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- 1-Reciprocating Compressors / Grasso VCM/12/12E/11/10/9/7S/8S/6/5HPSMS2012/v010

Reciprocating Compressors

Grasso VCM/12/12E/11/10/9/7S/8S/6/5HP

Service and Maintenance Schedules (SMS)

pador9130

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- 2- Reciprocating Compressors / Grasso VCM/12/12E/11/10/9/7S/8S/6/5HP SMS2012/v010

Copyright

All Rights reserved. No part of this publication may becopied or published by means of printing, photocopying,microfilm or otherwise without prior written consent ofGrasso.This restriction also applies to the correspondingdrawings and diagrams.

Legal Notice

This publication has been written in good faith.However, Grasso cannot be held responsible, neither forany errors occurring in this publication nor for theirconsequences.

This manual must be carefully read and understood priorto installing and servicing the compressor (package)

General Safety

All service operations described in this servicemanual areonly to be carried out by well-trained/qualifiedpersonnel 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 regulations during reinstalling, repairingand connecting the compressor (package).

Mechanical safety

If the compressor does not have to be removed from itsbase, it is advisable to put warning labels on vital partsof the compressor saying that the plant isout-of-operation and must not be started up.If the compressor has to be opened for service,therefrigerant has to be pumped down and the electricsupply has to be cut off.After having run the initial 100 operating hours,it isessential (in both new and modified plants) to replacethe red running-in discharge oil filter element with the

permanent grey filter element. Also replace therunning-in suction gas filter element.Check the direction of rotation is correct beforere-starting the compressor.

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Table of Contents

Section Title Page

1 MAINTENANCE 9

1.1 SMS FACTOR 9

1.2 Legend 9

1.2.1 Grasso VCM 10

1.2.2 Grasso 12E 12

1.2.3 Grasso 12 14

1.2.4 Grasso 10 16

1.2.5 Grasso 7S and Grasso 8S 18

1.2.6 Grasso 6 20

1.2.7 Grasso 5HP R744 & R717 22

1.2.8 Grasso 11 (RC11) and Grasso 9 (RC9) 24

1.2.9 Checklist 26

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Preface documentations

Typographic signs:

Indicates a WARNING. READ IT CAREFULLY!

Indicates an IMPORTANT note or procedure to whichyou should pay special attention.

Indicates a HINT.

General1 All documentation can be downloaded via

grasso-global.com.2 Grassos technical manuals includes generic

paragraphs; this means thatit can occurthat notall data as described is relevant for the currentcompressor series as mentioned in this manual. (Forinstance, not all compressor series are suitable for allmentioned refrigerants or not all compressor seriesincludes two-stage compressors)

1) Product Information (PI)

Contents

All product information (engineering data) for this seriescompressor and the corresponding accessories. It ismeant to be a guide to the selection of thesecomponents.

User group

Project engineers, application engineers, sales managers,product managers for both sales representatives,contractors and end-users.

2) Installation and maintenance manual (IMM)

(Supplied together with the compressor)

ContentsThis manual will provide information on how totransport, install, start-up and maintain the compressor(package). It also contains a number of "ProductInformation Sheets" and the current "Parts List"

User group

To be used in the field by qualified personnel for bothsales representatives, contractors and end-users.

3) Service Instruction Manual (SIM)

Contents

Description of (re)assembling, inspection, repair and partor total overhaul of the bare shaft compressor. Thismanual should be used together with the 'Installationand Maintenance Manual'.

User group

To be used in the field by qualified personnel ofcontractors.

4) Parts list (PL-xxx) *)

*) per compressor series (xxx)

Contents

All current parts of the compressor together with thedesign changes (if applicable) to previous suppliedcomponents ("History").

User group

Service and parts departments for both salesrepresentatives, contractors and end-users.

5) Parts list (PL-Acc)

Contents

All current parts of the accessories together with thedesign changes (if applicable) to previous suppliedcomponents ("History").

User group

Service and parts departments for both salesrepresentatives, contractors and end-users.

