Service and Training

99AX Reciprocating Booster Assembly Manual

1
 INDEX

Section 1
• 1.1 Booster Safety Procedure
• 1.3 Pre-Start Checks
• 1.4 Start-up
• 1.5 Technical Specifications

Section 2
• Assembly

Appendix
A – Rebuild Specifications – Clearances and torques

2
 SECTION
1.1 Booster Safety Procedure
1
SAFETY PROCEDURES
The following procedures must be followed to safeguard personnel and
equipment. Failure to comply with safety procedures may cause serious or
fatal injury.

PRE-OPERATION SAFETY PRECAUTIONS

Before turning on air supply to system, make certain that all valves
and controls are in OFF position.

Before turning on main air supply, check the safety chain or cable
to ensure proper attachments to hoses and anchors.

WARNING !

IF SAFETY CHAIN OR CABLE IS NOT PROPERLY SECURED, MINE AIR

SUPPLY LINE COULD UNCOUPLE AND WHIP, ENDANGERING
PERSONNEL.

OPERATION PRECAUTIONS

Always wear a hard hat, work gloves, safety glasses and safety shoes.
Do not wear loose clothing that became entangled in flywheel or belt.
Keep hands away from the flywheel and belt.

MAINTENANCE AND REPAIR SAFETY

Observe cleanliness and safety during disassembly, repair and

reassemble. Keep solvents, oils, or any flammable liquids in
covered, safe containers. Discard clothes saturated with flammable
liquids. Avoid smoking or flame in combustible areas.

Before disassembling any component, ensure that machine is

positioned for maximum safety.

Disconnect air supply to system and bleed all air pressure before attempting to
repair, replace, or remove any air system component.

3
1.2 Maintenance and PM Tasks
The booster compressor efficiency and life depend on the quality of maintenance
the unit receives. Clean work space and tools with cleaning solvents. Wiping rags
are necessary to avoid contaminating the unit. Clean the exterior of the
compressor before starting work.
The following are recommended maintenance practices and schedules for the
CUBEX 99AX compressor booster under typical mine climate and working
conditions.

Daily Maintenance (Before Starting)

1. Wash down outside of compressor to get optimum cooling capacity.
2. Drain moisture from air receiver and mine air filter.
3. Visually check all air and hydraulic hoses and fittings for leaks.
4. Check oil level on booster compressor and fill if required.
5. Check belt tension on compressor. Adjust tension to a point where belt
does not slip.
6. Push lamp test button on panel. All fault indicator lights should be
illuminated, if not call and electrician.
7. Check complete machine for loose bolts and nuts.

Daily Maintenance (Running)

1. Listen for unusual noises from compressor and motor.

2. Check for hydraulic and air leaks in components. Have a mechanic repair
any damaged components immediately.

3. Check pressure at which compressor automatically unloads.

4. Ensure compressor oil pressure remains stable at 15 to 50 psi (1.3 to 3.5

bar). If pressure is less call a mechanic.

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250 Hour Maintenance

1. Repeat all daily maintenance.

2. Drain and inspect mine air filter, replace element if required.
3. Check atmospheric air filter, replace if required.
4. Check inlet selector valve (3-way) for smooth operation and clean if
required.
5. Activate safety valve on air receiver to ensure proper operation. Drain
water from receiver.
6. Grease electric motor bearings (by an electrician only). Too much
grease may overheat motor.
7. Change compressor oil and filter. Use shell Corena P122 or equivalent.
8. Remove, disassemble, clean and inspect pilot unloader valve. Refer to
pilot unloader valve for adjustment.
9. Remove and inspect suction valves (3). Refer to P/N CO48001-0201
for illustration. Soak felt seal in lubricating oil before installation. Coat
sleeve thread with Anti-Sieze Thread Compound. Torque sleeve to
100 ft-lbs (136nm).
10. Remove and inspect discharge valves. You must replace discharge
valve gaskets every time valves are removed. Coat sleeve threads with
Anti-Seize Thread Compound. Torque sleeve to 100 ft-lbs (136nm).

500 Hour Maintenance

Repeat 250hr maintenance.

