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Reciprocating Compressors
Grasso VCM/12/12E/11/10/9/7S/8S/6/5HP
Service and Maintenance Schedules (SMS)
pador9130
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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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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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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
Running hours * 1000a
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
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 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 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
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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 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
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
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1. MAINTENANCE
SMS2012/v010
1.2.3 GRASSO 12
SERVICEANDMAINTENANCESCHEDULES Grasso 12
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 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 12
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
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1. MAINTENANCE
SMS2012/v010
1.2.4 GRASSO 10
SERVICEANDMAINTENANCESCHEDULES GRASSO 10
Item
Description
Actions
Checkpoint
Running hours * 1000a
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)
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 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
SERVICEANDMAINTENANCESCHEDULES GRASSO 10
Item
Description
Actions
Checkpoint
Running hours * 1000a
0.1YEARLY
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
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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
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
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1. MAINTENANCE
SMS2012/v010
1.2.6 GRASSO 6
SERVICEANDMAINTENANCESCHEDULES GRASSO 6
Item
Description
Actions
Checkpoint
Running hours * 1000a
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
SERVICEANDMAINTENANCESCHEDULES GRASSO 6
Item
Description
Actions
Checkpoint
Running hours * 1000a
0.1YEARLY
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
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1. MAINTENANCE
SMS2012/v010
1.2.7 GRASSO 5HP R744 & R717
SERVICEANDMAINTENANCESCHEDULES GRASSO 5HP
Item
Description
Actions
Checkpoint
Running hours * 1000a
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
Running hours * 1000a
0.1YEARLY
R744 (CO2) R717(NH3)
5 10 5 10
15 20 15 20
25 30 - -
35 40 25 30
- - 35 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
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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
Running hours * 1000a
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
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)
SERVICEANDMAINTENANCESCHEDULES GRASSO 11 AND GRASSO 9
Item
Description
Actions
Checkpoint
Running hours * 1000a
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
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
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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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