6) Service & Maintenance Schedules

Contents

Service and maintenance schedules up to the date ofrequired overhaul of the bare compressor.

User group

Service and parts departments and in the field byqualified personnel for both sales representatives,contractors and end-users.

7) Instructions for accessories

(Supplied together with the compressor)

Contents

All the relevant mounting and installation instructionsand spare parts information for those accessoriessupplied with the compressor.

User group

To be used in the field by qualified personnel for bothsales representatives, contractors and end-users.

8) Directives

Equipment supplied according to Pressure EquipmentDirective (PED 97/23/EG) regulations and MachineDirective (MD 2006/42/EG) regulations.

The applied standards are:NEN-EN-IEC 60204, NEN-EN-ISO 12100, NEN-EN-ISO13857, NEN-EN 378

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NEVER CHANGE POSITIONS!

Never change positions of parts when re-assembling the

compressor. E.g. cylinder liners, suction valves, discharge

valves and relief valves have to be replaced always in the

origional position.

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- 9-Reciprocating Compressors / Grasso VCM/12/12E/11/10/9/7S/8S/6/5HP

1. MAINTENANCE

SMS2012/v010

1. MAINTENANCE

1.1 SMS FACTOR

General

The running hours mentioned in the SMS tables should

only be used as a reference for maintenance intervals.

The running hours mentioned in the tables are based on

a single stage compressor running at -10o

C/+35o

C, NH3at nominal speed. In this case the SMS factor = 1, in allother cases the maintenance intervals have to beadjusted accordingly.

The number of running hours mentioned in the SMS

tables have to be adjusted accordingly depending on the

operating conditions of the compressor (speed,

evaporating temperature, condensing temperature,

refrigerant, start frequency, capacity control steps, etc..

This means that the service intervals could be

significantly different.

1.2 LEGEND

These operations cover routine maintenance and are

meant as a guide only. Lack of maintenance, frequency

of stop/starting, extreme operating conditions etc could

lead to accelerated wear.

General;

The service and maintenance schedules use the codes as

explained in the table below;

Table 1.2-1 Actions

Legend for service and maintenance schedules (SMS)

Item Code/Actions Description

1 ICInspection / Alternatively renewal - correcting

/ Testing

2 IVInspection Visual / Alternatively electrical

testing

3 RE Renewal

4 ME Measure

5 CL Clean

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- 10- Reciprocating Compressors / Grasso VCM/12/12E/11/10/9/7S/8S/6/5HP

1. MAINTENANCE

SMS2012/v010

1.2.1 GRASSO VCM

SERVICEANDMAINTENANCESCHEDULES Grasso VCM

Item

Description

Actions

Checkpoint

Running hours * 1000a

0.1 YEARLY

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

1

Oil

CL CL/RE IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Oil suction filter

2 REb RE RE RE RE RE RE RE Oil discharge filterc

3 - ME ME ME ME ME ME ME Oil analysis

4 RE RE - RE 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 IC/CL IC/CL IC/CL Housing and element

6 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Control and lubrication oil pressure regulator

7a

Crankshaft

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

7b - - - - - - IC/ME IC/MERunning surfaces main and intermediate bearings

crankshaft

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

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

10 Conrod - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Big and small end bearings

11

Pistons

- IC - IC IC IC IC IC Piston

12 - IC - IC IC IC IC IC Piston rings

13 - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Gudgeon pin

14 Thrust bearing - IV/ME - IV/ME IV/ME IV/ME IV/ME IV/ME Running surfaces/Axial play

15

Capacity control

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

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

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

18

Compressorhousing

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

19 CL CL - CL CL CL CL CL Crankcase

20 - - - - IC IC IC IC Non return valves LP/Restrictions HP

21 - IV - IV IV IV IV IV Relief valves

22 REd IC/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, springs and damper rings

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

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

26Cylinder liners

- IV - IV IV IV IV IV Cap. Control lifting mechanism

27 - IV/ME - IV/ME IV/ME IV/ME IV/ME IV/ME Dimension and running 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

