance Gasket, 4th Stage; [P/N: 035 826, Manufacture: Sauer]

8. O-ring, 4th Stage; [P/N: 035 893, Manufacture: Sauer]

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9. Packing, 1st and 2nd Stage Cooler; [P/N: 056 334, Manufacture: Sauer] (quantity: 4) (if required)

10. Valve, Concentric, 1st Stage; [P/N: 033 210, Manufacture: Sauer]

11. Valve, Reed, 2nd Stage; [P/N: 035 787, Manufacture: Sauer]

12. Valve, Concentric, 3rd Stage; [P/N: 031 526, Manufacture: Sauer]

13. Valve, Concentric, 4th Stage; [P/N: 035 793, Manufacture: Sauer, NSN 4820-12-334-8060]

14. Bearing, Needle Roller, [P/N: 033 213, Manufacturer: Sauer, NSN 3110-01-523-2399] (quantity:

4)

15. Pin, Piston 1st Stage, [P/N: 033 187, Manufacturer: Sauer, NSN 4310-12-334-5125]

16. Pin, Piston 2nd, 3rd, 4th Stage, [P/N: 053 727, Manufacturer: Sauer] (quantity 3)

17. Circlip, [P/N: 002 984, Manufacturer: Sauer] (quantity: 8)

18. M-ring, piston 1st stage [P/N: 035 199, Manufacturer: Sauer, NSN 5325-01-522-5660] (quantity:

1)

19. N-ring, piston 1st stage [P/N: 033 188, Manufacturer: Sauer, NSN 4310-01-522-5661] (quantity:

1)

20. G-ring, piston 1st stage [P/N: 035 200, Manufacturer: Sauer, NSN 4310-12-334-5128] (quantity:

1)

21. R-ring, piston 2nd stage [P/N: 033 220, Manufacturer: Sauer, NSN 4310-12-349-4646] (quantity:

1)

22. N-ring, piston 2nd stage [P/N: 034 213, Manufacturer: Sauer] (quantity: 1)

23. S-ring, piston 2nd stage [P/N: 033 221, Manufacturer: Sauer] (quantity: 1)

24. R-ring, piston 3rd stage [P/N: 002 662, Manufacturer: Sauer] (quantity: 2)

25. N-ring, piston 3rd stage [P/N: 002 543, Manufacturer: Sauer] (quantity: 2)

26. R-ring, piston 4th stage [P/N: 038 249, Manufacturer: Sauer] (quantity: 16)

27. Packing, Cylinder Foot 1st Stage [P/N: 062 375, Manufacturer: Sauer]

28. Packing, Cylinder Foot 2nd, 3rd, 4th Stage [P/N: 062 376, Manufacturer: Sauer] (quantity: 3)

29. Solenoid Valve Rebuild Kit; [P/N: 038 528, Manufacturer: Sauer] (quantity:1)

30. Condensate Drain Solenoid Valve; [P/N: 037 680, Manufacture: Sauer, NSN 4810-12-373-6834]

(quantity: 2)

31. Pneumatic Drain Valve Rebuild Kit; [P/N; 063 633, Manufacturer: Sauer] (quantity:1)

32. Drive Coupling Flexible Insert; [P/N: 033 423, Manufacturer: Sauer, NSN: 3010-016-42-6086].

Flexible insert is included with P/N: 038 528.

33. Gasket, Inspection Cover, [P/N: 063 748, Manufacturer: Sauer] (quantity 2)

TOOLS / MATERIALS

1. Compressed air

2. Lint free rags

3. O-ring Grease; [P/N: OLUBE 884-2, Manufacture: Parker] (or similar; Grease, Aircraft and

Instrument NSN 9150-00-961-8995)

4. Scotch-Brite pads

5. Screwdrivers

6. Industrial Cleaner (Simple Green or approved equivalent)

7. Socket, Set (metric)

8. Torque Wrench, 0 – 200 ft-lbs (min.)

9. Vacuum, Shop, with soft bristle brush attachment

10. Wrench, Set

11. Snap Ring Plier set

12. Bearing removal/installation tool

Rev. 0, June 2024

13. Tap and Die set

14. Gloves, Oil Resistant

TEST EQUIPMENT

1. None

PROCEDURE

REFERENCE: Sauer Compressors Maintenance Instructions, WP4351 Basic, Hurricane Series, 2015.