Replace suction valves, felt seals and o-rings. Soak felt seals in lubricating
oil before installation.
Replace discharge valves and discharge valve gaskets.

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1.3 Pre-Start Checks
1. Check all bolts and nuts for tightness.
2. Inspect air intake for line for dirt and loose connections
3. Check crankcase oil level.
4. Check drive belt alignment and tension.
5. Turn compressor by hand to ensure free movement.
6. Ensure belt guard is in place.

1.4 Start-up
1. Turn drilling air to on position to allow a no load start. Do not
connect the mine air until the compressor is warm.
2. Bump motor to check for correct rotation, the flywheel fan should
push air at the compressor (counter clockwise while standing on the
flywheel side of the compressor looking at the flywheel).
3. Continue to bump motor to prime the reciprocating parts with oil.
4. Run the compressor and ensure the oil pressure steadies between 15
psi to 55 psi (1.0 – 3.5 bar).
5. Stay alert for odd noises or excessive vibration. If problems are
noticed shut down the compressor and recheck all work procedures.

1.5 Technical Specifications

Rating: 700 CFm @ 350 PSI

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 SECTION

2.0 Assembly 2
All parts must be cleaned and inspected to manufactures specifications
before assembly.

Install CP48001-0414 bearings into CP48001-0404 con-rods. Bearings must be

kept as a matched set. Do not touch the bearing surface with your hands.

Place the CP48001-0300 crankshaft in a vice and install CP48001-0404 con-rods

with bearings onto the crankshaft. Do not lubricate the bearings at this time.
(Note; care must be taken to insure the con-rods are kept as a matched set and
that the bearing tabs are aligned.). Check Rod Gap with Feeler Gauge. The gap
must be .016” (0.406 mm) to .044” (1.118).

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Check the running clearance of the con-rods at this time. Place a piece of .001”
to .003” plastic gauge (red) under the caps, while holding the con-rods firmly,
torque the CP48001-0408 rod nut to 175 ft-lbs (237 Nm). Hold the rods firmly and
carefully remove the nuts and caps. Check the plastic gauge reading for each
rod, the clearance must be .0015” (0.381 mm) to .0045” (0.368 mm). Clean the
plastic gauge off the crankshaft and bearings using a brake clean or similar
product. (Note; be careful not to damage the bearings while cleaning.)

Check the fit of the CP48001-0620 oil pump rotor to the crankshaft, the rotor
must slide freely on the crankshaft. Check the fit of the CP48001-0617 key to the
keyway in the rotor, the key must slide freely.

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Using a suitable style of bearing warmer heat the CP48001-0303 bearings to 200
°F (93°c) and install on the crankshaft.

Insure that the bearings are pressed tightly against the shoulders of the
crankshaft. Allow the crankshaft and bearings to cool.

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 Install the CP48001-0601 bearing cup into the CP48001-0701 housing using a
brass punch.

Install the CP48001-0702 seal into the CP48001-0727 seal housing. Install the
seal housing with CP48001-0726 gasket to the housing with 4 EACH 3/8” x 1.0”
UNC grade 8 bolts and 3/8” lock washers. Torque the bolts to 40 ft-lbs (54Nm).
(Note; check to be sure the bearing cup is firmly against the seal housing.)

Seal housing
Apply Flange Sealant
Loctite 518,
Install gasket between
housing and crankcase.

Seal

10
 Install the CP48001-0723 baffle into the housing using 1 each 8 5/16” x ¾”
UNC grade 8 bolt and flat washer. Apply a small amount of Medium Strength
Blue Loctite 243 to the threads and torque to 15 ft-lbs (20Nm).

Turn the housing over and install the crankshaft. Turn the crankshaft to ensure
the baffle will not be hit.

11
Install CP48001-0601 bearing cup into theCP48001-0600 rear bearing retainer
with a brass punch until it is firmly seated.

Use a small amount of red Loctite Maximum Strength Red Loctite 262 on the
threads and install the CP48001-0604 oil pick-up into the rear-bearing retainer.
(Note; excessive Loctite can plug the oil gallery.)

