SIM 5HP

Reciprocating Compressors for industrial refrigerationSeries Grasso 5HP

Service Instruction Manual (SIM)0087233- 1-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

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.- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Table of Contents

Section Title Page

1 REPAIR AND OVERHAUL 11

1.1 INTRODUCTION 11

1.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 11

1.3 EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE 11

1.3.1 EVACUATION OF REFRIGERANT BEFORE SERVICING 11

1.3.2 LEAK-TIGHTNESS AFTER SERVICING 11

1.3.3 EVACUATION AFTER SERVICING 11

1.3.4 START-UP AFTER SERVICING 11

1.4 GENERAL RECOMMENDATIONS 12

2 DISASSEMBLY 13

2.1 DISMANTLING COUPLING 13

2.2 DISMANTLING SUCTION GAS FILTER 14

2.3 DISMANTLING OVERFLOW VALVE 14

2.4 REMOVING CYLINDER HEAD 15

2.5 REMOVING DISCHARGE VALVE AND SUCTION VALVE ASSEMBLY 15

2.6 REMOVING PISTON/CONNECTING ROD ASSEMBLY 16

2.7 DISMANTLING ROTARY SHAFT SEAL 18

2.8 REMOVING OIL DISCHARGE FILTER ELEMENT 21

2.9 REMOVING OIL PUMP ASSEMBLY 22

2.10 REMOVING CRANKSHAFT 25

3 INSPECTION AND PREASSEMBLY 29

3.1 BACK PRESSURE INDEPENDENT RELIEF VALVE 29

3.2 LUBRICATING OIL PRESSURE REGULATOR 30

3.3 CAPACITY CONTROL MECHANISM 30

3.4 INSPECTION DISCHARGE VALVES 33

3.5 INSPECTION SUCTION VALVES 37

3.6 INSPECTION PISTONS AND CONNECTING RODS 38

3.7 PRE ASSEMBLING PISTON AND CONNECTING ROD 41

3.8 INSPECTION CYLINDER LINER 42

3.9 OIL PUMP AND FILTERS 43

3.9.1 DISASSEMBLING OIL PUMP 43

3.9.2 REMOVING PUMP ELEMENT/BEARING ASSEMBLY 44

3.9.3 INSERTING OIL PUMP ELEMENT 45

3.9.4 OIL FILTER HOUSING 48

3.10 MAIN BEARINGS 48

3.11 THRUST BEARING 49

3.12 PRE ASSEMBLING BEARING COVERS 50- 3-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

3.13 ROTARY SHAFT SEAL 50

3.14 CRANKSHAFT 51

3.15 CRANKCASE 52

4 REASSEMBLING 53

4.1 CRANKSHAFT AND MAIN BEARINGS 53

4.2 THRUST BEARING 56

4.3 OIL PUMP ASSEMBLY 58

4.4 OIL DISCHARGE FILTER 59

4.5 OIL SUCTION FILTER 60

4.6 OIL LUBRICATION PRESSURE REGULATOR 60

4.7 CYLINDER LINER, PISTON AND CONNECTING ROD 60

4.8 DETERMINING PISTON CLEARANCE 64

4.9 SUCTION VALVES AND DISCHARGE ASSEMBLE 65

4.10 ROTARY SHAFT SEAL 67

4.11 CRANKCASE SERVICE COVERS 68

4.12 SUCTION FILTER 69

4.13 PRESSURE RELIEF VALVE ASSEMBLY 70

4.14 OIL FILLING AND PRE LUBRICATION 70

4.15 COUPLING 71

5 MISCELLANEOUS 73

5.1 TABLE OF TORQUES FOR BOLTS AND NUTS GRASSO 5HP 73

5.2 WEAR LIMITS AND TOLERANCES GRASSO 5HP 73

5.3 REQUIRED SERVICE TOOLS AND MATERIALS 75

5.4 FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING 76

Section Title Page- 4- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Preface documentations

Typographic signs:

Indicates a WARNING. READ IT CAREFULLY!

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

Indicates a HINT.

General

1 All documentation can be downloaded via grasso-global.com.

2 Grassos technical manuals includes generic paragraphs; this means that it can occur that not all data as described is relevant for the current compressor series as mentioned in this manual. (For instance, not all compressor series are suitable for all mentioned refrigerants or not all compressor series includes two-stage compressors)

1) Product Information (PI)

Contents

All product information (engineering data) for this series compressor and the corresponding accessories. It is meant to be a guide to the selection of these components.

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)

Contents

This manual will provide information on how to transport, install, start-up and maintain the compressor (package). It also contains a number of "Product Information Sheets" and the current "Parts List"

User group

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

3) Service Instruction Manual (SIM)

User group

To be used in the field by qualified personnel of contractors.

4) Parts list (PL)

Contents

All current parts of the compressor and accessories together with the design changes (if applicable) to previous supplied components ("History").

User group

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

5) Service & Maintenance Schedules

Contents

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

User group

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

6) Instructions for accessories(Supplied together with the compressor)

Contents

All the relevant mounting and installation instructions and spare parts information for those accessories supplied with the compressor.

User group

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

Grassos technical manuals includes generic paragraphs; this means that it can occur that not all data as described is relevant for the current compressor series. For instance, not all compressor series are suitable for all mentioned refrigerants or not all compressor series includes two-stage compressors.

7) DirectivesEquipment supplied according to PED regulations and Machine Directives EN60204, EN292, EN294, EN378- 5-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Contents

Description of (re)assembling, inspection, repair and part or total overhaul of the bare shaft compressor. This manual should be used together with the 'Installation and Maintenance Manual'.

- 6- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

General info SIM

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.

All bolts and nuts have to be mounted according to to the torques as given in table Survey of torques for bolts and nuts" as available in this manual. If you cannot find this information, consult Grasso.

General

This compressor service manual is intended to be used in the field by qualified personnel of refrigeration installers or contractors for proper(re)assembly, inspection,repair and part or total overhaul of Grasso single-stage and two-stage piston compressors.

Installation and maintenance intructionsThe manual should also and always be used together with the corresponding "Installation and Maintenance Manual" (IMM) meant for the operator. The IMM is supplied with every compressor or compressor package.

Additional design details

Additional design details are available in the manual Product Information

How to read the pages of this manual

Important tables, refer to Chapter 5!