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1. MAINTENANCE

SMS2012/v010

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 control system

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

38 IV IV IV IV IV IV IV IV Thermistors

39 IC IC IC IC IC IC IC IC Vibration dampers and bolts

40 IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME Intermediate cooler and injection valve

41 CL CL - CL CL CL CL CLOil separator refreshing oil and cleaning/testing of float

valve

42 - IC IC IC IC RE IC IC Heavy duty thrust bearing

43 CL CL CL CL CL CL CL CL Oil cooler, air side

44 RE RE - RE RE RE RE RE Oil cooler, oil side, refrigeration oil

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

46 ME ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL Cylinder head water cooling system

a. Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to the Service Instruction Manual(SIM)

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

c. Oil discharge filter change every 3000 hours or check optional pressure drop indicatord. A running-in suction gas filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter

is supplied together with the compressor

SERVICEANDMAINTENANCESCHEDULES Grasso VCM

Item

Description

Actions

Checkpoint


0.1 YEARLY

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36

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1. MAINTENANCE

SMS2012/v010

1.2.2 GRASSO 12E

SERVICEANDMAINTENANCESCHEDULES GRASSO 12E

Item

Description

Actions

Checkpoint


0.1 YEARLY

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





5Oil pump



7a

Crankshaft



crankshaft




11

Pistons





15

Capacity control




18

Compressorhousing






23 Discharge valvese - IC - IC RE RE IC RE Valves, springs and damper rings


25 Suction valvesf - IC - IC RE RE IC RE Valves, springs and damper rings

26Cylinder liners



28Drive




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1. MAINTENANCE

SMS2012/v010

31

Optionals












valve









is supplied together with the compressore. Discharge valves for compressors < machine number 00081502 must be changed every 6000 running hours in case not converted to latest standardf. If the machine is running on refrigerant R507 or 404A suction valves must always be changed every 3000 running hours

SERVICEANDMAINTENANCESCHEDULES GRASSO 12E

Item

Description

Actions

Checkpoint


0.1 YEARLY

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36


Item Code/Action Description

1 IC Inspection / Alternatively renewal - correcting / Testing

2 IV Inspection Visual / Alternatively electrical testing

3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.3 GRASSO 12

SERVICEANDMAINTENANCESCHEDULES Grasso 12

Item

Description

Actions

Checkpoint


0.1 YEARLY

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





5Oil pump



7a

Crankshaft



crankshaft




11

Pistons





15

Capacity control




18

Compressorhousing






23 Discharge valves - IC - RE RE RE RE RE Valves, springs and damper rings


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

26Cylinder liners



28Drive




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1. MAINTENANCE

SMS2012/v010

31

Optionals












valve










SERVICEANDMAINTENANCESCHEDULES Grasso 12

Item

Description

Actions

Checkpoint


0.1 YEARLY

3 6 - - -

9 - 12 - -

15 - 18 -

21 - - 24 - -

27 30 - - -

33 - - - 36





3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.4 GRASSO 10

SERVICEANDMAINTENANCESCHEDULES GRASSO 10

Item

Description

Actions

Checkpoint


0.1YEARLY

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48

1

Oil

CL RE CL RE CL RE RE CL RE Oil suction filter

2 REb RE RE RE RE RE RE RE RE Oil discharge filterc

3 - ME ME ME ME ME ME ME ME Oil analysis

4 RE RE - RE - RE RE - REOil refreshment (If hygroscopical oil is usedreplace this always after each opening of

compressor 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 oil pressure regulator

7A

Crankshaft

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

7B - - - - - - IC/ME - IC/MEMain and intermediate bearing surfaces

crankshaft

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

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

10 Conrod - IC/ME - IC/ME - IC/ME IC/ME - IC/ME Big and small end bearings

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 - IC/ME Gudgeon pin

14 Thrust bearing - IC - IV/ME - IV/ME IV/ME - IV/ME Running surfaces/Axial play

15

Capacity control

IC/IV IC/IV 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 piston

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 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 REd IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter

