Sim 5HP

Reciprocating Compressors for industrial refrigeration
Series Grasso 5HP

Service Instruction Manual (SIM)
0087233
SIM2010/v002
Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP
- 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.
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SIM2010/v002
Table of Contents
Section
Title
Page
REPAIR AND OVERHAUL
11
1.1
INTRODUCTION
11
1.2
EVACUATION/DRYING THE REFRIGERATING SYSTEM
11
1.3
EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE
11
1.3.1
EVACUATION OF REFRIGERANT BEFORE SERVICING
11
1.3.2
LEAK-TIGHTNESS AFTER SERVICING
11
1.3.3
EVACUATION AFTER SERVICING
11
1.3.4
START-UP AFTER SERVICING
11
1.4
GENERAL RECOMMENDATIONS
12
DISASSEMBLY
13
2.1
DISMANTLING COUPLING
13
2.2
DISMANTLING SUCTION GAS FILTER
14
2.3
DISMANTLING OVERFLOW VALVE
14
2.4
REMOVING CYLINDER HEAD
15
2.5
REMOVING DISCHARGE VALVE AND SUCTION VALVE ASSEMBLY
15
2.6
REMOVING PISTON/CONNECTING ROD ASSEMBLY
16
2.7
DISMANTLING ROTARY SHAFT SEAL
18
2.8
REMOVING OIL DISCHARGE FILTER ELEMENT
21
2.9
REMOVING OIL PUMP ASSEMBLY
22
2.10
REMOVING CRANKSHAFT
25
INSPECTION AND PREASSEMBLY
29
3.1
BACK PRESSURE INDEPENDENT RELIEF VALVE
29
3.2
LUBRICATING OIL PRESSURE REGULATOR
30
3.3
CAPACITY CONTROL MECHANISM
30
3.4
INSPECTION DISCHARGE VALVES
33
3.5
INSPECTION SUCTION VALVES
37
3.6
INSPECTION PISTONS AND CONNECTING RODS
38
3.7
PRE ASSEMBLING PISTON AND CONNECTING ROD
41
3.8
INSPECTION CYLINDER LINER
42
3.9
OIL PUMP AND FILTERS
43
3.9.1
DISASSEMBLING OIL PUMP
43
3.9.2
REMOVING PUMP ELEMENT/BEARING ASSEMBLY
44
3.9.3
INSERTING OIL PUMP ELEMENT
45
3.9.4
OIL FILTER HOUSING
48
3.10
MAIN BEARINGS
48
3.11
THRUST BEARING
49
3.12
PRE ASSEMBLING BEARING COVERS
50
3.13
ROTARY SHAFT SEAL
50
3.14
CRANKSHAFT
51
3.15
CRANKCASE
52
REASSEMBLING
53
SIM2010/v002
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Section
Title
Page
4.1
CRANKSHAFT AND MAIN BEARINGS
53
4.2
THRUST BEARING
56
4.3
OIL PUMP ASSEMBLY
58
4.4
OIL DISCHARGE FILTER
59
4.5
OIL SUCTION FILTER
60
4.6
OIL LUBRICATION PRESSURE REGULATOR
60
4.7
CYLINDER LINER, PISTON AND CONNECTING ROD
60
4.8
DETERMINING PISTON CLEARANCE
64
4.9
SUCTION VALVES AND DISCHARGE ASSEMBLE
65
4.10
ROTARY SHAFT SEAL
67
4.11
CRANKCASE SERVICE COVERS
68
4.12
SUCTION FILTER
69
4.13
PRESSURE RELIEF VALVE ASSEMBLY
70
4.14
OIL FILLING AND PRE LUBRICATION
70
4.15
COUPLING
71
MISCELLANEOUS
73
5.1
TABLE OF TORQUES FOR BOLTS AND NUTS GRASSO 5HP
73
5.2
WEAR LIMITS AND TOLERANCES GRASSO 5HP
73
5.3
REQUIRED SERVICE TOOLS AND MATERIALS
75
5.4
FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING
76
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SIM2010/v002
Preface documentations
Typographic signs:
Indicates a WARNING. READ IT CAREFULLY!
Indicates an IMPORTANT note or procedure to which

you should pay special attention.
User group
To be used in the field by qualified personnel of
contractors.
4) Parts list (PL)
Contents
All current parts of the compressor and accessories
together with the design changes (if applicable) to
previous supplied components ("History").
User group
Service and parts departments for both sales
representatives, contractors and end-users.
Indicates a HINT.
General
1 All documentation can be downloaded via
grasso-global.com.
2 Grassos technical manuals includes generic
paragraphs; this means that it can occur that not
all data as described is relevant for the current
compressor series as mentioned in this manual. (For
instance, not all compressor series are suitable for all
mentioned refrigerants or not all compressor series
includes two-stage compressors)
5) Service & Maintenance Schedules

Contents
Service and maintenance schedules up to the date of
required overhaul of the bare compressor.
User group
Service and parts departments and in the field by
qualified personnel for both sales representatives,
contractors and end-users.
1) Product Information (PI)

Contents
All product information (engineering data) for this series
compressor and the corresponding accessories. It is
meant to be a guide to the selection of these
components.
User group
Project engineers, application engineers, sales managers,
product managers for both sales representatives,
contractors and end-users.
2) Installation and maintenance manual (IMM)
(Supplied together with the compressor)
Contents
This manual will provide information on how to
transport, install, start-up and maintain the compressor
(package). It also contains a number of "Product
Information Sheets" and the current "Parts List"
User group
To be used in the field by qualified personnel for both
sales representatives, contractors and end-users.
6) Instructions for accessories