Dowels

12
Using all of the CP48001-0612, 0613, 0614 shims install the rear-bearing retainer
onto the housing. (Note; the use of two (2) guide studs will make this job easier)

Shims

Install 4 - 3/8” x 1.0” UNC grade 8 bolts equally spaced around the rear bearing
retainer and torque to 40 ft-lbs (54Nm).

13
 Install #8 Tee, #8 Cap and #8 to #6 Reducer
Using a dial indicator, pry, using a pry-bar, simultaneously measure the amount
of crankshaft end play. The end play must be .003” to .005” add or remove shims
as needed. Install 11 each 3/8” x 1.0” grade 8UNC bolts and 3/8” lock washers
then torque to 40 ft-lbs (54Nm). Recheck the end play measurement.

#8 JIC FEMALE TO
#6 MALE REDUCER

End Play should be 0.003” (0.0762

mm) to 0.005” (0.127 mm)

#8 CAP
#8 PIPE TO
#8 JIC TEE

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Install the CP48001-0617 key into the crankshaft.

Install the CP48001-0619 oil pump stator with the arrow up and pointing in the
direction of rotation (clockwise looking at the back of the compressor) and
CP48001-0620 oil pump rotor into the rear bearing retainer. Using a depth
micrometer, measure the height clearance between the stator and rotor; the
clearance must be .0015” (0.0381 mm) to .0035” (0.0889 mm).

15
Install the four (4) CP48001-0621 oil pump vane with the four (4) CP48001-0622
springs into the oil pump rotor. The slot in the vane faces the direction of rotation.
(Clockwise looking at the back of the compressor) Be careful while installing the
springs that the springs do not fold in half.

Install the CP48001-0517 o-ring on the rear bearing retainer.

16
Install the CP48001-0501 oil pump cover using 6 each ¼” x 1.0” UNC grade
8bolts with ¼” lock washers and torque to 10ft-lb (120 inch-lbs) (13.6 Nm). Install
a ¼” pipe to #4 JIC straight fitting in the oil pump cap.

Install CM48003-004 oil inlet cover with a CP48006 o-ring using six (6) #12 x 1.0”
cap screws with #12 lock washers and tighten firmly.

17
Adjust the position of the oil pick-up until it lies flat on the bottom of the housing.

Using one (1) piston ring, check the ring gap on all three (3) cylinders. The ring
gap must be .013” (.330 mm) to .023” (0.584 mm)

18
Lubricate the con-rod bearings and crankshaft with clean compressor oil. Install
the left and right side con-rods first, making sure that they are a matched con-rod
and cap (stamped with numbers) and that the bearing tabs are on the same side
of the con-rod. Turn the bolthole at the top of the con-rod up and carefully install
on the crankshaft. Torque the con-rod nuts to 175 ft-lbs (102 Nm).
Using Feeler Gauge, check connecting rod gap, to be between 0.016” to 0.044”

19
Lubricate the CP48001-0403 piston pin bushing and the CP48001-0402 piston
pin with clean compressor oil. Install the CM48001-0400C pistons on the con-
rods with the piston pin; be sure to line up the slot on the piston pin with the
bolthole on the con-rod. Install the CP48001-0410 lock on a ½” x 2 ¼” UNF
grade 8 bolt with the long side away from the con-rod and torque to 79 ft-lbs
(102Nm).

Bend the tabs on the lock over the flats on the bolt.

Bend Tab

20
Install the CP48001-0411 piston ring kits on the pistons. Install the three (3)
piece oil control ring first in the bottom groove of the piston. Next install the two
scraper rings making sure that the mark on the ring is facing the top of the piston,
install the compression ring last in the top groove making sure the mark on the
ring is facing the top of the piston. (Note; the scraper rings will have the bevel
facing down with the mark on top, the compression ring will have the bevel facing
up with the mark on top.) Align the piston ring gaps 120 degrees apart.

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Measure the piston ring groove clearance it should be .002” (0.051 mm) to .004”
(0.102 mm).

Apply a coat of Loctite 518 gasket sealer to the cylinders and install the
CP48001-0103 cylinder gaskets.