Tables like Wear limits and tolerances and Torques for bolts and nuts can be found at Chapter 5

Cylinder numbering- 7-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 1 Cylinder numbering Grasso reciprocating compressors

Table 1 Main setup data Grasso 5HP

Legend

1, 2, 3, ... Cylinder numbers

T Top view of compressor

M Motor/Drive end of compressor

O Oil pump of compressor

Legend

Description Value Remark

Start frequency max. 6 starts per hour

Time interval between stopping and re-starting min. 2 minutes

Time interval between starting and re-starting min. 10 minutes

Time interval between capacity steps min. 3 minutes

For continuous minimum part-load (i.e. more than 30 minutes) consult Grasso

Adjust the steps between up and down loading, in such a way that the system is

running stable

Oil level 25-75% crankcase sight glass

Min. oil temperature warmer than surroundings and 10 C for R744(CO2)> Saturated temperature for R717(NH3)

Max. oil temperature Refer to oil selection table/applied type of oilRequired oil viscosity;

10 cSt during operation at location of bearings

Lubricating oil pressure difference between 1.3 and 3.0 bar Setting approx. 2.0 bar After a mimimum of 15 minutes running time at an oil temperature of approx. 35 oC (95 oF)

General limits of operation Refer to Product Informatin manual

Oil discharge - running in - filter Red coloured filter element Factory mounted; to be replaced after max. 100 running hours by permanent oil discharge filter element

Oil discharge - permanent - filter Grey filter element Supplied loose; replacement for factory mounted running in filter

Standard direction of rotation of compressor drive shaft Counterclockwise when facing shaft end- 8- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Cylinder numbering

Fig. 2 Top view compressor (S=Shaft end)- 9-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

- 10- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

1. REPAIR AND OVERHAUL


1.1 INTRODUCTION

Compressor and plant

All activities described can be carried out without taking the compressor off its base and without detaching it from the plant. In case of complete overhaul, it may, however, be useful to carry this out detached from the plant in a separate working area, whether or not in a workshop equipped for this purpose.

Accessories

This chapter only deals with the disassembly and assembly of a so-called "bare compressor" in standard design. This implies that, depending on the dismantling degree, it may be necessary to first completely or partially remove certain accessories.It is recommended to distinctly mark the dismounted accessories or parts of them (for instance oil control lines and pressure gauge or safety switch lines, transducers, pressure and temperature sensors, V-belt pulleys and torsionally-stiff coupling) in order to avoid mistakes at reassembling.

Tools

For proper performance of the operations, at least the standard service tools and materials should be available.Besides, for certain operations additional special GRASSO tools are required, which can be obtained as a complete standard service set.

Service SetsWorn out parts are to be replaced by new parts which are available in sets with a brief service manual.

General

Although all the assembly and disassembly procedures shown relate to the two-stage compressor, they are basically applicable universally to all compressors. If not, it is explicitly stated in the text.

1.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM

For evacuation of compressor only, refer to Section 1.3

Procedure to evacuate and to dry a system:

i) STATUS: System is filled with nitrogen and no oil has been added (oil prevents any trapped moisture from boiling off).

connection as mentioned in the plant manual and evacuate the system to approx. 5 mm Hg (=6.6 mBar).

iv) Break vacuum by charging dry nitrogen into the system.

v) Repeat step iii, 'Connect vacuum pump ...'.vi) Wait approx. 24 hours.vii) If pressure has increased (system still contains

moisture), repeat steps iv, vand vi, otherwise, continue with the "Initial oil charge" procedure.

1.3 EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE

To evacuate the refrigeration system refer to Section 1.2,

Use always a vacuum pump or pump-down unit to evacuate the refrigerant from the compressor.

1.3.1 EVACUATION OF REFRIGERANT BEFORE SERVICING

Procedure to evacuate the compressor:1. Switch off main control panel2. Remove main fuses3. Close shut-off valves4. Remove the refrigerant by means of a vacuum pump

or pump-down unit, via the evacuation/purging valve(s) as prescribed by local safety regulations. For the location of these valves refer to the "Product Information".

5. Drain the oil from the compressor and oil separator, oil return /oil rectifier system if present.

1.3.2 LEAK-TIGHTNESS AFTER SERVICING

The necessary safety precautions should be taken before carrying out the leak-tightness test. To check leak-tightness use dry nitrogen at a positive pressure which is less than the admissible operating pressure of the low pressure stage.

1.3.3 EVACUATION AFTER SERVICINGAfter the pressure test has been completed, the compressor (package) must be evacuated and undergo a vacuum test. Evacuation is used to remove air and moisture from the compressor (package)

1.3.4 START-UP AFTER SERVICING

1 STATUS: Compressor (package) is dried and still evacuated.

2 Charge the oil separator, if present, with oil.See the appropriate Product Information for the correct quantity.

3 Charge the compressor crankcase with oil via the oil - 11-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

ii) Verify that all valves in that part of the system to be evacuated are opened (refer also to the plant manual).

iii) Connect vacuum pump to the evacuation/purging valve(s) of the compressor (for location of these valves refer to the "Product Information" or to a

charge valve until the minimum level is seen at the sight glass at the level as indicated in IMM.It is mandatory to pre-lubricate the oil circuit by adding the final quantity of oil via the charge valve mounted onto the oil pump by means of a separate


oil filling pump. The required oil level is indicated in the IMM.

4 Re-install all accessories such as coupling, V-belt guard etc.

5 Open the shut-off valves. 6 Check the start-stop procedure. 7 Check all safeties and controls. 8 Re-install the main fuses. 9 Start up the compressor. 10 Check running condition.

Note: The job isn't finished until the paper work is done! Complete the service report, e.g. Grasso report 00.89.062.

1.4 GENERAL RECOMMENDATIONS1. Do not disassemble more compressor parts than is

necessary for the purpose (inspection, repair, overhaul).

2. Use clean and well-conditioned tools.3. Make sure that there is a clean and neatly arranged

working area well-equipped to provide temporary and adequately protected storage of dismantled components. Preferably use a table or working bench with a clean, moisture-free and non-scratching surface.

4. Immediately clean every dismantled part, check it for wear or damage and oil the machined surfaces of bright parts. The oiling is particularly important when the parts are not to be reassembled until after some time. Otherwise they will certainly become rusty.

5. The dismantled parts of every cylinder (cylinder liner, piston, connecting rod, valves) or of other main components should be kept together separately and marked if necessary. Thus they can later be replaced in their original place in the compressor.

6. All major parts that are not beyond repair have to be checked before reassembly for wear by measuring them and comparing the outcome with the wear limits and tolerances given in documentation.

7. Always replace damaged or worn compressor parts that are beyond repair by new GRASSO standard spare parts. These parts can always be fitted into the compressor without previous inspection or readjustments (if applicable, e.g. valves, connecting rods, etc.).

8. When fitting any moving parts, it is recommended to oil all running surfaces.

9. Always use new gaskets, O-rings and locking rings when reassembling after inspection or repair.

10.Use a torque wrench to tighten the threaded connections. (Survey of torques for bolts and nuts refer to Chapter 5)- 12- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

2. DISASSEMBLY

2. DISASSEMBLY

Fig. 2-1 How to read this manual

2.1 DISMANTLING COUPLING

Fig. 2.1-1 Use an auxiliary bolt (1) to avoid rotation of the shaft to remove the coupling bolts

Fig. 2.1-2 Remove all coupling bolts

Fig. 2.1-3 Oil bolts and Insert three bolts in coupling half- 13-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

2. DISASSEMBLY

Fig. 2.1-4 Tighten the bolts alternately until coupling half is loosened

2.2 DISMANTLING SUCTION GAS FILTER

Fig. 2.2-1 Remove the 4 nuts (1)

Fig. 2.2-2 Remove the O-ring (1

Fig. 2.2-3 Remove the suction gas filter element (1)

2.3 DISMANTLING OVERFLOW VALVE- 14- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

2. DISASSEMBLY

Fig. 2.3-1 Back pressure independent overflow valve; remove cap

Fig. 2.3-2 Remove the 4 bolts (1) and remove entire valve (2)