(Supplied together with the compressor)
Contents
All the relevant mounting and installation instructions
and spare parts information for those accessories
supplied with the compressor.
User group
To be used in the field by qualified personnel for both
sales representatives, contractors and end-users.
Grassos technical manuals includes generic

paragraphs; this means that it can occur that not all
data as described is relevant for the current compressor
series. For instance, not all compressor series are suitable
for all mentioned refrigerants or not all compressor
series includes two-stage compressors.
7) Directives
Equipment supplied according to PED regulations and
Machine Directives EN60204, EN292, EN294, EN378
3) 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'.
SIM2010/v002
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SIM2010/v002
General info SIM
How to read the pages of this manual
Never change positions of parts when re-assembling the

compressor. E.g. cylinder liners, suction valves, discharge
valves and relief valves have to be replaced always in the
origional position.
All bolts and nuts have to be mounted according to to

the torques as given in table Survey of torques for bolts
and nuts" as available in this manual. If you cannot find
this information, consult Grasso.
General
This compressor service manual is intended to be used in
the field by qualified personnel of refrigeration installers
or contractors for proper(re)assembly, inspection,repair
and part or total overhaul of Grasso single-stage and
two-stage piston compressors.
Installation and maintenance intructions
The manual should also and always be used together
with the corresponding "Installation and Maintenance
Manual" (IMM) meant for the operator. The IMM is
supplied with every compressor or compressor package.
Additional design details
Additional design details are available in the manual
Product Information
Important tables, refer to Chapter 5!
Tables like Wear limits and tolerances and Torques for
bolts and nuts can be found at Chapter 5
Cylinder numbering
Fig. 1 Cylinder numbering Grasso reciprocating compressors
SIM2010/v002
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Legend
Legend
1, 2, 3, ...
Cylinder numbers
Top view of compressor
Motor/Drive end of compressor
Oil pump of compressor
Table 1 Main setup data Grasso 5HP

Description
Value
Start frequency
max. 6 starts per hour
Time interval between stopping and

re-starting
min. 2 minutes
Time interval between starting and re-starting
min. 10 minutes
Time interval between capacity steps
min. 3 minutes
Remark
For continuous minimum part-load (i.e. more

than 30 minutes) consult Grasso
Adjust the steps between up and down
loading, in such a way that the system is
running stable
Oil level
25-75% crankcase sight glass
Min. oil temperature
warmer than surroundings and 10 C for R744(CO2)

> Saturated temperature for R717(NH3)
Max. oil temperature
Refer to oil selection table/applied type of oil
Required oil viscosity;

10 cSt during operation at location of
bearings
Lubricating oil pressure difference
between 1.3 and 3.0 bar Setting approx. 2.0 bar
After a mimimum of 15 minutes running time

at an oil temperature of approx. 35 oC (95 oF)
General limits of operation
Refer to Product Informatin manual
Oil discharge - running in - filter
Red coloured filter element
Factory mounted; to be replaced after

max. 100 running hours by permanent
oil discharge filter element
Oil discharge - permanent - filter
Grey filter element
Supplied loose; replacement for factory

mounted running in filter
Standard direction of rotation of compressor

drive shaft
Counterclockwise when facing shaft end
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SIM2010/v002
Cylinder numbering
Fig. 2 Top view compressor (S=Shaft end)
SIM2010/v002
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SIM2010/v002
1. REPAIR AND OVERHAUL

1.1
INTRODUCTION
Compressor and plant

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

evacuate the system to approx. 5 mm Hg (=6.6 mBar).
iv) Break vacuum by charging dry nitrogen into the
system.
v) Repeat step iii, 'Connect vacuum pump ...'.
vi) Wait approx. 24 hours.
vii) If pressure has increased (system still contains
moisture), repeat steps iv, vand vi, otherwise,
continue with the "Initial oil charge" procedure.
1.3
Accessories
This chapter only deals with the disassembly and
assembly of a so-called "bare compressor" in standard
design. This implies that, depending on the dismantling
degree, it may be necessary to first completely or
partially remove certain accessories.
It is recommended to distinctly mark the dismounted
accessories or parts of them (for instance oil control lines
and pressure gauge or safety switch lines, transducers,
pressure and temperature sensors, V-belt pulleys and
torsionally-stiff coupling) in order to avoid mistakes at
reassembling.
Tools
For proper performance of the operations, at least the
standard service tools and materials should be available.
Besides, for certain operations additional special
GRASSO tools are required, which can be obtained as a
complete standard service set.
Service Sets
Worn out parts are to be replaced by new parts which
are available in sets with a brief service manual.
General
Although all the assembly and disassembly procedures
shown relate to the two-stage compressor, they are
basically applicable universally to all compressors. If not,
it is explicitly stated in the text.
1.2
EVACUATION/DRYING THE
REFRIGERATING SYSTEM
For evacuation of compressor only, refer to Section 1.3

Procedure to evacuate and to dry a system:
i) STATUS: System is filled with nitrogen and no oil has
been added (oil prevents any trapped moisture from
boiling off).
ii) Verify that all valves in that part of the system to be
evacuated are opened (refer also to the plant
manual).
iii) Connect vacuum pump to the evacuation/purging
valve(s) of the compressor (for location of these
valves refer to the "Product Information" or to a
SIM2010/v002
EVACUATION, LEAK TESTING AND

START-UP OF THE
COMPRESSOR/PACKAGE
To evacuate the refrigeration system refer to Section 1.2,

Use always a vacuum pump or pump-down unit to
evacuate the refrigerant from the compressor.
1.3.1
EVACUATION OF REFRIGERANT BEFORE

SERVICING
Procedure to evacuate the compressor:
1. Switch off main control panel
2. Remove main fuses
3. Close shut-off valves
4. Remove the refrigerant by means of a vacuum pump
or pump-down unit, via the evacuation/purging
valve(s) as prescribed by local safety regulations. For
the location of these valves refer to the "Product
Information".
5. Drain the oil from the compressor and oil separator,
oil return /oil rectifier system if present.
1.3.2
LEAK-TIGHTNESS AFTER SERVICING
The necessary safety precautions should be taken before
carrying out the leak-tightness test. To check
leak-tightness use dry nitrogen at a positive pressure
which is less than the admissible operating pressure of
the low pressure stage.
1.3.3
EVACUATION AFTER SERVICING
After the pressure test has been completed, the
compressor (package) must be evacuated and undergo
a vacuum test. Evacuation is used to remove air and
moisture from the compressor (package)
1.3.4
START-UP AFTER SERVICING
1 STATUS: Compressor (package) is dried and still
evacuated.
2 Charge the oil separator, if present, with oil.
See the appropriate Product Information for the
correct quantity.
3 Charge the compressor crankcase with oil via the oil
charge valve until the minimum level is seen at the
sight glass at the level as indicated in IMM.
It is mandatory to pre-lubricate the oil circuit by
adding the final quantity of oil via the charge valve
mounted onto the oil pump by means of a separate
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4
5
6
7
8
9
10
oil filling pump. The required oil level is indicated in