NOTE: Perform every 8000 hours of service in conjunction with 2000 hour (AHP-R-1) maintenance.

Only perform those portions of AHP-R-1 not performed during this maintenance item.

ONLY TECHNICIANS EXPERIENCED IN COMPRESSOR DISASSEMBLY AND

ASSEMBLY SHALL PERFORM THIS MAINTENANCE PROCEDURE.

Preliminary:

1. Shutdown the HPAC.

2. Perform energy isolation on HPAC.

3. Verify OPEN AHP-V-150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 164, and 165 for HPAC-

1 (AHP-V-250, 251, 252, 253, 254, 255, 256, 257, 258, 259, 264, and 265 for HPAC-2).

4. Depressurize purifier as follows:

i Slowly crack OPEN bleed valve AHP-V-168 (AHP-V-268).

ii Slowly crack OPEN bleed valve AHP-V-162 (AHP-V-262) at the particle filter.

iii Slowly crack OPEN AHP-FLT-111(AHP-FLT-211) drain valve.

iv Verify the filter assembly is depressurized by observing pressure gauge AHP-PG-6

(AHP-PG-7) reads 0 psig and there is no detectable air flow at the bleed valves.

v Leave AHP-V-168 (AHP-V-268), AHP-V-162 (AHP-V-262) and AHP-FLT-111(AHP-

FLT-211) in the OPEN position.

NOTE: All steps and sub-steps (except completion section) may be performed in any order provided the intent of the MRC is met unless otherwise specified in the procedure. Detailed instructions are provided for guidance only.

NOTE: Removal of the air cooler is optional but will facilitate removal of the 1st and 2nd stage cylinder heads. It will also allow cleaning of the air cooler and easier rotation of the compressor by hand for coupling inspection. Removal and installation described in MRC AHP-R-1.

NOTE: The cylinder head nuts, cylinder head and valve may remain on cylinder and disassembled later if the cylinder and piston are removed as an assembly.

NOTE: Alternate means for cylinder and piston removal is to remove the oil sump cover to access the connecting rod bolts. Note position of connecting rod on crankshaft then remove connecting rod bolts and lift entire stage cylinder, piston, and connecting rod out as an assembly after disconnecting necessary piping and cylinder nuts.

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1. If optional removal of an air cooler is performed:

1. Prior to installation of 1st/2nd stage air cooler, inspect 3rd/4th stage Air Cooler Tube Clamps to ensure no leakage at clamp area. Verify no leakage from 1st/2nd stage Air Cooler Tube Clamps upon completion of all maintenance and restart of HPAC.

2. If leaks are identified, shutdown HPAC and replace tube or tighten clamp for affected air cooler.

2. Replace HPAC Cylinder Check Valves, Piston Rings, Piston Pins, and Piston Pin Bearing.

1. Replace compressor valves, piston rings, pins, and piston pin bearing for compressor 1st stage as follows, refer to Figures R-2-1, R-2-2, R-2-6, R-2-7, R-2-11, R-2-12:

i. Disconnect the following at the 1st stage cylinder:

1) Crankcase breather tube (at the hose clamp).

2) Air inlet filter housing.

3) Air discharge pipe.

ii. Remove six cylinder head nuts.

iii. Remove 1st stage cylinder head, upper cylinder head gasket, and low tolerance O-ring.

iv. Remove 1st stage valve and lower cylinder head gasket.

v. Remove 1st stage cylinder, piston and connecting rod:

1) Remove 1st stage cylinder base nuts.