23 Discharge valves - IC IC IC RE IC RE IC RE Valves, springs and damper rings

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

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

26Cylinder liners

- IV - IV - IV IV - IV Cap. Control lifting mechanism

27 - IV/ME - IV/ME - IV/ME IV/ME - IV/ME Dimension and running profile

28Drive

IC IC IC IC IC IC IC IC IC Alignment

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

30 Electric motor Refer to specification of motor manufacturer

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1. MAINTENANCE

SMS2012/v010

31

Optionals

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

32 IC IC IC IC IC IC IC IC IC Safety switches

33 IC IC IC IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC IC IC IC Thermostats

35 IC IC IC IC IC IC IC IC IC Thermometers

36 IC IC IC IC IC IC IC IC IC Electrical control system

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

38 IV IV IV IV IV IV IV IV IV Thermistors

39 IC IC IC IC IC IC IC IC IC Vibration dampers and bolts

40 IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME Intermediate cooler and injection valve

41 CL CL - CL - CL CL - CLOil separator refreshing oil and cleaning/testing

of float valve

42 - IC IC IC IC IC RE IC IC Heavy duty thrust bearing

43 CL CL CL CL CL CL CL CL CL Oil cooler, air side

44 RE RE - RE - RE RE - RE Oil cooler, oil side, refrigeration oil

45 Refer to specification of motor manufacturer Oil cooler, electric motor (fan)






Item

Description

Actions

Checkpoint


0.1YEARLY

4 8 12 16 - - -

20 - - - 24 28 -

- - - 32 - - -

- - 36 - - - -

- 40 - - - 44 -

- - - - - - 48





3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.5 GRASSO 7S AND GRASSO 8S

SERVICEANDMAINTENANCESCHEDULES GRASSO 7S and Grasso 8S

Item

Description

Actions

CheckpointRunning hours * 1000a

0.1YEARLY

3 6 -

9 12 -

15 18 -

21 - 24

1

Oil

CL CL CL CL RE Oil suction filter

1a - - - CL CL Oil ejector

2 REb 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

opening 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 regulator

7a

Crankshaft

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

7b - - - - IC/CL Main and intermediate bearing surfaces crankshaft

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 ringsc

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/ME IV/ME 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

a. Check after every maintenace job the settings and working of all safety devices, regulators and the running conditions according to the Service Instruction Manual(SIM)

b. Supplied together with compressorc. Dampers rings; not for Grasso 8S

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1. MAINTENANCE

SMS2012/v010





3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.6 GRASSO 6


Item

Description

Actions

Checkpoint


0.1YEARLY

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 REOil refreshment (If hygroscopical oil is used replace this always

after each opening of compressor 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 oil pressure regulator

7a

Crankshaft

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

7b - - - - - IC/ME IC/ME Main and intermediate bearing surfaces crankshaft

8 - IC/ME - IC/ME IC/ME IC/ME IC/ME Running surfaces con. rods/Axial play

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

10 Conrod - IC/ME - IC/ME IC/ME IC/ME IC/ME Big and small end bearings

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

14 Thrust bearing - IV/ME - IV/ME IV/ME IV/ME IV/ME Running 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

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 (Throttle 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

23 Discharge valves - IC IC RE RE RE RE Valves, springs and damper rings

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

25 Suction valvesb - IC IV IC RE IC RE Valves, springs and damper rings

26Cylinder liners

- IV - IV IV IV IV Cap. Control lifting mechanism

27 - IV/ME - IV/ME IV/ME IV/ME IV/ME Dimension 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

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1. MAINTENANCE

SMS2012/v010

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 and bolts

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

42 ME ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL Cylinder head water cooling, incl. oil cooler

a. Check after every maintenance job the settings and working of all safety devices, regulators and the running condition according to the service instruction manual(SIM)