the IMM.
Re-install all accessories such as coupling, V-belt guard
etc.
Open the shut-off valves.
Check the start-stop procedure.
Check all safeties and controls.
Re-install the main fuses.
Start up the compressor.
Check running condition.
Note:
The job isn't finished until the paper work is done!
Complete the service report, e.g. Grasso report
00.89.062.
1.4
GENERAL RECOMMENDATIONS
1. Do not disassemble more compressor parts than is

necessary for the purpose (inspection, repair,
overhaul).
2. Use clean and well-conditioned tools.
3. Make sure that there is a clean and neatly arranged
working area well-equipped to provide temporary
and adequately protected storage of dismantled
components. Preferably use a table or working bench
with a clean, moisture-free and non-scratching
surface.
4. Immediately clean every dismantled part, check it for
wear or damage and oil the machined surfaces of
bright parts. The oiling is particularly important when
the parts are not to be reassembled until after some
time. Otherwise they will certainly become rusty.
5. The dismantled parts of every cylinder (cylinder liner,
piston, connecting rod, valves) or of other main
components should be kept together separately and
marked if necessary. Thus they can later be replaced
in their original place in the compressor.
6. All major parts that are not beyond repair have to be
checked before reassembly for wear by measuring
them and comparing the outcome with the wear
limits and tolerances given in documentation.
7. Always replace damaged or worn compressor parts
that are beyond repair by new GRASSO standard
spare parts. These parts can always be fitted into the
compressor without previous inspection or
readjustments (if applicable, e.g. valves, connecting
rods, etc.).
8. When fitting any moving parts, it is recommended to
oil all running surfaces.
9. Always use new gaskets, O-rings and locking rings
when reassembling after inspection or repair.
10.Use a torque wrench to tighten the threaded
connections. (Survey of torques for bolts and nuts
refer to Chapter 5)
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SIM2010/v002
2. DISASSEMBLY
2. DISASSEMBLY
Fig. 2-1 How to read this manual

Fig. 2.1-2 Remove all coupling bolts
2.1
DISMANTLING COUPLING
Fig. 2.1-3 Oil bolts and Insert three bolts in coupling half
Fig. 2.1-1 Use an auxiliary bolt (1) to avoid rotation of the shaft to
remove the coupling bolts
SIM2010/v002
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2. DISASSEMBLY
Fig. 2.1-4 Tighten the bolts alternately until coupling half is loosened
2.2
DISMANTLING SUCTION GAS FILTER

Fig. 2.2-2 Remove the O-ring (1
Fig. 2.2-1 Remove the 4 nuts (1)

Fig. 2.2-3 Remove the suction gas filter element (1)
2.3
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DISMANTLING OVERFLOW VALVE
SIM2010/v002
2. DISASSEMBLY
2.4
REMOVING CYLINDER HEAD
Fig. 2.4-1
Remove dirt and paint from the cylinder head studs
using a steel brush

Unscrew the bolts (1)
Remove cylinder head (2)
2.5
REMOVING DISCHARGE VALVE AND

SUCTION VALVE ASSEMBLY
Fig. 2.3-1 Back pressure independent overflow valve; remove cap
Fig. 2.3-2 Remove the 4 bolts (1) and remove entire valve (2)
Fig. 2.5-1
Unscrew bolts in sequence (1)

Never use an impact wrench
Remove (2) and (3)
SIM2010/v002
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2. DISASSEMBLY
Remove discharge assemby
Fig. 2.6-2
Fig. 2.5-2
Remove the discharge valve assembly and suction
spring (1) and suction valve (2)

Remove spacer ring (3)
2.6
REMOVING PISTON/CONNECTING ROD

ASSEMBLY
Fig. 2.6-3
Rotate the crankshaft in such a way that the the
bottom side of the big end (1) of the connecting rod

becomes easily accessible
Fig. 2.6-1
Place an oil drip tray under the service cover to collect
the residual oil

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

In case of vertical cylinders, remove the opposing
service cover
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SIM2010/v002
2. DISASSEMBLY
Fig. 2.6-4
Unscrew the two nuts from the connecting rod bolts
(1) and remove the locking rings

Tap up both connecting rod bolts (1) slightly, in order
to remove connecting rod easily
Remove cap (2)
Pull both connecting rod bolts (1) back to the original
location in the connecting rod
Fig. 2.6-6
Pull the cylinder liner (1) with the special tool

Push the cylinder liner from below. A synthetic
hammer could be used
Fig. 2.6-5
A special tool as shown above, could be used to
remove the cylinder liners (tool is not included)
SIM2010/v002
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2. DISASSEMBLY
Fig. 2.6-8
Each connecting rod cap is marked (1) and belongs to
one specific connecting rod and can be fitted in one

way only.
Never exchange connecting rod cap with another
connecting rod!
2.7
DISMANTLING ROTARY SHAFT SEAL
Fig. 2.6-7
Withdraw cylinder liner with piston and conrod (1)

Remove spacer ring (2)
Fig. 2.7-1
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SIM2010/v002
2. DISASSEMBLY
Unscrew the oil leakage drain (1)

Place an oil drip tray under the housing
Remove shaft seal bolts (3) to remove shaft seal
housing (2)
Fig. 2.7-4 Remove the three grubscrews (1)
Fig. 2.7-2 Use two bolts to push the shaft seal housing from the
crankcase using holes (1)
Fig. 2.7-5 Use an auxilairy tool (e.g. a bolt) to ease the shaft seal from
the cover
Fig. 2.7-6 Remove O-ring (1)
Fig. 2.7-3 Slide the shaft seal housing over the shaft joumal
SIM2010/v002
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2. DISASSEMBLY
Avoid touching the black graphite composite ring. If

necessary wear gloves or rub your hands with oil.
Fig. 2.7-9 Slide the rotary slip ring (1) from the crankshaft
Fig. 2.7-7
Unscrew bolts (2) to remove rotary slip ring (1)

