GE Ajax DPC 2804 LE, Operation & Maintenance Manual

Page 1: ...GE Oil Gas Ajax Compressor Ajax DPC 2804 LE Non LE Operation Maintenance Manual ...

Page 2: ...stallation Operating and Maintenance Manual GE Oil Gas Compression Systems LLC can be contacted as follows Phone 1 866 754 3562 Website www geoilandgas com Cameron is not affiliated with this manual and any reference to Cameron or Cameron International herein is unintentional ...

Page 3: ...11 09 2012 Prabhu 1 GE Cover Page Update 7 9 2014 Prabhu 2 GE Contact Information Lubrication System Baffle Update 09 03 2015 Prabhu 3 Content added in Sections General Data Fuel System Power Cylinder 10 19 2015 Prabhu 4 Sealing Compound Instructions added in Section 6 03 22 2016 Prabhu ...

Page 4: ......

Page 5: ...tems LLC Contact Information 16 Section 2 Safety Information 17 Introduction 17 Danger Caution and Note Symbols 17 DANGER SYMBOL 17 CAUTION SYMBOL 17 NOTE SYMBOL 17 Safety Decals 18 Danger Caution and Note Decals 18 Figure 2 1 Safety Decals 19 Figure 2 2 Safety Decals 20 General Precautions 21 Engine Maintenance Precautions 21 Compressor Maintenance 22 Section 3 Warranty 25 Warranties to Original ...

Page 6: ...d Weighs Dimensions 32 Table 5 7 Engine Component Dimensional Clearance Data 32 Table 5 8 Compressor Component Dimensional and Clearance Data 33 Table 5 9 Torque Table for Critical Ajax Fasteners 33 Table 5 10 General Torque Table for Fasteners for use when a specific torque is not specified 35 Clearance and Torque 37 Figure 5 1 Crankcase and Main Bearing Journal Group 37 Figure 5 2 Power Cylinder...

Page 7: ...X Compressor Unit 47 Figure 6 3 Typical Concrete filled AJAX Inertia base Skid 48 Figure 6 4 Typical Pit Dimensions for Inertia base Units 49 Figure 6 5 Recommended Pit Depth and Sand Pad Specification 50 Setting Inertia Base Compressor Unit and Cooler 50 Figure 6 6 Recommended Sand Placement following Unit Placement 51 Fabricated Piping Assembly 51 Keyless Flywheel Installation and Ignition Timin...

Page 8: ...tings 60 Sealing Electrical Fittings in Hazardous Locations using CHICO A Sealing Compound 61 Installation 61 Dam 61 Use the EYS TOOL KIT to pack a proper fiber dam do not use metal tools Proceed as follows 61 Compound 61 Follow these instructions carefully 61 For Applications Involving Groups C and D 62 For Group B Applications 62 Section 7 Unit Start Up 63 General Information 63 Overview 63 Powe...

Page 9: ...s 75 Figure 8 5 Lube Oil from Frame Mounted Supply Reservoir 76 Figure 8 6 Lube Oil from Frame Mounted Supply Reservoir 77 Lubrication System Components 77 SMX Divider Valve 77 Base 78 Table 8 2 Metering Elements 78 Table 8 3 SMX Divider Valve Specifications 78 DNFT LED Digital No Flow Timer 79 Table 8 4 DNFT LED Specifications 79 DNFT LED Operation 79 Power Cylinder Lubrication 80 Power Cylinder ...

Page 10: ...6 Hydraulic Fluid 87 Fluid supply Tank 87 Pump Assembly 87 Flow Control Valve 87 Injection Valve Assembly 87 Bleeder Cock 87 Bleeding of Air Before Starting 88 Gas Pressure 88 Adjusting Fuel Injection Valves 88 Figure 9 3 Fuel Injection Valve adjustments 88 Gas Injection Timing Instructions 89 Checking the gas injection timing on the DPC 2804LE engine 89 Figure 9 4 2804LE Crankshaft with Straight ...