2) Secure the piston to ensure that it will not strike the crankcase then pull the cylinder off.

3) If cylinder and piston removed as an assembly, separate piston from the cylinder and complete disassembly of head and valve.

4) Separate piston and connecting rod by removing the circlips and pushing piston pin out to take off piston.

5) If not already performed remove connecting rod bolts and cover with bearing bushing, then lift connecting rod out of compressor.

vi. Press piston pin bearing out of the connecting rod small end and discard bearing.

vii. Clean and Inspect as follows:

1) Clean and inspect cylinder, piston, and connecting rod for signs of damage, excessive or unusual wear.

2) Clean and inspect seating surfaces.

3) Inspect the crankshaft for wear where the connecting rod attaches to it for signs of damage or unusual wear.

viii. Press new piston pin bearing into connecting rod small end.

ix. Measuring Pistons, Cylinder Liners, and Cylinder Wear.

1) 1st measurement – Push a new piston ring into the cylinder about 5mm below the upper edge of the cylinder and above the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

2) 2nd measurement – Push a new piston ring into the cylinder about 50mm below the upper edge of the cylinder and within the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

3) Calculate the difference between the gap clearances from the 1st and 2nd measurement for each stage and compare with the permitted values below.

Piston Diameter Permissible Gap Clearance > 100mm 0.45mm < 100mm 0.30mm

4) If the permissible gap clearance is exceeded, the cylinder will have to be replaced as Sauer Compressors deems the cylinder sleeve as not serviceable.

x. Replace piston rings on 1st stage piston with new rings. Position the piston rings so that the joint gaps are offset. Piston rings may be secured in position using grease.

xi. Fix piston onto connecting rod:

1) Apply oil to piston pin bearing and new piston pin.

2) With piston in place, insert piston pin into piston and connecting rod.

3) Insert new circlips.

xii. Install piston and connecting rod:

1) Apply lubrication to connecting rod crankshaft bearing.

2) Install connecting rod with piston onto crankshaft ensuring proper orientation.

3) Install bearing cap and tighten bearing cap bolts hand tight.

4) Torque bearing cap bolts to 52 ft-lbs. Do not exceed 10ft-lbs increments.

5) After tightening, the connecting rods should rotate on the crankshaft.

xiii. Install 1st stage cylinder:

1) Install new cylinder base gasket.

2) Lubricate piston and cylinder and carefully lower cylinder onto piston. If there is too much resistance, check piston ring position.

3) Tighten cylinder base nuts.

xiv. Install head and valve assembly:

1) Fit new valve and cylinder head to the 1st stage cylinder using new cylinder head gaskets and new low tolerance gasket.

2) Install six cylinder head nuts and tighten in alternating sequence.

3) Torque head nuts to 55 ft-lbs. Do not exceed 10ft-lbs increments.

xv. Connect the following at the 1st stage cylinder:

1) Crankcase breather tube.

2) Air inlet filter housing, pointing the air inlet pipe downward at a 45-degree angle away from the compressor.

3) Air discharge pipe, if disconnected.

xvi. Reinstall Air Cooler, as required.

2. Replace compressor valves, piston rings, pins, and piston pin bearing for compressor 2nd stage as follows, refer to Figures R-2-1, R-2-3, R-2-6, R-2-11, & R-2-13:

i. Disconnect the following at the 2nd stage cylinder:

1) Air inlet pipe. If air cooler removed, disconnection of inlet pipe is not necessary.

2) Pressure sensor sample line tube.

3) Air discharge pipe. If air cooler removed, disconnection of discharge pipe is not necessary.

ii. Remove four cylinder head nuts.

iii. Remove 2nd stage cylinder head and upper cylinder head gasket.

iv. Remove 2nd stage valve.

v. Remove 2nd stage cylinder, piston and connecting rod:

1) Remove 2nd stage cylinder base nuts.