Be sure that the bolts (2) are unscrewed, in order to
clear the groove in the crankshaft
Fig. 2.7-10 Remove both internal O-rings (1) and put all parts aside
with the other shaft seal parts
Fig. 2.7-8 Place the legs of the pulley puller (special Grasso tool set)
behind the rotary slip ring and carefully pull the slip
ring until it is loose
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SIM2010/v002
2. DISASSEMBLY
2.8
REMOVING OIL DISCHARGE FILTER

ELEMENT
Fig. 2.8-3 Place an oil drip tray under the filter
Fig. 2.8-1 Remove bolts (1), in order to remove the entire oil discharge
filter
Fig. 2.8-4 Unscrew the grooved filter nut (1)
Fig. 2.8-2 Special tool to remove oil filters
SIM2010/v002
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2. DISASSEMBLY
2.9
REMOVING OIL PUMP ASSEMBLY
Fig. 2.8-5 The filter element (1) is marked with a colour;Red: running-in
filter, to be replace after 100 running hours
Fig. 2.9-1
Place an oil drip tray under the pump

Unscrew bolts (2) in order to remove oil pump (1)
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SIM2010/v002
2. DISASSEMBLY
If required, the oil pump can also be removed while the

oil filter is still mounted
Fig. 2.9-3 Carrier disk
Fig. 2.9-2 Take due care with the pressure springs (1) mounted in the
oil pump housing
Fig. 2.9-4 Remove the carrier disk from the crankshaft
SIM2010/v002
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2. DISASSEMBLY
Fig. 2.9-5 Hold down disc (1)
Fig. 2.9-6
Lock the crankshaft with (for instance) a wooden
block (1) in order to remove the bolts from hold

down disc
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SIM2010/v002
2. DISASSEMBLY
Fig. 2.9-7
Remove bolts (1) and the hold down disc from the
crankshaft
Fig. 2.9-8
Remove the thrust bearing (1) from the bearing cover

Keep parts together!
All running surfaces of the washers in contact with the

cylindrical thrust bearing are hardened and machined
smooth. Damage of these surfaces can lead to
breakdown of other parts of the compressor in a short
period of time!
2.10 REMOVING CRANKSHAFT

Before removing the crankshaft, the following
components have to be disassembled;
1 All discharge valves
2 All pistons and connecting rods
3 Shaft seal
4 Oil pump
5 Thrust bearing
SIM2010/v002
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2. DISASSEMBLY
Fig. 2.10-1 Remove bolts (1)

Fig. 2.10-3
Remove the bearing cover (1) and O-ring.
The crankshaft is supported by the bearing on the

drive-end only
Fig. 2.10-4 Auxiliary tool, to remove ring (Fig. 2.10-5)
Fig. 2.10-2
Screw two bolts (1) into the threaded holes

Tighten these bolts evenly in order to loosen the
bearing cover
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SIM2010/v002
2. DISASSEMBLY
Fig. 2.10-5 Remove ring (2)
Fig. 2.10-7
Assisted by another person, the crankshaft (1)can be
removed carefully, via the oil pump side

Store the crankshaft in a clean and dry area
Fig. 2.10-6 Auxiliary tool for removing crankshaft

Fig. 2.10-8 Remove oil pressure regulator (1)
SIM2010/v002
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2. DISASSEMBLY
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SIM2010/v002
3. INSPECTION AND PREASSEMBLY

Fig. 3.1-2

3.1
BACK PRESSURE INDEPENDENT RELIEF

VALVE
Fig. 3.1-3
Inspect carefully the teflon seal (1, 3);
Fig. 3.1-1
SIM2010/v002
Malfunctioning of the relief valve is usually caused by

a minor damage of the teflon seal (1)
If damage or wear of the teflon ring (1,3) is detected,
check whether this can be remedied by polishing with
an abrasive paper
Do not dismantle the valve;
The relief valve is adjusted by the factory;
Check the valve seat (2) in the crankcase.
Slight wear can be remedied with polishing paper
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3.2
LUBRICATING OIL PRESSURE

REGULATOR
Fig. 3.2-1 1. Cap; 2. Housing; 3. Pressure ring; 4. Ball; 5. Circlip ring; 6.

Set bolt; 7. O-ring; 8. Alu ring
Fig. 3.3-2 Remove the bolts (1)
Fig. 3.2-2 Oil pressure regulator
Renew O-ring (1) and Alu-ring (2)

Clean all disassembled regulator parts
Oil all regulator parts
Reassemble all regulator parts
The oil pressure can be adjusted during operation, using

a screw driver
3.3
CAPACITY CONTROL MECHANISM
Fig. 3.3-3 Remove the cover (1)
Fig. 3.3-1 Cylinderhead cover
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SIM2010/v002
Fig. 3.3-6 Pull thecapacity control piston (2) out of the cylinder, using
the special tool (1)
Fig. 3.3-4 Remove the pressure spring (1)
Fig. 3.3-5 Special tool (M6 bolt is also possible) (refer Fig. 3.3-6)
Fig. 3.3-7 Check the piston rings (1) for damage or wear
SIM2010/v002
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Fig. 3.3-8 Check the cylinder liners (1, 2) for damages

Fig. 3.3-10 Insert the pressure spring (1)
Fig. 3.3-9 Insert the capacity control piston (1) in the cylinder; be sure
not to damage the piston rings
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Fig. 3.3-11 Renew the O-rings (1)
SIM2010/v002
Fig. 3.3-12
Mount the cover (1)

Be sure that the spring (2) will be positioned in the
proper hole
Tighten the cover bolts
Fig. 3.4-2 Special tool A (refer Fig. 3.4-6)
3.4
INSPECTION DISCHARGE VALVES
Fig. 3.4-3 Optional special tool B