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


Item

Description

Actions

Checkpoint


0.1YEARLY

3 6 - - -

9 - 12 - -

15 - - 18 -

21 - 24 - -

27 30 - - -

33 - - - 36





3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.7 GRASSO 5HP R744 & R717

SERVICEANDMAINTENANCESCHEDULES GRASSO 5HP

Item

Description

Actions

Checkpoint


0.1YEARLY

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

2 REb RE RE RE RE RE Oil discharge filterc

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 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 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 bearing - IV - IV - IV Running surfaces

15

Capacity controlIC/IV IC/IV

-RE

-RE Solenoid valves and coils

16 - -

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

22 REd IC/CL - IC/CL - IC/CL Suction gas strainer

23 Discharge valves - IC - RE - RE Valves, springs and damper rings

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

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

26Cylinder liners

- - -

27 - IV/ME - IV/ME - IV/ME Dimension and running profile

28Drive IC IC IC IC IC IC

Alignment

29

30 Electric motor Refer to specification of motor supplier

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1. MAINTENANCE

SMS2012/v010

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

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

42

a. Check after every maintenance job the settings and working of all safety devices, regulators and the running condition according to the service instruction manual(SIM)

b. A running in oil discharge filter is factory mountedc. The permanent oil discharge filter has to be changed every 5000 hours or check (optional) oil differential pressure indicatord. A running in suction gas filter is factory mounted

SERVICEANDMAINTENANCESCHEDULES GRASSO 5HP

Item

Description

Actions

Checkpoint


0.1YEARLY

R744 (CO2) R717(NH3)

5 10 5 10

15 20 15 20

25 30 - -

35 40 25 30

- - 35 40





3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.8 GRASSO 11 (RC11) AND GRASSO 9 (RC9)

SERVICEANDMAINTENANCESCHEDULES GRASSO 11 AND GRASSO 9

Item

Description

Actions

Checkpoint


0.1YEARLY

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 REOil refreshment (If hygroscopical oil is used replace this always

after each opening of compressor 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 intermediate bearing bushes

7bCrankshaft

- - - - - IC/ME IC/ME Main and intermediate bearing surfaces crankshaft

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

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

10 Conrod - IC/ME - IC/ME IC/ME IC/ME IC/ME Big and small end bearings

11

Pistons

- IC - IC IC IC IC Piston

12 - IC - IC IC IC IC Piston rings

13 - IC - IC IC IC IC Gudgeon pin

14 Thrust bearing - IV/ME - IV/ME IV/ME IV/ME IV/ME Running 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 piston

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 and damper rings

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

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

26Cylinder liners

- IV - IV IV IV IV Cap. Control lifting mechanism

27 - IV/ME - IV/ME IV/ME IV/ME IV/ME Dimension 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

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1. MAINTENANCE

SMS2012/v010

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

39 IC IC IC IC IC IC IC Vibration dampers and bolts

40 IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME Intermediate cooler and injection valve

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

42 ME ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL Cylinder head water cooling


SERVICEANDMAINTENANCESCHEDULES GRASSO 11 AND GRASSO 9

Item

Description

Actions

Checkpoint


0.1YEARLY

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





3 RE Renewal

4 ME Measure

5 CL Clean

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1. MAINTENANCE

SMS2012/v010

1.2.9 CHECKLIST

SERVICEANDMAINTENANCESCHEDULES 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

J General Notes

1

Oil

Oil suction filter

2 Oil discharge filter

3 Oil analysis

4Oil refreshment (If hygroscopic oil is used replace this always after each

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 bearing Running surfaces/Axial play

15

Capacitycontrol

Solenoid valves and coils

16 Seals of cap. control piston

17 Cap. Control mechanism

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1. MAINTENANCE

SMS2012/v010

Table 1.2-2 Settings pressure safeties

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 Suction valves Valves, springs and damper rings

26

Cylinder liners

Cap. Control lifting mechanism

27 Dimension and running profile

28Drive

Alignment

29 V-belts

30 Electric motor 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

SERVICEANDMAINTENANCESCHEDULES GRASSO RECIPROCATING COMPRESSORS

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

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

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Pador9130 SMS

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