Reciprocating Compressors for industrial refrigeration

Series Grasso 12E

Service Instruction Manual (SIM)

ca0156_0087127_sim_rc12e_v006_gbr_

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 1-

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 12E SIM0611/v006

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 OF THE COMPRESSOR 11
1.4 GENERAL RECOMMENDATIONS 11
2 DISASSEMBLY 13
2.1 REMOVING FLYWHEEL 13
2.2 DISMANTLING SUCTION GAS FILTER 15
2.3 DISMANTLING THE PRESSURE RELIEF VALVE HOUSING 15
2.4 REMOVING DISCHARGE VALVE ASSEMBLY 16
2.5 EXPLANATION CYLINDER LINER VERSIONS 17
2.5.1 REMOVING THE PISTON/CONNECTING ROD ASSEMBLY 17
2.6 REMOVING THE VALVE-LIFTING HOUSING AND THE CYLINDER LINER 19
2.7 DISMANTLING THE ROTARY SHAFT SEAL 20
2.8 REMOVING OIL SUCTION AND OIL DISCHARGE FILTERS 21
2.9 REMOVING OIL PUMP ASSEMBLY 22
2.10 THRUST BEARING 25
2.10.1 DISMANTLING STANDARD THRUST BEARING 25
2.10.2 HEAVY DUTY THRUST BEARING CONSTRUCTION 26
2.10.2.1 DISMANTLING HEAVY DUTY THRUST BEARING 26
2.11 REMOVING CRANKSHAFT, INTERMEDIATE BEARING AND MAIN BEARINGS 27
2.11.1 Introduction 27
2.11.2 Intermediate bearings in 4, 6, 9 and 12 cylinder compressors 27
2.11.3 2 and 3 cylinder compressors (i.e. without intermediate bearing) 28
2.11.4 4, 6, 9 and 12 cylinder compressors (with intermediate bearing) 28
2.11.5 Removing the crankshaft, METHOD A (without auxiliary tools) 29
2.11.6 Removing the crankshaft method B (with auxilary tools) 29
2.11.7 Internal oil connection line 29
2.11.8 Line coupling pieces 29
3 INSPECTION AND PREASSEMBLY 31
3.1 PRESSURE RELIEF VALVE ASSEMBLY 31
3.1.1 Back pressure dependent relief valve 32
3.1.2 Back pressure independent relief valve 32
3.2 LUBRICATING OIL PRESSURE REGULATOR 32
3.3 CONTROL OIL PRESSURE REGULATOR 33
3.4 VALVE-LIFTING CONTROL MECHANISM RC12E 33
3.5 DISCHARGE VALVE ASSEMBLY AND SUCTION VALVE 35
3.5.1 DISCHARGE VALVE ASSEMBLIES 35
3.5.1.1 DIFFERENT TYPE OF DISCHARGE VALVE ASSEMBLIES 35
3.5.1.2 DISMANTLING AND INSPECTION DISCHARGE VALVE ASSEMBLY 36
3.5.1.3 PREASSEMBLING DISCHARGE VALVES 36

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 3-

 Section Title Page
3.5.2 SUCTION VALVE 36
3.6 PISTON/CONNECTING ROD 37
3.6.1 General 37
3.6.2 Connecting rod 37
3.6.3 Piston 38
3.6.4 Preassembling the piston/connecting rod 38
3.7 CYLINDER LINER AND VALVE-LIFTING MECHANISM 39
3.7.1 CYLINDER LINER WITH SLEEVES AND VALVE-LIFTING MECHANISM 39
3.7.1.1 General 39
3.7.1.2 Preassembling the valve-lifting mechanism 40
3.7.2 CYLINDER LINER (WITH HOLES, OLD VERSION) AND VALVE-LIFTING MECHANISM 41
3.8 OIL PUMP AND OIL FILTERS 42
3.9 MAIN BEARINGS 45
3.10 ROTARY SHAFT SEAL 47
3.11 CRANKSHAFT 48
3.12 THRUST BEARINGS 49
3.12.1 STANDARD BRONZE THRUST BEARING, MARK 2 49
3.12.2 HEAVY DUTY THRUST BEARING 49
3.13 CRANKCASE 49
4 REASSEMBLING 51
4.1 CRANKSHAFT, MAIN BEARINGS AND INTERMEDIATE BEARING 52
4.1.1 Bearing cover driving side 52
4.1.2 Assembly procedure of 2 and 3 cylinder compressors 52
4.1.3 ASSEMBLY PROCEDURE 4, 6, 9 AND 12 CYLINDER COMPRESSORS 52
4.1.4 Pump side 52
4.1.5 Bearing cover oil pump side (with two lugs): 53
4.1.6 Standard thrust bearing 53
4.1.7 Heavy duty thrust bearing 54
4.1.8 Measuring the axial crankshaft play 55
4.1.9 Procedure for 4, 6, 9 and 12 cylinder compressors 55
4.1.10 Assembling counter weights 56
4.2 OIL PUMP 56
OIL SUCTION FILTER, OIL DISCHARGE FILTER, LUBRICATING OIL PRESSURE REGULATOR AND CONTROL OIL PRESSURE
4.3 57
REGULATOR
4.3.1 Oil discharge filter 57
4.3.2 Oil suction filter 57
4.3.3 Lubricating oil pressure regulator (without groove) 57
4.3.4 Control oil pressure regulator (with groove) 57
4.4 VALVE-LIFTING CONTROL MECHANISM 57
4.5 CYLINDER LINER 59
4.5.1 CYLINDER LINER (LATEST VERSION, WITH SLOTS) 59
4.5.2 CYLINDER LINER (OLD VERSION, WITH HOLES) 61
4.6 PISTON/CONNECTING ROD ASSEMBLY 62

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 Section Title Page
4.7 DETERMINING THE PISTON CLEARANCE 63
4.8 SUCTION/DISCHARGE VALVE ASSEMBLY 63
4.9 ROTARY (SLIP RING) SHAFT SEAL 65
4.10 SUCTION GAS FILTER 66
4.11 PRESSURE RELIEF VALVE ASSEMBLY 67
4.12 OIL FILLING 67
4.13 MOUNTING FLYWHEEL 68
4.14 DISCHARGE VALVES, LEAKAGE TEST PROCEDURE 69
5 MISCELLANEOUS 71
5.1 SURVEY OF TORQUES FOR BOLTS AND NUTS 71
5.2 WEAR LIMITS AND TOLERANCES 73
5.3 REQUIRED SERVICE TOOLS AND MATERIALS 75
5.4 GRASSO SPECIAL TOOLS AND AIDS GRASSO 12E 75
5.5 FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING 77
5.6 MASS OF SEPARATE COMPONENTS AND COMPRESSORS 77
5.7 RELIEF VALVE POSITIONS 77
6 APPENDIX; Product Information (PI) 81
6.1 MAIN DIMENSIONS AND SPACE REQUIREMENTS 83
7 NOTES 85

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 5-

- 6- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E SIM0611/v006
Preface 4) Installation and maintenance manual (IMM)

This preface gives a survey of the types of Contents

documentation available for reciprocating Grasso This manual will provide information on how to
compressor series. transport, install, start-up and maintain the compressor
(package). It also contains a number of "Product
Information Sheets" and the current "Parts List"
All documentation and selection software is on-line
available on www.grasso-global.com User group
To be used in the field by qualified personnel for both
end-user and contractor.
1) Product Information (PI)
Distribution
Contents Supplied together with the compressor.
All product information (engineering data) for this series
compressor and the corresponding recommended
accessories. It is meant to be a guide to the selection of 5) Product Descriptions, Instructions for Accessories
these components. (PD)

User group Contents

Project engineers, application engineers, sales managers, All the relevant mounting and installation instructions
product managers for both end-users and contractors. and spare parts information for those accessories
supplied with the compressor.
Distribution
Your Grasso contact only. User group
To be used in the field by qualified personnel for both
end-user and contractor.
2) Operating manual (OM)
Distribution
Contents
Supplied together with the compressor.
General operation guide lines; safety instructions,
periodical inspections, fault analysis, periodical
maintenance. 6) Parts list (PL)

User group Contents

To be used in the field by the end-user. All current parts of the compressor and accessories
together with the design changes applicable to previous
Distribution supplied components ("History").
Supplied together with the compressor.
User group
Service and parts department for both end-user and
3) Safety instructions refrigerant ammonia contractor.
Contents Distribution
Strict safety provisions have been defined to protect Your Grasso contact only.
human beings and facilities. Reference is made to the
main guidelines and provisions to be observed
inplanning and operating refrigerating plants. With 7) Service & Maintenance Schedules (SMS)
regard to their operation, the detailed operating
manuals of the plant manufacturers shall be taken into Contents
account as well. Manual will be supplied with all Complete set of service and maintenance schedules for
compressors 100 operating hours up to 48000 operating hours
(inspection, renewal, measuring, cleaning, ...) of the bare
User group shaft compressor.
To be used in the field by qualified personnel for both
end-user and contractor. User group
Service and parts department and in the field by
Distribution qualified personnel for both end-user and contractor.
(If applicable supplied together with the compressor)
Distribution
Your Grasso contact only.

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 7-

8) Service Instruction Manual (SIM)

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'.
User group
To be used in the field by qualified personnel of
refrigeration installers or contractors.
Distribution
Your Grasso contact only.

9) Typographic signs

Indicates a WARNING. READ IT CAREFULLY!

Indicates an IMPORTANT note or procedure to which

you should pay special attention.

Indicates a HINT.

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Main setup data Grasso 12E Table 1 Main setup data

Description Value Remark

Start frequency max. 4 starts per hour
Time interval between stopping and re-starting min. 2 minutes
Time interval between starting and re-starting min. 15 minutes
For continuous minimum
Time interval between capacity steps min. 3 minutes part-load (i.e. more than 30
minutes) consult Grasso.
Oil level 25-75% crankcase sight glass

Min. oil temperature warmer than surroundings and ≥ 20 °C for NH3 and ≥ 30
°C for halocarbons
Required oil viscosity;
Max. oil temperature Refer to oil selection table/applied type of oil ≥ 10 cSt during operation at
location of bearings
Control oil pressure suction pressure + 8 bar
After a mimimum of 15
minutes running time at an oil
Lubricating oil pressure difference between 1.3 and 3.0 bar Setting approx. 2.0 bar temperature of approx. 50 oC
(122 oF)
Max. discharge temperature 170 °C
Min. suction pressure 0.3 bar (a)
NH3 - 7.0 bar (a)
Max. intermediate pressure R22 - 7.0 bar (a)
Max. suction pressure R134a - 6.2 bar (a)
R404A - 6.0 bar (a)
Pdischarge - Psuction ≤19.0 bar
>0 K for NH3,
Superheat >15 K for R404A, R507 and R134a
Oil suction filter Blue coloured filter element

Factory mounted; to be
Oil discharge - running in - filter Red coloured filter element 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

Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end

General info SIM Manual" (IMM) meant for the operator. The IMM is
supplied with every compressor or compressor package.

General Cylinder numbering

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 intructions

The manual should also and always be used together
with the corresponding "Installation and Maintenance

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 9-

Fig. 1 Cylinder numbering Grasso reciprocating compressors

Legend
1, 2, 3, ... Cylinder numbers
T Top view of compressor
M Motor/Drive end of compressor
O Oil pump of compressor

OUT OF PRODUCTION

2 AND 3 CYLINDER COMPRESSOR MODELS

Although this manual contains information on the 2, 3,

4, 6, 9 and 12 cylinder compressors, since the 1st
October, 2003, the 2 and 3 cylinder compressors are no
longer in production (single stage and two stage).