2.4 REMOVING CYLINDER HEAD

Fig. 2.4-1

Remove dirt and paint from the cylinder head studs using a steel brush

Unscrew the bolts (1)

Remove cylinder head (2)

2.5 REMOVING DISCHARGE VALVE AND SUCTION VALVE ASSEMBLY- 15-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 2.5-1

Unscrew bolts in sequence (1)

Never use an impact wrench

Remove (2) and (3)

2. DISASSEMBLY

Remove discharge assemby

Fig. 2.5-2

Remove the discharge valve assembly and suction spring (1) and suction valve (2)

Remove spacer ring (3)

2.6 REMOVING PISTON/CONNECTING ROD ASSEMBLY

Fig. 2.6-1

Place an oil drip tray under the service cover to collect

Fig. 2.6-2

Fig. 2.6-3

Rotate the crankshaft in such a way that the the bottom side of the big end (1) of the connecting rod becomes easily accessible- 16- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

the residual oil

Remove the crankcase cover (1) with O-ring opposite the cylinder under repair

In case of vertical cylinders, remove the opposing service cover

2. DISASSEMBLY

Fig. 2.6-4

Unscrew the two nuts from the connecting rod bolts (1) and remove the locking rings

Tap up both connecting rod bolts (1) slightly, in order to remove connecting rod easily

Remove cap (2)

Pull both connecting rod bolts (1) back to the original location in the connecting rod

Fig. 2.6-5

A special tool as shown above, could be used to remove the cylinder liners (tool is not included)

Fig. 2.6-6

Pull the cylinder liner (1) with the special tool

Push the cylinder liner from below. A synthetic hammer could be used- 17-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

2. DISASSEMBLY

Fig. 2.6-7

Withdraw cylinder liner with piston and conrod (1)

Remove spacer ring (2)

Fig. 2.6-8

Each connecting rod cap is marked (1) and belongs to one specific connecting rod and can be fitted in one way only.

Never exchange connecting rod cap with another connecting rod!

2.7 DISMANTLING ROTARY SHAFT SEAL- 18- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 2.7-1

2. DISASSEMBLY

Unscrew the oil leakage drain (1)

Place an oil drip tray under the housing

Remove shaft seal bolts (3) to remove shaft seal housing (2)

Fig. 2.7-2 Use two bolts to push the shaft seal housing from the crankcase using holes (1)

Fig. 2.7-4 Remove the three grubscrews (1)

Fig. 2.7-5 Use an auxilairy tool (e.g. a bolt) to ease the shaft seal from the cover

Fig. 2.7-6 Remove O-ring (1)- 19-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 2.7-3 Slide the shaft seal housing over the shaft joumal

2. DISASSEMBLY

Avoid touching the black graphite composite ring. If necessary wear gloves or rub your hands with oil.

Fig. 2.7-7

Unscrew bolts (2) to remove rotary slip ring (1)

Be sure that the bolts (2) are unscrewed, in order to clear the groove in the crankshaft

Fig. 2.7-8 Place the legs of the pulley puller (special Grasso tool set) behind the rotary slip ring and carefully pull the slip ring until it is loose

Fig. 2.7-9 Slide the rotary slip ring (1) from the crankshaft

Fig. 2.7-10 Remove both internal O-rings (1) and put all parts aside with the other shaft seal parts- 20- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

2. DISASSEMBLY

2.8 REMOVING OIL DISCHARGE FILTER ELEMENT

Fig. 2.8-1 Remove bolts (1), in order to remove the entire oil discharge filter

Fig. 2.8-2 Special tool to remove oil filters

Fig. 2.8-3 Place an oil drip tray under the filter

Fig. 2.8-4 Unscrew the grooved filter nut (1)- 21-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

2. DISASSEMBLY

Fig. 2.8-5 The filter element (1) is marked with a colour;Red: running-in filter, to be replace after 100 running hours

2.9 REMOVING OIL PUMP ASSEMBLY

Fig. 2.9-1

Place an oil drip tray under the pump

Unscrew bolts (2) in order to remove oil pump (1)- 22- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

2. DISASSEMBLY

Fig. 2.9-2 Take due care with the pressure springs (1) mounted in the oil pump housing

If required, the oil pump can also be removed while the oil filter is still mounted

Fig. 2.9-3 Carrier disk

Fig. 2.9-4 Remove the carrier disk from the crankshaft- 23-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

2. DISASSEMBLY

Fig. 2.9-5 Hold down disc (1) Fig. 2.9-6

Lock the crankshaft with (for instance) a wooden block (1) in order to remove the bolts from hold down disc- 24- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

2. DISASSEMBLY

Fig. 2.9-7

Remove bolts (1) and the hold down disc from the crankshaft

Fig. 2.9-8

Remove the thrust bearing (1) from the bearing cover

Keep parts together!

All running surfaces of the washers in contact with the cylindrical thrust bearing are hardened and machined smooth. Damage of these surfaces can lead to breakdown of other parts of the compressor in a short period of time!

2.10 REMOVING CRANKSHAFT

Before removing the crankshaft, the following components have to be disassembled;

1 All discharge valves2 All pistons and connecting rods3 Shaft seal4 Oil pump5 Thrust bearing- 25-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

2. DISASSEMBLY

Fig. 2.10-1 Remove bolts (1)Fig. 2.10-3

Remove the bearing cover (1) and O-ring.

The crankshaft is supported by the bearing on the drive-end only

Fig. 2.10-4 Auxiliary tool, to remove ring (Fig. 2.10-5)- 26- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 2.10-2

Screw two bolts (1) into the threaded holes

Tighten these bolts evenly in order to loosen the bearing cover

2. DISASSEMBLY

Fig. 2.10-5 Remove ring (2)

Fig. 2.10-6 Auxiliary tool for removing crankshaft

Fig. 2.10-7

Assisted by another person, the crankshaft (1)can be removed carefully, via the oil pump side

Store the crankshaft in a clean and dry area

Fig. 2.10-8 Remove oil pressure regulator (1)- 27-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

2. DISASSEMBLY- 28- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

3. INSPECTION AND PREASSEMBLY




3.1 BACK PRESSURE INDEPENDENT RELIEF VALVE

Fig. 3.1-2

Fig. 3.1-3

Inspect carefully the teflon seal (1, 3);

Malfunctioning of the relief valve is usually caused by a minor damage of the teflon seal (1)If damage or wear of the teflon ring (1,3) is detected, check whether this can be remedied by polishing with - 29-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 3.1-1 an abrasive paper

Do not dismantle the valve;

The relief valve is adjusted by the factory; Check the valve seat (2) in the crankcase.

