Dresser-Rand B412KVSRA Engine Driven Compressor Service Manual (2009)

Description

Dresser-Rand B412KVSRA Engine Driven Compressor Service Manual (2009) PDF DOWNLOAD

Description

🔧 Manual Overview

This OEM service manual covers Type B412KVSRA engine-driven compressors (15.00″ stroke type), including serial range B412KVSRA177S thru B412KVSRA185S (December 2009 publication). It’s designed for technicians and operators who need safe operating guidance and proper service documentation for the unit.

🧭 What’s Inside (Contents / Sections)

✅ Main Included Sections

• Disclaimer / Warning Notice

• Safety Precautions

• Safety Labels

• Sales, Support, Operations Information

• Service Centers

• Technical Compressor Training

• Service Literature Reader Survey

• Metric Conversions

🔎 Electronic Manual Navigation (How to Use)

• Using Bookmarks + Table of Contents for fast section access

• Using the Find/Search tool to quickly locate keywords and topics inside the manual

Table of Contents (from PDF bookmarks)

FRONT MATTER

• PG662A – Safety Precautions

• PG2914A – Safety Labels

• PG2697E – Product Support / Service Centers

• PG2551A – Technical Compressor Training

• PG2915 – Service Literature Reader Survey

• PG732C – Metric Conversion Equivalents

• P/L6297A – Flywheel Lock Warning

• P/L5933I – Approved Lube Oils List

• PG931 – Performance Pages

• TX11409A/B/C – Performance Curves

SECTION 1 – ENGINE INSTRUCTIONS

PG840 – KVSR, A Series

PART I – INSTALLATION

• General

• Storage

• Location

• Building

• Foundation Size & Design

• Setting & Leveling Frame

• Grouting

• Engine Assembly

• Compressor End Assembly

• Engine & Compressor Piping

• Electrical Wiring

PART II – SYSTEMS

• General

• Starting System – Air/Gas Motor Starting

• Starting System – Air to Head Starting

• Fuel System

• Inlet Air System

• Exhaust System

• Cooling System

• Lubrication System

• Ignition System

• Starting Controls & Safety Shutdown System

PART III – OPERATION

• General

• Preparation for Initial Start

• Starting Procedures

• Break-In Run

• Routine Shutdown

• Emergency Shutdown

• Shutdown for an Extended Period

• Routine Operation & Maintenance

• Trouble Shooting

• H36792G – Starting Motor & Piping

PART IV – MAINTENANCE

• General

• Safety Precautions

• Initial Adjustments

• Frame & Frame Top

• Crankshaft

• Flywheel

• Crankshaft Oil Seal

• Main Bearings

• Power Cylinder Head

• Valves & Valve Gear

• Hydraulic Valve Lifters

• Mechanical Valve Lifters

• Valve Tappets & Push Rods

• Camshaft & Cam Box

• Accessory Drives

• Water Pumps

• Power Cylinders & Liners

• Power Pistons & Rings

• Power Connecting Rods & Bearings

• Compressor Connecting Rods & Bearings

• Compressor Crossheads

• Balance Weight Cylinders – Size B412 Units

PART V – GENERAL DATA

• KVSR Engine Specifications

• Operating Data

• Power End Weights

• Part Fits & Tolerances

• Tightening Requirements

SECTION 2 – COMPRESSOR END INSTRUCTIONS

PG738 – TFE Compressor Piston Rings

• General

• Special Operating & Handling Instructions

• Establishing Ring Wear Rate

• Ring Replacement or Adjustment

• Installing One-Piece Piston Rings & Split Riders

• Installing Two & Three Piece Piston Rings

• Breaking in New Piston & Rider Rings

• Piston & Ring Clearances (US)

• Piston & Ring Clearances (Metric)

PG738 Add B – Lubricated TFE Piston & Rider Rings

PG641 – Warning Valve Locations

PG628C – Compressor Cylinders

• General

• Cylinder Nameplate Data

• Compressor Piping

• Recommendations for Installation/Fabrication/Testing/Cleaning of Air or Gas Piping