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 Install two (2) 5/8” x 2 1/2” UNC guide studs in the housing. Lubricate the
inner diameter of the CP48001-0102 cylinder and the piston and rings with
clean compressor oil. Apply a coat of gasket sealer to the gasket area of the
cylinder. Slowly install the cylinder over the piston using a slight side-to-side
motion, the cylinder has a bevel at the bottom that will allow the piston rings
to compress and slide into the cylinder. (Note; forcing the cylinder down will
result in broken piston rings, a screwdriver may be used to help compress the
rings into the cylinder.) Install four (4) 5/8” x 1 ¾” UNC grade 8 bolts and
torque to 150 ft-lbs (203 Nm).
Install outside
cylinder first

Use Blue Loctite 243

on bolt threads

Install Gasket with

cutouts facing sides
(Intake & Exhaust)

Using a straight edge and feeler gauge measure from the piston top to the
cylinder top. The measurement must be .006” (0.152 mm) to .026” (0.660mm).

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Run tap thru all threads
Install CP48001-0232 copper valve gasket into CP48001-0202 cylinder head as
shown.

Install CP48001-0222 discharge valve and CP48001-0203 suction valve into

cylinder head.

Suction Valve Discharge Valve

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 Install two (2) CP48001-0219 felt seal in the top and bottom groove of the suction
valve sleeve. (Note; the felts might be slightly oversized, use a used CP48001-
0220 unloader plunger turned upside down and drive through the seals, this will
cut the seals to size.) Install the CP48001-0218 O-ring in the middle groove and
lubricate well with light grease.

When felts are installed,

Ensure angles are up and down,
not side to side

Lightly coat the threads on the CP48001-0217 suction valve sleeve and
CP48001-0233 discharge sleeve with anti-seize, (Note; excessive amounts of
anti-seize can lead to early valve failure.) and install into the cylinder head.

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Torque the sleeves using a CT48001-002 suction valve sleeve and CT48001-001
discharge valve sleeve tool to 150 ft-lbs (203Nm).

Lubricate and install the CP48001-0220 un-loader plunger in the suction valve
sleeve. Check to be sure the plunger moves up and down freely. Install the
CP48001-0235 o-ring on the suction valve sleeve and the CP48001-0236 copper
gasket over the discharge sleeve.

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Install the CP48001-0221 suction valve cap, (The one with the hole in it.) and
CP48001-0134 discharge valve cap and torque to 150 ft-lbs (203Nm).

Coat the gasket area of the cylinders with gasket sealer and install the CP48001-
0237 head gaskets. Use high temp – high tack gasket sealer Loctite 30525, on
one side of gasket only.

27
Install the cylinder head assembly’s on the cylinders with four (4) ½” x 3 ¾” UNC
grade 8 bolts, snug first then, torque to 90 ft-lbs (122Nm).

Use Blue Loctite 243

Using the Cylinder on bolt threads
Head Alignment Jig,
Install Cylinders
before applying
torque the bolts

Coat breather body CP48001-0718 with gasket sealer and install Breather Body
Gasket CP48001-0720. Coat breather body gasket with gasket sealer.

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 Install CP48001-0718 breather body with CP48001-0720 gasket using four (4)
5/16” x 1” UNC grade 8 bolts, (4) Lock washers and torque to 15 ft-lbs (20Nm).
Install CM70021 breather tube into the breather body.

Install CP48003 filter kit with CP48005 filter, (Note; pre-fill the filter with approved
compressor oil.) using two (2) ½” x 1 ¼” UNC grade 8 bolts with ½” lock washers
and torque to 75 ft-lbs (102Nm).

#4 JIC - #4 ORB
Straight
#4 JIC - #4 ORB TEE
#4 JIC - #4 ORB 90°
#6 JIC - #6 ORB 90°
#4 JIC - #4 ORB 90°

3/8 X 1 Hex Head Cap

Screws, 3/8 Lockwashers
Apply Blue Loctite 243

#4 JIC - #4 ORB 90°

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 Install the oil lines and fittings as per the diagram below.
Ø ¼ x 23” O/A length Oil Line #4 JIC
Ø ¼ x 24” O/A length Oil Line #4 JIC
Ø 3/8 - 90° X 23” O/A length Oil Line #4 JIC

Ø1/4” This fitting is hooked

Ø3/8” Bypass from filter to
up to the oil pressure gauge
the bottom of the Crankcase

This fitting is hooked up to

the unloader valve

Ø1/4” Discharge from pump

to oil filter

Oil Supply to Crank

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Fill the housing with approved compressor oil to the fill line on the side of the
housing.