Slight wear can be remedied with polishing paper


3.2 LUBRICATING OIL PRESSURE REGULATOR

Fig. 3.2-1 1. Cap; 2. Housing; 3. Pressure ring; 4. Ball; 5. Circlip ring; 6. Set bolt; 7. O-ring; 8. Alu ring

Fig. 3.2-2 Oil pressure regulator

Renew O-ring (1) and Alu-ring (2)

Clean all disassembled regulator parts

Oil all regulator parts

Reassemble all regulator parts

The oil pressure can be adjusted during operation, using a screw driver

3.3 CAPACITY CONTROL MECHANISM

Fig. 3.3-1 Cylinderhead cover

Fig. 3.3-2 Remove the bolts (1)

Fig. 3.3-3 Remove the cover (1)- 30- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002


Fig. 3.3-4 Remove the pressure spring (1)

Fig. 3.3-5 Special tool (M6 bolt is also possible) (refer Fig. 3.3-6)

Fig. 3.3-6 Pull thecapacity control piston (2) out of the cylinder, using the special tool (1)

Fig. 3.3-7 Check the piston rings (1) for damage or wear- 31-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002


Fig. 3.3-8 Check the cylinder liners (1, 2) for damages

Fig. 3.3-9 Insert the capacity control piston (1) in the cylinder; be sure not to damage the piston rings

Fig. 3.3-10 Insert the pressure spring (1)

Fig. 3.3-11 Renew the O-rings (1)- 32- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002


Fig. 3.3-12

Mount the cover (1)

Be sure that the spring (2) will be positioned in the proper hole

Tighten the cover bolts

3.4 INSPECTION DISCHARGE VALVES

Fig. 3.4-1 Discharge valve assembly

Fig. 3.4-2 Special tool A (refer Fig. 3.4-6)

Fig. 3.4-3 Optional special tool B- 33-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002


Fig. 3.4-4 Fit special tool A into a vice (Fig. 3.4-2)

Fig. 3.4-5 Holes (1) to fit into special tool A ()

Fig. 3.4-6 Discharge valve assembly located onto special tool A (Fig. 3.4-2)

Remove central bolt (1)- 34- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 3.4-7 Valve seat, removed from the stroke limitor


Fig. 3.4-8 Remove the bolts (1)

Fig. 3.4-9 Ease the bolts carefully, to loosen the valve plate(1)

Fig. 3.4-10 Remove the valve ring (1)

Fig. 3.4-11 Remove the spring (2)- 35-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002


Fig. 3.4-12 Check the valve ring and spring for damage or wear

Fig. 3.4-13 Check the valve seat and valve plate for damage or wear

Fig. 3.4-14 Check the valve seat and valve plate for damage or wear- 36- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 3.4-15 Check the valve seat and valve plate for damage or wear


In case of wear or damage, parts have to be renewed

Fig. 3.4-16 Reassemble the discharge valve assembly

Fig. 3.4-17 Be sure that the sinoidal spring (1) is positioned properly

Fig. 3.4-18 Be sure that the sinoidal spring (1) is positioned properly

3.5 INSPECTION SUCTION VALVES

Fig. 3.5-1 Cylinder liner including suction valves and rings

Fig. 3.5-2 Check spring (1) and valve ring (2) for damage and wear- 37-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002


Fig. 3.5-3 Check valve seats (1 and 2) for damage and wear

In case of wear or damage, parts have to be renewed

3.6 INSPECTION PISTONS AND CONNECTING RODS

Fig. 3.6-1 Place the assembly upside down on the working bench and remove on circlip ring from the gudgeon pin bore

Fig. 3.6-2

Push the gudgeon pin out of the piston

Check the gudgeon pin for wear and measure the outer diameter using an outside micrometer and replace the pin if the diameter is smaller as given in table Wear limits and tolerances- 38- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002


Assemble the bearing shells and the connecting rod cap together

Tighten the nuts (1) on the connecting rod bolts to the torque as given in table Survey of Torques for bolts and nuts

Measure the bore of the clamped bearing with an

Measure with an inside micrometer the bore of the still fitted bearing bush and replace if it is larger than as given in table Wear limits an tolerances

Insert a new bearing bush by lowering the non-heated bearing bush into the small end of the connecting rod which has been heated to approx 100 oC

Fig. 3.6-3 Remove the two piston rings and oil scraper ring using the appropriate piston ring pliers

Fig. 3.6-4 Check the piston groove for burrs, notch effects and cracked or broken groove edges- 39-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

inside micrometer and replace if it is larger than as given in table Wear limits and tolerance

Check the bearing bush in the small end of the connecting rod for wear or damage

Fig. 3.6-5


Roll each piston ring and oil scraper ring in the corresponding groove around the piston to trace parts that may have become wedged. This can be remedied, for example, by using a smooth file

Chech the piston for wear or damage

Fig. 3.6-6 Check the gap in each piston ring

Fig. 3.6-7 Check the gap (1) in each piston ring by placing it in an

Fig. 3.6-8

The maximum gap must not exceed 0.8 mm

Replace the piston rings if tolerance is larger than as given in table Wear limits and tolerances

Fig. 3.6-9

If the piston rings and oil scraper ring are no longer on the piston, fit them in the sequence as shown

1. Chrome ceramic

2. Black

3. Oil ring

Fig. 3.6-10 Never use a combination of old and new rings. While placing the rings, pay attention to the word TOP on each ring, to place it at the right position- 40- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

unworn part of the cylinder liner. An anworn part can be found at about 15 mm from the top and bottom of the cylinder liner


Never use new piston rings in combination with a worn out cylinder liner

3.7 PRE ASSEMBLING PISTON AND CONNECTING ROD

passageway in the connecting rod

When replacing the bearing bushes, heat the small end of the connecting rod to approximately 80 oC

Insert the bearing bush

Let the connecting rod cool off in ambient air

Fit the bearing shells in both connecting rod ends

Fig. 3.7-2 Due to the built-in fixing cams (1) one assembled position is possible only

Fig. 3.7-3 Place the connecting rod into the piston and slide the oiled gudgeon pin through the piston into the connecting rod onto the still fitted circlip ring- 41-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 3.7-1

Clean the connecting rod and blow out the oil


Fig. 3.7-4

3.8 INSPECTION CYLINDER LINERClean all parts

Fig. 3.8-1 Check the outer surface of the cylinder liner for damage and polish out slight damage with a abrasive paper

Fig. 3.8-2 Check the suction valve seats (1, 2) in the cylinder liner

Fig. 3.8-3 Its not necessary to check the cylinder liner diameter if the honing marks in the cylinder bore are still completely visible. Irregularities can be polished out with abrasive paper carefully- 42- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002


3.9 OIL PUMP AND FILTERS

3.9.1 DISASSEMBLING OIL PUMP

Fig. 3.9-1 Place the pump house on the working bench and unscrew the bolts and washers (1) to remove the pump cover with integrated pump element

Fig. 3.9-2 Use 2 bolts (1) to push the cover from the housing

Fig. 3.9-3 Remove O-ring (1)

Fig. 3.9-4 Back side; push shaft slightly(1) to remove pump element from housing- 43-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002


Fig. 3.9-5 Remove pump gear (1) and crown wheel (2)

Fig. 3.9-6 Remove pump gear (1) from crown wheel (2)

Fig. 3.9-7 Clean housing with non-fibrous cloth; Clean the internal oil passageways with compressed air

3.9.2 REMOVING PUMP ELEMENT/BEARING ASSEMBLY

Fig. 3.9-8 Renew pump element/bearing assembly in case of irrepairable damage or malfunctioning of the oil pump

