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Reciprocating Compressors for industrial refrig-erationGrasso

Maintenance checklistpador9130gbr_6

COPYRIGHT

All Rights reserved. No part of this publication may be copied or published bymeans of printing, photocopying, microfilm or otherwise without prior written con-sent of Grasso.This restriction also applies to the corresponding drawings and diagrams.

LEGAL NOTICE

This publication has been written in good faith. However, Grasso cannot be heldresponsible, neither for any errors occurring in this publication nor for their conse-quences.

pador9130gbr_62 15.03.2017

SAFETY INSTRUCTIONS

Hint!

This manual must be carefully read and understood prior to installingand servicing the compressor (package)

General Safety

All service operations described in this servicemanual are only to be carried outby well-trained/qualified personnel and even then only after this service manualhas been read carefully and is fully understood.

Personal safety

Observe all (inter)national and/or local safety standards, measures and regula-tions during reinstalling, repairing and connecting the compressor (package).

Mechanical safety

If the compressor does not have to be removed from its base, it is advisable toput warning labels on vital parts of the compressor saying that the plant is out-of-operation and must not be started up.If the compressor has to be opened for service,the refrigerant has to be pumpeddown and the electric supply has to be cut off.After having run the initial 100 operating hours,it is essential (in both new andmodified plants) to replace the red running-in discharge oil filter element with thepermanent grey filter element. Also replace the running-in suction gas filter ele-ment.Check the direction of rotation is correct before re-starting the compressor.

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PREFACE

General

1. All documentation can be downloaded via our web site.

2. Grasso’s technical manuals includes “generic paragraphs”; this means that itcan occur that not all data as described is relevant for the current compres-sor series as mentioned in this manual. (For instance, not all compressor ser-ies are suitable for all mentioned refrigerants or not all compressor seriesincludes two-stage compressors)

Directives

Equipment is based on Pressure Equipment Directive (PED 97/23/EG) regula-tions and according to Machine Directive (MD 2006/42/EG) regulations.

The applied standards are:NEN-EN-IEC 60204, NEN-EN-ISO 12100, NEN-EN-ISO 13857, NEN-EN 378

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NEVER CHANGE POSITIONS!

Warning

Never change positions of parts when re-assembling the compressor.E.g. cylinder liners, suction valves, discharge valves and relief valveshave to be replaced always in the origional position.

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TABLE OF CONTENTS1 MAINTENANCE 91.1 Replacement piston rings and cylinder liners 91.2 Running-in oil filter has to be installed after an overhaul or big repair 101.3 SMS FACTOR 101.4 Legend 111.5 Description Maintenance ABC when GMM is applied 111.5.1 Compressor 121.5.2 Package components 141.6 Grasso V 300 .. 1800 (T), WITHOUT GMM 151.7 Grasso VCM (CLASSIC MECHANISM, Nmax=1000 min-1 191.8 Grasso 5HP R744 & R717 221.9 Grasso 12E 251.10 Grasso 12 291.11 Grasso 10 321.12 Grasso 6 371.13 Grasso 7S and Grasso 8S 401.14 Grasso 11 (RC11) and Grasso 9 (RC9) 421.15 Checklist 44

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1 MAINTENANCE

1.1 Replacement piston rings and cylinder liners

Hint!

Recommendation/warning!For major overhauls or every repair where piston rings are beingreplaced it is strongly recommended to replace the cylinder liners aswell. This is very important for the next reasons:

For the best sealing between piston rings and cylinder liners, piston rings have torun in on the cylinder liner’s inner surface. Therefor a new cylinder liner with ahoning profile (crosshatching) in the best condition is absolutely required. Pistonrings cannot run in properly on worn out or partly worn out cylinder liners. Withouta decent honing profile no proper sealing between liners and rings can be ach-ieved which may result in- or contribute to a bad performance of the compressor.Further on, this honing profile with the right crosshatching is demanded for agood lubrication between piston rings and liners and for the right oil distributionon the liner’s inner surface.

Fig.1: New honing profile and crosshatching with the right angle

After being in operation for many running hours cylinder liners and piston ringswill wear out and most cylinder liners will become unworn ridges (bumper rims oredges) due to the displacement of the piston rings inside the liner. The upperunworn ridge occurs at the upper death end and upper side of the upper pistonring and the lower ridge occurs at the death end of the lower side of the lower (oilscraper) ring. In many cases intermediate and oil scraper rings cause their ownbumper ridges. (Bumper steps) Also, both upper and lower edge are set by theworn shape of the piston rings. This clearly explains why new piston rings canbreak when used in old/worn cylinder liners due to hitting the unworn bumperridges at high speed. (See also picture below)Therefor: Never install new pistons with new piston rings in old cylinder liners. Itis strongly recommended to replace the cylinder liners too.

MAINTENANCEReplacement piston rings and cylinder liners

pador9130gbr_6 15.03.2017 9

Fig.2: Don't use new piston rings on old cylinder liner

N Shape of new piston ring (sharp)

O Shape of old piston ring (rounded)

1.2 Running-in oil filter has to be installed after an overhaul or big repair

Hint!

This is why and when the running in oil filters are required:

Warning

A running in oil filter has always to be installed after an overhaul orbig repair for the 1st 100 hours of operation!The oil and oil oil filters have to be replaced by new oil and filters.Due to running-in wear of liners and piston rings, it's normal that theoil becomes grey during the 1st 100 operating hours.After 100 operating hours, the oil could slightly become clear again.