Page 11: ...99 Belt Tensioning Procedure 99 Belt Tensioning Procedure Peerless Pump 100 Figure 10 5 Belt Tensioning Procedure Peerless Pump 100 Figure 10 6 Belt Tensioning Procedure Peerless Pump 100 Belt Tensioning Procedure 100 Cooler 101 Cooler Operation and Maintenance 101 Fan and Drive 101 Lubrication 101 Tube Cleaning 102 Plug Leaks 102 Tube Leaks 102 Section 11 Power Cylinder Assembly 103 Power Cylinde...

Page 12: ... Cam Timing 109 Figure 11 6 Control Box and Cams 110 Ignition Timing 110 Igniter Assembly Installation 110 Figure 11 7 Igniter Assembly 111 Accessories 111 Spark plugs 111 Air intake filter 111 Breather cap 112 Main Bearing Crankshaft Installation 112 Main Bearing Installation 112 Figure 11 8 DPC 2804 Series Main Bearing Installation 112 Crankshaft Installation 113 Figure 11 9 DPC 2804 Series Cran...

Page 13: ...ip Liners 120 Shrink Liners 120 Compressor Pistons 120 Compressor Piston Rings 121 Table 12 1 Piston Ring Clearance 121 Compressor Piston Rods 121 Compressor Pressure Packing 121 Compressor Valves 122 Compressor Cylinder and Pressure Packing Lubrication 123 Compressor Lubrication 123 Packing Lubrication Quantities 124 Fire Resistant Lubricants 124 Section 13 Ignition 127 Altronic III Ignition DPC ...

Page 14: ... Section 16 Preventive Maintenance Program 139 Preventive Maintenance 139 Section 17 Engineering Standards 143 Contents 143 ES 1002 LUBRICATION RECOMMENDATIONS FOR SUPERIOR RECIPROCATING COMPRESSORS 143 ES 1006 LUBRICATING OIL RECOMMENDATIONS FOR AJAX ENGINES COMPRESSORS 143 ES 4025 CRANKSHAFT WEB DEFLECTIONS FOR THREE AND FOUR CYLINDER AJAX ENGINES 143 Section 18 Technical Documentation 161 Conte...

Page 15: ...PURPOSE OF PROVIDING INFORMATION TO FACILITATE USE AND MAINTENANCE OF AJAX SERIES COMPRESSOR FRAMES PURCHASED FROM GE OIL GAS COMPRESSION SYSTEMS LLC BY RECEIVING THIS DOCUMENT YOU AGREE NOT TO USE SUCH CONFIDENTIAL INFORMATION FOR ANY PURPOSE OTHER THAN PURPOSE STATED HEREIN AND FUTHER AGREE NOT TO DISCLOSE SUCH INFORMATION TO OTHERS EXCEPT IN ACCORDANCE WITH THE PURPOSE STATED HEREIN All specifi...

Page 16: ...ter it has been delivered to the Purchaser 4 Purchaser shall pay freight charges in connection with the return or replacement of the defective Equip ment or parts b Performance Warranty The Seller warrants that the Equipment of its own manufacture when shipped and or installed will operate within any performance characteristics which are expressly specified herein as a performance guarantee Any pe...

Page 17: ...ade by the Seller or as a result of removal improper use improper operation or mis application of the Equipment after it has been delivered to the Purchaser d Warranty As To Equipment Not Made By The Seller Equipment parts and accessories made by other manufacturers and supplied hereunder by the Seller are warranted only to the extent of the original manufacturer s warranty to the Seller e EXCEPT ...

Page 18: ...ncy shutdown and compressor performance control Description and application of recommended maintenance maintenance critical repairs and troubleshooting For training contact the GE Oil Gas Compression Systems LLC s Learning Center by phone 713 354 1296 or by email recip tlc ge com Additional Information Unrestricted copies of Service Bulletins are available at the GE Oil Gas Compression Systems LLC...

Page 19: ... Compression Systems LLC s Learning Center by phone 713 354 1296 or by email recip tlc ge com Danger Caution and Note Symbols DANGER SYMBOL A DANGER Symbol indicates that if the specified precaution is not heeded there is a substantial risk of serious injury or death along with damage to property A DANGER may appear as follows CAUTION SYMBOL A CAUTION Symbol indicates that if the specified precaut...

Page 20: ...afety Decals Danger Caution and Note Decals Danger Caution and Notice decals will be placed so that they are visible to the operator while the engine is running The Ajax 2804LE units have the following decals AJAX 18 ...