Fig. 3.9-9

Place the pump housing under a press (2) to push the pump parts out, using a pipe (1) to support the housing- 44- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002


Fig. 3.9-10 Press bearing from the housing

Fig. 3.9-12

Check the carrier lug for wear

Check the teeth of both pump parts (1, 2) for broken or worn teeth

Replace entire pump element if at least one of the parts shows irrepairable wear

Minor damage may be eliminated

3.9.3 INSERTING OIL PUMP ELEMENT- 45-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 3.9-11 Clean all parts and remove possible sharp edges and/or burrs

Fig. 3.9-13

Ensure that the bore and the contact face in the pump housing are clean and oiled

Ensure the the oil channels (1) of the oil bearing and pump housing are in line


Fig. 3.9-14 Place the cover on the housing; ensure that pin (1) and hole (2) are in line

Fig. 3.9-15 Place the cover on the housing; ensure that pin (1) and hole (2) are in line

Fig. 3.9-16

Ensure that pin and hole are in line

Carefully press the pump element into the housing with the cover until the contact face has been reached clearly- 46- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002


Use a pipe which fits the size of the hole-pattern

Never press in the middle of the cover; it could burst

Fig. 3.9-17 Slide the pump gear (1) onto the shaft of the pump cover

Fig. 3.9-18 Place the crown wheel (1)

Fig. 3.9-19 Place the crown wheel

Fig. 3.9-20 Insert the pre-assembled pump cover element provided with a new O-ring in such a way that the fixing pin fits into the corresponding hole- 47-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 3.9-21


Tighten the bolts and washers (1), corresponding the torques as given in table Survey of torques for bolts and nuts

Check that the pump rotates smoothly

Place the pre-assembled pump in separate clean area, to be mounted later on

Fig. 3.9-22 Remove the carrier disc from the crankshaft joumal and check the condition of the slot (1) and the holes of the carrier disc

3.9.4 OIL FILTER HOUSING The removal of the oil filters and oil filter housing, has

been decribed in Section 2.8.

Renew a poluted grey-marked oil discharge elment

The red running-in oil discharge filter element has to be replaced for a grey one after 100 running hours

Clean oil filter housing and the internal passageways

Insert the filter element in the housing and re-assemble it with new O-rings and seal

In order to avoid damaging of the seals, the housing should not revolve together with the grooved filter nut (refer Fig. 2.8-4)

REMARK

After having dis-assembled the discharge filter element, check this for contamination, in particular for the presence of aluminium and/or white metal slide-bearing particles which would require further investigation in other parts of the compressor. In this case, regularly check the oil quality by means of an oil analysis.

3.10 MAIN BEARINGS

Fig. 3.10-1 The notch has to be pressed at a position of 12 Oclock- 48- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 3.9-23

Remove the O-rings (1, 2) and seal (3)


Fig. 3.10-2

Check the main bearing bushes, while these are in the respective bearing cover, for worn out white metal inner lining

Replace the bush(es) if the inner lining shows abnormal wear, and also if the bore is over 65.092 mm

Especially check those crankshaft parts rotating in the bearing covers. Eliminate slight damage using fine polishing paper.

3.11 THRUST BEARINGUse a self made auxiliary tool, refer Fig. 2.10-4

Fig. 3.11-2 Remove ring (1), using auxiliary tool

Fig. 3.11-3 Clean all thrust bearing parts. Check all running surfaces which are in contact with cylindrical roller thrust bearing and the needle thrust bearing for (ir)regular wear and other damage such as pits, marks or scratches- 49-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 3.11-1

Fig. 3.11-4 Replace the complete thrust bearing set when the rollers, needles or running surfaces show signs of wear


3.12 PRE ASSEMBLING BEARING COVERS

Fig. 3.12-1

Fig. 3.12-2

Push or press (using a hydraulic press) the bearing bush out of the bearing cover

opposite side of the oil channels (3)

Oil the bearing bush

Fig. 3.12-3 Press carefully the bearing bush (1) in the bearing cover (2)

3.13 ROTARY SHAFT SEAL

Fig. 3.13-1 Avoid touching the carbon part (1)! Preferably rub your hands with oil or wear gloves before servicing.- 50- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Place the bearing cover with the oil pump side downwards.

Ensure the position of the lubrication groove (1). The opening of the groove (2) must point downwards. The lubrication groove must be postitioned on the


Fig. 3.13-2 Remove both internal O-rings (1, 2) from the rotary slip ring

Fig. 3.13-3 Remove the O-ring (1)

Clean the housing and all other parts

When one of the sliding surfaces is affected, replacment of both parts is required

Renew all O- rings

Renew entire shaft seal in case of damage or wear

3.14 CRANKSHAFT

Fig. 3.14-1 Thoroughly clean the entire crankshaft and Check whether the axial oil passageways in the crankshaft are unobstructed by cleaning them with compressed air or a brush.

Fig. 3.14-2 In order to be sure that the lubricating oil transmission within the crankshaft will proceed smoothly, unscrew the socket head screws (1) locked with centre punches out of the crankshaft webs. - 51-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 3.13-4

Check both sliding surfaces (1, 2) of counter slip ring and rotary slip ring for wear or damage


Fig. 3.14-3 Remove the dirt accumulated in the oil passageway (1)(in the case of damage to bearings, white metal particles may be present) with a 6 mm rod. Brush and blow out the crankshaft again until all oil passageways are unobstructed

Fig. 3.14-4 After cleaning, reassemble all oil passageway sealing bolt (1)(socket head screws) and lock them with centre punches.

Fig. 3.14-5

It should be at least 64.95 mm. Should these measurements show that any of the

shaft diameters are beyond the tolerance limits and there is any doubt about the serviceability of this crankshaft, then it is recommended to contact our service department.

3.15 CRANKCASE

Fig. 3.15-1 Crankcase: service opening

Thouroughly clean the crankcase interior and dry it with a non-fibrous cloth

Inspect all exterior gasket faces and remove possible residual gasket material

Thoroughly blow through all connections on the inside and on the outside

Clean the sight glass

Fig. 3.15-2 Inspect the return plugs, clean them and tighten them after refitting at location 1 of Fig. 3.15-1.- 52- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Check the diameters of the shaft journals (1) and shaft ends (2) with an outside micrometer in at least 2 directions and dead square to the measuring surface.