1.3 SMS FACTOR

General

The following maintenance has to be distinguished:

1. Grasso Maintenance Monitor (GMM) is appliedMaintenance A, B and C, service intervals are determined on measured val-ues of GMM

2. GMM is not applied:Service intervals according to Service and Maintenance Schedules (SMS)tables in combination with operating conditions

MAINTENANCERunning-in oil filter has to be installed after an overhaul or big repair

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Warning

GMM is not used: The running hours mentioned in the SMS tablesshould only be used as a reference for maintenance intervals.The number of running hours mentioned in the SMS tables have to beadjusted accordingly depending on the operating conditions of thecompressor (speed, evaporating temperature, condensing tempera-ture, refrigerant, start frequency, capacity control steps, etc.. Thismeans that the service intervals could be significantly different.The running hours mentioned in the tables are based on a single stagecompressor running at -10oC/+35oC, NH3 at nominal speed. In thiscase the SMS factor = 1, in all other cases the maintenance intervalshave to be adjusted accordingly.

1.4 Legend

Warning

These operations cover routine maintenance and are meant as a guideonly. Lack of maintenance, frequency of stop/starting, extreme operat-ing conditions etc could lead to accelerated wear.

General;

The service and maintenance schedules use the codes as explained in the tablebelow;

Actions

Legend for service and maintenance schedules (SMS)

Item Code/Actions Description

1 IC Inspection / Alternatively renewal - correcting / Testing

2 IV Inspection Visual / Alternatively electrical testing

3 RE Renewal

4 ME Measure

5 CL Clean

1.5 Description Maintenance ABC when GMM is appliedThe information in this section has to be used when GMM is applied.

Hint!

This section is only valid in case the Grasso Maintenance Monitor(GMM) is applied.

General

The following maintenance has to be distinguished;

1. Small maintenance, Maintenance A, Yearly inspection

2. Medium maintenance, Maintenance B

MAINTENANCELegend

pador9130gbr_6 15.03.2017 11

3. Large maintenance, Maintenance C

Description maintenance A;

1. Replace/clean oil discharge filter, clean oil suction filter

2. Visual inspection of cylinders and crankcase

3. Visual inspection of cylinder no. 1

4. Check compressor running conditions

5. Check/test safety equipment

Description maintenance B;

1. Maintenance A +

2. Replace suction and discharge valve rings and springs (“top end“ overhaul)

3. Inspection of pistons and cylinder liners

Description maintenance C;

1. Maintenance B +

2. Major inspection/overhaul;Depending on requirements and expectations, required actions have to betaken. (complete disassembly, replacement of bearings, inspection/replace-ment of all main components like crankshaft, cylinder liners, pistons, ...)

1.5.1 Compressor

General remarks about check list;

1. Check list for compressor only; all other components have to be maintainedaccording to their specific manuals (IMM and SIM).

2. All items of the list below marked “check“, have to be checked visually andchecked for proper working.

3. Some components have to be measured.For measuring details refer to SIM.

4. Measuring means also that visual inspection is required.

5. Visual inspections:The visual inspections during maintenance are of importance; measurementsshould be carried out at the moment that visually abnormalities are detected.The result of the inspection determines whether one or more parts have to bereplaced. For more detailed information refer (SIM) and Installation and Main-tenance Manual (IMM).

MAINTENANCEDescription Maintenance ABC when GMM is applied

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6. Oil and oil return systems:The quality of the oil effects the oil consumption and the life time of the mov-ing parts. For oil return systems or systems in which soluble oil is being used,we advise to check (or have checked) the quality of the oil every 5000 hoursand - if necessary - to renew the oil and/or filters. If there is no oil analysisavailable, we advise to renew the oil. By regularly carrying out oil analysesand registering them in a log, aberrations will be noticed in an early stage,which may prevent or reduce resultant damage(s).

Note 1:When renewing the oil, in the crankcase the oil in the oil separator and the oilreturn or oil rectifier system (if fitted) has to be renewed.

Note 2:Pre-lubricate the compressor before re-starting. Used or filtered oil shouldNEVER be added to a compressor under any circumstance. Use only new oilas selected from the Grasso oil table. Oil charging via the suction line of thecompressor is not allowed.

Grasso Maintenance Monitor (GMM) is applied

Maintenance compressorDescription

A B C

Check Check CheckCapacity control

Solenoid valve and coils

Check Replace Seals of cap control piston / lifting mechanism

Check Check Check Compressor hous-ing Oil return orifice (LP and) HP

Check Check Check Crankcase heater

Measure Crankshaft Main (and intermediate) bearings, running sur-face

Visualinspection

Connecting rod

Cylinder located nearest to the shaft-end of thecompressor:

Visualinspection Measure Big and small end bearing, running surface

Clean Clean Clean Compressor hous-ing Inside and outside

Visualinspection Measure

Cylinder linersCylinder located nearest to the shaft-end of the

compressor

Measure All cylinder liners

Check Check Check Drive Coupling alignment

Check Check Check Interstage cooler Inspections and injection valves

Clean Clean Clean

Filters

Oil suction filter

Replace. Replace Replace Oil discharge filter

Check Clean Clean Suction gas

Check Check Check

Oil

Oil analysis recommended

If hygro-scopic oilis applied:Replace

Replace Replace Oil refreshment compresssor, oil separator andoil system

Visualinspection

Visualinspection

Oil pump element, oil control and lubrication pres-sure regulator


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Grasso Maintenance Monitor (GMM) is applied

