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Refrigeration Division
Grasso
Reciprocating Compressors for industrial refrigerationRC12/12E/11/9/6, Grasso 10/7S/8S
Service and Maintenance Schedules (SMS)
Page 1Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso ca0319_0089000_v003
Refrigeration Division
Grasso
Copyright
All Rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent 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 held responsible, neither for any errors occurring in this publication nor for their consequences.
This manual must be carefully read and understood prior to installing and servicing the compressor (package)
General Safety
All service operations described in this servicemanual are only to be carried out by well-trained/qualified personnel and even then only after this service manual has been read carefully and is fully understood.
Personal safety
Observe all (inter)national and/or local safety standards, measures and regulations 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 to put 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 pumped down and the electric supply has to be cut off.After having run the initial 100 operating hours,it is essential (in both new and modified plants) to replace the red running-in discharge oil filter element with the permanent grey filter element. Also replace the running-in suction gas filter element.Check the direction of rotation is correct before
re-starting the compressor.
Page 2 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso
Table of Contents
Section Title Page
1 MAINTENANCE 5
1.1 Legend and release notes 5
1.1.1 RC12 and RC12E 6
1.1.2 Grasso 10 8
1.1.3 Grasso 7S and Grasso 8S 10
1.1.4 RC6 12
1.1.5 RC11 and RC9 14
1.1.6 Grasso Service and Maintenance Checklist 16
Page 3Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso
Page 4 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1. MAINTENANCE
1.1 Legend and release notes
Table 1.1-1 Release notes of this manual
General;
The service and maintenance schedules use the codes as explained in the table below;
Table 1.1-2 Actions
Version Description Date
001 Intial version 23-April-2002
002 RC11 and RC9 added 24-April-2002
003Front page RC11 and RC9 added
Misc. small fixes for all product groupsGrasso 8S added
30-Aug-2002
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
Page 5Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1.1.1 RC12 and RC12E
SERVICE AND MAINTENANCE SCHEDULES RC12E AND RC12
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 RE CL RE RE RE RE RE 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 or installation)
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/ME Running 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
Compressor housing
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 Throttle valves LP/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 valvese - IC - IC RE RE IC 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 valvesf - IC - IC RE RE IC 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
Page 6 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
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 CL Oil 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 filter is 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 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
SERVICE AND MAINTENANCE SCHEDULES RC12E AND RC12
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1 YEARLY
3 6 - - -
9 - 12 - -
15 - 18 -
21 - - 24 - -
27 30 - - -
33 - - - 36
Legend for service and maintenance schedules (SMS)
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
Page 7Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1.1.2 Grasso 10
SERVICE AND MAINTENANCE SCHEDULES GRASSO 10
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
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 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
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
Compressor housing
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
Page 8 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
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 - CL Oil 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)
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 filter is supplied togehter with the compressor.