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. REPAIR AND OVERHAUL

1. REPAIR AND OVERHAUL

Table of Contents

Section Title Page

1.1 INTRODUCTION 11
1.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 11
1.3 EVACUATION OF THE COMPRESSOR 11
1.4 GENERAL RECOMMENDATIONS 11

1.1 INTRODUCTION Procedure to evacuate and to dry a system:

i) STATUS: System is filled with nitrogen and no oil has
Compressor and plant been added (oil prevents any trapped moisture from
boiling off).
All activities described can be carried out without taking ii) Verify that all valves in that part of the system to be
the compressor off its base and without detaching it evacuated are opened (refer also to the plant
from the plant. In case of complete overhaul, it may, manual).
however, be useful to carry this out detached from the iii) Connect vacuum pump to the evacuation/purging
plant in a separate working area, whether or not in a valve(s) of the compressor (for location of these
workshop equipped for this purpose. valves refer to the "Product Information" or to a
connection as mentioned in the plant manual and
Accessories evacuate the system to approx. 5 mm Hg (=6.6 mBar).
iv) Break vacuum by charging dry nitrogen into the
This chapter only deals with the disassembly and system.
assembly of a so-called "bare compressor" in standard v) Repeat step iii, 'Connect vacuum pump ...'.
design. This implies that, depending on the dismantling vi) Wait approx. 24 hours.
degree, it may be necessary to first completely or vii) If pressure has increased (system still contains
partially remove certain accessories. moisture), repeat steps iv, vand vi, otherwise,
It is recommended to distinctly mark the dismounted continue with the "Initial oil charge" procedure.
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 1.3 EVACUATION OF THE COMPRESSOR
torsionally-stiff coupling) in order to avoid mistakes at
reassembling.
Use always a vacuum pump to evacuate the compressor.
Tools To evacuate the refrigeration system refer to Section 1.2,
For proper performance of the operations, at least the Procedure to evacuate the compressor:
standard service tools and materials should be available. i) Switch off main control panel.
Besides, for certain operations additional special ii) Remove main fuses.
GRASSO tools are required, which can be obtained as a iii) Remove the refrigerant by means of a vacuum pump,
complete standard service set. via the evacuation/purging valve(s) as prescribed by
local safety regulations. For the location of these
Service Sets valves refer to the "Product Information".
Worn out parts are to be replaced by new parts which
are available in sets with a brief service manual. 1.4 GENERAL RECOMMENDATIONS
1. Do not disassemble more compressor parts than is
General necessary for the purpose (inspection, repair,
overhaul).
Although all the assembly and disassembly procedures 2. Use clean and well-conditioned tools.
shown relate to the two-stage compressor, they are 3. Make sure that there is a clean and neatly arranged
basically applicable universally to all compressors. If not, working area well-equipped to provide temporary
it is explicitly stated in the text. and adequately protected storage of dismantled
components. Preferably use a table or working bench
1.2 EVACUATION/DRYING THE with a clean, moisture-free and non-scratching
surface.
REFRIGERATING SYSTEM 4. Immediately clean every dismantled part, check it for
For evacuation of compressor only, refer to Section 1.3 wear or damage and oil the machined surfaces of

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 11-
 1. REPAIR AND OVERHAUL

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)

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 2. DISASSEMBLY

2. DISASSEMBLY

Table of Contents

Section Title Page

2.1 REMOVING FLYWHEEL 13
2.2 DISMANTLING SUCTION GAS FILTER 15
2.3 DISMANTLING THE PRESSURE RELIEF VALVE HOUSING 15
2.4 REMOVING DISCHARGE VALVE ASSEMBLY 16
2.5 EXPLANATION CYLINDER LINER VERSIONS 17
2.5.1 REMOVING THE PISTON/CONNECTING ROD ASSEMBLY 17
2.6 REMOVING THE VALVE-LIFTING HOUSING AND THE CYLINDER LINER 19
2.7 DISMANTLING THE ROTARY SHAFT SEAL 20
2.8 REMOVING OIL SUCTION AND OIL DISCHARGE FILTERS 21
2.9 REMOVING OIL PUMP ASSEMBLY 22
2.10 THRUST BEARING 25
2.10.1 DISMANTLING STANDARD THRUST BEARING 25
2.10.2 HEAVY DUTY THRUST BEARING CONSTRUCTION 26
2.10.2.1 DISMANTLING HEAVY DUTY THRUST BEARING 26
2.11 REMOVING CRANKSHAFT, INTERMEDIATE BEARING AND MAIN BEARINGS 27
2.11.1 Introduction 27
2.11.2 Intermediate bearings in 4, 6, 9 and 12 cylinder compressors 27
2.11.3 2 and 3 cylinder compressors (i.e. without intermediate bearing) 28
2.11.4 4, 6, 9 and 12 cylinder compressors (with intermediate bearing) 28
2.11.5 Removing the crankshaft, METHOD A (without auxiliary tools) 29
2.11.6 Removing the crankshaft method B (with auxilary tools) 29
2.11.7 Internal oil connection line 29
2.11.8 Line coupling pieces 29

2.1 REMOVING FLYWHEEL

For many service and repair operations the flywheel or
the V-belt pulley has to be removed.

Fig. 2.1-1

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 13-
 2. DISASSEMBLY

S Alternately unscrew the four M12-bolts five rotations

(screwing anticlockwise).

Fig. 2.1-4
Fig. 2.1-2
S Remove the locking disc.
S Remove the locking plate.
S Unscrew the centre M24-bolt five rotations (screwing
anticlockwise).
S Loosen the wheel by alternately tightening the four
M12-bolts clockwise. Keep screwing until the wheel is
entirely loose.

Fig. 2.1-5

S Now slide the wheel or V-belt pulley hanging in the

sling off the compressor shaft.

Fig. 2.1-3

S Remove the four M12 hexagon head bolts.

S Fix a sling on the top of the wheel. Pull the sling in
such a way that the wheel can still move freely on the
shaft.

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 2. DISASSEMBLY

2.2 DISMANTLING SUCTION GAS FILTER 2.3 DISMANTLING THE PRESSURE RELIEF
VALVE HOUSING

Fig. 2.2-1

Legend
1 Cover
Fig. 2.3-1 Back pressure dependent relief valve
2 Spring
3 Filter
The LP pressure relief valve housing is mounted against
the cylinder block.
S Remove the bolts from the left cover of the suction S Unscrew four of the six M12 bolts out of the cylinder
gas filter housing. block and remove the bolts.
S Remove the cover with the pression spring and filter S Unscrew the two remaining M12 bolts and remove
mounted to it from the housing. the housing.
S After the circlip ring has been removed from the
centring pin, the filter can be easily removed.
S Remove the O-ring from suction gas filter and replace
a suction filter if it is dirty.
S NOT FOR 21, 42, 63 and 84 compressors1:
Remove the cover on the right handed side of the
suction gas filter housing in the same way and clean
the inside of the housing.

1. Right side cover does not exist for 21, 42, 63 and 84 compressors

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 15-
 2. DISASSEMBLY

If there is any doubt about the proper performance of a In some compressors blind flanges have been fitted at
pressure relief valve, then the relief valve should be the connecting opening. There is no need to remove
renewed immediately. When a pressure relief valve these blind flanges during normal servicing or repair.
works improperly, discharge gas starts circulating
through the cylinder head, which makes this cylinder 2.4 REMOVING DISCHARGE VALVE
head feel much warmer compared to other cylinder
ASSEMBLY
heads.

Never test the relief valve by closing the discharge valve

of a running compressor. This will damage the seat of
the relief valve.

Fig. 2.4-1

S Remove dirt and paint particles from the cylinder

head studs using a steel brush.
S Oil all studs.
Fig. 2.3-2 Back pressure independent relief valve S Remove all M16 bolts from the short studs.
S Release the buffer spring tension by alternately
unscrewing the two nuts on the longer studs.
For regular service it is not necessary to remove the
pressure relief valve from its housing. However, if it has
worked once, it can be dismantled/serviced as described
in this manual.

Fig. 2.3-3 Blind flanges

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 2. DISASSEMBLY

Legend
3 Discharge valve assembly
4 Sinusoidal springs2
5 Suction valve ring
S Remove the cylinder head cover, the buffer spring,
the pressure spring cup1, the discharge valve
assembly with the two or three2 suction valve
sinusoidal springs and the suction valve ring.

2.5 EXPLANATION CYLINDER LINER

VERSIONS
Grasso 12E can have two different cylinder liner versions;
1 Latest version with suction sleeves; from approx
August 2003
2 Olde version with suction holes; Before approx
August 2003
For more details refer to Section 4.5.

2.5.1 REMOVING THE PISTON/CONNECTING ROD

ASSEMBLY

Fig. 2.4-2 Discharge valve assy (From serial number 00081502)

Fig. 2.5-1

S Place an oil drip tray under the service cover that is to

be removed to collect the residual oil in the inclined
crankcase openings.
S Remove the service cover with O-ring opposite the
cylinder under repair.
S In the case of vertical cylinders, remove the opposing
service covers.
Fig. 2.4-3 Discharge valve assy (Up to serial number 00081502

Legend
1 Buffer spring 1. Old version of discharge valve model only
2. The number of sinusoidal springs is dependent on refrigerant and/or
2 Pressure spring cup operating conditions.

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 17-
 2. DISASSEMBLY

Fig. 2.5-4
Fig. 2.5-2
S Tap up both connecting rod bolts a small amount of
S Rotate the crankshaft in such a way that the big end
force so that the connecting rod cap can be removed
of the connecting rod becomes easily accessible. easily.
S Pull both connecting rod bolts back to their original
places in the connecting rod.
S Move the piston that is to be removed to top position
by rotating the crankshaft by hand.

Fig. 2.5-5
Fig. 2.5-3
S Insert the T-handle (from auxiliary tool kit) into the
S Unscrew the two M16 nuts from the connecting rod threaded hole at the top of the piston and carefully
bolts and remove the (double) locking rings. pull the piston and the connecting rod out of the
cylinder liner, making sure that the big end of the
connecting rod does not damage the cylinder liner.

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 2. DISASSEMBLY

The connecting rod cap is marked and belongs to a In order to able to dismantle the cylinder liner, it is not
specific connecting rod. There is only one way to refit it necessary to remove the valve-lifting housing.
onto the connecting rod. Therefore conrod numbers
should always be situated on one side. Keep the
corresponding connecting rod parts together!
S Inspect the cylinder liner bore

Measure the bore in three places of the empty and

cleaned cylinder liner, being at the top, in the middle and
at the bottom, and replace if the bore is larger than is
given, or if the honing marks have (partly) disappeared.

2.6 REMOVING THE VALVE-LIFTING

HOUSING AND THE CYLINDER LINER

Fig. 2.6-2

S Place the longer bar1 over two studs of the cylinder

head.
S Insert the threaded rod with nut and washer into this
bar.
S Place the short bar centrally across the bottom of the
cylinder liner.
 Screw the threaded rod into this short bar until
the assembly is fully closed.
 Now tighten the nut until the cylinder liner is
Fig. 2.6-1 loose.
S Disconnect the oil line on the valve-lifting housing.
S Mark the position of (each) valve-lifting housing on
the corresponding mounting flange.
S Remove the entire housing, including the control
piston in it, by unscrewing the M10 bolts from the
cylinder jacket.
S Check the still mounted lever and carrier disc with
dowel pin (= ø8 mm) for irreparable damage.

Fig. 2.6-3

 Remove the auxiliary tools and take out the

cylinder liner by hand.

1. All these parts are included in the auxiliary tool kit ETA.

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 19-
 2. DISASSEMBLY

S For cylinder liners with suciont holes only (old

version):
 Remove the gasket of the cylinder liner collar,
determine the original thickness of the gasket
(1.0, 1.25 or 1.50 mm) and write down this value
on the corresponding cylinder wall.

2.7 DISMANTLING THE ROTARY SHAFT

SEAL

Fig. 2.7-3

S Place the oil drip tray under the shaft seal housing
and remove the M12 bolts from the shaft seal
housing.

Fig. 2.7-1

S Dismantle and remove the leakage drain from the

bottom of the shaft seal housing.

Fig. 2.7-4

S Slide the shaft seal housing over the shaft journal out
of the bearing cover.
S Take the counter slip ring from the shaft seal housing,
remove the O-rings from the counter slip ring and
from the rear side of the housing.
Fig. 2.7-2

S Remove the drive key from the crankshaft driving

end.

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 2. DISASSEMBLY

Fig. 2.7-7

S Slide the slip ring from the shaft .

Fig. 2.7-5
2.8 REMOVING OIL SUCTION AND OIL
S Unscrew the three locking screws at the
DISCHARGE FILTERS
circumference of the slip ring shaft seal using the M4
allen key from the auxiliary tool kit .
Pictures of oil pump are without the normally fitted oil
charge valve.

It is also possible to remove the oil pump and the filters

mounted to it as a whole. If the filter elements only have
to be inspected or replaced, it suffices to unscrew the
grooved filter nut and the filter housing that has to be
supported by hand, after an oil drip tray has been placed
under it.

Use the special tool key for removing oil filters.

Fig. 2.7-6

S Place two similar screwdrivers behind the slip ring and

carefully push the grips into the direction of the
crankcase until the slip ring is loose.
 Do not scratch the crankshaft! Fig. 2.8-1 Special tool for removing oil filters

Avoid touching the (black) carbon ring (if necessary wear

gloves or rub your hands with oil) and the lapped
counter surface of the ring.

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 2. DISASSEMBLY

Fig. 2.8-4

S In order to remove the entire oil suction filter (left)

and/or the oil discharge filter (right), only the two
M10 mounting bolts of each filter have to be
Fig. 2.8-2 Oil pump and filter
removed.
S Mark the filter housing to prevent interchange!

As both filter housings are identical and can possibly be

interchanged, every filter element is marked with a
colour: - Red for the running-in oil discharge filter which
must be replaced within the first 100 hours with a grey
coloured oil discharge filter. The oil suction filter is
coloured blue.

2.9 REMOVING OIL PUMP ASSEMBLY

S Put an oil drip tray under the pump to collect the
residual oil.
 Unscrew the M12 nuts from the studs and slide
the pump as a whole over the studs.

Fig. 2.8-3

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 2. DISASSEMBLY

If required, the oil pump can also be removed with both On the crankshaft side this hold down disc is provided
oil filters still mounted to it. with a lapped surface. Damage to this surface as a result
of rough use are very hard to repair and reuse of such a
hold down disc can damage the compressor within a
short time!

Fig. 2.9-1

S Remove the carrier disc which was left behind after

removal of the oil pump.