Maintenance compressorDescription

A B C

Check Check Check Lubrication and control system

Check Clean Clean Oil separator, test oil return system

Clean Clean Clean Oil cooler fan / heat exchanger

Visualinspection Replace

PistonRings

Visualinspection Measure Gudgeon pin

Visual

inspection+ TEST

Visualinspection+ TEST

Relief valve(s)

Check Check Check Shaft seal Oil & Refrigerant leak range

Visualinspection Compressor valves

Cylinder located nearest to the shaft-end of thecompressor:

Suction and discharge valves, springs, damperrings

Check Replace Replace Suction and discharge compressor valves

Check Thrust bearing Running surface

1.5.2 Package components

Checklist package components

Description/checkpoint

1 Drive guard

2 V-belts and alignment

3 Coupling alignment

4 Oil level float switch on compressor and oil separator

5 Pressure safety switches

6 Pressure gauges

7 Thermostats and thermometers

8 Electrical control system

9 Oil return protection and oil return system

10Electric motor and thermistors(Consult motor manufacturer)

11 Base frame, vibration dampers and bolts

12 Piping

13 Interstage cooler, interstage injection

15 Oil cooler (oil side and air side) and fan

16 Thermo-Master


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1.6 Grasso V 300 .. 1800 (T), WITHOUT GMM

The schedule below has to be used when GMM is not applied.

Hint!

In case Grasso Maintenance Monitor (GMM) is applied, the mainte-nance intervals will be based on actual measured values. If GMM isapplied, refer to Section 1.5, Page 11

Service and maintenance schedules Grasso V 300 .. 1800 (T), excl. GMM

Item Description

Actions

Checkpoint

Running hours * 10001

0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

1

Oil

CL RE CL RE RE RE RE RE Oil suction filter

2 RE2 RE RE RE RE RE RE RE Oil discharge fil-ter

3 - ME ME ME ME ME ME ME Oil analysis

4 RE RE - RE RE RE RE RE

Oil refreshment(If hygroscopical

oil is usedreplace this

always after eachopening of com-pressor or instal-

lation)

5

Oil pump

- IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Housing and ele-ment

6 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CLControl and lubri-

cation oil pres-sure regulator

7a

Crankshaft

- - - - - - IC/ME

IC/ME

Main and inter-mediate bearing

bushes

7b - - - - - - IC/ME

IC/ME

Running surfacesmain and inter-

mediate bearingscrankshaft

1 Check after every maintenance job the settings and working of all safety devices, regulators and the run-ning conditions according to the Service Instruction Manual (SIM)

2 A running-in oil discharge filter is factory mounted. This running-in filter has to be replaced after max. 100running hours by a permanent filter. One permanent filter is supplied together with the compressor.

MAINTENANCEGrasso V 300 .. 1800 (T), WITHOUT GMM

pador9130gbr_6 15.03.2017 15


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

8 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

ERunning surfaces

con. rods

9 Shaft seal - IC IC IC IC IC IC IC Oil/refrigerantleakage

10 Conrod - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

EBig and smallend bearings

11

Pistons

- IC - IC IC IC IC IC Piston

12 - IC - IC IC IC IC IC Piston rings

13 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

E Gudgeon pin

14 Thrust bearing - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EIV/M

ERunning surfa-ces/Axial play

15

Capacity control

IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Solenoid valvesand coils

16 - RE - RE IV IV RE RE Seals of cap.control piston

17 - IC - IC IC IC IC IC Cap. Controlmechanism

18

Compressorhousing

IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Crankcaseheater

19 CL CL - CL CL CL CL CL Crankcase

20 - - - - IC IC IC ICNon returnvalves LP/

Restrictions HP

21 - IV - IV IV IV IV IV Relief valves

22 RE3 IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter

23

Discharge valves

- IC - IC RE RE IC RE Valves, springsand damper rings

24 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CLStroke limitor/

Discharge valveseat


3 A running-in suction gas filter is factory mounted. This running-in filter has to be replaced after max. 100running hours by a permanent filter. One permanent filter is supplied together with the compressor


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Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

25 Suction valves - IC - IC RE RE IC RE Valves, springsand damper rings

26Cylinder liners

- IV - IV IV IV IV IV Cap. Control lift-ing mechanism

27 - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EIV/M

EDimension andrunning profile

28Drive

IC IC IC IC IC IC IC IC Alignment

29 IC IC IC IC IC IC IC IC V-belts

30 Electric motor Refer to specifications of motor manufacturer

31

Optionals

IC IC IC IC IC IC CL/IC CL/IC Oil level switch

32 IC IC IC IC IC IC IC IC Safety switches

33 IC IC IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC IC IC Thermostats

35 IC IC IC IC IC IC IC IC Thermometers

36 IC IC IC IC IC IC IC IC Electrical controlsystem

37 IC IC IC IC IC IC CL/IC CL/IC Valve oil returnprotection

38 IV IV IV IV IV IV IV IV Thermistors

39 IC IC IC IC IC IC IC IC Vibration damp-ers and bolts

40 IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

Intermediatecooler and injec-

tion valve

41 CL CL - CL CL CL CL CL

Oil separatorrefreshing oil andcleaning/testing

of float valve

42 - IC IC IC IC RE IC IC Heavy duty thrustbearing

43 CL CL CL CL CL CL CL CL Oil cooler, airside



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Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

