LESSON

8
REMOVAL AND CARE OF CROSSHEAD
AND CONNECTING ROD
LECTURE
SUB - OBJECTIVE
At the end of the lesson the T!"nee #"ll $e !$le to de%onst!te !n &ndest!nd the
e%o'!l !nd (!e of (osshe!d !nd (onne(t"n) od*
+*, INTRODUCTION
The crosshead design in compressor may be adjustable type or non-adjustable type
and the crosshead guide may be closed type like cylinder or side open.
In cylindrical crosshead guide the crosshead can only removed with connecting rod
and in side open guides, crosshead can remove by detaching piston, rod and
connecting rods crosshead pin.
-*, RE.UIREMENT FOR REMOVAL OF CROSSHEAD
1. Compressor complete shutdown and depressurized.
. !ll necessary tools.
". #verhead hoist, sligs, eye bolts etc.
-*+ TAS/ 0ROCEDURE 1F")* +,-8-+2
$%T&#' 1
The crosshead is o( one piece aluminum construction. )o adjustment is necessary.
1. #n vertical units block the belt wheel to prevent rotation and block the
crosshead prior to removal o( the connecting rod. *emove connecting rod
+re(er to section to removal o( piston and rod,. -ower the crosshead to
bottom o( the stroke and reblock.
. -oosen the piston rod crosshead lock nut and star wahser.
". .se a strap wrench to screw the piston rod out o( the crosshead.
/. *emove the crosshead blocking and take the crosshead out through the
(rame opening.
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F")* +,-8-+ Cosshe!d3 Cosshe!d 0"n !nd Ret!"n"n) R"n)
!-T%*)!T% $%T&#'
1. 6lock the belt wheel to prevent rotation.
. .nscrew the piston rod (rom the crosshead +*e(er to step " above,.
". *emove the complete cylinder and assembly.
)#T%7 This is accomplished by removing the he8 nuts which secure the
(rame head and distance piece to the (rame. 6ecause o( limited
space, an e8tension wrench must be used to remove these nuts.
/. *emove one o( the crosshead pin retaining rings.
9. *emove the crosshead pin.
:. *emove the crosshead.
)#T%7 'uring steps / and 9 above, be care(ul not to allow connecting rod to
drop (orcibly on the crosshead guide.
2ig. 14-5- shown a non-adjustable type crosshead assembly with cylindrical guide.
MECHANICAL MAINTENANCE MODULE 10 SPECIFIC COURSE FOR ENGINEERS
LESSON 5 PAGE 2 PLANT COMPRESSORS MAINTENANCE
F")* +,-8--*A 4 B* Coss he!d Asse%$l5 #"th C5l"nd"(!l G&"de 4 T56"(!l Coss he!d*
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-*- 0ROCEDURE 1F")* +,-8--2
1. *emove crosshead hood by removing the hood clamps.
. &ole or support the hood in ma8imum upward position.
". .nlocked the tap washer +9,.
/. *emove the bolts +/, in cross pattern.
9. *emove +1, (lange and clamping bush +,.
:. 1ush the piston upward +(or that the cylinder head must be removed, (or that
(ollow cylinder head removal procedure,.
)#T%7 In this stage crosshead is (rom piston rod but still connected with
connecting rod.
a. In this stage i( re;uire to remove the packing then (ollow the packing
and scraper ring procedure.
b. Then i( re;uire remove the piston (rom cylinder.
c. 2or removing the crosshead (rom guide (ollow the connecting rod
procedure.
7*, CONNECTING ROD
2ig. 14-5-" shown the connecting rod has a solid eye at the crosshead end and a
split eye at the crank pin end. ! drilled oil passage connects the ends.
The connecting rod cap is held on by two bolts, which are wired together at
assembly.
Two dowels are used at the joint where the rod and cap (it together. These dowels
maintain alignment and must not be removed when removing the connecting rod
cap (rom the connecting rod. <hen the rod is removed, one dowel remains in the
cap and one dowel remains in the rod.
This prevents wrong(ul assembly when replacing the cap. The crank pin bushing is
(ull (loating and no adjustment is needed.
MECHANICAL MAINTENANCE MODULE 10 SPECIFIC COURSE FOR ENGINEERS
LESSON 5 PAGE 4 PLANT COMPRESSORS MAINTENANCE
F")* +,-8-7 A Conne(t"n) Rod !nd Coss he!d Asse%$l5*
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7*+ TAS/ 0ROCEDURE FOR REMOVAL OF CONNECTING ROD 1F")* +,-8-72
1. *otate the cranksha(t so that the connecting rod bolts are accessible
through the opening in the (rame, and then remove the cap bolts. +I( the
compressor is vertical or =-shape then be(ore removing the cap bolts, put a
eye bolt on the tap hole on crosshead and hold with rope through piston rod
hole in cylinder side,
. *emove the connecting rod cap through the opening in the (rame.
". *otate the cranksha(t (ree o( the connecting rod.
/. *emove the connecting rod through the (rame opening.
9. In other case release the rope downward with care and remove the
connecting rod with crosshead through the (rame opening.
7*- CARE AND INS0ECTION OF CROSSHEAD AND CONNECTING ROD
1. Clean all the parts with recommended solvent.
)#T%7 'o not use any hard tools or hard brush (or cleaning the parts.
. Clean the oil passage in the connecting rod by inserting thin steel wire or by
blowing the air through passage.
7*7 INS0ECT
1. =isual inspect all parts (or hair cracks or other damages.
. %8amine the big end journal +crank pin, crankpin bushing or bearings,
crosshead pin and bushing (or wear or scoring.
<%!* C&%C>I)3 1*#C%'.*%
a. 6etween crosshead pin and bushing by di((erences o( diameters.
b. 6etween crank pin and crank pin bushing7
? This can be measured by assembling the connecting rod cap with
bushing and measuring the di((erences o( diameters or
? 1laced the connecting rod on the crank pin and put a lead wire
between the cap and crank pin
? Tighten the cap up to speci(ied tor;ue
? *emove the cap and measure the thickness o( lead wire
)#T%7 The above method can also be used while cranksha(t and
connecting rod is steel in crankcase.
MECHANICAL MAINTENANCE MODULE 10 SPECIFIC COURSE FOR ENGINEERS
LESSON 5 PAGE 6 PLANT COMPRESSORS MAINTENANCE
8*, CONCLUSION
*eplace the bearing bush or pin i( these have e8cess clearance, because e8cess
clearance causes the rod to become noisy.
9*, REASSEMBL:
In this stage i( re;uired to reassemble the compressor then (ollow the reverse o(
disassembly procedure, but some point keep in mind.
1. .se enough oil while assembling the bearings.
. )ever (ile the joint or use shins between the cap and the connecting rod or in
any other way disturb the relationship between these two precision (itted
parts.
". The cap bolts must be tight up to speci(ied tor;ue recommended by
manu(acturer.
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