Fig. 2.9-2

S Remove the now accessible four M10 socket bolts

connecting the hold down disc with the crankshaft.
 Carefully remove the hold down disc with the
fitted dowel pin from the crankshaft.

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 2. DISASSEMBLY

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 2. DISASSEMBLY

2.10 THRUST BEARING 2.10.1 DISMANTLING STANDARD THRUST BEARING

Two types of thrust bearings have to be considered
1. Standard
a Bronze, mark 2, (latest version), refer Fig. 2.10-1
b Aluminium (old version), refer Fig. 2.10-2
2. Heavy duty

Fig. 2.10-3

S The released thrust bearing can now be carefully

removed with an allen key (from the shaft seal kit or
auxiliary tool set).
Fig. 2.10-1 Standard bronze thrust bearing, “mark 2”

As the adhesive power behind the thrust bearing has to

be overcome, the ring can suddenly slip off.

Fig. 2.10-2 Old version of standard thrust bearing, aluminium.

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 2. DISASSEMBLY

2.10.2 HEAVY DUTY THRUST BEARING B) Remove heavy duty thrust bearing
CONSTRUCTION
In addition to the standard design there is an alternative
"heavy duty" roller thrust bearing available for certain
applications and consists of a twin type roller assembly.
One main bearing for the outward pull of the crankshaft
and a second one for inward push of the crankshaft
during vacuum operation. The total assembly is
pre-loaded by means of springs to ensure proper running
conditions are achieved.

Compressors fitted with roller thrust bearings can be

easily recognised by an external oil overflow line running
from the oil pump to one of the crankcase covers and a
marking on the top of the oil pump. (Compressors fitted
with the standard thrust bearing arrangement have an
internal overflow back to the crankcase and no marking) Fig. 2.10-5 Heavy duty thrust bearing

2.10.2.1 DISMANTLING HEAVY DUTY THRUST

BEARING All running surfaces of the washers in contact with the
cylindrical roller thrust bearing and the needle thrust
A) Remove external oil line, oil pump and carrier disk bearing are hardened and smooth machined. Damages
to these surfaces as a result of rough use are very hard
to repair and reuse of such rings can damage the
compressor within a short time
S Remove the 7 mm. thick housing washer (1) from the
hold down disc (4).
S Remove the needle thrust bearing (2) from the hold
down disc (4).
S Remove the now accessible four M10 socket bolts (3)
and the hold down disc (4) which is connected to the
shaft washer (5).
Fig. 2.10-4 External oil line
S Remove the shaft washer (5) from the crankshaft.
S Remove the cylindrical roller thrust bearing (6) from
S Remove the external oil line (1) which is connected the crankshaft.
from the top of the oil pump to the service cover.
S The released 1 mm. thick thrust washer (7) can be
S .Remove the oil pump. Unscrew the M12 nuts, take carefully removed with a wire hook as shown Fig.
off the washers and slide the oil pump of the M12 2.10-6.
studs
 Pay attention not to lose the springs or the spring
retainer.
S Remove the carrier disc.

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 2. DISASSEMBLY

In case of direct drive, preferably remove the crankshaft

via the pump side.

Fig. 2.10-6 Remove thrust washer with hook (1)

 The bearing cover has been equipped with three

round shaped chambers to create space for a wire Fig. 2.11-1
hook to grip behind the thrust washer for
removal. 2.11.2 INTERMEDIATE BEARINGS IN 4, 6, 9 AND 12
CYLINDER COMPRESSORS

As the adhesive power behind the 1 mm. thick thrust

washer (7) has to be overcome, the ring can suddenly slip
off.
S Remove the spring retainer (8) from the oil pump
housing.
S Remove the springs (9) from the spring retainer(8)

2.11 REMOVING CRANKSHAFT,

INTERMEDIATE BEARING AND MAIN
BEARINGS
2.11.1 INTRODUCTION
S Before starting, the following components must have
been removed:
 All discharge valves
 All pistons and connecting rods Fig. 2.11-2
 Shaft seal and key S Mark both bearing block parts of each intermediate
 Oil pump bearing so that they can later be refitted in the same
 Thrust bearing position. For easy reference the crankshaft has been
left out!
 Remove both M20 bolts with corresponding
toothed spring washers from the intermediate
bearing support(s) in the crankcase.
It is not necessary to remove the counter weights
from the crankshaft, but on account of the
crankshaft weight, the counter weights may
preferably be dismantled.

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 2. DISASSEMBLY

 Remove the bearing cover with the corresponding

O-ring on the pump side. Now the crankshaft of
the 2 and 3 cylinder compressor only rests in the
bearing cover on the driving side.
 Assisted by a second person, now carefully
remove the crankshaft from the crankcase
through the opening on the oil pump side.
 Put the crankshaft down on a clean place.
If the bearing is only to be inspected, there is no need
to remove the parts mentioned.

2.11.4 4, 6, 9 AND 12 CYLINDER COMPRESSORS

(WITH INTERMEDIATE BEARING)
S Remove the swivel on top of the bearing cover on the
pump side.
Fig. 2.11-3  Unscrew all M16 nuts from the studs of the
S Write down the markings of the counterweights bearing cover on the pump side.
before they are taken off the crankshaft for faultless  Screw two M10 (jacking) bolts into the threaded
replacement later on. holes on both sides of the bearing cover.
 Unscrew both M16 bolts from each  Tighten these two bolts evenly and alternately
counterweight. until the bearing cover is loose.
 Remove the counterweights with the (double) S Remove the bearing cover (and the O-ring) and put it
locking rings. aside separately.
REMARK: As the 4 and 6 cylinder compressor has only
2.11.3 2 AND 3 CYLINDER COMPRESSORS (I.E. one intermediate bearing, the crankshaft has
WITHOUT INTERMEDIATE BEARING) to be supported.
S Remove the swivel on top of the bearing cover on the
pump side.
 Unscrew all M16 nuts from the studs of the
bearing cover on the pump side.
 Screw two M10 (jacking) bolts into the threaded
holes on both sides of the bearing cover.
 Tighten these two bolts evenly and alternately
until the bearing cover is loose.

Fig. 2.11-5

S Unscrew all M16 nuts from the studs of the bearing

cover on the driving side.
 Tighten the two jacking bolts further until the
bearing cover is loose.
 Remove the bearing cover (and the O-ring) and
put it aside separately.

Fig. 2.11-4

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 2. DISASSEMBLY

2.11.5 REMOVING THE CRANKSHAFT, METHOD A crankshaft can now be easily removed from the
(WITHOUT AUXILIARY TOOLS) crankcase with assistance from a second person.
 With the 4, 6, 9 and 12 cylinder compressor
unscrew the M16 intermediate bearing bolts.
 Take both bearing block halves from the
crankshaft and prepare them for inspection by
reassembling them to each other leaving out the
crankshaft.

2.11.7 INTERNAL OIL CONNECTION LINE

Fig. 2.11-6

S Remove the crankshaft of the 4, 6, 9, and 12 cylinder

compressor in steps.
 Make use of the intermediate bearings and/or
crank webs and the still mounted counter
weights, for use as supports on the edges of the
crankcase openings.
 With the 4, 6, 9 and 12 cylinder compressor,
unscrew the four M16 intermediate bearing bolts. Fig. 2.11-8
 Remove both bearing block halves from the S Uncouple and remove the internal oil connecting line
crankshaft and prepare them for inspection by and remove the oil line.
reassembling them to each other leaving out the
crankshaft. 2.11.8 LINE COUPLING PIECES
S The crankshaft can be removed more easy by making
use of a simple tool. This method B (with auxiliary
tool) is described below.

2.11.6 REMOVING THE CRANKSHAFT METHOD B

(WITH AUXILARY TOOLS)

Fig. 2.11-9

S Remove all line coupling pieces from both sides of the

crankcase.
Fig. 2.11-7

S By sliding the long tool (not available from Grasso)

over the shaft end on the pump side and the short
tool over the shaft end on the driving side, the

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 3. INSPECTION AND PREASSEMBLY

3. INSPECTION AND PREASSEMBLY

Table of Contents

Section Title Page

3.1 PRESSURE RELIEF VALVE ASSEMBLY 31
3.1.1 Back pressure dependent relief valve 32
3.1.2 Back pressure independent relief valve 32
3.2 LUBRICATING OIL PRESSURE REGULATOR 32
3.3 CONTROL OIL PRESSURE REGULATOR 33
3.4 VALVE-LIFTING CONTROL MECHANISM RC12E 33
3.5 DISCHARGE VALVE ASSEMBLY AND SUCTION VALVE 35
3.5.1 DISCHARGE VALVE ASSEMBLIES 35
3.5.1.1 DIFFERENT TYPE OF DISCHARGE VALVE ASSEMBLIES 35
3.5.1.2 DISMANTLING AND INSPECTION DISCHARGE VALVE ASSEMBLY 36
3.5.1.3 PREASSEMBLING DISCHARGE VALVES 36
3.5.2 SUCTION VALVE 36
3.6 PISTON/CONNECTING ROD 37
3.6.1 General 37
3.6.2 Connecting rod 37
3.6.3 Piston 38
3.6.4 Preassembling the piston/connecting rod 38
3.7 CYLINDER LINER AND VALVE-LIFTING MECHANISM 39
3.7.1 CYLINDER LINER WITH SLEEVES AND VALVE-LIFTING MECHANISM 39
3.7.1.1 General 39
3.7.1.2 Preassembling the valve-lifting mechanism 40
3.7.2 CYLINDER LINER (WITH HOLES, OLD VERSION) AND VALVE-LIFTING MECHANISM 41
3.8 OIL PUMP AND OIL FILTERS 42
3.9 MAIN BEARINGS 45
3.10 ROTARY SHAFT SEAL 47
3.11 CRANKSHAFT 48
3.12 THRUST BEARINGS 49
3.12.1 STANDARD BRONZE THRUST BEARING, MARK 2 49
3.12.2 HEAVY DUTY THRUST BEARING 49
3.13 CRANKCASE 49

3.1 PRESSURE RELIEF VALVE ASSEMBLY

General
A defect or malfunctioning pressure relief valve can and
may not be repaired. In these cases a new relief valve has
to be ordered (safety regulation).
Two different types of relief valves can be applied:
1 Back pressure dependent
2 Back pressure independent

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 3. INSPECTION AND PREASSEMBLY

3.1.1 BACK PRESSURE DEPENDENT RELIEF VALVE 5 Slight wear can be remedied with polishing paper.
6 Reassemble all parts into a whole after
inspection/repair.

3.2 LUBRICATING OIL PRESSURE

REGULATOR

Fig. 3.1-1 Back pressure dependent

REMARK: This type of relief valve can be supplied with

different factory settings. Never change Fig. 3.2-1 Oil pressure regulators
these relief valve(s) from compressor and/or
position. S The lubricating oil pressure regulator (not equipped
with a groove in the hexagon nut) (see Fig. 3.2-1) is
3.1.2 BACK PRESSURE INDEPENDENT RELIEF fitted in the left-hand side of the pump and can be
VALVE taken out with the help of a ring spanner or socket
spanner 41, provided that the oil suction filter has
been removed.

Fig. 3.1-2 Back pressure independent

Fig. 3.2-2
This back pressure dependent pressure relief valve
consists of two major components, the pressure relief Table 3.2-1
valve housing (1) and the pressure assembly (2). With Legend
this pressure relief valve it is permitted to replace only
the pressure assembly (2) without the valve housing (1). 1 Cap
1 The cause of a malfunctioning pressure relief valve is 2 Housing
usually a minor damage in the teflon seal of the
pressure assembly (2). 3 Pressure spring
2 Check the valve seat in the pressure relief valve 4 Ball
housing (1).
3 In order to inspect this, only the four M12 bolts (3) 5 Circlip ring
have to be unscrewed from the pressure relief valve 6 Set bolt
housing to remove the pressure assembly (2).
4 If damage or wear of the teflon ring of the pressure 7 O-ring
assembly (2) is detected, check whether this can be 8 Alu-ring
remedied by polishing.

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 3. INSPECTION AND PREASSEMBLY

S Renew O-ring (7) and Alu-ring(8) 3.4 VALVE-LIFTING CONTROL MECHANISM

All parts forming the regulator do not need wear RC12E
inspection, but it is recommended to clean all
(disassembled) regulator parts, to oil them with
compressor oil and to reassemble.

The pressure can be adjusted with a screwdriver only

during operation.

3.3 CONTROL OIL PRESSURE REGULATOR

Fig. 3.4-1

A) Parts of the valve-lifting housing

S Remove the cover (1) from the housing (6) and
remove the control piston (3) from the housing.
 Remove pressure spring (5) with O-ring (4) and
clean the piston.
Fig. 3.3-1 Oil pressure regulators  Clean the control piston bore in the valve-lifting
housing and check this for wear or slight damage
(which may be remedied with polishing paper)
and replace the housing if the bore is over 40.070
mm.
 Check the pressure spring and replace it if the
untensioned length is less than 51 mm.
 Place the pressure spring and the lubricated piston
with a new O-ring (4) into the housing, mount the
cover with a new O-ring (2) and put it a side to be
reassembled later.