44 RE RE - RE RE RE RE REOil cooler, oil

side, refrigerationoil

45 Refer to specifications of motor manufacturer Oil cooler, electicmotor (fan)

46 ME ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

Cylinder headwater cooling

system



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1.7 Grasso VCM (CLASSIC MECHANISM, Nmax=1000 min-1

Service and maintenance schedules Grasso VCM

Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

1

Oil

CL IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Oil suction filter

2 RE5 RE - RE RE RE RE RE Oil discharge fil-ter

3 - ME - ME ME ME ME ME Oil analysis





lation)

5

Oil pump




7a

Crankshaft

- - - - - - IC/ME

IC/ME


bushes

7b - - - - - - IC/ME

IC/ME



8 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

ERunning surfaces

con. rods



EIC/M

EIC/M

EIC/M

EIC/M


11 Pistons - IC - IC IC IC IC IC Piston


5 A running-in oil discharge filter is factory mounted. This running-in filter has to be replaced after max. 100running hours by a permanent filter. One permanent filter is supplied togehter with the compressor.

MAINTENANCEGrasso VCM (CLASSIC MECHANISM, Nmax=1000 min-1

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Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36


13 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

E Gudgeon pin

14 HD thrust bearing - IC IC IC IC RE IC IC Running surfaces

15

Capacity control




18

Compressorhousing



20 - - - - IC IC - ICNon returnvalves LP/

Restrictions HP


22 CL IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter

23

Discharge valves

- IC - RE RE RE RE RE Valves, springsand damper rings


Discharge valveseat

25 Suction valves - IC - RE RE RE RE RE Valves, springsand damper rings

26Cylinder liners


27 - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EIV/M


28Drive

IC IC - IC IC IC IC IC Alignment





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Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

31

Optionals










40 IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME


tion valve



of float valve





45 ME ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL


system



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1.8 Grasso 5HP R744 & R717

Service and maintenance schedules Grasso 5HP

Item Description

Actions

Checkpoint


0.1Ye

arly

R744(CO2)

R717(NH3)

5 10 5 10

15 20 15 20

25 30 - -

35 40 25 30

- - 35 40

1

Oil

CL CL CL CL CL CL Oil suction strainer

2RE

7 RE RE RE RE RE Oil discharge filter8

3 - ME ME ME ME ME Oil analysis

4 RE RE - RE - REOil refreshment (If hygroscopical oil is used replace

this always after each opening of compressor orinstallation)

5Oil pump

- IC/CL - IC/

CL - IC/CL Housing and element

6 - IC/CL - IC/

CL - IC/CL Control and lubrication oil pressure regulator

7a

Crankshaft

- - - IC/ME - IC/

ME Main bearing bushes

7b - - - IC/ME - IC/

ME Main bearing surfaces crankshaft

8 - IC/ME - IC/

ME - IC/ME Running surfaces con. rods

9 Shaft seal - IC IC IC IC IC Oil/refrigerant leakage

10 Conrod - IC/ME - IC/

ME - IC/ME Big and small end bearings

11

Pistons

- IC - IC - IC Piston

12 - IC - IC - IC Piston rings

13 - - - IC - IC Gudgeon pin

14 Thrust bear-ing - IV - IV - IV Running surfaces

15 Capacitycontrol

IC/IV

IC/IV

-RE

-RE Solenoid valves and coils

16 - -

6 Check after every maintenance job the settings and working of all safety devices, regulators and the run-ning condition according to the service instruction manual (SIM)

7 A running in oil discharge filter is factory mounted8 The permanent oil discharge filter has to be changed every 5000 hours or check (optional) oil differential

pressure indicator

MAINTENANCEGrasso 5HP R744 & R717

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Item Description

Actions

Checkpoint


0.1

Year

ly

R744(CO2)

R717(NH3)

5 10 5 10

15 20 15 20

25 30 - -

35 40 25 30

- - 35 40

17 - IC/CL - IC - IC Cap. Control mechanism, spring

18

Compressorhousing

IV/CL

IV/CL - - Crankcase heater

19 - CL - CL - CL Crankcase

20 - - - CL - CL Orifice crankcase

21 - IV - IV - IV Relief valves

22RE

9IC/CL - IC/

CL - IC/CL Suction gas strainer

23Discharge

valves

- IC - RE - RE Valves, springs and damper rings

24 - IC/CL - IC - IC Stroke limitor/Discharge valve seat

25 Suctionvalves - IC - RE - RE Valves, springs and damper rings

26Cylinder lin-

ers

- - -

27 - IV/ME - IV/

ME - IV/ME Dimension and running profile

28Drive IC IC IC IC IC IC Alignment

29

30 Electricmotor

Refer to specification of motorsupplier

31

Optionals

IC IC IC IC IC IC Oil level switch

32 IC IC IC IC IC IC Safety switches

33 IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC Thermostats

35 IC IC IC IC IC IC Thermometers

36 IC IC IC IC IC IC Electrical control system

37 IC IC IC IC IC IC Valve oil return protection

39 IC IC IC IC IC IC Vibration dampers and bolts


9 A running in suction gas filter is factory mounted


pador9130gbr_6 15.03.2017 23


Item Description

Actions

Checkpoint


0.1

Year

ly

R744(CO2)

R717(NH3)