Fig. 3.4-1 Discharge valve assembly
SIM2010/v002
- 33-
Fig. 3.4-4 Fit special tool A into a vice (Fig. 3.4-2)
Fig. 3.4-6 Discharge valve assembly located onto special tool A (Fig.
3.4-2)
Remove central bolt (1)
Fig. 3.4-5 Holes (1) to fit into special tool A ()
Fig. 3.4-7 Valve seat, removed from the stroke limitor
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SIM2010/v002
Fig. 3.4-10 Remove the valve ring (1)

Fig. 3.4-8 Remove the bolts (1)
Fig. 3.4-9 Ease the bolts carefully, to loosen the valve plate(1)
Fig. 3.4-11 Remove the spring (2)
SIM2010/v002
- 35-
Fig. 3.4-14 Check the valve seat and valve plate for damage or wear
Fig. 3.4-12 Check the valve ring and spring for damage or wear
- 36-
SIM2010/v002
3.5
INSPECTION SUCTION VALVES
In case of wear or damage, parts have to be renewed
Fig. 3.4-16 Reassemble the discharge valve assembly
Fig. 3.5-1 Cylinder liner including suction valves and rings
Fig. 3.4-17 Be sure that the sinoidal spring (1) is positioned properly
Fig. 3.4-18 Be sure that the sinoidal spring (1) is positioned properly
Fig. 3.5-2 Check spring (1) and valve ring (2) for damage and wear
SIM2010/v002
- 37-
Fig. 3.6-2
Fig. 3.5-3 Check valve seats (1 and 2) for damage and wear
Push the gudgeon pin out of the piston

Check the gudgeon pin for wear and measure the
In case of wear or damage, parts have to be renewed
3.6
outer diameter using an outside micrometer and

replace the pin if the diameter is smaller as given in
table Wear limits and tolerances
INSPECTION PISTONS AND

CONNECTING RODS
Fig. 3.6-1 Place the assembly upside down on the working bench and
remove on circlip ring from the gudgeon pin bore
- 38-
SIM2010/v002
Measure with an inside micrometer the bore of the
still fitted bearing bush and replace if it is larger than

as given in table Wear limits an tolerances
Insert a new bearing bush by lowering the
non-heated bearing bush into the small end of the
connecting rod which has been heated to approx 100
o
C
Fig. 3.6-3 Remove the two piston rings and oil scraper ring using the
appropriate piston ring pliers
Fig. 3.6-4 Check the piston groove for burrs, notch effects and cracked
or broken groove edges
Assemble the bearing shells and the connecting rod
cap together
Tighten the nuts (1) on the connecting rod bolts to
the torque as given in table Survey of Torques for

bolts and nuts
Measure the bore of the clamped bearing with an
inside micrometer and replace if it is larger than as
given in table Wear limits and tolerance
Check the bearing bush in the small end of the
connecting rod for wear or damage
Fig. 3.6-5
SIM2010/v002
- 39-
Roll each piston ring and oil scraper ring in the
corresponding groove around the piston to trace

parts that may have become wedged. This can be
remedied, for example, by using a smooth file
Chech the piston for wear or damage
Fig. 3.6-8
The maximum gap must not exceed 0.8 mm

Replace the piston rings if tolerance is larger than as
given in table Wear limits and tolerances
Fig. 3.6-9
If the piston rings and oil scraper ring are no longer
on the piston, fit them in the sequence as shown

1. Chrome ceramic
2. Black
Fig. 3.6-6 Check the gap in each piston ring
Fig. 3.6-7 Check the gap (1) in each piston ring by placing it in an
unworn part of the cylinder liner. An anworn part can
be found at about 15 mm from the top and bottom of
the cylinder liner
- 40-
3. Oil ring
Fig. 3.6-10 Never use a combination of old and new rings. While
placing the rings, pay attention to the word TOP on
each ring, to place it at the right position
SIM2010/v002
Never use new piston rings in combination with a worn

out cylinder liner
3.7
PRE ASSEMBLING PISTON AND

CONNECTING ROD
passageway in the connecting rod

When replacing the bearing bushes, heat the small
end of the connecting rod to approximately 80 oC
Insert the bearing bush
Let the connecting rod cool off in ambient air
Fit the bearing shells in both connecting rod ends
Fig. 3.7-2 Due to the built-in fixing cams (1) one assembled position is
possible only
Fig. 3.7-3 Place the connecting rod into the piston and slide the oiled
gudgeon pin through the piston into the connecting
rod onto the still fitted circlip ring
Fig. 3.7-1
Clean the connecting rod and blow out the oil
SIM2010/v002
- 41-
Fig. 3.7-4
3.8
INSPECTION CYLINDER LINER
Clean all parts
Fig. 3.8-2 Check the suction valve seats (1, 2) in the cylinder liner
Fig. 3.8-3 Its not necessary to check the cylinder liner diameter if the
honing marks in the cylinder bore are still completely
visible. Irregularities can be polished out with abrasive
paper carefully
Fig. 3.8-1 Check the outer surface of the cylinder liner for damage and
polish out slight damage with a abrasive paper
- 42-
SIM2010/v002
3.9
3.9.1
OIL PUMP AND FILTERS

DISASSEMBLING OIL PUMP
Fig. 3.9-1 Place the pump house on the working bench and unscrew
the bolts and washers (1) to remove the pump cover
with integrated pump element
Fig. 3.9-3 Remove O-ring (1)
Fig. 3.9-2 Use 2 bolts (1) to push the cover from the housing
Fig. 3.9-4 Back side; push shaft slightly(1) to remove pump element
from housing
SIM2010/v002
- 43-
3.9.2
REMOVING PUMP ELEMENT/BEARING

ASSEMBLY
Fig. 3.9-5 Remove pump gear (1) and crown wheel (2)
Fig. 3.9-8 Renew pump element/bearing assembly in case of

irrepairable damage or malfunctioning of the oil pump
Fig. 3.9-6 Remove pump gear (1) from crown wheel (2)
Fig. 3.9-9
Place the pump housing under a press (2) to push the
pump parts out, using a pipe (1) to support the

housing
Fig. 3.9-7 Clean housing with non-fibrous cloth; Clean the internal oil
passageways with compressed air
- 44-
SIM2010/v002
Fig. 3.9-12
Check the carrier lug for wear