Fig. 3.3-2 Control oil pressure regulator

S The control pressure regulator (equipped with a

groove in the hexagon nut, see lower regulator in Fig.
3.3-1) fitted in the right-hand side of the pump can be
taken out with a ring spanner or socket spanner 41,
provided that the oil discharge filter has been
removed.
S Disassemble, inspect and reassemble as described in
relation to the lubrication oil pressure regulator.

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 3. INSPECTION AND PREASSEMBLY

B) Parts valve lifting mechanism

Fig. 3.4-2

S If the lever (1) does not easily fit inside the (firmly
tightened) set screw (2) (on the side of every cylinder
head), slight wear or damage of the lever shaft and
in the bore of the still fitted set screw may be
remedied with polishing paper after dismantling the
disc (3) and lever (1).
 In the case of irreparable damage or wear, both
the set screw and lever have to be replaced.

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 3. INSPECTION AND PREASSEMBLY

3.5 DISCHARGE VALVE ASSEMBLY AND

SUCTION VALVE
3.5.1 DISCHARGE VALVE ASSEMBLIES

3.5.1.1 DIFFERENT TYPE OF DISCHARGE VALVE

ASSEMBLIES
Following different types of discharge valve assemblies
are possible;

Fig. 3.5-1 OPTION 1; E3-2; Discharge valve assembly NH3 (From serial
number 04010001)

Fig. 3.5-3 OPTION 3; M2.2; Discharge valve assembly (Up to serial

number 00081502)

Table 3.5-1 Legend discharge valve assemblies

Legend
1 Valve seat 6 Nut
2 Central bolt 7 Stroke limitor
Damper rings, valve rings and
3 springs 8 Double locking ring

Fig. 3.5-2 OPTION 2; E3-3 Discharge valve assembly for halocarbons,

type E (From serial number 00081502)

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 3. INSPECTION AND PREASSEMBLY

3.5.1.2 DISMANTLING AND INSPECTION DISCHARGE 3.5.1.3 PREASSEMBLING DISCHARGE VALVES

VALVE ASSEMBLY
S Insert an allen key into center bolt (1).
S Remove the M16 nut (6) from the central bolt (1), the
double locking ring (8), the discharge valve stroke
limitor (7), the sets of damper rings, sinusoidal springs
and valve rings (3).
S Thoroughly clean all valve parts and the valve seat
(2).
S Inspect the valve plate (2) for damange, wear or
scoring. Replace the valve plate if one of the seats is
damaged or when the seat is wider than 1.2 mm.If
during this inspection the stroke limitor appears to
have made contact with the piston, the connecting
rod bearings have to be checked as well; the Fig. 3.5-5 Preassembling discharge valves
clearance should then be determined.
S Place each damper ring in their respective grooves of
S Inspect the PEEK valve and damper rings for the discharge valve stroke limitor, then the sinusoidal
discoloured, cracks or other signs of damage. Always springs (with the convex side facing the stroke
replace the rings when they are close to the limitor) and finally the discharge valve rings into the
maximum allowed running hours. stroke limitor.
S Inspect the discharge valve stroke limitor (7) and the S Place the combined valve plate (2) over the stroke
valve ring guide cams on the bottom side of the limitor.
stroke limitor for wear.
S If necessary, adjust the clamped valve rings and valve
In case of wear (shifting of valve rings and valve springs with a screwdriver until all cams of the stroke
springs) or damage due to another cause, the
discharge valve stroke limitor has to be renewed. limitor touch the valve seat.
S Fit the (M16) central bolt with a nut and a new
double locking ring.
S Tighten this bolt/nut joint to the torque as
given(Section 5.1).

Fig. 3.5-4 Discharge valve, sinoidal spring

To check leakage of the discharge valves, a leak test after
S Replace the discharge valve sinusoidal springs when 4 running hours of the compressor is strongly
they are damaged/discoloured and when the recommended. (Refer Section 4.14)
untensioned height 'h' is less than as given ( Table
3.5-2) 3.5.2 SUCTION VALVE
Table 3.5-2 Minimum untensioned heights

Sinusoidal spring
DISCHARGE VALVE ASSY h min
diameter
(mm)a
1 smallest 5.5
NH3
E3-2 largest 8.5
2 smallest 2.8
Halocarbons
from serial medium 5.5 Fig. 3.5-6 Suction valve, sinoidal spring
no. 00081502
E3-3 largest 8.5 S Replace the suction valve sinusoidal springs when
smallest 2.5 they are damaged or discoloured and when the
3
Up to serial untensioned height 'h' is less than 9.6 mm.
medium 3.5
no. 00081502
M2.2 S Inspect the cylinder liner for wear of the seats.
largest 5.5
Replace the cylinder liner if one of the seats is
a. Refer Fig. 3.5-4 damaged or when the seat is wider than 2.2 mm.

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 3. INSPECTION AND PREASSEMBLY

3.6 PISTON/CONNECTING ROD 3.6.2 CONNECTING ROD

3.6.1 GENERAL

Fig. 3.6-3

S Assemble the bearing shells and the connecting rod

cap into a whole.
 Tighten the nuts on the connecting rod bolts to
Fig. 3.6-1 the torque given(Section 5.1).
 Measure the bore of the clamped bearing with an
S Place the assembly upside down on the working
inside micrometer and replace if it is larger as the
bench and remove one circlip ring from the gudgeon
value given(Table 5.2-1).
pin bore.
 Check the bearing bush (for the LP cylinders) in
the small end of the connecting rod for wear or
damage.
 With an inside micrometer measure the bore of
the still fitted bearing bush and replace if it is
larger as the value given(Table 5.2-1).
 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
80 °C.
 Check the condition of the double-row needle
bearing (for the HP cylinders) and replace if
necessary.
 Insert the needle bearing as described for the
Fig. 3.6-2 bearing bush.
S Heat the piston to approximately 80 °C
S NEVER HEAT WITH OPEN FLAME! Pouring a little
spirit into the piston and lighting it works just as well.
 Push the gudgeon pin out of the piston.
 Check the (cooled) gudgeon pin for wear and
measure the outer diameter using an outside
micrometer and replace the pin if the diameter is
smaller than the value given(Table 5.2-1).

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 3. INSPECTION AND PREASSEMBLY

3.6.3 PISTON

Fig. 3.6-6
Fig. 3.6-4
S Check the gap in each piston ring by placing it in an
S Remove the two piston rings and oil scraper ring unworn part of the cylinder liner. These unworn parts
using the appropriate piston ring pliers. can be found at about 10 mm from the bottom of the
 Check the piston grooves for burrs, notch effects cylinder liner. The maximum gap may not exceed 2.1
and cracked or broken grooved edges. mm.

3.6.4 PREASSEMBLING THE PISTON/CONNECTING

ROD

Never use new piston rings in combination with a worn

out cylinder liner.

Fig. 3.6-5

S Roll each piston ring and oil scraper ring in the

corresponding groove around the piston to trace
parts that have become wedged. This can be
remedied, for example, by using a smooth file.
 Also check the rest of the piston for wear or
damage.

Fig. 3.6-7 Pistion

Legend
T Top
CHR Chromium-plated
S If the piston rings and oil scraper ring are no longer
on the piston, fit them in the sequence as shown.
Never mix old and new rings together. When placing
the rings, pay attention to the word 'TOP' on each
ring.

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 3. INSPECTION AND PREASSEMBLY

 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.

Fig. 3.6-8

S Clean the connecting rod and blow out the oil

passageway in the connecting rod.
 When replacing the bearing bushes or needle
bearings, heat the small end of the connecting rod
to approximately 80 °C. Fig. 3.6-10
 Insert the bearing bush (for LP cylinders) or
S Lock the gudgeon pin with the other circlip ring.
respectively the needle bearing, distance ring and
needle bearing (for HP cylinders) into the small
end of the connecting rod. 3.7 CYLINDER LINER AND VALVE-LIFTING
 Check whether the needle bearings project MECHANISM
equally on both connecting rod ends.
 Let the connecting rod cool off in ambient air. General
 Fit the bearing shells in both connecting rod parts. Compressors older than approx. August 2003 can be
Due to the raised fixing cams only one building-in applied with cylinder liners having suction HOLES. These
position is possible. cylinder liners can be re-newed for cylinder liners having
suction SLEEVES, however in combination with the
proper suction and discharge valves(Consult Grasso). The
latest version of cylinder liners are those with suction
sleeves, however the re-assembling procedure is
described below for both types.

3.7.1 CYLINDER LINER WITH SLEEVES AND

VALVE-LIFTING MECHANISM

3.7.1.1 GENERAL

Fig. 3.6-9

S Heat the piston to approximately 80 °C, DEFINITELY

NOT IN OPEN FIRE!
S Pouring a little spirit into the piston and lighting it
works just as well.
 Degrease the gudgeon pin and oil it.
 Check that the gudgeon pin fits properly into the
connecting rod.

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 39-
 3. INSPECTION AND PREASSEMBLY

 Also check the cam ring on the inside.

 After truing up the inner and/or outer surfaces,
check that the cam ring moves smoothly around
the cylinder liner.

3.7.1.2 PREASSEMBLING THE VALVE-LIFTING

MECHANISM

Fig. 3.7-1 Cam ring

S Place the cylinder liner upside down on the working

bench, remove the 2 hexagon bolts (2) from the cam
ring (1). Now the cam ring can be removed from the
cylinder liner.

Fig. 3.7-3

S Before starting, oil all parts with compressor

lubricating oil.
 Place the cylinder liner with the collar on the
working bench.
 Mount the 8 push pins (sphere side must face to
the cam ring!) (1) through the holes of the lowest
guide ring (2) of the cylinder liner, fit the washers
Fig. 3.7-2
(3) and springs (4) and subsequently insert the
S If necessary, remove the locking rings (1) of the 8 push pins through the holes of the upper guide
push pins (2) and the washers (3) and springs( 4) ring (5)and the holes of the cylinder liner collar.
S Clean all parts  Place the locking rings (6) on the push pins so the
 Check the suction valve ring seat in the cylinder washer will be between the spring and locking
liner collar for damage or locally worn honing ring.
tracks.  Build the cam ring with the cams facing the
 It is not necessary to check the cylinder liner suction sleeves onto the cylinder liner(refer Fig.
diameter if the honing tracks in the cylinder liner 3.7-1). Mount 2 hexagon bolts with the spacers
bore are still intact. Irregularities can be carefully into the cam ring.
eliminated with abrasive paper.  Check the cam ring manually for proper
 Check the outer surface of the cylinder liner for operating.
damage and eliminate slight damages with
abrasive paper.

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 3. INSPECTION AND PREASSEMBLY

3.7.2 CYLINDER LINER (WITH HOLES, OLD

VERSION) AND VALVE-LIFTING MECHANISM

A) General

Fig. 3.7-6

S Clean all parts

 Check the suction valve ring seat in the cylinder
liner collar for damage or locally worn honing
Fig. 3.7-4 tracks.
 It is not necessary to check the cylinder liner
S Place the cylinder liner upside down on the working
diameter if the honing tracks in the cylinder liner
bench, remove the locking spring (1) and
bore are still intact. Irregularities can be carefully
subsequently slide the cam ring (2) from the cylinder
eliminated with abrasive paper.
liner.
 Check the outer surface of the cylinder liner for
damage and eliminate slight damages with
abrasive paper.
 Also check the cam ring on the inside.
 After truing up the inner and/or outer surfaces,
check that the cam ring moves smoothly around
the cylinder liner.

B) Preassembling the valve-lifting mechanism

Fig. 3.7-5

S If necessary, remove the locking rings (1) of the 8

push pins (2) and the washers (3) and springs (4).

Fig. 3.7-7

S Before starting, oil all parts with compressor

lubricating oil.
 Place the cylinder liner with the collar on the
working bench.

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 3. INSPECTION AND PREASSEMBLY

 Mount the 8 push pins (1) through the holes of 3.8 OIL PUMP AND OIL FILTERS
the lowest guide ring (2) of the cylinder liner, fit
the washers (3) and springs (4) and subsequently A) General
insert the push pins through the holes of the
upper guide ring (5) and the holes of the cylinder
liner collar.
 Place the locking rings (6) on the push pins so the
washer will be between the spring and locking
ring.
 Slide the cam ring with the cams facing
downwards onto the cylinder liner.

Fig. 3.8-1

S Place the pump on the working bench and unscrew

the eight M6 fixing bolts (1) in the pump cover out of
the housing and remove the washers (2) and the
pump cover (3) with the integrated pump element.
Fig. 3.7-8
 Remove the O-ring (4).
S Insert the locking spring in the groove of the cylinder
liner. During mounting align the gap in the locking
spring with the guide pin of the cam ring then rotate
the spring aprox. 1/4 turn around the liner.
 Check that the push pins drop just beneath the
suction valve ring when resting on the lower part
of the cam ring.

Fig. 3.8-2

S Remove the pump gear (5) from the crown wheel (6)
of the pump element/bearing assembly.
S Remove all plugs with alu-washers from the pump
housing as well as the O-rings which seal the internal
oil passageways.
 Clean the packing face of the pump housing and
the pump cover and if still present: Remove the
lubricating oil and control pressure regulators.
 Clean the pump housing with a non-fibrous cloth
and the internal oil passageways of the pump
housing with compressed air.