4. REASSEMBLING

4. REASSEMBLING



4.1 CRANKSHAFT AND MAIN BEARINGSFig. 4.1-2 Mount bearing (1) with drill-mark (2) facing outside and

upwards, and tighten the bolts (3)- 53-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 4.1-1 Check bearing for damage (1)

Fig. 4.1-3 Check surface for damage (1) and oil surface (1)

4. REASSEMBLING

Fig. 4.1-4 Auxiliary tool in order to enable easy mounting of the crankshaft

Fig. 4.1-5 Auxiliary tool in order to enable easy mounting of the crankshaft

A) Drive end side

Fig. 4.1-6

Insert the crankshaft through the crankcase opening on the oil pump side into the opposing bearing bush

B) Pump side- 54- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 4.1-7

Bearing cover oil pump side (with two lugs)

Place a new O-ring (1) on the rear side of the bearing cover

4. REASSEMBLING

Place a new O-ring on both pipes of the internal oil passageway

Fig. 4.1-8 Oil the bearing

Fig. 4.1-9 Oil the shaft

Fig. 4.1-10 Place the cover in such a way that the holes (1) in each lug of the bearing cover are opposite the pipes (2) of the internal oil passageways and slide the bearing cover into the crankcase- 55-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

4. REASSEMBLING

Fig. 4.1-11 Tighten the bolts in opposing sequence and check that the crankshaft rotates freely

4.2 THRUST BEARING

Fig. 4.2-1

Check whether all components are clean, including the inside of the bearing cover and crankshaft on oil pump side

Ring (1) and ring (5) running surfaces have to point to the roller bearings

Ring (3) is allowed to turn 180o

Rolling bearing (2) and (4) are allowed to be changed

Ring (1) has to be mounted first. Ensure that the running surface points to the roller bearing, and is located tight to the edge in the bearing cover. Ring (1) can be used on one side only

Fig. 4.2-3 Mount the remaining parts (2, 3, 4) and ensure that the running surface of ring (5) points to the roller bearing. Ring (5) can be used on one side only- 56- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 4.2-2

4. REASSEMBLING

Fig. 4.2-4 Mount the oiled hold down disc (1), which fits exactly in the chamber of the crankshaft

Fig. 4.2-5

Fig. 4.2-6 Stop the crankshaft turning by using a wooden block

Fig. 4.2-7 Tighten the bolts- 57-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

4. REASSEMBLING

Check that the crankshaft rotates freely

4.3 OIL PUMP ASSEMBLY

Fig. 4.3-1 Place the carrier disc on the hold down disc

The enlarged slot (1) of the carrier disc must face the crankshaft

Fig. 4.3-2 Position the slot of the carrier disc in vertical or horizontal position by rotating the crankshaft

Fig. 4.3-3

Place 2 new O-rings (1) around the oil in- and outlet holes at the bearing cover

Place a new O-ring (2) on the rear side of the oil pump

Fig. 4.3-4

Check that the oil pump is clean

Insert the oiled springs (1) in the holes of the spring retainer- 58- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

4. REASSEMBLING

Fig. 4.3-5 Position the carrier lug (1) of the pump element with the slot in the carrier disc (2)

Fig. 4.3-6

Check that all the springs are at the proper position

Push the oil pump as far as possible towards the bearing cover and fit the bolts and washers slightly

The oil pump cannot be pushed fully against the bearing cover, because of the springs

Tighten the bolts

Check that the crankshaft rotates freely

4.4 OIL DISCHARGE FILTER

Fig. 4.4-1 Replace the oil filter housing O-rings (1) - 59-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 4.4-2

4. REASSEMBLING

After the first 100 operating hours the red-marked discharge filter has to be replaced with a grey-marked filter element!

Fit the preassembled (red/grey) marked discharge filter housing using the two bolts with washers on the right-hand side of the pump

Tighten the bolts to the torque given in table Survey of torques for bolts and nuts

4.5 OIL SUCTION FILTER

Fig. 4.5-1 In case of polution, renew oil suction filter

4.6 OIL LUBRICATION PRESSURE REGULATOR

Fig. 4.6-1

Install the lubricating oil pressure regulator (1) using a new alu ring (2) in the compressor housing

Finally fit the cap nut (3) handtight on the regulator

Final adjustment of a reassembled lubricating oil pressure regulator must be done during compressor operation. This adjustment procedure is described in the Installation and Maintenance Manual.

4.7 CYLINDER LINER, PISTON AND CONNECTING ROD

Fig. 4.7-1 Piston and connecting rod

Fig. 4.7-2 Insert the connecting rod bolts (1) into the big end of the connecting rod (make sure that the flat side of the bolthead is positioned correctly!)- 60- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

4. REASSEMBLING

Fig. 4.7-3 Place the bearing shells (1) into the connecting rod

Fig. 4.7-4 Due to the built-in fixing cams (1) only one assembled position is possible

Fig. 4.7-5 Oil bearing shells, piston and piston rings.

Fig. 4.7-6 Oil cylinder liner

Slide the piston carefully into the cylinderliner; be sure not to damage the piston and oil scraper rings- 61-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

4. REASSEMBLING

Fig. 4.7-7 Push the cylinder liner entirely on the piston; be sure not to damage the piston and oil scraper rings.

Fig. 4.7-8

Turn the crankshaft into the position that the crank (1) is located in the centre of the bore of the cylinder liner

Oil the crank

Fig. 4.7-9 Place spacer ring (1) into the cylinder bore

Fig. 4.7-10 Place the cylinder liner, including connecting rod and piston into the cylinder bore- 62- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

4. REASSEMBLING

Fig. 4.7-11 Check that the connecting rod properly embraces the crankshaft journal. Check that the bearing shell in the connecting rod has not been displaced

Fig. 4.7-12 make sure that the flat side of the bolthead (1) is positioned correctly!

Fig. 4.7-13 Fit the connecting rod parts with the machine codes(1) on one side.

Fig. 4.7-14

Fig. 4.7-15 Locking rings as used for connecting rods

Slide the corresponding connecting rod cap over the connecting rod bolts

Fit both nuts with new (double) locking rings on the connecting rod bolts and tighten to the torque given in table Survey of torques for bolts and nuts- 63-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

4. REASSEMBLING

4.8 DETERMINING PISTON CLEARANCE

Fig. 4.8-1 Place a 1 mm thick lead or tin soldering wire (1) which is buckled on both ends into the threaded holes of the piston

Fig. 4.8-2

Place the discharge valve assembly on the cylinder liner

Replace the springs, for example for pipes (1) with a length of approx 30 mm

Tighten the nuts (2)

Never use an impact wrench

Fig. 4.8-3 Turn the crankshaft a few times (Use a M16 bolt)

Fig. 4.8-4 Remove all measuring aids and measure the thickness of the flattened wire. This thickness, which is equal to the clearance, should be as given in Table 5.2-1(Piston clearance). If the measuring result is beyond these limits, it is necessary to contact the service department of Grasso- 64- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

4. REASSEMBLING

4.9 SUCTION VALVES AND DISCHARGE ASSEMBLE

Fig. 4.9-1 Place spacer ring (1) in the cylinder bore

Fig. 4.9-2 Place the suction valve ring (1) on its seat in the cylinder liner collar

Fig. 4.9-4 Place the sinusoidal spring with the sharp side downwards on the suction valve

REMARK;The sinusoidal springs in the inclined cylinders can easily fall out of the cylinder liner during assembly. This can be prevented by placing the sinusoidal springs in such a way on the valve ring that the springs touch the valve ring at the highest and the lowest point in the inclined cylinder liner.