Check the teeth of both pump parts (1, 2) for broken
or worn teeth
Replace entire pump element if at least one of the
parts shows irrepairable wear
Minor damage may be eliminated
3.9.3
INSERTING OIL PUMP ELEMENT
Fig. 3.9-10 Press bearing from the housing
Fig. 3.9-13
Fig. 3.9-11 Clean all parts and remove possible sharp edges and/or
burrs
Ensure that the bore and the contact face in the
pump housing are clean and oiled

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

SIM2010/v002
- 45-
Fig. 3.9-14 Place the cover on the housing; ensure that pin (1) and hole
(2) are in line
Fig. 3.9-16
Ensure that pin and hole are in line

Carefully press the pump element into the housing
with the cover until the contact face has been

reached clearly
Fig. 3.9-15 Place the cover on the housing; ensure that pin (1) and hole
(2) are in line
- 46-
SIM2010/v002
Use a pipe which fits the size of the hole-pattern
Never press in the middle of the cover; it could burst
Fig. 3.9-19 Place the crown wheel
Fig. 3.9-17 Slide the pump gear (1) onto the shaft of the pump cover
Fig. 3.9-20 Insert the pre-assembled pump cover element provided

with a new O-ring in such a way that the fixing pin fits
into the corresponding hole
Fig. 3.9-18 Place the crown wheel (1)
Fig. 3.9-21
SIM2010/v002
- 47-
Tighten the bolts and washers (1), corresponding the
Clean oil filter housing and the internal passageways
torques as given in table Survey of torques for bolts

and nuts
Check that the pump rotates smoothly
Place the pre-assembled pump in separate clean area,
to be mounted later on
Insert the filter element in the housing and
re-assemble it with new O-rings and seal
In order to avoid damaging of the seals, the housing

should not revolve together with the grooved filter nut
(refer Fig. 2.8-4)
REMARK
After having dis-assembled the discharge filter element,
check this for contamination, in particular for the
presence of aluminium and/or white metal slide-bearing
particles which would require further investigation in
other parts of the compressor. In this case, regularly
check the oil quality by means of an oil analysis.
3.10 MAIN BEARINGS
Fig. 3.9-22 Remove the carrier disc from the crankshaft joumal and
check the condition of the slot (1) and the holes of the
carrier disc
3.9.4
OIL FILTER HOUSING
The removal of the oil filters and oil filter housing, has
been decribed in Section 2.8.
Renew a poluted grey-marked oil discharge elment
The red running-in oil discharge filter element has to
be replaced for a grey one after 100 running hours
Fig. 3.10-1 The notch has to be pressed at a position of 12 Oclock
Fig. 3.9-23
Remove the O-rings (1, 2) and seal (3)
- 48-
SIM2010/v002
Fig. 3.11-2 Remove ring (1), using auxiliary tool
Fig. 3.10-2
Check the main bearing bushes, while these are in the
respective bearing cover, for worn out white metal

inner lining
Replace the bush(es) if the inner lining shows
abnormal wear, and also if the bore is over 65.092
mm
Especially check those crankshaft parts rotating in the
bearing covers. Eliminate slight damage using fine
polishing paper.
Fig. 3.11-3 Clean all thrust bearing parts. Check all running surfaces
which are in contact with cylindrical roller thrust
bearing and the needle thrust bearing for (ir)regular
wear and other damage such as pits, marks or
scratches
3.11 THRUST BEARING

Use a self made auxiliary tool, refer Fig. 2.10-4
Fig. 3.11-4 Replace the complete thrust bearing set when the rollers,
needles or running surfaces show signs of wear
Fig. 3.11-1
SIM2010/v002
- 49-
3.12 PRE ASSEMBLING BEARING COVERS
opposite side of the oil channels (3)

Oil the bearing bush
Fig. 3.12-3 Press carefully the bearing bush (1) in the bearing cover (2)
3.13 ROTARY SHAFT SEAL
Fig. 3.12-1
Fig. 3.12-2
Push or press (using a hydraulic press) the bearing
bush out of the bearing cover
Fig. 3.13-1 Avoid touching the carbon part (1)! Preferably rub your
hands with oil or wear gloves before servicing.
Place the bearing cover with the oil pump side
downwards.
Ensure the position of the lubrication groove (1). The
opening of the groove (2) must point downwards.
The lubrication groove must be postitioned on the
- 50-
SIM2010/v002
Clean the housing and all other parts

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

Renew all O- rings
Renew entire shaft seal in case of damage or wear
3.14 CRANKSHAFT
Fig. 3.13-2 Remove both internal O-rings (1, 2) from the rotary slip ring
Fig. 3.14-1 Thoroughly clean the entire crankshaft and Check whether
the axial oil passageways in the crankshaft are
unobstructed by cleaning them with compressed air or
a brush.
Fig. 3.13-3 Remove the O-ring (1)

Fig. 3.14-2 In order to be sure that the lubricating oil transmission
within the crankshaft will proceed smoothly, unscrew
the socket head screws (1) locked with centre punches
out of the crankshaft webs.
Fig. 3.13-4
Check both sliding surfaces (1, 2) of counter slip ring
and rotary slip ring for wear or damage

SIM2010/v002
- 51-
It should be at least 64.95 mm.