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 3. INSPECTION AND PREASSEMBLY

 Renew the pump element/bearing assembly in C) Inserting a new pump element

case of irreparable damage or malfunctioning of
the oil pump.

B) Removing the pump element/bearing assembly

Fig. 3.8-3

S Place the pump housing with the pump cover fixing

face in central position and pointing downwards
under a press (take precautionary measures that the Fig. 3.8-4
fixing pin, indicated with arrow! does not break). S Ensure that the bore and the contact face in the
 Place an auxiliary bush (B) with an outer diameter pump housing are clean and oiled.
øD < 60mm and an inner bore ød > 45 mm over S Place the pump housing with the bearing cover fixing
the crown wheel shaft. In this position the pump face in central position and pointing downwards,
element/bearing assembly can easlily be pressed using the pump cover(3)(!), under a press.
out with a hydraulic press. S Position the pump element/bearing assembly with
S Clean all pump parts and remove possible sharp the oil passageway (= notched groove in the running
edges and/or burrs. surface) at 12.00 h (visible via the small bores inside
 Check the carrier lug for wear. crown wheel surface.
 Check the teeth of both pump elements for S Carefully press the pump element into the housing
broken or worn teeth. with the cover until the contact face has been clearly
 Replace the entire pump element if at least one of reached.
the pump elements shows irreparable wear.
 Minor damage may be eliminated.

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 3. INSPECTION AND PREASSEMBLY

Check that pump element can be rotated by hand! The shorter control pressure regulator has a groove on
the hexagon nut. The longer lubricating oil pressure
regulator does not have a groove.

Fig. 3.8-5 Carrier disc

 Remove the carrier disc from the crankshaft

journal and check the condition of the slot and the
holes of the carrier disc.

D) Reassembling the oil pump

Fig. 3.8-7 Pump detail

S Slide the pump gear (5) onto the shaft (7) of the
pump cover (3).
Fig. 3.8-6
 Place the pump housing on its side and insert the
S Lightly oil all parts mentioned below before preassembled pump cover element provided with
reassembly! a new O-ring in such a way that the fixing pin (P)
 Insert into the housing: new O-rings in the internal fits into the corresponding hole.
oil passageways, the plugs provided with new S Tighten the eight M6 bolts (8) provided with washers
alu-washers, the lubricating oil pressure regulator (9) in the pump housing to the torque given in table
(1) in the left-hand part of the housing and the “Survey of torques for bolts and nuts“(Chapter 5).
control pressure regulator (2) in the right-hand  Check that the pump rotates smoothly; if this is
part of the housing. not the case, the pump element is not pressed far
enough inside the oil pump housing.
 Place the preassembled pump in a separate clean
area to be mounted onto the bearing cover later.

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 3. INSPECTION AND PREASSEMBLY

E) Filter elements

Filter elements can also be replaced when the filter

housings are still mounted to the compressor.

Use special tool to remove oil filters (refer )Section 2.8

S In order to reach the oil suction filter or oil discharge
filter element, only the lower housing half has to be
removed by supporting the housing and unscrewing
the grooved nut.

Fig. 3.8-9

Remove the O-rings (2 and 4) and the seal (3).

 Clean both filter housings (1 and 5) and the
internal (connecting) passageways.
 Insert each filter in the corresponding filter
Fig. 3.8-8 Oil suction and oil discharge filter housing and reassemble them with a new set of
seals1, a washer (3) and new O-rings (2 and 4).
 Pay attention to the residual oil in this filter
bottom
 For a total inspection both the upper filter In order to avoid damaging the seals, the filter housing
housings can be removed from the pump housing (5) should not revolve together with the grooved nut
by unscrewing both M10 bolts. (6).
 Remove the filters as described (Section 2.8) REMARK: After having dis-assembled the discharge
 Whilst the the oil suction filter element is filter element, check this for contamination,
cleanable, it shoul be replaced in case of damage in particular for the presence of aluminium
or serious pollution. and/or white metal slide-bearing particles
which would require further investigation in
 The red 'running-in' oil discharge filter element is other parts of the compressor. In this case,
to be replaced by a grey one after 100 running regularly check the oil quality by means of an
hours. oil analysis.
 Renew a polluted grey-marked oil discharge filter
element. 3.9 MAIN BEARINGS

A) General

1. Only available as set under Ref. No. 09.90.030.

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 3. INSPECTION AND PREASSEMBLY

bush out of the bearing cover.

 Draw, for instance with a felt pen, a longitudinally
line and over the full length on the outside of the
new bearing bush above the centre of the oil
chamber.

Fig. 3.9-1 41

S Check both main bearing bushes, while they are in

their respective bearing covers, for worn out white
metal inner lining. Fig. 3.9-3 43
 Replace the bush(es) if the inner lining shows
S Oil the bearing bush and place it with the internal
abnormal wear and also if the bore is over 90.16
chamfer facing upward and above the bore in the
mm.
bearing cover in such a way that the oil passageway
 Especially check those crankshaft parts rotating in
is in the centre of the locking pin.
the bearing covers. Eliminate slight damage using
 Slowly press the bearing bush (using a hydraulic
fine polishing paper.
press) into the bearing cover, making sure that
 Check the thrust face (see arrow 'A') on the collar
the bearing bush is not displaced.
of the bearing bush on oil pump side for wear and
replace it if one of the oil grooves has virtually Bearing cover on pump side;
disappeared.

B) Preassembling the bearing covers

Bearing cover on driving side:

Fig. 3.9-4 44

When the bearing bush requires replacement, proceed

as follows:
S Push or press (using a hydraulic press) the old bearing
bush out of the bearing cover.
Fig. 3.9-2 42

S When replacing a bearing bush, proceed as follows:

S Push or press (using a hydraulic press) the old bearing

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 3. INSPECTION AND PREASSEMBLY

 Draw a longitudinal line, for instance with a felt 3.10 ROTARY SHAFT SEAL
pen, on the outside of the new bearing bush from
the centre of recess 'A' (to the left of oil chamber
'B') as far as the collarless end. Avoid touching the carbon part! Preferably rub your
hands with oil or wear gloves.

Fig. 3.9-5 Bearing cover with mounted splash guard

S Oil the bearing bush and position it above the bore in

the bearing cover, so that the line drawn with the Fig. 3.10-1
(felt) pen is in the centre of the locking pin. S Remove the O-ring (3a) from the counter slip ring (3)
 Slowly press the bearing bush (using a hydraulic and the O-ring (2a) in the rotating ring (2).
press) into the bearing cover, making sure that  Check the sliding surfaces of the counter slip ring
the drawn line is not displaced, in order for the (3) and the rotating ring (2) for wear or damage.
locking pin on the left-hand side (projecting 3 mm
 Clean the housing (1) and all other parts.
above the bearing cover) to be pressed entirely
 When one of the sliding surfaces is affected,
into recess 'A'.
replacement of both parts is required.
 Renew all O-rings (1a, 2a and 3a).

Fig. 3.9-6 46

S Inspect the intermediate bearing(s) for visual wear

and for possible scoring of the white metal inner
Fig. 3.10-2
lining and collar bearings.
 Assemble the intermediate bearing(s) with the S Renew the entire shaft seal in the case of damage or
stamped-in numbers on one side and tighten the wear of the slip ring.
intermediate bearing bolts.
 Measure the inside diameter and replace it when
it is over 90.14 mm.

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 47-
 3. INSPECTION AND PREASSEMBLY

3.11 CRANKSHAFT

A) General

Fig. 3.11-3 51

S Check the diameters of the shaft journals and shaft

ends with an outside micrometer in at least 2
directions and dead square to the measuring surface.
 Here measure 'A' should be at least 89.933 mm
Fig. 3.11-1 49 and measure 'B' 89.945 mm.
 Should these measurements show that the shaft
S Only with 2 cylinder compressors, remove the spacer
diameter(s) is (are) beyond the tolerance limits
(compensating mass) from the crankshaft and
and there is any doubt about the serviceability of
reassemble both halves into a whole, separately from
this crankshaft, then the shaft should be replaced.
the crankshaft.
B) Preassembling the crankshaft

Fig. 3.11-2 50

S Thoroughly clean the entire crankshaft:

 Check whether the axially fitted oil passageways Fig. 3.11-4 52
in the crankshaft are unobstructed by cleaning S In the case of 4, 6, 9 and 12 cylinder compressors,
them with compressed air or a brush. place the shells of the intermediate bearings into the
 In order to be sure that the passage of lubricating bearing block(s).
oil within the crankshaft is unobstructed, unscrew
 Oil both bearing shells well and fit the
the socket head screws (locked with centre
intermediate bearing(s) on the crankshaft
punches) out of the crankshaft webs.
(intermediate bearing halves with stamped-in
 Remove the dirt accumulated in the oil numbers on one side).
passageway (in the case of damage to bearings
 Tighten the four M16 bolts to the torque
white metal particles) with a 6 mm bar.
given.(refer Chapter 5)
 Brush and blow out the crankshaft again until all
 Check that the intermediate bearing(s) freely
oil passageways are unobstructed.
revolve(s) around the crankshaft.
 After cleaning, reassemble all oil passageway
sealing bolts (socket head screws) and lock them
with centre punches.

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 3. INSPECTION AND PREASSEMBLY

3.12.2 HEAVY DUTY THRUST BEARING

Fig. 3.12-2 Heavy duty thrust bearing

Fig. 3.11-5 53 S Clean all thrust bearing parts. Check all running
surfaces which are in contact with the cylindrical
S In the case of a 2 cylinder compressor, fit the spacer
roller thrust bearing and the needle thrust bearing
onto the crank web on the driving side using two M8
for (ir)regular wear and other damage such as pits,
bolt/nut joints and tighten these to the torque as
marks or scratches.
given.(refer Chapter 5)
 Replace the complete heavy duty thrust bearing
set when the rollers, needles or running surfaces
3.12 THRUST BEARINGS show signs of wear.
Besides a standard mounted thrust bearing, a heavy duty
thrust bearing can be mounted (optional)
3.13 CRANKCASE
3.12.1 STANDARD BRONZE THRUST BEARING,
MARK 2

Refer Section 2.10

Fig. 3.13-1
Fig. 3.12-1 Standard bronze thrust bearing; refer also Fig. 2.10-2
S Thoroughly clean the crankcase interior and dry it
S Clean the thrust bearing and check the lapped with a non-fibrous cloth.
running surface on the bronze side for (ir)regularly  Inspect all exterior packing faces and remove
worn oil grooves and for material deposits. possible residual packing particles.
 Replace this thrust ring if it shows signs of wear  Thoroughly blow through all connections on the
and when the thickness is less than 5.50mm. inside and on the outside.
 Clean the sight glass.

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 3. INSPECTION AND PREASSEMBLY

 Do not forget to remove the packing remains

from the flanges of the main connections of the
compressor!

Fig. 3.13-2

S Remove the oil return plug from the lowest landing

of the cylinder jackets for the LP cylinders {see left
plug in Fig.}
 Inspect the return plugs, clean them and tighten
them after refitting.
 The plug for the HP cylinders {see right plug in
fig.} does not need inspection and can therefore
remain fitted.

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 4. REASSEMBLING

4. REASSEMBLING

Table of Contents

Section Title Page

4.1 CRANKSHAFT, MAIN BEARINGS AND INTERMEDIATE BEARING 52
4.1.1 Bearing cover driving side 52
4.1.2 Assembly procedure of 2 and 3 cylinder compressors 52
4.1.3 ASSEMBLY PROCEDURE 4, 6, 9 AND 12 CYLINDER COMPRESSORS 52
4.1.4 Pump side 52
4.1.5 Bearing cover oil pump side (with two lugs): 53
4.1.6 Standard thrust bearing 53
4.1.7 Heavy duty thrust bearing 54
4.1.8 Measuring the axial crankshaft play 55
4.1.9 Procedure for 4, 6, 9 and 12 cylinder compressors 55
4.1.10 Assembling counter weights 56
4.2 OIL PUMP 56

4.3 OIL SUCTION FILTER, OIL DISCHARGE FILTER, LUBRICATING OIL PRESSURE REGULATOR AND CONTROL OIL PRESSURE 57
REGULATOR
4.3.1 Oil discharge filter 57
4.3.2 Oil suction filter 57
4.3.3 Lubricating oil pressure regulator (without groove) 57
4.3.4 Control oil pressure regulator (with groove) 57
4.4 VALVE-LIFTING CONTROL MECHANISM 57
4.5 CYLINDER LINER 59
4.5.1 CYLINDER LINER (LATEST VERSION, WITH SLOTS) 59
4.5.2 CYLINDER LINER (OLD VERSION, WITH HOLES) 61
4.6 PISTON/CONNECTING ROD ASSEMBLY 62
4.7 DETERMINING THE PISTON CLEARANCE 63
4.8 SUCTION/DISCHARGE VALVE ASSEMBLY 63
4.9 ROTARY (SLIP RING) SHAFT SEAL 65
4.10 SUCTION GAS FILTER 66
4.11 PRESSURE RELIEF VALVE ASSEMBLY 67
4.12 OIL FILLING 67
4.13 MOUNTING FLYWHEEL 68
4.14 DISCHARGE VALVES, LEAKAGE TEST PROCEDURE 69

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 4. REASSEMBLING

4.1 CRANKSHAFT, MAIN BEARINGS AND 4.1.3 ASSEMBLY PROCEDURE 4, 6, 9 AND 12

INTERMEDIATE BEARING CYLINDER COMPRESSORS

4.1.1 BEARING COVER DRIVING SIDE

Fig. 4.1-3

S With assistance and using auxiliary tools, insert the

Fig. 4.1-1
crankshaft (with/without counterweights1) through
S Place a new O-ring on the inner side of the bearing the crankcase opening on the pump side into the
cover. crankcase. The crankshaft now rests on the
intermediate bearing block(s).
 Remove the auxiliary tools, clean the shaft
journals and oil them.