Fig. 4.9-5 Spring dish, spring and locking nut- 65-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

Fig. 4.9-3 Place the sinusoidal spring (1) with the convex side pointing upwards on the suction valve ring

4. REASSEMBLING

Fig. 4.9-6

Place the preassembled discharge valve assembly in the cylinder

Fix the valve assembly, using the spring, spring dish and locking nut

Tighten alternately the locking nuts, to the torque given in table Survey of torques for bolts and nuts

Never use an impact wrench!

the edge on the cylinder head itself

Two different type of gaskets are distinguished

1= cylinder head incl. capacity control2= cylinder head excl. capacity control

Use the appropriate gastket

Fig. 4.9-8 Use studs (1) as auxilairy tool in order to enable easy mouting the cylinder cover

Fig. 4.9-9 Tighten the cylinder cover nuts in opposing sequence to the torque given in table Survey of torques for bolts and nuts - 66- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 4.9-7

Clean the sealing edge of the cylinder head cover and

4. REASSEMBLING

4.10 ROTARY SHAFT SEAL

Fig. 4.10-1

When using new parts, check that the protective foil has not been removed

Avoid touching the contact faces of these parts; slightly rub your hands with oil or wear gloves

Especially inspect the crankshaft part where the O-ring moves

Remove all (rubber) deposits by rubbing or polishing

Oil all parts with compressor lubricating oil, as well as the crankshaft part where the shaft seal sits

Fig. 4.10-2

Slide the rotary slip ring part (face with text towards the crankshaft boss) over the crankshaft and push

Fig. 4.10-3

Fig. 4.10-4 Insert the counter slip ring with the O-ring (1) into the shaft seal housing- 67-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

through until the rear side is positioned against the crankshaft boss

Lock the slip ring on the crankshaft by tightening the three grub screws with the allen key1. (torque given in table Survey of torques for bolts and nuts

Fig. 4.10-5

4. REASSEMBLING

Screw the three allen head screws (1) through the housing into the stationary slip ring

Tighten the screws alternately until the slip ring is properly seated

Fig. 4.10-6

Place a ew O-ring (1) into the groove of the cleaned shaft seal housing and oil channel (2)

Oil sealing surfaces

Fig. 4.10-7

Mount the shaft seal housing (with oil leakage drain opening facing downwards) onto the crankcase

Place the nuts (1) and tighten them alternately crosswise to the torque given in table Survey of torques for bolts and nuts

Screw the oil leakage drain line into the bottom of the shaft seal housing

Place the oil leakage drain

4.11 CRANKCASE SERVICE COVERS- 68- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Fig. 4.11-1

4. REASSEMBLING

Fig. 4.11-2

Check that the crankcase is clean and dry and, subsequently, fit all crankcase covers with new O-rings

Place the nuts and tighten them in opposing sequence to the torque given in table Survey of torques for bolts and nuts

4.12 SUCTION FILTER

Fig. 4.12-1 - 69-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

4. REASSEMBLING

Fig. 4.12-2

Place a new O-ring (1) into the suction gas filter cover

Place the suction filter into the housing

Tighten the nuts to the torque given in table Survey of torques for bolts and nuts

4.13 PRESSURE RELIEF VALVE ASSEMBLY

Fig. 4.13-1 Place a new gasket (1) in the crankcase

Fig. 4.13-2 Place the pressure relief valve into the crankcase and tighten the bolts (1) to the torque given in table Survey of torques for bolts and nuts

4.14 OIL FILLING AND PRE LUBRICATION

(Re)Fill with clean or fresh original oil only!

Prelubricate the lubrication oil circuit via the oil charge valve mounted on top of the oil pump housing

Remove oil filling plug and fill the oil suction filter with oil

Refit the oil filling plug with new aluminium ring

Connect oil filling pump pre-lubrication stop valve and fill the oil discharge filter, shaft seal and crankshaft with oil to lubricate the oil circuit- 70- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

4. REASSEMBLING

4.15 COUPLING

Fig. 4.15-1

Fig. 4.15-2 Slide the coupling half on the compressor shaft and place the bolts

Fig. 4.15-3 To avoid rotation, use an auxilairy bolt (1) and a wrench- 71-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

4. REASSEMBLING

Fig. 4.15-4 Tighten the bolts in opposing sequence to the torque given in table Survey of torques for bolts and nuts- 72- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

5. MISCELLANEOUS

5. MISCELLANEOUS

5.1 TABLE OF TORQUES FOR BOLTS AND NUTS GRASSO 5HP

Refer to Grasso information sheet 00.86.005-v002 and to Grasso 5HP partslist manual;

Table 5.1-1

Position Dims Item description Item number Quality Torque in Nm

1 Assembly cover M12x35 Hexagon headed bolt 0110635 8.8 86

2 Sight glass M6x16 Hexagon headed bolt 0110316 8.8 9

3 Head cover M12x110 Hexagon headed bolt 0189611 12.9 140

4 Bearing cover M12X35 Hexagon headed bolt 0110635 8.8 86

5 Shaft seal housing M12X45 Hexagon headed bolt 0110645 8.8 86

6 Shaft seal M4x... Hexagon socket head screw - 316 ST 2-2.9

7 Oil pump housing M12x50 Hexagon headed bolt 0110650 8.8 86



10 Pump element M6x20 Hexagon headed bolt 0110320 8.8 7

11 Oil filter M10x80 Hexagon headed bolt 0110581 8.8 50

12 Suction flange M12 Hexagon nut 0115610 8 86

13 Suction filter flange M12 Hexagon nut 0110610 8 86

14 Pressure flange M12 Hexagon nut 0110610 8 86

15 Bearing cover M10x40 Hexagon headed bolt 0110540 8.8 50

16 Cylindrical roller bearing M10x55 Hexagon socket head screw 0104555 8.8 50

17 Connecting rod MF12x1.5 Hexagon nut 0145605 8 34-44

18 Valve central M12x25 Stud 0151665 8.8 86

19 Valve central M12 Hexagon nut 0145600 8 86

20 Valve M5x35 Hexagon socket head screw 0106240 8.8 8

21 Valve screw M10x76 Hexagon socket head screw 0176572 CrMo4 40

22 Valve screw nut M10 Hexagon nut 0145500 8 30

23 Flange cap. control M10x40 Hexagon socket head screw 0104540 8.8 50

24 Flange cap. control M5x10 Hexagon socket head screw 0123010 12.9 5

25 Relief valve M10x55 Hexagon socket head screw 0104555 8.8 50

26 Sealing plug G1/8 Plug G10 0136108 ST 20




30 Oil regulator G1 Plug G33 1241132 ST 200

31 Oil heater pipe G1 Pipe 0385136 ST 200- 73-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

5.2 WEAR LIMITS AND TOLERANCES GRASSO 5HP

Not only do the wear limits determine whether a part is

to be replaced, but moreover the condition of the part; have the honing or grinding tracks of precision machined butting or running faces not been worn off irregularly, are there any visible discolouring of material, has the

5. MISCELLANEOUS

roundness remained correct and are there any signs of glazing of grind. All these wear factors make a part virtually unserviceable, even if this part remains within its wear limits.