Should these measurements show that any of the
shaft diameters are beyond the tolerance limits and

there is any doubt about the serviceability of this
crankshaft, then it is recommended to contact our
service department.
3.15 CRANKCASE
Fig. 3.14-3 Remove the dirt accumulated in the oil passageway (1)(in
the case of damage to bearings, white metal particles
may be present) with a 6 mm rod. Brush and blow out
the crankshaft again until all oil passageways are
unobstructed
Fig. 3.15-1 Crankcase: service opening
Thouroughly clean the crankcase interior and dry it
with a non-fibrous cloth

Inspect all exterior gasket faces and remove possible
residual gasket material

Thoroughly blow through all connections on the
inside and on the outside
Clean the sight glass
Fig. 3.14-4 After cleaning, reassemble all oil passageway sealing bolt
(1)(socket head screws) and lock them with centre
punches.
Fig. 3.15-2 Inspect the return plugs, clean them and tighten them after
refitting at location 1 of Fig. 3.15-1.
Fig. 3.14-5
Check the diameters of the shaft journals (1) and
shaft ends (2) with an outside micrometer in at least

2 directions and dead square to the measuring
surface.
- 52-
SIM2010/v002
4. REASSEMBLING
4. REASSEMBLING

4.1
CRANKSHAFT AND MAIN BEARINGS

Fig. 4.1-2 Mount bearing (1) with drill-mark (2) facing outside and
upwards, and tighten the bolts (3)
Fig. 4.1-1 Check bearing for damage (1)
Fig. 4.1-3 Check surface for damage (1) and oil surface (1)
SIM2010/v002
- 53-
4. REASSEMBLING
A) Drive end side
Fig. 4.1-4 Auxiliary tool in order to enable easy mounting of the

crankshaft
Fig. 4.1-6
Insert the crankshaft through the crankcase opening
on the oil pump side into the opposing bearing bush

B)
Pump side
Fig. 4.1-5 Auxiliary tool in order to enable easy mounting of the

crankshaft
Fig. 4.1-7
Bearing cover oil pump side (with two lugs)

Place a new O-ring (1) on the rear side of the bearing
cover
- 54-
SIM2010/v002
4. REASSEMBLING
Place a new O-ring on both pipes of the internal oil
passageway
Fig. 4.1-8 Oil the bearing
Fig. 4.1-10 Place the cover in such a way that the holes (1) in each lug
of the bearing cover are opposite the pipes (2) of the
internal oil passageways and slide the bearing cover
into the crankcase
Fig. 4.1-9 Oil the shaft
SIM2010/v002
- 55-
4. REASSEMBLING
Check whether all components are clean, including
the inside of the bearing cover and crankshaft on oil

pump side
Ring (1) and ring (5) running surfaces have to point
to the roller bearings
Ring (3) is allowed to turn 180o
Rolling bearing (2) and (4) are allowed to be changed
Ring (1) has to be mounted first. Ensure that the
running surface points to the roller bearing, and is
located tight to the edge in the bearing cover. Ring
(1) can be used on one side only
Fig. 4.1-11 Tighten the bolts in opposing sequence and check that the
crankshaft rotates freely
4.2
THRUST BEARING
Fig. 4.2-1
Fig. 4.2-3 Mount the remaining parts (2, 3, 4) and ensure that the
running surface of ring (5) points to the roller bearing.
Ring (5) can be used on one side only
Fig. 4.2-2
- 56-
SIM2010/v002
4. REASSEMBLING
Fig. 4.2-6 Stop the crankshaft turning by using a wooden block
Fig. 4.2-4 Mount the oiled hold down disc (1), which fits exactly in the
chamber of the crankshaft
Fig. 4.2-7 Tighten the bolts
Fig. 4.2-5
SIM2010/v002
- 57-
4. REASSEMBLING
Check that the crankshaft rotates freely
4.3
OIL PUMP ASSEMBLY
Fig. 4.3-3
Place 2 new O-rings (1) around the oil in- and outlet
holes at the bearing cover

Place a new O-ring (2) on the rear side of the oil pump
Fig. 4.3-1 Place the carrier disc on the hold down disc
The enlarged slot (1) of the carrier disc must face the
crankshaft
Fig. 4.3-4
Check that the oil pump is clean

Insert the oiled springs (1) in the holes of the spring
retainer
Fig. 4.3-2 Position the slot of the carrier disc in vertical or horizontal
position by rotating the crankshaft
- 58-
SIM2010/v002
4. REASSEMBLING
Check that the crankshaft rotates freely
4.4
OIL DISCHARGE FILTER
Fig. 4.3-5 Position the carrier lug (1) of the pump element with the slot
in the carrier disc (2)
Fig. 4.4-1 Replace the oil filter housing O-rings (1)
Fig. 4.3-6
Check that all the springs are at the proper position

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

The oil pump cannot be pushed fully against the
bearing cover, because of the springs
Tighten the bolts
Fig. 4.4-2
SIM2010/v002
- 59-
4. REASSEMBLING
After the first 100 operating hours the red-marked
discharge filter has to be replaced with a grey-marked

filter element!
Fit the preassembled (red/grey) marked discharge
filter housing using the two bolts with washers on the
right-hand side of the pump
Tighten the bolts to the torque given in table Survey
of torques for bolts and nuts
4.5
Final adjustment of a reassembled lubricating oil

pressure regulator must be done during compressor
operation. This adjustment procedure is described in the
Installation and Maintenance Manual.
4.7
CYLINDER LINER, PISTON AND

CONNECTING ROD
OIL SUCTION FILTER
Fig. 4.7-1 Piston and connecting rod
Fig. 4.5-1 In case of polution, renew oil suction filter
4.6
OIL LUBRICATION PRESSURE

REGULATOR
Fig. 4.7-2 Insert the connecting rod bolts (1) into the big end of the
connecting rod (make sure that the flat side of the
bolthead is positioned correctly!)
Fig. 4.6-1
Install the lubricating oil pressure regulator (1) using
a new alu ring (2) in the compressor housing

Finally fit the cap nut (3) handtight on the regulator
- 60-
SIM2010/v002
4. REASSEMBLING
Fig. 4.7-5 Oil bearing shells, piston and piston rings.
Fig. 4.7-3 Place the bearing shells (1) into the connecting rod
Fig. 4.7-4 Due to the built-in fixing cams (1) only one assembled
position is possible
Fig. 4.7-6 Oil cylinder liner
Slide the piston carefully into the cylinderliner; be
sure not to damage the piston and oil scraper rings
SIM2010/v002
- 61-
4. REASSEMBLING
Fig. 4.7-7 Push the cylinder liner entirely on the piston; be sure not to
damage the piston and oil scraper rings.
Fig. 4.7-9 Place spacer ring (1) into the cylinder bore
Fig. 4.7-8
Turn the crankshaft into the position that the crank
(1) is located in the centre of the bore of the cylinder

liner
Oil the crank
Fig. 4.7-10 Place the cylinder liner, including connecting rod and piston
into the cylinder bore
- 62-
SIM2010/v002
4. REASSEMBLING
Fig. 4.7-13 Fit the connecting rod parts with the machine codes(1) on
one side.
Fig. 4.7-11 Check that the connecting rod properly embraces the
crankshaft journal. Check that the bearing shell in the
connecting rod has not been displaced
Fig. 4.7-14
Fig. 4.7-12 make sure that the flat side of the bolthead (1) is positioned
correctly!
Fig. 4.7-15 Locking rings as used for connecting rods
Slide the corresponding connecting rod cap over the
connecting rod bolts