4.1.4 PUMP SIDE

Fig. 4.1-2

S Place the bearing cover on the driving side in such a

way that the hole in the lug of the bearing cover is
opposite the internal oil passageway pipe.
 Then slide the bearing cover over the crankcase Fig. 4.1-4
studs. S Place a new O-ring on the pipe of the internal oil
 Screw all M16 nuts provided with washers on the passageway.
studs and tighten them alternately and crosswise
to the torque given in (Chapter 5).

4.1.2 ASSEMBLY PROCEDURE OF 2 AND 3

CYLINDER COMPRESSORS
S Insert the crankshaft (with/without counterweights)
through the crankcase opening on the oil pump side
into the bearing cover.
1. For mounting the counter weights see further on in this chapter "Assembling
counter weights".

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 4. REASSEMBLING

Fig. 4.1-7
Fig. 4.1-5
S Screw all M16 nuts provided with washers on the
4.1.5 BEARING COVER OIL PUMP SIDE (WITH TWO studs.
LUGS):
S Finally tighten the nuts alternately and crosswise to
S Place a new O-ring on the inner side of the bearing the torque given(Chapter 5).
cover.
 Check that the crankshaft rotates freely.
 Place a new O-ring on both pipes of the internal
oil passageway Fig. 4.1-4. 4.1.6 STANDARD THRUST BEARING

Fig. 4.1-6

S Place the cover in such a way that the holes in each

Fig. 4.1-8 Standard thrust bearing; refer also Fig. 2.10-2
lug of the bearing cover are opposite the pipes of the
internal oil passageways and slide the bearing cover S Fit the oiled thrust ring with the oil grooves directing
over the crankcase studs. outwards on the crankshaft on oil pump side in such
a way that the locking pin in the bearing cover fits
into the hole in this thrust ring surface.

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 53-
 4. REASSEMBLING

Pos. 1, 2, 4, 5, 6 and 7 can be mounted together in any

crankshaft angle
S Fit the oiled 1 mm. thick thrust washer (7) on the
crankshaft on oil pump side.
 The thrust washer (7) can be used on both sides.
S Fit the oiled cylindrical roller thrust bearing (6) on the
crankshaft on oil pump side.
 The cylindrical roller thrust bearing (6) can be used
on both sides.
S Fit the oiled shaft washer (5) on the crankshaft on oil
pump side. The shaft washer if recessed to fit exactly
around the crankshaft.
S Fit the oiled hold down disc (4) into the shaft washer
(5), using the four M10 socket head screws (3) with
Fig. 4.1-9
the torque given(Chapter 5).
S Check that the crankshaft boss is still clean and oiled.  Check that the crankshaft rotates freely.
 Fit the hold down disc onto the crankshaft boss, S Fit the oiled needle thrust bearing (2) on the hold
using the four M10 socket head screws with the down disc (4).
torque given(Chapter 5).  The needle thrust bearing (2) can be used on both
 Check that the crankshaft rotates freely. sides.
S Mate the oiled 7 mm. thick housing washer (1)
4.1.7 HEAVY DUTY THRUST BEARING
against the needle thrust bearing (2).
The reassembling of the heavy duty thrust bearing is split
into two parts, the heavy duty thrust bearing itsself and  The housing washer (1) must be mated with its
the oil pump. running surface against the needle thrust bearing
(2), it can not be used on both sides.
1st step; Heavy duty thrust bearing
S Check whether all components are clean, including 2nd step; oil pump for heavy duty thrust
the inside of the bearing cover and crankshaft on oil bearing
pump side. S Place the carrier disc (10) on the hold down disk (4).
 The chamber of the slot of the carrier disc (10)
must face the crankshaft.
Check the crankshafts top surface on oil pump side for
having installed the closed M12 plug, without orifice.
Position the slot of the carrier disc (10) in vertical or
horizontal position by rotating the crankshaft
S Place 2 new O-rings around the oil inlet- and outlet
holes at the bearing cover (11).
S Check that the oil pump is clean.
S Place the oiled spring retainer (8) in the pump
housing counter bore.
 The opening of the holes should be pointed to the
outside of the oil pump housing.
S Insert the oiled springs (9) in the holes of the spring
retainer (8).
S Place a new O-ring on the inner side of the fully
pre-assembled oil pump.
S Slide the oil pump over the studs of the bearing
Fig. 4.1-10 Heavy duty thrust bearing
cover.
S Position the carrier lug of the pump element with the
slot in the carrier disc.

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 4. REASSEMBLING

 Pay at all times attention not to dislodge the 4.1.9 PROCEDURE FOR 4, 6, 9 AND 12 CYLINDER
springs (9) or the spring retainer (8). COMPRESSORS
S Push the oil pump as far as possible towards the
bearing cover and screw the M12 nuts with washers
on the studs.
 The oil pump cannot be pushed fully against the
bearing cover, because of the springs and will only
seat correctly when the nuts are tightened
 Check all springs to be present and in place.
S Reinstall the external oil line. It is connected from the
top of the oil pump to the service cover.

4.1.8 MEASURING THE AXIAL CRANKSHAFT PLAY

Procedure for 2 and 3 cylinder compressors

Fig. 4.1-12

S Measure the axial play proceeding in the same way as

for the 2 and 3 cylinder compressors.
 Position the intermediate bearing block(s) and fit
handtight the 2 sets of toothed spring washers
and the M20 bolts in the cross frame.
 Check that the crankshaft rotates freely.
 Subsequently, firmly tighten the bearing block(s)
after the intermediate bearing(s) has(ve) been
adjusted in accordance with the drawing
(measure "=" + 0.5 mm)(Fig. 4.1-12).
Fig. 4.1-11
 Further tighten the intermediate bearing bolts to
S For this measurement a magnet (clock) gauge with the torque given(Chapter 5).
an extended gauge can be set up on the bearing
cover.
 Remove a stud and screw in the M12 eye bolt.
 Screw another eye bolt into the threaded hole on
the crankshaft.
 Pull out the crankshaft and set the gauge on 0.00
(zero).
 Push the crankshaft inwards and check/write
down the axial play on the gauge.
For every compressor the play is determined between
0.05 and 0.85 mm.
Contact the service department of Grasso if the axial
play is not within the tolerance limits.

Fig. 4.1-13

S If there is no clock gauge available, the axial play in

situ of the collar bearing can also be measured with
the help of feeler gauges. Here again the axial play is
measured by the difference between the pulled out
and pushed in crankshaft (see also measuring
procedure with clock gauge).

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 4. REASSEMBLING

4.1.10 ASSEMBLING COUNTER WEIGHTS

The chamber of the slot of the carrier disc must face the
crankshaft.

Position the slot of the carrier disc in vertical or

horizontal position by rotating the crankshaft.
S Place a new O-ring on the inner side of the fully
pre-assembled oil pump.
 Slide the oil pump over the studs of the bearing
cover.

Fig. 4.1-14

S Fit the counterweights with new locking rings and

bolts onto the crankshaft if dismantled.

Pay attention to numbers and marks!

Counterweights are not interchangeble!

S Fit the double locking rings in the proper position!

Fig. 4.2-2
S Tighten the bolts with a torque wrench to the torque
given(Chapter 5).  Position the carrier lug of the pump element with
the slot in the carrier disc.
 Push the oil pump fully against the bearing cover
4.2 OIL PUMP
and screw the M12 nuts with washers on the
studs.
 Tighten all nuts evenly and crosswise to the torque
given.

Fig. 4.2-1

S Place the carrier disc on the hold down disc.

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 4. REASSEMBLING

4.3 OIL SUCTION FILTER, OIL DISCHARGE

FILTER, LUBRICATING OIL PRESSURE
REGULATOR AND CONTROL OIL
PRESSURE REGULATOR
4.3.1 OIL DISCHARGE FILTER

Fig. 4.3-2

S Install the lubricating oil pressure regulator with a

new aluminium ring on the left-hand side of the
pump.
 Finally fit the cap nut handtight on the regulator
using a new alu-ring.
REMARK: Final adjustment of a reassembled
lubricating oil pressure regulator can be
Fig. 4.3-1
done during compressor operation. This
adjustment procedure is described in the
Installation and Maintenance Manual.

After the first 100 operating hours the red-marked 4.3.4 CONTROL OIL PRESSURE REGULATOR (WITH
discharge filter has to be replaced by a grey-marked filter GROOVE)
element! S Install the control pressure regulator with a new
S Fit the preassembled (red1/grey) marked discharge aluminium ring on the right-hand side of the
filter using the two M10 bolts with washers on the pump.Fig. 4.3-2
right-hand side of the pump.  Finally fit the cap nut handtight on the regulator
 Tighten the bolts to the torque given(Section 5.1). using a new alu-ring.
REMARK: Final adjustment of a re-assembled control
4.3.2 OIL SUCTION FILTER oil pressure regulator can be done during
S Fit the preassembled (marked blue) suction filter compressor operation. This adjustment
using the two M10 bolts with washers on the procedure is described in the Installation and
left-hand side of the pump. Maintenance Manual.
 Tighten the bolts to the torque given(Section 5.1).
4.4 VALVE-LIFTING CONTROL MECHANISM
4.3.3 LUBRICATING OIL PRESSURE REGULATOR Assembling dowel pin in carrier disc
(WITHOUT GROOVE)
If not built in yet;

1. Always fit a new red-marked oil discharge filter element into a modified plant.

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 4. REASSEMBLING

Fig. 4.4-1

S Press the dowel pin (7) perpendicular into the carrier

disc (4).

Fig. 4.4-2

 Pin location in the carrier disc depends on the

position of the valve lifting housing on to the
cylinder wall.
Assembling set screw and lever (in case the
Fig. 4.4-3
set screw has been removed/replaced):
S Screw the set screw (2) in to the threaded bore of the S Prior to mounting the carrier disc the free space
mounting flange and subsequently the nut (3) between cylinder liner and lever must be set to
handtight on the set screw (2). between0,5 -1,5 mm. This is the distance between the
 Place the shaft of the lever (1) into the bore of the lever front side and inner side of the lowest
set screw. supporting ring in the cylinder jacket which can be
adjusted by turning the set screw.
Lever adjustment:  After adjusment screw down the nut (4),
subsequently carrier disc (5) and mount socket
screw (7, screw tight to the torque setting as given
(Section 5.1) with locking ring (6).

Assembling valve-lifting housing:

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Fig. 4.4-4
Fig. 4.5-2 Use compressor oil to oil the O-ring location
S Place O-ring (1) and mount the valve lifting housing
(2) with built-in piston in its original position to the
flange of the cylinder jacket and fit the four
M10-bolts (4) with washers (3).
 Tighten the bolts to the torque given (Section
5.1).
 Connect the control pressure oil line to the
housing.
REMARK: After assembling the valve lifting housing,
the lever is in part load situation.

4.5 CYLINDER LINER

General
Compressors older than approx. August 2003 had
cylinder liners with holes to allow suction gas to pass
through. These liners can be exchanged for the later
execution having slots but only in combination with the Fig. 4.5-3 Fit the O-ring
corresponding suction and discharge valves (consult
Grasso for advice).
The re-assembly procedure for both types is given below.

4.5.1 CYLINDER LINER (LATEST VERSION, WITH

SLOTS)

Fig. 4.5-1 Cylinder housing with hydraulic actuated lever mounted

Fig. 4.5-4 O-ring fitted

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 4. REASSEMBLING

Fig. 4.5-5 Positioning cylinder liner (refer also Fig. 4.5-6)

Table 4.5-1 Legend

Top view cylinder liner

Fig. 4.5-7 Fit the cylinder liner
A, B, C Parallel lines
p valve lifting pin
q location pin, refer to Fig. 4.5-6 Check whether the inserted cylinder liner is positioned
properly by comparing it with the other cylinder liners
LS Long stud that were assembled earlier. Check the valve lifting
action with compressed air. Make sure that the cylinder
liner does not rotate!