2) Secure the piston to ensure that it will not strike the crankcase then pull the cylinder off.

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3) If cylinder and piston removed as an assembly, separate piston from the cylinder and complete disassembly of head and valve.

4) Separate piston and connecting rod by removing the circlips and pushing piston pin out to take off piston.

5) If not already performed remove connecting rod bolts and cover with bearing bushing, then lift connecting rod out of compressor.

vi. Press piston pin bearing out of the connecting rod small end and discard bearing.

vii. Clean and Inspect as follows:

1) Clean and inspect cylinder, piston, and connecting rod for signs of damage, excessive or unusual wear.

2) Clean and inspect seating surfaces.

3) Inspect the crankshaft for wear where the connecting rod attaches to it for signs of damage or unusual wear.

viii. Press new piston pin bearing into connecting rod small end.

ix. Measuring Pistons, Cylinder Liners, and Cylinder Wear

1) 1st measurement – Push a new piston ring into the cylinder about 5mm below the upper edge of the cylinder and above the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

2) 2nd measurement – Push a new piston ring into the cylinder about 50mm below the upper edge of the cylinder and within the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

x. Replace piston rings on 2nd stage piston with new rings. Position the piston rings so that the joint gaps are offset. Piston rings may be secured in position using grease.

xi. Fix piston onto connecting rod:

1) Apply oil to piston pin bearing and new piston pin.

2) With piston in place, insert piston pin into piston and connecting rod.

3) Insert new circlips.

xii. Install piston and connecting rod:

1) Apply lubrication to connecting rod crankshaft bearing.

2) Install connecting rod with piston onto crankshaft ensuring proper orientation.

3) Install bearing cap and tighten bearing cap bolts hand tight.

4) Torque bearing cap to 52 ft-lbs. Do not exceed 10ft-lbs increments.

5) After tightening, the connecting rods should rotate on the crankshaft.

NOTE: 2nd stage head gasket has two tabs that connect them. Remove the tabs before install.

xiii. Install 2nd stage cylinder:

1) Install new cylinder base gasket.

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2) Lubricate piston and cylinder and carefully lower cylinder onto piston. If there is too much resistance, check piston ring position.

3) Tighten cylinder base nuts.

xiv. Install head and valve assembly:

1) Fit new valve and cylinder head to the 2nd stage cylinder using new cylinder head gaskets.

2) Install four cylinder head nuts and tighten in alternating sequence.

3) Torque head nuts to 55 ft-lbs. Do not exceed 10ft-lbs increments.

xv. Connect the following at the 2nd stage cylinder as required:

1) Air inlet pipe.

2) Pressure sensor sample line tube.

3) Air discharge pipe.

xvi. Reinstall Air Cooler, as required.

3. Replace compressor valves, piston rings, pins, and piston pin bearing for compressor 3rd stage as follows, Refer to Figures R-2-1, R-2-4, R-2-6, R-2-11, & R-2-14:

i. Disconnect the following at the 3rd stage cylinder:

1) Air inlet pipe.

2) Air discharge pipe.

ii. Remove four cylinder head nuts.

iii. Remove 3rd stage cylinder head.

iv. Remove 3rd stage valve.

v. Remove 3rd stage cylinder, piston and connecting rod:

1) Remove 3rd stage cylinder base nuts.

2) Secure the piston to ensure that it will not strike the crankcase then pull the cylinder off.

3) If cylinder and piston removed as an assembly, separate piston from the cylinder and complete disassembly of head and valve.

4) Separate piston and connecting rod by removing the circlips and pushing piston pin out to take off piston.

5) If not already performed remove connecting rod bolts and cover with bearing bushing, then lift connecting rod out of compressor.

vi. Press piston pin bearing out of the connecting rod small end and discard bearing.

vii. Clean and Inspect as follows:

1) Clean and inspect cylinder, piston, and connecting rod for signs of damage, excessive or unusual wear.