c. Oil discharge filter change every 4000 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
SERVICE AND MAINTENANCE SCHEDULES GRASSO 10
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
4 8 12 16 - - -
20 - - - 24 28 -
- - - 32 - - -
- - 36 - - - -
- 40 - - - 44 -
- - - - - - 48
Legend for service and maintenance schedules (SMS)
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
Page 9Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1.1.3 Grasso 7S and Grasso 8S
SERVICE AND MAINTENANCE SCHEDULES GRASSO 7S and Grasso 8S
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
2.5 5 - -
7.5 - 10 -
12.5 15 - -
17.5 - - 20
1
Oil
CL CL CL CL CL CL Oil suction filter
2 REb RE RE RE RE RE Oil discharge filter
3 - ME ME ME ME ME Oil analysis
4 RE RE RE RE RE RE Oil 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 Main and intermediate bearing bushes
7b - - - - - IC/ME Main and intermediate bearing surfaces crankshaft
8 - IC - IC IC/CL IC/CL Running surfaces con. rods
10 Conrod - IC/ME - IC/ME IC/ME IC/ME Big and small end bearings
11
Pistons
- IC - IC IC IC Piston
12 - 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 Running surfaces/Axial play
15
Capacity controlIC/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 Cap. Control mechanism
18
Compressor housing
IV/CL IV/CL IV/CL IV/CL IV/CL IV/CL Crankcase heater
19
CL CL CL CL CL CL Crankcase20
21
22 REb IC/CL - IC/CL IC/CL IC/CL Suction gas filter
23 Discharge valves - RE RE RE RE RE Valves, springs and damper rings
24 - IC/CL IC IC/CL IC/CL IC/CL Stroke limitor/Discharge valve seat
25 Suction valves - RE RE RE RE RE Valves, springs and damper rings
27 Cylinder liners - IV/ME - IV/ME IV/ME IV/ME Dimension and running profile
28Drive ME ME ME ME ME ME Insulation resistance with qualified device
29
31
Optionals
IC IC/CL IC IC/CL IC/CL IC/CL Oil level float switch
32 IC IC/CL IC IC/CL IC/CL IC/CL Valve oil return
33 ME 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 compressor
Page 10 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
Legend for service and maintenance schedules (SMS)
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
Page 11Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1.1.4 RC6
SERVICE AND MAINTENANCE SCHEDULES RC6
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
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 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
Compressor housing
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 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
Page 12 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
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 lates standard
SERVICE AND MAINTENANCE SCHEDULES RC6
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
3 6 - - -
9 - 12 - -
15 - - 18 -
21 - 24 - -
27 30 - - -
33 - - - 36
Legend for service and maintenance schedules (SMS)
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
Page 13Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1.1.5 RC11 and RC9
SERVICE AND MAINTENANCE SCHEDULES RC11 AND RC9
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
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 filterb
3 - ME ME ME ME ME ME Oil analisys
4 RE RE - RE RE RE RE Oil 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
Compressor housing
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
Page 14 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
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
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
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. Oil discharge filter change every 2500 hours or check optional pressure drop indicator
SERVICE AND MAINTENANCE SCHEDULES RC11 AND RC9
Item Description
Actions
Checkpoint
Running hours * 1000a
0.1
YEA
RLY
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
Legend for service and maintenance schedules (SMS)
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
Page 15Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
1.1.6 Grasso Service and Maintenance Checklist
Table 1.1-3 Check list
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
J General Notes
1
Oil
Oil suction filter
2 Oil discharge filter
3 Oil analisys
4 Oil 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
15Capacity control
Solenoid valves and coils
16 Seals of cap. control piston
17 Cap. Control mechanism
Page 16 Reciprocating Compressors for industrial refrigeration / RC12/12E/11/9/6, Grasso SMS0208/v003
Refrigeration Division
Grasso1. MAINTENANCE
Table 1.1-4 Settings pressure safeties
18
Compressor housing
Crankcase heater
19 Crankcase
20 Throttle valves LP/HP
21 Relief valves
22 Suction gas filter
23 Discharge valves
Valves, springs and damper rings
24 Stroke limitor/Discharge valve seat
25 Suction valves Valves, springs and damper rings
26Cylinder 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
SERVICE AND MAINTENANCE SCHEDULES 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
8
9
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Refrigeration Division
Grasso1. MAINTENANCE
10
Safety Remark Value
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Refrigeration Division
Grasso1. MAINTENANCE
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Refrigeration Division
Grasso
Grasso Products B.V. • P.O. Box 343 • 5201 AH ‘s-Hertogenbosch • The NetherlandsPhone: +31 (0)73 - 6203 911 • Fax: +31 (0)73 - 6231 286E-Mail: [email protected] • URL: www.grasso-global.comGrasso GmbH Refrigeration Technology • Holzhauser Straße - 165 • 13509 Berlin • GermanyPhone: +49 (0)30 - 43 592 6 • Fax: +49 (0)30 - 43 592 777E-Mail: [email protected] • URL: www.grasso-global.com
Please contact the technical department of your supplier for extra information.
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