• Temporary Line Filters

• Starting Loading Bypass Piping

• Water Piping

• Safety Valves

• Intercooler, Aftercooler & Receiver

• Cylinder Installation

• Completing Cylinder Assembly

• Adjusting Piston End Clearance

• Adjusting Piston Rod Runout

• Cylinder Lubrication System

• Cylinder Cooling System

• Water Cooled Cylinders

• Static Cooled Cylinders

• Thermo-Syphon Cooling

• Water Cooled Packing

• Regulation

• Break-In & Operation – Lubricated Cylinders

• Break-In & Operation – Mini Lube Cylinders

• Break-In & Operation – Non-Lube Cylinders

• Extended Shutdown

• Lubricated Cylinders

• Non-Lubricated Cylinders

• Routine Maintenance

• Operator’s Hourly Routine

• Every Eight Hours

• Semi-Annual

• Annual

• Periodic

• Maintenance Hints

• Cleaning the Cylinders

• Locating Cylinder Leakage

• Trouble Shooting

• Cylinder Maintenance

• Safety Precautions

• Cylinder Disassembly

• Outer Head Removal

• Disassembly & Assembly of Pistons & Piston Rods

• Reapplication of Babbitt Sprayed Rider Bands

• Reclamation of Piston Rods

• Compressor Piston Rings

• Piston Rod Pressure Packing

• Assembly Clearances

• Compressor Cylinder Bolting

PG631A – Compressor Cylinder Lubrication

• General

• Break-In Considerations

• Lubricating Oil Recommendations

• General Requirements

• Service Considerations

• Lube Recommendations for Ammonia Refrigeration Compressor Cylinders

• Inspection

• Synthetic Lubricants

• Piston Rod Packing Lubrication

• Cylinder Lubricator

PG652 – General Instructions for Compressor Valves

• Introduction

• General Recommendations

• Valve Maintenance

• Troubleshooting

PG454A – Importance of Maintaining Valve Records

• How Does a Valve Operate

• What Causes Valve Failure & Remedies

• How Valve Records Help (Case Histories)

• Typical Valve Record Systems

• For Best Valve Life

PG773 – Type A Channel Valves (Lubricated)

• General

• Description of Operation

• Valve Maintenance Recommendations

• To Disassemble & Service Valve

• To Reassemble Valve

PG771 – Reconditioning Data for Type A Channel Valves

PG825 – UL47 Outside Operated Clearance Valve

• General

• Control & Vent Piping

SECTION 3 – PARTS LIST

Parts Index

• PG557K – How to Order Replacement Parts

• PG707B – Reporting Service Part Defects

• Tab “A” – Frame Parts

• Tab “B” – 28.50″ Compressor Cylinder

• Tab “C” – 18.00″ Compressor Cylinder

• Tab “D” – 10.50″ Compressor Cylinder

SECTION 4 – ACCESSORY LITERATURE

Accessory Literature Index

• Tab “A” – Ignition System

• Tab “B” – Governor

• Tab “C” – Lubrication System

• Tab “D” – Control & Shutdown System

• Tab “E” – Miscellaneous

• Tab “F” – Control Panel

SECTION 5 – DRAWINGS

Drawing Index

• Post Cooling Schematic (R82000)

• Engine Control Schematic (F26482AW)

• Shutdown Schematic (R58391K)

• Lube Oil System (W134751A)

• Lubrication System (R51482LL)

• Lubricating Oil Piping Schematic (R50055AC)

• Header to MB Pipe Arrangement (R57955A)

• Power Valve Stem Lubrication (W102736P3)

• Compressor Cylinder Lube Schematic (H39586P17)

• Woodward PG Governor Linkage Setting (R37411)

• Fuel Gas Piping Details (R47972Y)

• Altronic II Ignition Wiring Diagram (R51349D)

• Timing Light Adapter Schematic (W124319)

• Pneumatic Schematic (H31984H)

• Cooling Water System BOM (W95554AZ)

• Cooling System (R41897CN)

• Space Required to Remove Power Piston & Rod (W31380F)

• Compressor Balance Weight P/L (6804)

• Balance Weight Record (W88236)

• Critical Speed Blank-Out Circuit (R44569C)

• General Plan (L9642)

• Foundation Plan (L9643)

⚠️ Safety Emphasis (Important)

The manual stresses reading and understanding all safety instructions before installation, operation, or service. It also explains the safety signal words used throughout the document (DANGER / WARNING / CAUTION / NOTE) so you can recognize risk levels instantly.

📄 File Details

Stop guessing and service your compressor with the correct OEM documentation—download this manual now and keep the right safety and service guidance at your fingertips for faster, safer maintenance.