Fig. 4.5-6 Positioning cyliner liner (refer also Fig. 4.5-5)

S Fix the cam ring through the slots of the cylinder liner
with location pin of the auxiliary toolkit(refer to Fig.
4.5-5 and Fig. 4.5-6) .
S Position the pressure pins of the cylinder liner in line Fig. 4.5-8 Fit the cylinder liner
with the centre of the long cylinder head studs(refer
to Fig. 4.5-5 and Fig. 4.5-6) S Place the short bar1 on the upper cylinder liner collar
and the long bar over 2 cylinder head studs.
S Insert the cylinder liner carefully as far as possible into
the cylinder jacket. S Fix the long bar with two M16 nuts and place a steel
disc on the threaded hole in the lower bar to protect
The guide pin must locate in the fork of the lever of
the valve lifting mechanism. the threaded hole from damaging.
S Check this by rotating the carrier disc of the valve S Screw the long M24 bolt into the long bar and
lifting mechanism. tighten it turning clockwise until the cylinder liner is
There must be only a very limited play on this fully seated in the inner landing of the cylinder jacket.
mechanism. S Remove the auxiliary tools.

1. Parts of the auxiliary tool kit.

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 A pressure pin (Pos. 2) is now in line with the

guide pin of the cam ring (Pos 3)
S Mark (Pos 1) the second bridge between the suction
gas opening and the pressure pin (Pos 2)
 Insert the cylinder liner push bolt (Pos. 5, part of
the auxiliary tool kit) through hole (Pos. 6; 6th
hole) of the suction gas openings in the cylinder
liner. Ensure that it locates in the corresponding
recess (Pos. 8) in the cam ring (Pos. 7)
REMARK: The cylinder liner push bolt (Pos. 5) has to be
inserted through the 6th suction gas
opening, counted from the mark (Pos. 1)
 Position the marking (Pos 1) in line with the centre
of the long cylinder head stud (Pos. 4, sketch B).

Fig. 4.5-9 Top view, suction valve with slots

4.5.2 CYLINDER LINER (OLD VERSION, WITH

HOLES)
REMARK: Prior to mounting the cylinder liner, first
position the valve lifting-control mechanism.
S Examine the thickness of the gasket which was
originally placed on the lower landing of the cylinder
jacket and under the cylinder liner collar.
 Select a new gasket of the same thickness, being
1, 1.25 or 1.5 mm.
 Check that the gasket face of the cylinder jacket is
still clean and place the greased gasket into the
landing.
 Write down the thickness of the gasket on the
outside of the cylinder jacket. Fig. 4.5-11

 Press the cylinder liner as far as possible into the

cylinder jacket.

Fig. 4.5-10

S To ensure that the guide pin (3) of the cam ring(Pos.

7) locates in the fork of the lever, proceed as follows:
Fig. 4.5-12
 Turn the cam ring (Pos. 7) to part load position
(pressure pins up)

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 Place the short green bar1 on the upper cylinder

liner collar and the long green bar over 2 cylinder
head studs.
 Fix the long bar with two M16 nuts and place a
steel disc on the threaded hole in the lower bar to
protect the threaded hole from damaging.
 Screw the long M24 bolt into the long bar and
tighten it turning clockwise until the cylinder liner
is fully seated in the inner landing of the cylinder
jacket.
 Remove the auxiliary tools.
REMARK: Check that the inserted cylinder liner is
positioned properly by comparing it with the
other cylinder liners that were assembled
earlier. Check the valve lifting action with
compressed air. Make sure that the cylinder
liner does not rotate!
Fig. 4.6-2
4.6 PISTON/CONNECTING ROD ASSEMBLY S Insert the piston/connecting rod assembly into the
cylinder liner.
 Lower it very carefully until the ring compression
bush strikes the cylinder liner and after that slowly
push on until the piston is almost entirely located
inside the cylinder liner.
 Check that the connecting rod properly embraces
the crankshaft journal. If so, push through to the
crankshaft journal and check that the bearing
shell in the connecting rod has not been displaced.

Fig. 4.6-1

S Slide the connecting rod bolts into the big end of the
connecting rod (make sure that the flat side is
positioned correctly!).
 Place the bearing shells into the connecting rod
cap.
 Oil baring shells, piston and piston rings.
Fig. 4.6-3
 Slide the ring compression bush2 with the
chamfered end pointing downwards over the S Slide the corresponding connecting rod cap over the
connecting rod, the piston and the oil scraper ring connecting rod bolts.
and piston rings.  Fit both MF16 nuts with new (double) locking
 Oil and set the relevant crankshaft journal in the rings on the connecting rod bolts and tighten to
uppermost position of the cylinder centre. the torque given.
 Screw the T-handle (from the auxiliary tool kit)
into the threaded hole of the piston.

1. Parts of the auxiliary tool kit.

2. Parts of the auxiliary tool kit.

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 4. REASSEMBLING

 Screw the M24 push bolt into the long bar and
after that revolve the crankshaft two or three
Fit the connecting rod parts with the machine codes on times.
one side.

Determining the piston clearance according to Section

4.7, is required for cylinder liners with holes (old version)
only.

4.7 DETERMINING THE PISTON CLEARANCE

Fig. 4.7-3

S Remove all measuring aids and measure the thickness

of the flattened wire. This thickness, which is equal to
the clearance, should be at least 1.05 mm and at most
1.45 mm. If the measuring result is beyond these
limits, it is necessary to remove the piston/connecting
rod again and replace the sealing ring under the
Fig. 4.7-1 cylinder liner collar by a thicker or thinner one,
according to whether the clearance was too small or
S Place a solid 2 mm thick lead or tin soldering wire
too large.
which has been shaped to fit into the threaded hole
of the piston and laid parallel with the crankshaft or
gudgeon pin. 4.8 SUCTION/DISCHARGE VALVE
ASSEMBLY
S Place the suction valve ring on its seat in the cylinder
liner collar.

Fig. 4.7-2

S Oil the discharge valve assembly and place it on the

cylinder liner.
Fig. 4.8-1 Top view piston
 Place the bar from the auxiliary tool kit on the
studs as well as on the discharge valve centre. S Place the sinusoidal springs with the convex side
 Screw two M16 nuts on the studs . pointing upwards on the suction valve ring.
REMARK: During the assembly the sinusoidal springs in

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inclined cylinders can fall out of the cylinder

liner. 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. 4.8-4 Top view of discharge valve assy (new version)

Fig. 4.8-2 Top view of discharge valve assy (new version)

Fig. 4.8-5 Top view of discharge valve assy (old version)

S For old version only; Place the oiled pressure spring

cup on the discharge valve assembly.

Fig. 4.8-3 Top view of discharge valve assy (old version)

S Place the preassembled discharge valve assembly on

the sinusoidal springs of the suction valve.
 Clean the sealing edge of the cylinder head cover
and also the edge on the cylinder head itself.
 Rub both packing faces and the studs with grease.

Fig. 4.8-6 Top view buffer spring (old version)

S For old version only; Subsequently, fit the buffer

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 4. REASSEMBLING

spring which has to be prevented from tipping by a 4.9 ROTARY (SLIP RING) SHAFT SEAL
steel strip placed against the two studs.
S Insert a new gasket into the cylinder cover groove
and slide the cylinder head cover over the studs on
the buffer spring.

Fig. 4.9-1 40

S In the case of new parts, check that the protective foil

has been removed.
 Avoid touching the contact faces of these parts;
slightly rub your hands with oil or wear gloves.
Fig. 4.8-7 Top view cylinder cover  Especially inspect the crankshaft part where the
 Remove the strip. O-ring moves.
 Screw two M16 nuts on the two long and oiled  Remove all (rubber) deposit by sanding or
studs. polishing.
 Oil all parts with compressor lubricating oil, as well
as the crankshaft part in situ of the shaft seal.
 Slide the slip ring part over the crankshaft and
push through until the rear side is positioned
against the crankshaft boss.

Fig. 4.8-8 Top view cylinder cover

 Tighten these two nuts alternately to the torque

given(Section 5.1).
 After that, fit the other nuts in the same way.
Fig. 4.9-2 41

S Lock the slip ring on the crankshaft by tightening the

three grub screws with an allen key1. (Torque refer
Section 5.1)

1. Part of the auxiliary tool kit.

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Fig. 4.9-3 42
S Check that the crankcase is clean and dry and,
S Insert the counter slip ring with the O-ring into the
subsequently, fit all crankcase covers with new
shaft seal housing.
O-rings.
 Place a new O-ring into the groove of the cleaned
shaft seal housing.
 Mount the shaft seal housing (only one mounting
4.10 SUCTION GAS FILTER
position is possible) onto the crankcase.

Fig. 4.10-1
Fig. 4.9-4 43 S Place a new gasket into the groove of the suction gas
S Place the M12 nuts and tighten them alternately filter cover.
crosswise to the torque given.  Slide the preassembled cover of the suction gas
 Screw the nipple coupling for the oil leakage drain filter assembly into the housing in such a way that
line into the bottom of the shaft seal housing and the centring profile around the filter fits into the
then the drain line. fixed centring edge.
S Screw the eight bolts into the housing and tighten
them to the torque given(Section 5.1).

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4.11 PRESSURE RELIEF VALVE ASSEMBLY

Fig. 4.12-1 Shaft seal housing

Fig. 4.11-1 Relief valves

Legend
1 Back pressure dependent
2 Back pressure independent

Refer to the valve position table (Section 5.7) for the

location of pressure relief valves.
S Place a new O-ring in (each) pressure relief valve
housing.
 Put the pressure relief valve housing into the
proper mounting position (only one mounting
position is possible!) against the cylinder jacket.
 Screw the six M12 bolts into the cylinder jacket Fig. 4.12-2 Oil filters and location oil charge valve (A); not shown!
and tighten them evenly and crosswise to the
torque given(Section 5.1). Oil discharge filter:
Remove all oil filling plugs and fill the corresponding
components with the amount of oil given(Table
4.12 OIL FILLING 4.12-1).
 Fit the oil filling plugs with new aluminium rings.
 Fit the other nipples and couplings and tap the
Use clean or fresh original oil only! key into the crankshaft key way.
S The following components have to be filled with oil
before starting up via the oil charge valve, mounted Table 4.12-1 Quantity of oil
on the oil pump, refer Fig. 4.12-2: QUANTITY OF OIL TO BE FILLED (IN dm3)
 Crankcase Shaft seal
 Shaft seal housing(Fig. 4.12-1) Number of housing incl. Oil Oil
cylinders internal circuit of filters pump Crankcase
 Oil pump crankshaft
 Oil discharge filter 2
 Oil lubrication circuit 0.63 7.8
3
S Oil suction filter(Fig. 4.12-2 ,left filter): Charge 4 0.72 13.6
1.5
through the filling openings or prelubricating valves each
0.5
6 0.73 14.7
(if present) on the top of the filter housing.
9 0.83 21.7
12 0.93 28.7

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4.13 MOUNTING FLYWHEEL

Fig. 4.13-3
Fig. 4.13-1
S Screw three (3) M12-bolts fully into the flywheel hub.
S Place the flywheel on the crankshaft using a
suspension gear with sling.

Fig. 4.13-4

S Tighten the central M24-bolt with a torque wrench to

the torque given(Section 5.1).
Fig. 4.13-2

S Place the locking disc and screw the centre bolt as far
as possible into the crankshaft.

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 4. REASSEMBLING

Fig. 4.13-5

S Lock the central bolt with locking plate, together

with the fourth M12 bolt.

4.14 DISCHARGE VALVES, LEAKAGE TEST

PROCEDURE
A leak test after 4 running hours of the compressor is
strongly recommended;
S Stop compressor
S Immediately close the discharge stop valve and
record the discharge pressure (must be at least 6 bar)
S Measure the time it take for the discharge pressure to
fall to 3 bar. (decrease from 6 to 3 bar)

If equalizing time is less than 60 seconds, all the

discharge valves have to be checked.