5 10 5 10

15 20 15 20

25 30 - -

35 40 25 30

- - 35 40

41CL CL - CL - CL Oil separator refreshing oil and cleaning/testing of

float valve42



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1.9 Grasso 12E

Service and maintenance schedules Grasso 12E

Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

1

Oil


2 RE11 RE RE RE RE RE RE REOil discharge fil-

ter12






lation)

5

Oil pump




7a

Crankshaft

- - - - - - IC/ME

IC/ME


bushes

7b - - - - - - IC/ME

IC/ME



8 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

ERunning surfaces

con. rods



EIC/M

EIC/M

EIC/M

EIC/M





12 Oil discharge filter change every 3000 hours or check optional pressure drop indicator

MAINTENANCEGrasso 12E

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Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36


13 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

E Gudgeon pin


EIV/M

EIV/M

EIV/M

EIV/M


15

Capacity control




18

Compressorhousing




Restrictions HP



23Dischargevalves14

- IC - IC RE RE IC RE Valves, springsand damper rings


Discharge valveseat

25 Suction valves15 - IC - IC RE RE IC RE Valves, springsand damper rings

26 Cylinder liners - IV - IV IV IV IV IV Cap. Control lift-ing mechanism



14 Discharge valves for compressors < machine number 00081502 must be changed every 6000 runninghours in case not converted to latest standard

15 If the machine is running on refrigerant R507 or 404A suction valves must always be changed every 3000running hours


pador9130gbr_626 15.03.2017


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

27 - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EIV/M


28Drive

IC IC IC IC IC IC IC IC Alignment



31

Optionals










40 IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME


tion valve



of float valve







pador9130gbr_6 15.03.2017 27


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36


46 ME ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL


system



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1.10 Grasso 12

Service and maintenance schedules Grasso 12

Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

1

Oil


2 RE17 RE RE RE RE RE RE REOil discharge fil-

ter18






lation)

5

Oil pump




7a

Crankshaft

- - - - - - IC/ME

IC/ME


bushes

7b - - - - - - IC/ME

IC/ME



8 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

ERunning surfaces

con. rods



EIC/M

EIC/M

EIC/M

EIC/M






MAINTENANCEGrasso 12

pador9130gbr_6 15.03.2017 29


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36


13 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

EIC/M

E Gudgeon pin


EIV/M

EIV/M

EIV/M

EIV/M


15

Capacity control




18

Compressorhousing




Restrictions HP



23

Discharge valves

- IC - RE RE RE RE RE Valves, springsand damper rings


Discharge valveseat

25 Suction valves - IC - RE RE RE RE RE Valves, springsand damper rings

26Cylinder liners


27 - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EIV/M


28 Drive IC IC IC IC IC IC IC IC Alignment




pador9130gbr_630 15.03.2017


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36



31

Optionals










40 IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME


tion valve



of float valve






46 ME ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL


system



pador9130gbr_6 15.03.2017 31

1.11 Grasso 10


Item Description

Actions

Check-point


0.1

Year

ly

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48

1

Oil

CL RE CL RE CL RE RE CL RE Oil suc-tion filter

2 RE21 RE RE RE RE RE RE RE REOil dis-chargefilter22

3 - ME ME ME ME ME ME ME ME Oil analy-sis

4 RE RE - RE - RE RE - RE

Oilrefresh-ment (Ifhygro-

scopicaloil isused

replacethis

alwaysaftereach

openingof com-pressoror instal-lation)