Table 5.2-1 Wear limits and tolerances

Item Description of part Ref. Limits (mm) Remarks

1 Main bearing bush pump side11.46.759 Max. internal diameter 65+0.110 When fitted

2 Main bearing bush driving side

3 Bearing bush small end of the connecting rod 11.46.026 36+0.13 When fitted

4 Bearing bush big end of the connecting rod 11.44.336 Max. internal diameter 65+0.105 When fitted

5 Crankshaft (main bearing and crankshaft journal) 22.95.xxx Min. external diameter 65-0.057

6 Crankshaft (axial play) 22.95.xxx11.48.165 No play

7 Cylinder liner 23.94.086 Max. internal diameter 85+0.05

8 Gudgeon pin 24.94.026 Max. internal diameter 26-0.007

9 Piston rings 20.94.020 max. gap 1.0 Measured in non-scored part of cylinder liner

10 Piston / valve clearance - 0.46 .. 0.89

11 Control pressure piston rings 09.70.05609.70.040 Wear 75% of the circumference

12 Control pressure piston housing 23.94.xxx max. 56.06

13 Bearing bush 27.36.500 Max. diameter 40.07

14 Spring valve lifting housing 11.31.133 Min. 60, Max. 64

15 Die spring 11.35.431 Min. 37.5, Max. 38.1- 74- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

5. MISCELLANEOUS

5.3 REQUIRED SERVICE TOOLS AND MATERIALS

In order to properly carry out the disassembly, inspection and assembly procedures described in this manual, the service engineer should possess the following tools, measuring equipment and aids.

Table 5.3-1

Description

-Sp

ann

ers:

Ring spanners and socket spanners (metric):

8-10 (2x) -13-14-17-19-24-27-30-32-36-41

Hexagon socket head spanners (metric): 8-13-10-17

Torque spanners (metric) 19-24-30-36

Pin-face wrench (metric) for shaft seal M4

-Mea

suri

ng

eq

uip

men

t:

Inside micrometer of 0-50 mm

Inside micrometer of 50-100 mm

Outside micrometer of 0-50 mm

Outside micrometer of 50-100 mm

Depth micrometer of 0-50 mm

Vernier gauge of 10"

Feeling gauges of 0.05-1.00 mm

Magnetic gauge with extended plunger

Mis

c:

Grasso special tool kit TA various service activities

Vacuum pump

Centre punch

Circlip pliers

Hammer (steel)

Hammer (soft)

Pair of pliers Remove split pin valve-lifting mechanism

Loctite

Lead or tin soldering wire 2 mm for measuring piston clearance

Polishing paper

Polishing (compound) paste

(two) Screwdrivers (small) e.g. for removing shaft seal

Screwdiver (large) removing key

Abrasive linen

Silicon grease

Wire brush

Piston ring pliers

Grease

Self-made (crankshaft) auxiliary tool

removing and inserting crankshaft

Auxiliary tools for shaft seal

Steel strip support buffer spring

Oil drip tray

Tube brush 10 mm cleaning crankshaft oil passageways

Bar 6 mm cleaning crankshaft oil passageways

Compressed air device cleaning e.g. crankshaft oil passageways

Hydraulic press

Heater approx. 80 C removing and inserting connecting rod bearings

Description- 75-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

5. MISCELLANEOUS

5.4 FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING

Fig. 5.4-1 Pipe couplings

Fig. 5.4-2 Double locking ring

A) Preparation

Saw off the pipe at right angles.

Deburr and clean the pipe end.

Oil thread, taper and clamping sleeve (facilitates fitting).

In bends, the minimum length of the straight pipe end must be twice the height of the union nut.

A = Coupling threaded piece B = clamping sleeve C = Union nut D = Pipe

B) Fitting

Slide union nut and clamping sleeve on the pipe (mind the assembling sequence).

Press pipe against stop and tighten union nut by hand.

Tighten a further half a turn (clamping sleeve is about to grip).- 76- Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP SIM2010/v002

Slack the union nut and retract pipe from stop by 2 - 3 mm.

Tighten 3/4 - 1 turn (ridges now penetrate into pipe).

On reassembly, only tighten up the union nut.

5. MISCELLANEOUS- 77-Reciprocating Compressors for industrial refrigeration / Series Grasso 5HPSIM2010/v002

1. REPAIR AND OVERHAUL1.1 INTRODUCTION1.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM1.3 EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE1.3.1 EVACUATION OF REFRIGERANT BEFORE SERVICING1.3.2 LEAK-TIGHTNESS AFTER SERVICING1.3.3 EVACUATION AFTER SERVICING1.3.4 START-UP AFTER SERVICING

1.4 GENERAL RECOMMENDATIONS

2. DISASSEMBLY2.1 DISMANTLING COUPLING2.2 DISMANTLING SUCTION GAS FILTER2.3 DISMANTLING OVERFLOW VALVE2.4 REMOVING CYLINDER HEAD2.5 REMOVING DISCHARGE VALVE AND SUCTION VALVE ASSEMBLY2.6 REMOVING PISTON/CONNECTING ROD ASSEMBLY2.7 DISMANTLING ROTARY SHAFT SEAL2.8 REMOVING OIL DISCHARGE FILTER ELEMENT2.9 REMOVING OIL PUMP ASSEMBLY2.10 REMOVING CRANKSHAFT

3. INSPECTION AND PREASSEMBLY3.1 BACK PRESSURE INDEPENDENT RELIEF VALVE3.2 LUBRICATING OIL PRESSURE REGULATOR3.3 CAPACITY CONTROL MECHANISM3.4 INSPECTION DISCHARGE VALVES3.5 INSPECTION SUCTION VALVES3.6 INSPECTION PISTONS AND CONNECTING RODS3.7 PRE ASSEMBLING PISTON AND CONNECTING ROD3.8 INSPECTION CYLINDER LINER3.9 OIL PUMP AND FILTERS3.9.1 DISASSEMBLING OIL PUMP3.9.2 REMOVING PUMP ELEMENT/BEARING ASSEMBLY3.9.3 INSERTING OIL PUMP ELEMENT3.9.4 OIL FILTER HOUSING

3.10 MAIN BEARINGS3.11 THRUST BEARING3.12 PRE ASSEMBLING BEARING COVERS3.13 ROTARY SHAFT SEAL3.14 CRANKSHAFT3.15 CRANKCASE

4. REASSEMBLING4.1 CRANKSHAFT AND MAIN BEARINGS4.2 THRUST BEARING4.3 OIL PUMP ASSEMBLY4.4 OIL DISCHARGE FILTER4.5 OIL SUCTION FILTER4.6 OIL LUBRICATION PRESSURE REGULATOR4.7 CYLINDER LINER, PISTON AND CONNECTING ROD4.8 DETERMINING PISTON CLEARANCE4.9 SUCTION VALVES AND DISCHARGE ASSEMBLE4.10 ROTARY SHAFT SEAL4.11 CRANKCASE SERVICE COVERS4.12 SUCTION FILTER4.13 PRESSURE RELIEF VALVE ASSEMBLY4.14 OIL FILLING AND PRE LUBRICATION4.15 COUPLING

5. MISCELLANEOUS5.1 TABLE OF TORQUES FOR BOLTS AND NUTS GRASSO 5HP5.2 WEAR LIMITS AND TOLERANCES GRASSO 5HP5.3 REQUIRED SERVICE TOOLS AND MATERIALS5.4 FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING

Documents

SIM 5HP