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5. MISCELLANEOUS

Table of Contents

Section Title Page

5.1 SURVEY OF TORQUES FOR BOLTS AND NUTS 71
5.2 WEAR LIMITS AND TOLERANCES 73
5.3 REQUIRED SERVICE TOOLS AND MATERIALS 75
5.4 GRASSO SPECIAL TOOLS AND AIDS GRASSO 12E 75
5.5 FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING 77
5.6 MASS OF SEPARATE COMPONENTS AND COMPRESSORS 77
5.7 RELIEF VALVE POSITIONS 77

5.1 SURVEY OF TORQUES FOR BOLTS AND

NUTS
Table 5.1-1

Item Threaded connection Thread size Torque in Remarks

N.m.a
1 Bearing cover nuts (both sides) M16 120
2 Coupling bearing cover on pump side G1/4” tightened
3 Shaft seal housing nuts M12 40
4.1 Oil pump housing bolts M12 40
4.2 Pump element bolts M6 7
5 Connecting rod bolts MF16x1.5 100
6 Gudgeon pin locking bolt M12 40
7 Valve-lifting housing bolts M10 35
8 Coupling of the control line valve-lifting housing G1/8” tightened
9 Discharge valve (centre bolt) M16 120
10 Cylinder head nuts M16 120
11 Cylinder liner tie bolt - nut M6 ---
12 Sight glass flange bolts M6 7
13 Crankcase side cover bolts M12 80
14 Pressure relief valve cover bolts M12 80
15 Pressure relief valve assembly mounting bolts M12 80
16 Oil discharge filter bolts M10 35
16 Oil suction filter bolts M10 35
18 Suction filter housing bolts 2, 3 and 4 cyl. compressor M12 40
19 Suction filter housing bolts 6, 9 and 12 cyl. compressor M16 120
20 Bearing block bolts M16 120
21 Intermediate bearing block bolts M20 tightened
22 Counterweight bolts M16 120
23 Crankshaft spacer ring bolts M8 17.5
Standard and heavy duty thrust bearing (pressure piece) socket head
24 screws M10 35

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Torque in
Item Threaded connection Thread size N.m.a Remarks

25 Shaft seal (locking) screws M4 handtight

26 Socket head screw of disc/lever M5 5.5
27 Coupling leakage drain shaft seal G1/8” tightened
28 Oil splash plate bolts M6 7
29 Sealing plug G1/4” tightened
30 Sealing plug G1/2” tightened
31 Hand nut suction/discharge filter M90x3 handtight
32 Threaded rod auxiliary tool M12 ---
33 Lubricating oil pressure regulator - hexagon M27 tightened
34 Control oil pressure regulator - hexagon M27 tightened
35 Crankshaft sealing plugs M8 centre punch
36 Non-return valve in cylinder liner collar M22 tightened
37 Tapered plug in cylinder liner collar G1/4” tightened
38 Push bolt from auxiliary tools M24 ---
39 Pulley puller for shaft seal M8 ---
40 Foundation bolts M20 tightened

41 Drive coupling bolts refer to service instreuction

00.87.537
42 Hub securing bolts (4x) M12 tightened
43 Hub securing (centre) bolt M24 400
44 Shaft seal - Crankshaft M6 15 - 18.3
a. 1 N.m = 0,102 kgf.m = 0,738 lbf.ft

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5.2 WEAR LIMITS AND TOLERANCES are there any visible discolouring of material, has the
roundness remained correct and are there any signs of
glazing. All these wear factors make a part virtually
unserviceable, even if this part remains within its wear
Not only the wear limits determine whether a part is to limits.
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, Table 5.2-1 Wear limits and tolerances

Item Description of part Ref. Limits (mm) Remarks

1 Main bearing bush pump side 20.38.110 max. inside diam. 90+0,16 When fitted
2 Main bearing bush driving side 20.38.102 max. inside diam. 90+0,16 When fitted
3 Bearing bush small end of the connecting rod 11.46.640 max. inside diam. 40+0,14 When fitted
4 Bearing shell big end of the connecting rod 20.38.140 max. inside diam. 90+0,14 When fitted
5 Crankshaft (main bearing and crankshaft journal) 22.39..... min. outside diam. 90-0.07
6 Crankshaft (intermediate bearing) 22.39..... min. outside diam. 90-0.05
7 Crankshaft (axial play) 22.39..... min. 0.05 / max. 0.85 When fitted
8 Cylinder liner 23.18.010 max. inside diam. 160+0.12 When fitted
9 Gudgeon pin 24.70.040 min. outside diam. 40-0.00
10 Piston rings 09.74.163 max. gap 2+0.1 Measured in non-scored part of cylinder liner

11 Control pressure piston for valve lifting 27.70.670 / min. outside diam. 40-0.08
20.70.134
12 Control pressure piston housing 27.70.012 max. inside diam. 40+0.07
13 Spring valve lifting housing 11.31.332 min. 51 Length
14 Lever 27.70.112 min. outside diam. 14-0.25
11.16.112 /
15 Set screw 20.70.136 max. inside diam. 14+0.05 When fitted

16 Intermediate bearing 11.44.890 max. inside diam. 90+0.14 When fitted

17 Pivot disc ----------------- / min. thickness 5.50

20.38.106
18 Buffer spring 11.31.181 max. 115, min. 110

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5.3 REQUIRED SERVICE TOOLS AND Description

MATERIALS Grasso special tool kit TA various service activities
In order to properly carry out the disassembly, inspection Vacuum pump
and assembly procedures described in this manual, the
service engineer should possess the following tools, Centre punch
measuring equipment and aids. Circlip pliers

Table 5.3-1 Hammer (steel)

Description Hammer (soft)

Ring spanners and socket 8-10 (2x) Pair of pliers Remove split pin valve-lifting
spanners (metric): -13-14-17-19-24-27-30-32-36-41 mechanism
-Spanners:

Hexagon socket head Loctite

spanners (metric): 8-13-10-17
Lead or tin soldering wire 2
for measuring piston clearance
Torque spanners (metric) 19-24-30-36 mm

Pin-face wrench (metric) for Polishing paper

M4
shaft seal Polishing (compound) paste
Inside micrometer of 0-50 (two) Screwdrivers (small) e.g. for removing shaft seal
mm
Screwdiver (large) removing key
Inside micrometer of 50-100
mm Abrasive linen
Misc:
-Measuring equipment:

Outside micrometer of 0-50 Silicon grease

mm
Wire brush
Outside micrometer of
50-100 mm Piston ring pliers
Depth micrometer of 0-50 Grease
mm
Self-made (crankshaft) removing and inserting
Vernier gauge of 10" auxiliary tool crankshaft
Feeling gauges of 0.05-1.00 Auxiliary tools for shaft seal
mm
Steel strip support buffer spring
Magnetic gauge with
extended plunger Oil drip tray
cleaning crankshaft oil
Tube brush ø10 mm
passageways

Bar ø6 mm cleaning crankshaft oil

passageways

Compressed air device cleaning e.g. crankshaft oil

passageways
Hydraulic press
removing and inserting
Heater approx. 80 °C
connecting rod bearings

5.4 GRASSO SPECIAL TOOLS AND AIDS

GRASSO 12E
Certain operations which requires fitting and removing
pistons and cylinder liners can be substantially be
simplified by using special tools and aids which are
obtainable as standard auxiliary tool kit under ref. no.
20.70.010. A list of the content of this standard kit is
given below.

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5.5 FITTING INSTRUCTIONS FOR PIPE 5.6 MASS OF SEPARATE COMPONENTS

COUPLINGS AND DOUBLE LOCKING AND COMPRESSORS
RING
Table 5.6-1

Mass
Description Remarks
(kg)
Bearing cover drive end (assembly) 22.2
Bearing cover oil pump end 22.5
Mind the remaining oil
Oil pump housing, complete with still present when
filters 28.2 removing the oil pump
housing!
Cylinder liner assy 11.7
Intermediate bearing assy 10.2
number of -
cylinders
2 54.0
3 57.5
With the assistance of a
Crankshaft second person and using
4 66.5
auxiliary tools the
Fig. 5.5-1 Pipe couplings 6 81.0 crankshaft can be
removed or fitted.
9 124.0
12 145.0
Careful when removing!
Relief valve assy 13.0 The full weight is
released all at once.
Fig. 5.5-2 Double locking ring For weights of bare shaft compressor and flywheel, refer to Product
Information (ED).
A) Preparation
S Saw off the pipe at right angles. 5.7 RELIEF VALVE POSITIONS
S Deburr and clean the pipe end.
S Oil thread, taper and clamping sleeve (facilitates
fitting).
S 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
S Slide union nut and clamping sleeve on the pipe
(mind the assembling sequence).
S Press pipe against stop and tighten union nut by
hand. Fig. 5.7-1 Relief valve; back pressure independent
S Tighten a further half a turn (clamping sleeve is about
to grip).
S Slack the union nut and retract pipe from stop by 2 -
3 mm.
S Tighten 3/4 - 1 turn (ridges now penetrate into pipe).
S On reassembly, only tighten up the union nut.

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Fig. 5.7-2 Relief valve; Back pressure dependent

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Table 5.7-1 Relief valves NH3 Table 5.7-3 Relief valves R404A
Type of compr.

Type of compr.
Relief valve positions per cylinder number (LP = Low Pressure, Relief valve positions per cylinder number (LP = Low Pressure,
HP = High Pressure, B = Blind flange): HP = High Pressure, B = Blind flange):
NH3 R404A

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

2 LP 2 LP
3 LP 3 LP
4 LP 4 LP
6 LP 6 LP
9 B LP 9 LP LP
12 LP B 12 LP LP
21 LP HP 21 LP HP
31 LP HP 31 LP HP
42 LP HP 42 LP HP
51 LP HP 51 LP HP
63 LP HP 63 LP HP
72 LP HP 72 LP HP
84 LP HP B B 84 LP HP LP HP
93 LP HP B 93 LP HP LP
102 HP B LP 102 HP LP LP

Table 5.7-2 Relief valves R134a

Type of compr.

Relief valve positions per cylinder number (LP = Low Pressure,

HP = High Pressure, B = Blind flange):
R134a

1 2 3 4 5 6 7 8 9 10 11 12

2 LP
3 LP
4 LP
6 LP
9 B LP
12 LP LP
21 LP HP
31 LP HP
42 LP HP
51 LP HP
63 LP HP
72 LP HP
84 LP HP B HP
93 LP HP B
102 HP LP LP

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 6. APPENDIX; Product Information (PI)

6. APPENDIX; Product Information (PI)

Table of Contents

Section Title Page

6.1 MAIN DIMENSIONS AND SPACE REQUIREMENTS 83

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 6. APPENDIX; Product Information (PI)

- 82- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E SIM0611/v006
 6. APPENDIX; Product Information (PI)

6.1 MAIN DIMENSIONS AND SPACE

REQUIREMENTS

Table 6.1-1

COMPRESSOR 212 312 412 612 912 1212 2112 3112 4212 5112 6312 7212 8412 9312 10212
TYPE
Length A 977 987 1307 1377 1792 2182 987 1307 1377 1377 1792 1792 2182 2182 2182
Width B 1077 1171 1077 1171 1171 1171 1171 1110 1171 1171 1171 1171 1171 1171 1171
Height C 881 931 884 931 931 931 931 876 931 931 931 931 931 931 931
D 876 848 876 848 848 848 848 876 848 848 848 848 848 848 848
E 881 688 884 871 871 871 871 864 871 871 871 871 871 871 871
F 316 522 316 548 560 950 786 790 795 795 795 795 795 795 795
G 0 406 0 189 189 189 648 745 688 688 688 688 688 688 688
H 530 541 548 548 560 560 950 950 950
J 509 903 913 913 1315 1315 1705 1705 1705
K 149 224 163 163 163 163 163 163 163
L 195 108.5 195 195 195 195 195 195 195
M 406 331 406 406 406 406 406 406 406
N 205 205 205 205 217 217 205 205 205 205 217 217 217 217 217
O 295 295 625 685 1075 2x732.5 295 625 685 685 1075 1075 2x732.5 2x732.5 2x732.5
P 345 345 345 345 369 369 345 345 345 345 369 369 369 369 369

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 83-
 6. APPENDIX; Product Information (PI)

COMPRESSOR
TYPE 212 312 412 612 912 1212 2112 3112 4212 5112 6312 7212 8412 9312 10212

MINIMUM REQUIRED FREE SPACE for removal of:

flywheel U 700 700 700 700 700 700 700 700 700 700 700 700 700 700 700
crankshaft V 875 875 1205 1265 1655 2045 875 1205 1265 1265 1655 1655 2045 2045 2045

piston and Wa 1010 1160 1010 1160 1160 1160 1160 1010 1160 1160 1160 1160 1160 1160 1160
cylinder liner X 460 595 460 595 595 595 595 460 595 595 595 595 595 595 595
LOCATION OF CENTRE OF GRAVITY
length Y 197 197 280 405 600 795 197 280 405 405 600 600 795 795 795
width Z 405 423 423 435 440 445 423 423 435 435 440 440 445 445 445
MAIN CONNECTIONS DN (mm)
(LP) suction 1 80 80 100 125 125 125 65 65 100 125 100 100 100 100 100
LP dicharge/ 2/3 50 50 80 80 80 80 80 80 80
HP suction
(HP) discharge 4 65 65 80 100 100 100 40 40 65 65 65 65 65 65 65
AUXILIARY CONNECTIONS
suctionb
pressure 5

LP discharge
pressureb 6

HP suction
pressure 7

dicharge
pressureb 8 1/4” BSP (plugged off)

Crankcase
pressure 9

lubricating oil
pressure 10

Oil
temperature 11

Oil charge and

12 1/2” BSP (plugged off; separate stop valve, type TAH8, supplied loose with the compressor)
drain valve
Return from oil
separator or 13 1/2” BSP (plugged off; separate swivel coupling, supplied loose with the compressor)
rectifier
Crankcase 14 1/2” BSP (plugged off) to suit thread of heating element
heater
Oil leakage
drain of rotary 15 clamp coupling provided with ø12x1.5 mm steel precision tube
shaft seal
Control oil
pressure 16 T-coupling

a. Minimum required free space for interstage cooling system A or B.

b. When a microprocessor is applied (see also the relevant Data Sheet), these auxiliary connections are provided with a swivel coupling with two connections. The
straight-through and side connection of this swivel coupling are provided with a clamp coupling for ø6x1 mm steel precision tube, in order to accomodate the
temperature sensor element and the steel precision tube for the pressure transducer respectivily.

- 84- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E SIM0611/v006
 7. NOTES

7. NOTES

SIM0611/v006 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 85-