2) Clean and inspect seating surfaces.

3) Inspect the crankshaft for wear where the connecting rod attaches to it for signs of damage or unusual wear.

viii. Press new piston pin bearing into connecting rod small end.

ix. Measuring Pistons, Cylinder Liners, and Cylinder Wear

1) 1st measurement – Push a new piston ring into the cylinder about 5mm below the upper edge of the cylinder and above the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

2) 2nd measurement – Push a new piston ring into the cylinder about 50mm below the upper edge of the cylinder and within the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

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x. Install new piston rings on 3rd stage piston. Position the piston rings so that the joint gaps are offset. Piston rings may be secured in position using grease.

xi. Fix piston onto connecting rod:

1) Apply oil to piston pin bearing and new piston pin.

2) With piston in place, insert piston pin into piston and connecting rod.

3) Insert new circlips.

xii. Install piston and connecting rod:

1) Apply lubrication to connecting rod crankshaft bearing.

2) Install connecting rod with piston onto crankshaft ensuring proper orientation.

3) Install bearing cap and tighten bearing cap bolts hand tight.

4) Torque bearing cap to 52 ft-lbs. Do not exceed 10ft-lbs increments.

5) After tightening, the connecting rods should rotate on the crankshaft.

xiii. Install 3rd stage cylinder:

1) Install new cylinder base gasket.

2) Lubricate piston and cylinder and carefully lower cylinder onto piston. If there is too much resistance, check piston ring position.

3) Tighten cylinder base nuts.

xiv. Install head and valve assembly:

1) Fit new valve and cylinder head to the 3rd stage cylinder using new cylinder head gaskets and new low tolerance gasket. Refer to Figure R2-4.

2) Install four cylinder head nuts and tighten in alternating sequence.

3) Torque head nuts to 55 ft-lbs. Do not exceed 10 ft-lbs increments.

xv. Connect the following at the 3rd stage cylinder as required:

1) Air inlet pipe.

2) Air discharge pipe.

4. Replace compressor valves, piston rings, pins, piston pin bearing and connecting rod shell bearing for compressor 4th stage as follows, Refer to Figures R-2-1, R-2-5, R-2-6, R-2-11, & R-2-15:

i. Disconnect the following at 4th stage cylinder:

1) Air inlet pipe.

2) Air discharge pipe.

3) Cylinder oil supply line.

ii. Remove six cylinder head nuts.

iii. Remove 4th stage cylinder head, upper cylinder head gasket, and low tolerance O-ring.

iv. Remove 4th stage valve and lower cylinder head gasket.

v. Remove 4th stage cylinder, piston and connecting rod:

1) Remove 4th stage cylinder base nuts.

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2) Secure the piston to ensure that it will not strike the crankcase then pull the cylinder off.

3) If cylinder and piston removed as an assembly, separate piston from the cylinder and complete disassembly of head and valve.

4) Separate piston and connecting rod by removing the circlips and pushing piston pin out to take off piston.

5) If not already performed remove connecting rod bolts and cover with bearing bushing, then lift connecting rod out of compressor.

vi. Press piston pin bearing out of the connecting rod small end and discard bearing.

vii. Clean and Inspect as follows:

1) Clean and inspect cylinder, piston, and connecting rod for signs of damage, excessive or unusual wear.

2) Clean and inspect seating surfaces.

3) Inspect the crankshaft for wear where the connecting rod attaches to it for signs of damage or unusual wear.

viii. Press new piston pin bearing into connecting rod small end.

ix. Measuring Pistons, Cylinder Liners, and Cylinder Wear

1) 1st measurement – Push a new piston ring into the cylinder about 5mm below the upper edge of the cylinder and above the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

2) 2nd measurement – Push a new piston ring into the cylinder about 50mm below the upper edge of the cylinder and within the visible running surface of the piston rings. Measure the gap clearance with a feeler gage.

x. Install new piston rings on 4th stage piston. Position the piston rings so that the joint gaps are offset. Piston rings may be secured in position using grease.

xi. Fix piston onto connecting rod:

1) Apply oil to piston pin bearing and new piston pin.