Prime the lubrication system by filling the oil pump discharge hose with
compressor oil.

31
Install CP48301-PK line kit.

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Coat the crankshaft and CP48001-0304 key with anti-seize and install the
CP48001-0801 flywheel.

Hold the flywheel in position and torque the CP48001-0307 bolt with the CP48001-0305
washer and CP48001-00306 lock washer, Torque the 7/8 X 2 ¼” Grade 8 Bolt in steps,
150 ft-lbs, 200 ft-lbs finally to 250 ft-lbs (339Nm), Apply Blue Loctite 243 on bolt
threads.

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 REBUILD SPECIFICATIONS
CP48201 BOOSTER COMPRESSOR

Imperial CLEARANCES

PISTON CLEARANCE AT SKIRT ………………………...…………. 0.0045”-0.0075”

PISTON RING GAP-COMPRESSION …………………………...……… 0.013”-0.023”

PISTON RING GAP-OIL CONTROL ………………………………….. 0.013”-0.023”

PISTON RING GROOVE CLEARANCE COMPRESSION ………... 0.0020”-0.0035”

PISTON RING GROOVE CLEARANCE –OIL CONTROL …………… 0.0015”-0.0030”
PISTON TOP TO CYLINDER TOP ……………………………….…… -0.006”- +0.026”
CONNECTING ROD RUNNING CLEARANCE …………………….. 0.0025”-0.0044”
CRANKSHAFT END PLAY ……………………………………………. 0.003”-0.005”
OIL PUMP ROTOR END CLEARANCE ……………………………….. 0.0015”-0.0035”

TORQUES

OIL PUMP COVER BOLTS ….……………………………………………... 105in-lbs

VALVE NUT .………………………………………………………………. 200in-lbs
CONNECTING ROD BOLTS ………………………………..…………. …. 175ft-lbs
PISTON PIN BOLT …..………………………………………………….. …. 79ft-lbs
UNLOADER SLEEVE ……………………………..…………………… …. 150ft-lbs
FLYWHEEL RETAINER BOLT …………………………………………… 250ft-lbs
CYLINDER FLANGE BOLTS …………………………………………... .. 142ft-lbs
CYLINDER HEAD BOLTS ……………………………………………….. 73ft-lbs
REAR RETAINER BOLTS ……………………………………………….. . 30ft-lbs

Metric CLEARANCES

PISTON CLEARANCE AT SKIRT ……………………………...…. 0.1143-0.1905mm

PISTON RING GAP-COMPRESSION ……………………………… 0.3302-0.5842mm

PISTON RING GAP-OIL CONTROL ………………………………. 0.3302-0.5842mm

PISTON RING GROOVE CLEARANCE COMPRESSION ………… 0.0508-0.0889mm

PISTON RING GROOVE CLEARANCE –OIL CONTROL …..……. 0.0381-0.0762mm
PISTON TOP TO CYLINDER TOP …………………….……….… -0.1524- +0.6604mm
CONNECTING ROD RUNNING CLEARANCE ………………..…. 0.0635-0.1118mm
CRANKSHAFT END PLAY …………………………………….…… 0.0762-0.1270mm
OIL PUMP ROTOR END CLEARANCE ……………………………. 0.0381-0.0889mm

TORQUES

OIL PUMP COVER BOLTS ………………………………………………. 11.9Nm

VALVE NUT .……………………………………………………………..… 22.6Nm
CONNECTING ROD BOLTS ………………………………..………….... 237.3Nm
PISTON PIN BOLT …..………………………………………………….... 107.1Nm
UNLOADER SLEEVE ……………………………..…………………….... 135.6Nm
FLYWHEEL RETAINER BOLT ………………………………………..… 339.0Nm
CYLINDER FLANGE BOLTS …………………………………………….. 192.5Nm
CYLINDER HEAD BOLTS ……………………………………………..…. 99.0Nm
REAR RETAINER BOLTS ……………………………………………….... 40.7Nm

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