5

Oil pump

- IC/CL - IC/CL - IC/CL IC/CL - IC/CLHousingand ele-

ment

6 - IC/CL - IC/CL - IC/CL IC/CL - IC/CL

Controland lubri-cation oilpressureregulator





pador9130gbr_632 15.03.2017


Item Description

Actions

Check-point


0.1

Year

ly

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48

7A

Crankshaft

- - - - - - IC/ME - IC/M

E

Main andinter-

mediatebearingbushes

7B - - - - - - IC/ME - IC/M

E

Main andinter-

mediatebearingsurfacescrank-shaft

8 - IC/ME - IC/M

E - IC/ME

IC/ME - IC/M

E

Runningsurfacescon. rods

9 Shaft seal - IC IC IC IC IC IC IC ICOil/refrig-

erantleakage


E - IC/ME

IC/ME - IC/M

E

Big andsmallend

bearings

11

Pistons

- IC - IC - IC IC - IC Piston

12 - IC - IC - IC IC - IC Pistonrings

13 - IC/ME - IC/M

E - IC/ME

IC/ME - IC/M

EGudgeon

pin

14 Thrust bearing - IC - IV/ME - IV/M

EIV/M

E - IV/ME

Runningsurfaces/

Axialplay

15 Capacity control IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IVSolenoidvalves

and coils



pador9130gbr_6 15.03.2017 33


Item Description

Actions

Check-point


0.1

Year

ly

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48

16 - - - RE - RE RE - RE

Seals ofcap. con-trol pis-

ton

17 - IC - IC - IC IC - IC

Cap.Controlmecha-

nism

18

Compressorhousing

IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IVCrank-case

heater

19 CL CL - CL - CL CL - CL Crank-case

20 - - - - - IC - - ICThrottlevalvesLP/HP

21 - IV - IV - IV IV - IV Reliefvalves

22 RE23 IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suctiongas filter

23

Discharge valves

- IC IC IC RE IC RE IC RE

Valves,springs

anddamper

rings

24 - IC IC IC IC IC IC IC IC

Strokelimitor/

Dis-chargevalveseat




pador9130gbr_634 15.03.2017


Item Description

Actions

Check-point


0.1

Year

ly

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48

25 Suction valves - IC IC IC RE IC RE IC RE

Valves,springs

anddamper

rings

26

Cylinder liners

- IV - IV - IV IV - IV

Cap.Controllifting

mecha-nism

27 - IV/ME - IV/M

E - IV/ME

IV/ME - IV/M

E

Dimen-sion andrunningprofile

28Drive

IC IC IC IC IC IC IC IC IC Align-ment

29 IC IC IC IC IC IC IC IC IC V-belts

30 Electric motor Refer to specification of motor manufacturer

31

Optionals

IC IC IC IC IC IC CL/IC IC CL/IC Oil levelswitch

32 IC IC IC IC IC IC IC IC IC Safetyswitches

33 IC IC IC IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC IC IC IC Thermo-stats

35 IC IC IC IC IC IC IC IC ICTher-

mome-ters

36 IC IC IC IC IC IC IC IC ICElectricalcontrolsystem

37 IC IC IC IC IC IC CL/IC IC CL/IC

Valve oilreturnprotec-

tion



pador9130gbr_6 15.03.2017 35


Item Description

Actions

Check-point


0.1

Year

ly

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48

38 IV IV IV IV IV IV IV IV IV Thermis-tors

39 IC IC IC IC IC IC IC IC ICVibrationdampersand bolts

40 IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

Inter-mediatecoolerand

injectionvalve

41 CL CL - CL - CL CL - CL

Oil sepa-rator

refresh-ing oiland

cleaning/testing of

floatvalve

42 - IC IC IC IC IC RE IC IC

Heavyduty

thrustbearing

43 CL CL CL CL CL CL CL CL CLOil

cooler,air side

44 RE RE - RE - RE RE - RE

Oilcooler,oil side,

refrigera-tion oil

45 Refer to specification of motor manufacturer

Oilcooler,electricmotor(fan)



pador9130gbr_636 15.03.2017

1.12 Grasso 6


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - - 18 -

21 - 24 - -

27 30 - - -

33 - - - 36

1

Oil

CL CL CL CL CL CL CL Oil suction filter

2 - RE RE RE RE RE RE Oil discharge filter

3 - ME ME ME ME ME ME Oil analysis

4 RE RE - RE RE RE RE

Oil refreshment (If hygro-scopical oil is used

replace this always aftereach opening of com-pressor or installation)

5Oil pump

- IC/CL - IC/CL IC/CL IC/CL IC/CL Housing and element

6 - IC/CL - IC/CL IC/CL IC/CL IC/CL Control and lubrication oilpressure regulator

7a

Crankshaft

- - - - - IC/ME

IC/ME

Main and intermediatebearing bushes

7b - - - - - IC/ME

IC/ME

Main and intermediatebearing surfaces crank-

shaft

8 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

ERunning surfaces con.

rods/Axial play

9 Shaft seal - IC IC IC IC IC IC Oil/refrigerant leakage


EIC/M

EIC/M

EIC/M

EBig and small end bear-

ings

11

Pistons

- IC - IC IC IC IC Piston

12 - IC - IC IC IC IC Piston rings

13 - - - IC/ME

IC/ME

IC/ME

IC/ME Gudgeon pin


EIV/M

EIV/M

EIV/M

ERunning surfaces/axial

play

15

Capacity controlIC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Solenoid valves and coils

16

17 - IC/CL - IC/CL IC/CL IC/CL IC/CL Cap. Control mechanism


MAINTENANCEGrasso 6

pador9130gbr_6 15.03.2017 37


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - - 18 -

21 - 24 - -

27 30 - - -

33 - - - 36

18

Compressorhousing

IV/CL IV/CL IV/CL IV/CL IV/CL IV/CL IV/CL Crankcase heater

19 - CL - CL CL CL CL Crankcase

20 - - - IC IC IC IC Orifice crankcase (Throt-tle valves)

21 - IV - IV IV IV IV Relief valves

22 IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter

23Discharge valves

- IC IC RE RE RE RE Valves, springs anddamper rings

24 - IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Stroke limitor/Dischargevalve seat

25 Suction valves25 - IC IV IC RE IC RE Valves, springs anddamper rings

26Cylinder liners

- IV - IV IV IV IV Cap. Control lifting mech-anism

27 - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EDimension and running

profile

28Drive

IC IC IC IC IC IC IC Alignment

29 IC IC IC IC IC IC IC V-belts

30 Electric motor Refer to specification of motor supplier 31

Optionals

IC IC IC IC IC CL/IC CL/IC Oil level switch

32 IC IC IC IC IC IC IC Safety switches

33 IC IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC IC Thermostats

35 IC IC IC IC IC IC IC Thermometers

36 IC IC IC IC IC IC IC Electrical control system

37 IC IC IC IC IC CL/IC CL/IC Valve oil return protection

39 IC IC IC IC IC IC IC Vibration dampers andbolts


25 Suction valves for compressors < june 1999 (machine number < 9906****) must be changed every 6000running hours in case not converted to latest standard