2) With piston in place, insert piston pin into piston and connecting rod.

3) Insert new circlips.

xii. Install piston and connecting rod:

1) Apply lubrication to connecting rod crankshaft bearing.

2) Install connecting rod with piston onto crankshaft ensuring proper orientation.

3) Install bearing cap and tighten bearing cap bolts hand tight.

4) Torque bearing cap to 52 ft-lbs. Do not exceed 10ft-lbs increments.

5) After tightening, the connecting rods should rotate on the crankshaft.

xiii. Install 4th stage cylinder:

1) Install new cylinder base gasket.

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2) Lubricate piston and cylinder and carefully lower cylinder onto piston. If there is too much resistance, check piston ring position.

3) Tighten cylinder base nuts.

xiv. Install head and valve assembly:

1) Use thin coating O-ring grease on O-Ring.

2) Fit new valve and cylinder head to 4th stage cylinder using new precision gasket, new low tolerance gasket and new O-Ring.

3) Install cylinder head nuts and tighten in alternating sequence.

4) Torque head nuts to 184 ft-lbs. Do not exceed 40ft-lbs increments.

xv. Connect the following at the 4th stage cylinder as required:

1) Air inlet pipe.

2) Air discharge pipe.

3) Cylinder oil supply line.

5. Replace the crankcase inspection cover using a new gasket.

6. Verify and/or fill crankcase oil level to middle of band.

2. Rebuild Drain Solenoids (Figure R-2-9). If available, the solenoid may be replaced as a whole unit.

1. Unscrew the hexagon nut

2. Carefully lift the threaded element with the wrench.

3. Remove the coil from the solenoid armature.

4. Loosen the four hexagon socket head screws.

5. Remove the upper section of the valve.

6. Replace the following parts:

i. Spring

ii. Diaphragm

iii. O-rings

7. Clean the nozzle.

8. Attach the upper section of the valve. Screw in and tighten the four hexagon socket head screws.

9. Attach the coil to the solenoid armature.

10. Position the threaded element correctly and press it into the solenoid armature.

11. Carefully screw on the hexagon nuts by hand.

12. Slightly tighten the hexagon nuts

3. Rebuild Pneumatic Drain Valves (Figure R-2-10)

1. Disconnect all piping from the pneumatic drain valve.

2. Remove the pneumatic drain valve from the system.

3. Unscrew the socket head cap screws on the housing flange and remove the housing flange.

4. Replace O-rings. Check the valve seating surface one the housing flange.

5. Unscrew the socket head cap screws on the housing cover and remove the housing cover from the valve body. Replace O-rings.

6. Screw an M6 screw into the thread on the valve piston and remove the valve piston from the valve body. Replace O-rings and ring gaskets.

7. Remove valve piston and insert new lubricated valve piston into valve body.

8. Fit the housing cover onto the valve body with new ring gaskets.

9. Fit the housing flange with new O-rings.

10. Re-install the pneumatic drain valve.

11. Connect the drain lines of compression stages 3 and 4. The diameter of the drain line for stage 4 is smaller.

12. Connect the pipes to the pneumatic drain valve and tighten the union nuts at both ends.

4. Replace Drive Coupling (Figure R-2-8)

1. Support the compressor under the bell housing.

2. Unscrew motor fixing screws.

3. Carefully lift the motor using lifting eyes and pull the motor away from the crankcase.

4. Replace he elastomer element.

5. Carefully slide the motor onto the crankcase and tighten the fixing screws on the motor.

6. Remove the support from under the bell housing.

5. Completion.

1. Complete MRC AHP-R-1 with the exception of inspecting valves to fulfill remaining 8000-hour maintenance requirements.

2. SHUT bleed valves AHP-V-168 (AHP-V-268), AHP-V-162 (AHP-V-262) and drain valve on

AHP-FLT-111(AHP-FLT-211).

