Heavy Duty Balanced Opposed Compressors

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FOR MODELS: JG AND JGA SECTION 5 - MAINTENANCE ! CAUTION CROSSHEADS ARE HEAVY. CARE MUST BE TAKEN WHEN HANDLING TO AVOID PERSONAL INJURY. THE WEIGHT OF EACH CROSSHEAD IS LISTED IN THE BALANCE SHEET THAT COMES IN THE MANUAL WITH EACH COMPRESSOR. 1. Remove crosshead guide side covers and cylinder head. 2. Move the crosshead to its inner dead center position and back off, but do not remove, the crosshead nut set screws. Loosen the crosshead nut with the special slugging Peg or Open End Wrench shown in Figure 7-1: on page 7-3, depending on nut style, and a babbitt or plastic-faced slugging hammer. 3. Use the Piston Nut Spanner (Torquing Adaptor) shown in Figure 7-1: and a speed wrench to screw the piston rod out of the crosshead. The two dowels on the Adapter fit holes in the piston nut. Turn the crosshead nut off the piston rod. Push the rod end forward to the edge of the packing to provide a clearance for crosshead removal. 4. With the crosshead in its outer dead center position, remove the crosshead pin thru bolt, lock nut, end-plates and pin. 5. Turn the crankshaft to its inner dead center position. Move the crosshead to its outer dead center position to be free of the connecting rod. Make sure the connecting rod does not drop and damage the crosshead guide surface. 6. Roll the crosshead 90 degrees and remove it through the guide opening. 7. Check the crosshead pin to bushing clearance. (See Table 1-2 on page 1-8.) Wear on the pin can be determined by a visual inspection. Replace the pin if necessary. If the bushings need to be replaced, hacksaw or file to within 1/32 inches (1 mm) of their thickness. They can be easily drifted out. A press will be needed to install new bushings. The bushing can be installed in the crosshead by cooling the bushing in a dry ice and alcohol solution. The bushing needs to be left in the solution long enough to reach the same temperature as the solution, about -120° F (-85°C). DO NOT TOUCH COLD SURFACES WITHOUT PROPER INSULATION TO PREVENT INJURY. Bronze crossheads do not have bushings; if the crosshead pin bearing area is worn, these crossheads should be replaced. NOTE: THE SIDE OF THE CROSSHEAD RECEIVING THE NEW BUSHING SHOULD BE SUPPORTED DIRECTLY TO PREVENT POSSIBLE CRUSHING OF THE CROSSHEAD BY THE PRESS. (SEE FIGURE 5-3:) ABSOLUTE CLEANLINESS IS REQUIRED OF BOTH BUSHING AND CROSS- HEAD TO PREVENT DIRT FROM ACCUMULATING BETWEEN THE BUSHING AND CROSSHEAD BORE. 8. Visually inspect the shoe surfaces for scoring. Since they are constantly lubricated under pressure during operation, there should be virtually no wear. PAGE 5 - 6 11/01
FOR MODELS: JG AND JGA SECTION 5 - MAINTENANCE Crosshead - Installation Approximately 3 Tons (27 kN) Force Required Bushing Crosshead Inner Support Do Not Support Here FIGURE 5-3: CROSSHEAD BUSHING REPLACEMENT NOTE: BE SURE CROSSHEADS ARE RETURNED TO THEIR ORIGINAL THROW LOCATION. 1. With the crosshead on its side, slip it in the crosshead guide. Once inside, it can be rolled upright. Make sure it does not become cocked. Should the crosshead become wedged, do not force it. ease it off and start again. Be careful not to damage the crosshead shoe surface during installation. 2. Turn the crankshaft to its outer dead center position to locate the connecting rod in position and insert the crosshead pin. Install the end plates, thru bolt and locknut. Tighten the locknut to the torque value listed in Table 1-15. 3. Reinstall the crosshead nut on the piston rod. Be sure to have setscrew cup points on the crosshead side of the nut. Screw the piston/rod assembly into the crosshead using the Piston Nut Spanner and a speed wrench. Make sure all threads are well lubricated with clean fresh oil to ensure smooth installation. NOTE PISTON END CLEARANCE MUST NOW BE SET OR SERIOUS DAMAGE COULD OCCUR. REFER TO TABLE 1-2 ON PAGE 1-8 FOR PISTON END CLEARANCE SETTINGS. 4. Tighten the crosshead nut using the special slugging Peg Wrench or Open End Wrench shown in Figure 7-1: on page 7-3 and a slugging hammer. 5. Before installing the side covers, apply an anti-seize lubricant to the gaskets. This will aid to ease removal at a later date. 6. Replace the crosshead guide side covers; tighten all capscrews. 11/01 PAGE 5 - 7
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Heavy Duty Balanced Opposed Compressors

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