MAINTENANCEGrasso 6

pador9130gbr_638 15.03.2017


Item Description

Actions

Checkpoint


0.1

Year

ly

3 6 - - -

9 - 12 - -

15 - - 18 -

21 - 24 - -

27 30 - - -

33 - - - 36

41 CL CL - IC IC IC ICOil separator refreshing

oil and cleaning/testing offloat valve

42 ME ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

Cylinder head water cool-ing, incl. oil cooler


MAINTENANCEGrasso 6

pador9130gbr_6 15.03.2017 39

1.13 Grasso 7S and Grasso 8S

Service and maintenance schedules Grasso 7S and Grasso 8S

Item Description

Actions

CheckpointRunning hours * 100026

0.1

Year

ly

3 6 -

9 12 -

15 18 - 21 - 24

1

Oil

CL CL CL CL RE Oil suction filter

1a - - - CL CL Oil ejector

2 RE27 RE RE RE RE Oil discharge filter

3 - ME ME ME ME Oil analysis

4 RE - - RE REOil refreshment (If hygroscopical oil is

used replace this always after each open-ing of compressor or installation)

5Oil pump

- IC/CL - IC/CL IC/CL Housing and element

6 - IC/CL - IC/CL IC/CL Control and lubrication oil pressure regu-lator

7a

Crankshaft

- IC - IC/CL IC/CL Main and intermediate bearing bushes

7b - - - - IC/CL Main and intermediate bearing surfacescrankshaft

8 - - - IC/CL IC/CL Running surfaces con. rods

10 Conrod - IC - IC/ME

IC/ME Big and small end bearings

11

Pistons

- IC - IC IC/CL Piston

12 - IC - IC IC Piston rings

13 - IC - IC IC Gudgeon pin

14 15

Capacity controlIC IC IC/IV IC/CL IC/CL Solenoid valves and coils

16

17 - IC/CL - IC/CL IC/CL Cap. Control mechanism

18

Compressorhousing

IV/CL IV/CL IV IV/CL IV/CL Crankcase heater

19

CL CL - CL CL Crankcase20

21

22 IC/CL IC/CL - IC/CL RE Suction gas filter

23 Discharge valves - - - RE RE Valves, springs and damper rings28

26 Check after every maintenace job the settings and working of all safety devices, regulators and the run-ning conditions according to the Service Instruction Manual (SIM)

27 Supplied together with compressor28 Dampers rings; not for Grasso 8S

MAINTENANCEGrasso 7S and Grasso 8S

pador9130gbr_640 15.03.2017

Service and maintenance schedules Grasso 7S and Grasso 8S

Item Description

Actions

CheckpointRunning hours * 100026

0.1

Year

ly

3 6 -

9 12 -

15 18 - 21 - 24

24 - IC/CL - IC/CL IC/CL Stroke limitor/Discharge valve seat

25 Suction valves - - - RE RE Valves, springs and damper rings

27 Cylinder liners - IV/ME - IV/M

EIV/M

E Dimension and running profile

28Drive ME ME ME ME ME Insulation resistance with qualified device

29

31

Optionals

IC IC/CL IC IC/CL IC/CL Oil level float switch

32 IC IC/CL IC IC/CL IC/CL Valve oil return

33 ME/CL

ME/CL

ME/CL

ME/CL

ME/CL Cylinder head cooling

26 Check after every maintenace job the settings and working of all safety devices, regulators and the run-ning conditions according to the Service Instruction Manual (SIM)

MAINTENANCEGrasso 7S and Grasso 8S

pador9130gbr_6 15.03.2017 41

1.14 Grasso 11 (RC11) and Grasso 9 (RC9)

Service and maintenance schedules Grasso 11 and Grasso 9

Item Description

Actions

Checkpoint


0.1

Year

ly

2.5 5.0 - - -

7.5 - 10 - -

12.5 15.0 - - -

17.5 - - 20 -

22.5 25.0 - - -

27.5 - 30 - -

32.5 35.0 - - -

37.5 - - - 40

1

Oil

CL RE CL RE RE RE RE Oil suction filter

2 RE RE RE RE RE RE RE Oil discharge filter

3 - ME ME ME ME ME ME Oil analisys

4 RE RE - RE RE RE RE

Oil refreshment (If hygro-scopical oil is used

replace this always aftereach opening of com-pressor or installation)

5Oil pump

- IC/CL - IC/CL IC/CL IC/CL IC/CL Housing and element

6 - IC/CL - IC/CL IC/CL IC/CL IC/CL Oil pressure regulator

7a - - - - - IC/ME

IC/ME

Main and intermediatebearing bushes

7bCrankshaft

- - - - - IC/ME

IC/ME

Main and intermediatebearing surfaces crank-

shaft

8 - IC/ME - IC/M

EIC/M

EIC/M

EIC/M

ERunning surfaces con.

rods

9 Shaft seal - IC IC IC IC IC IC Oil/refrigerant leakage


EIC/M

EIC/M

EIC/M

EBig and small end bear-

ings

11

Pistons

- IC - IC IC IC IC Piston

12 - IC - IC IC IC IC Piston rings

13 - IC - IC IC IC IC Gudgeon pin


EIV/M

EIV/M

EIV/M

ERunning surfaces/Axial

play

15

Capacity control

IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Solenoid valves and coils

16 - - - RE RE RE RE Seals of cap. control pis-ton


MAINTENANCEGrasso 11 (RC11) and Grasso 9 (RC9)

pador9130gbr_642 15.03.2017


Item Description

Actions

Checkpoint


0.1

Year

ly

2.5 5.0 - - -

7.5 - 10 - -

12.5 15.0 - - -

17.5 - - 20 -

22.5 25.0 - - -

27.5 - 30 - -

32.5 35.0 - - -

37.5 - - - 40

17 - IC - IC IC IC IC Cap. Control mechanism

18

Compressorhousing

IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Crankcase heater

19 CL CL - CL CL CL CL Crankcase

20 - - - - - IC IC Throttle valves LP/HP

21 - IV - IV IV IV IV Relief valves

22 RE IC IC IC IC IC IC Suction gas filter

23Discharge valves

- IC IC RE RE RE RE Valves, springs anddamper rings

24 - IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Stroke limitor/Dischargevalve seat