3. Remove energy isolation from HPAC.

WARNING: Operate all valves slowly to minimize sudden loading and prevent compression-ignition. The heat of compression generated by the sudden influx of high pressure air into a space of lower pressure could cause an explosion resulting in component damage and personnel injury. Increase pressure slowly (not more than 200 psi/sec).

4. Slowly OPEN AHP-V-166 and AHP-V-167 for HPAC-1 (AHP-V-266 and AHP-V-267 for

HPAC-2).

5. Start HPAC per Ship System Manual Operating Instructions.

6. With compressor running, check all connections that were made-up during this maintenance procedure for leaks.

7. If any leakage is detected, secure the compressor. Isolate and depressurize the compressor prior to tightening leaking fitting.

8. Repeat steps 6.f. and 6.g. until no leakage detected.

9. Report maintenance completion and any discrepancies to work center supervisor.

Figure R-2-1; HPAC Components

Figure R-2-2; Stage 1 Figure R-2-3; Stage 2

1. Cylinder Head Nuts 1. Cylinder Head Nuts

2. Cylinder Head 2. Cylinder Head

3. Low Tolerance O-ring 3. Cylinder Head Gasket

4. Upper Cylinder Head Gasket 4. Valve

5. Valve

6. Lower Cylinder Head Gasket

Figure R-2-3a; Stage 2 Head Gasket

1. Strips

Figure R-2-4; Stage 3

1. Cylinder Head Nuts

2. Cylinder Head

3. Low Tolerance Ring

4. Upper Cylinder Head Gasket

5. Valve

Figure R-2-5; Stage 4 Figure R-2-6; Connecting Rod

1. Cylinder Head Nuts 1. Connecting Rod

2. Cylinder Head 2. Gudgeon Pin

3. Low Tolerance Ring 3. Gudgeon pin Bearing

4. Upper Cylinder Head Gasket 4. Circlips

5. Valve 5. Piston

Figure R-2-7; Piston Ring Figure R-2-8; Elastomeric Element

1. Piston Ring 1. Compressor Crankcase

2. Gap Clearance 2. Adapter plate

3. Elastomeric Element between the flange hub on the compressor side and the hub on the motor side

4. Motor

Figure R-2-10; Pneumatic Drain Valve

1. Housing Cover

2. Socket Head Cap Screw

3. Valve Body

4. Valve piston

Figure R-2-9; Solenoid Drain Valve 5. O-ring

1. Hexagon Nut 6. Housing Flange

2. Threaded Element 7. Spring

3. Coil 8. O-ring

4. Inner Hexagon Socket Head Screws 9. Gasket

5. Solenoid Armature 10. O-ring

6. Nozzle

7. Spring

8. Diaphragm

9. O-rings

10. Lower Valve Section

Figure R-2-11; Piston Ring Installation

Figure R-2-12; 1st Stage Piston Ring Arrangement Figure R-2-13; 2nd Stage Piston Ring

1. Piston Arrangement

2. Gudgeon Pin 1. Piston

3. M-ring 2. Gudgeon Pin

4. N-ring 3. Circlip

5. G-ring 4. R-ring

6. Circlip 5. N-ring

6. S-ring

Figure R-2-15; 4th Stage Piston Ring Arrangement

1. Piston

2. Gudgeon pin

3. R-ring

4. Circlip

Figure R-2-14; 3rd Stage Piston Ring Arrangement

1. Gudgeon pin

2. Piston

3. Circlip

4. R-ring

5. N-ring

Rev. 0, April 2024

Revision Control Page

Rev.

Number Rev. Date Change Request

Form Number Cognizant Engineer Change Synopsis

0 June XX, 2024 Original Issue