25 Suction valves - IC IC RE RE RE RE Valves, springs anddamper rings

26Cylinder liners

- IV - IV IV IV IV Cap. Control lifting mech-anism

27 - IV/ME - IV/M

EIV/M

EIV/M

EIV/M

EDimension and running

profile

28Drive

IC IC IC IC IC IC IC Alignment

29 IC IC IC IC IC IC IC V-belts

30 Electric motor Refer to motor manufacturer

31

Optionals

IC IC IC IC CL/IC CL/IC CL/IC Oil level switch

32 IC IC IC IC IC IC IC Safety switches

33 IC IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC IC Thermostats

35 IC IC IC IC IC IC IC Thermometers

36 IC IC IC IC IC IC IC Electrical control system

37 IC IC IC IC CL/IC CL/IC CL/IC Valve oil return protection

38 IV IV IV IV IV IV IV Thermistors


MAINTENANCEGrasso 11 (RC11) and Grasso 9 (RC9)

pador9130gbr_6 15.03.2017 43


Item Description

Actions

Checkpoint


0.1

Year

ly

2.5 5.0 - - -

7.5 - 10 - -

12.5 15.0 - - -

17.5 - - 20 -

22.5 25.0 - - -

27.5 - 30 - -

32.5 35.0 - - -

37.5 - - - 40

39 IC IC IC IC IC IC IC Vibration dampers andbolts

40 IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

IC/ME

Intermediate cooler andinjection valve

41 CL CL - CL CL CL ICOil separator refreshing

oil and cleaning/testing offloat valve

42 ME ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

ME/CL

Cylinder head water cool-ing

1.15 Checklist

Service and maintenance schedules Grasso RECIPROCATING COMPRESSORS

Item Description Checked/Remarks/Notes Checkpoint/Setting/Value

A Compressor type

B Machine number

C Date

D Running hours

E Refrigerant

E Evaporating temperature/pressure To/Po

F Intermediate temperature/pressure Tm/Pm

G Discharge temperature/pressure Tc/Pc

H Oil lubricating pressure

I Oil control pressure


MAINTENANCEChecklist

pador9130gbr_644 15.03.2017



J GeneralNotes

1

Oil

Oil suction filter

2 Oil discharge filter

3 Oil analysis

4 Oil refreshment (If hygroscopic oil is used replace this always aftereach opening of compressor or installation)

5Oil pump

Housing and element

6 Control and lubrication oil pressure regulator

7Crankshaft

Main and intermediate bearing bushes and running surfaces

8 Running surfaces con. rods

9 Shaft seal Oil/refrigerant leakage

10 Conrod Big and small end bearings

11

Pistons

Piston

12 Piston rings

13 Gudgeon pin

14 Thrust bear-ing Running surfaces/Axial play

15Capacitycontrol

Solenoid valves and coils

16 Seals of cap. control piston

17 Cap. Control mechanism

18

Compressorhousing

Crankcase heater

19 Crankcase

20 Non return valves LP/HP

21 Relief valves

22 Suction gas filter

23 Dischargevalves

Valves, springs and damper rings

24 Stroke limitor/Discharge valve seat

25 Suctionvalves Valves, springs and damper rings

26 Cylinder lin-ers

Cap. Control lifting mechanism

27 Dimension and running profile

28Drive

Alignment

29 V-belts

MAINTENANCEChecklist

pador9130gbr_6 15.03.2017 45



30 Electricmotor Consult motor manufacturer

31

Optionals

Oil level switch

32 Safety switches

33 Gauges

34 Thermostats

35 Thermometers

36 Electrical control system

37 Valve oil return protection

38 Thermistors

39 Vibration dampers and bolts

40 Intermediate cooler and injection valve

41 Oil separator refreshing oil and cleaning/testing of float valve

42 Heavy duty thrust bearing

43 Oil cooler, air side

44 Oil cooler, oil side, refrigeration oil

45 Consult motor manufacturer Oil cooler, electric motor (fan)

46 Cylinder head water cooling system

Settings pressure safeties

Safety Remark Value

1 Suction pressure

2 LP discharge pressure (safety) two stage only

3 LP discharge pressure (limitor) two stage only,TUV

4 High pressure suction (safety) two stage only

5 High pressure (safety)

6 High pressure (limitor) TUV only

7 OIl differential pressure

MAINTENANCE

pador9130gbr_646 15.03.2017

MAINTENANCE

pador9130gbr_6 15.03.2017 47

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA RefrigerationGEA Refrigeration Netherlands N.V.Parallelweg 255223 AL ‘s-Hertogenbosch,Netherlands

Phone +31 (0)73 6203 911

[email protected] gea.com

Grasso eration Reciprocating Compressors for industrial ... Documents/Grasso... · If the...

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