Fit both nuts with new (double) locking rings on the
connecting rod bolts and tighten to the torque given

in table Survey of torques for bolts and nuts
SIM2010/v002
- 63-
4. REASSEMBLING
4.8
DETERMINING PISTON CLEARANCE

Never use an impact wrench
Fig. 4.8-1 Place a 1 mm thick lead or tin soldering wire (1) which is
buckled on both ends into the threaded holes of the
piston
Fig. 4.8-3 Turn the crankshaft a few times (Use a M16 bolt)
Fig. 4.8-2
Place the discharge valve assembly on the cylinder
liner
Replace the springs, for example for pipes (1) with a
length of approx 30 mm
Tighten the nuts (2)
- 64-
Fig. 4.8-4 Remove all measuring aids and measure the thickness of the
flattened wire. This thickness, which is equal to the
clearance, should be as given in Table 5.2-1(Piston
clearance). If the measuring result is beyond these
limits, it is necessary to contact the service department
of Grasso
SIM2010/v002
4. REASSEMBLING
4.9
SUCTION VALVES AND DISCHARGE

ASSEMBLE
Fig. 4.9-4 Place the sinusoidal spring with the sharp side downwards
on the suction valve
REMARK;
The sinusoidal springs in the inclined cylinders can easily
fall out of the cylinder liner during assembly. This can be
prevented by placing the sinusoidal springs in such a way
on the valve ring that the springs touch the valve ring at
the highest and the lowest point in the inclined cylinder
liner.
Fig. 4.9-1 Place spacer ring (1) in the cylinder bore
Fig. 4.9-5 Spring dish, spring and locking nut
Fig. 4.9-2 Place the suction valve ring (1) on its seat in the cylinder liner
collar
Fig. 4.9-3 Place the sinusoidal spring (1) with the convex side pointing
upwards on the suction valve ring
SIM2010/v002
- 65-
4. REASSEMBLING
the edge on the cylinder head itself

Two different type of gaskets are distinguished
1= cylinder head incl. capacity control
2= cylinder head excl. capacity control
Use the appropriate gastket
Fig. 4.9-8 Use studs (1) as auxilairy tool in order to enable easy mouting
the cylinder cover
Fig. 4.9-6
Place the preassembled discharge valve assembly in
the cylinder
Fix the valve assembly, using the spring, spring dish
and locking nut

Tighten alternately the locking nuts, to the torque
given in table Survey of torques for bolts and nuts
Never use an impact wrench!
Fig. 4.9-9 Tighten the cylinder cover nuts in opposing sequence to the
torque given in table Survey of torques for bolts and
nuts
Fig. 4.9-7
Clean the sealing edge of the cylinder head cover and
- 66-
SIM2010/v002
4. REASSEMBLING
4.10 ROTARY SHAFT SEAL
Fig. 4.10-1
When using new parts, check that the protective foil
Fig. 4.10-3
has not been removed

Avoid touching the contact faces of these parts;
slightly rub your hands with oil or wear gloves
Especially inspect the crankshaft part where the
O-ring moves
Remove all (rubber) deposits by rubbing or polishing
Oil all parts with compressor lubricating oil, as well as
the crankshaft part where the shaft seal sits
Fig. 4.10-4 Insert the counter slip ring with the O-ring (1) into the shaft
seal housing
Fig. 4.10-2
Slide the rotary slip ring part (face with text towards
the crankshaft boss) over the crankshaft and push

through until the rear side is positioned against the
crankshaft boss
Lock the slip ring on the crankshaft by tightening the
three grub screws with the allen key1. (torque given
SIM2010/v002
Fig. 4.10-5
- 67-
4. REASSEMBLING
Screw the three allen head screws (1) through the
housing into the stationary slip ring

Tighten the screws alternately until the slip ring is
properly seated
Fig. 4.10-7
Mount the shaft seal housing (with oil leakage drain
opening facing downwards) onto the crankcase

Place the nuts (1) and tighten them alternately
crosswise to the torque given in table Survey of
torques for bolts and nuts
Screw the oil leakage drain line into the bottom of
the shaft seal housing
Place the oil leakage drain
4.11 CRANKCASE SERVICE COVERS
Fig. 4.10-6
Place a ew O-ring (1) into the groove of the cleaned
shaft seal housing and oil channel (2)

Oil sealing surfaces
Fig. 4.11-1
- 68-
SIM2010/v002
4. REASSEMBLING
4.12 SUCTION FILTER
Fig. 4.11-2
Check that the crankcase is clean and dry and,
subsequently, fit all crankcase covers with new

O-rings
Place the nuts and tighten them in opposing
sequence to the torque given in table Survey of
torques for bolts and nuts
Fig. 4.12-1
SIM2010/v002
- 69-
4. REASSEMBLING
Fig. 4.12-2
Place a new O-ring (1) into the suction gas filter cover
Place the suction filter into the housing
Tighten the nuts to the torque given in table Survey
of torques for bolts and nuts
4.13 PRESSURE RELIEF VALVE ASSEMBLY

Fig. 4.13-2 Place the pressure relief valve into the crankcase and
tighten the bolts (1) to the torque given in table
Survey of torques for bolts and nuts
4.14 OIL FILLING AND PRE LUBRICATION
Fig. 4.13-1 Place a new gasket (1) in the crankcase
(Re)Fill with clean or fresh original oil only!
Prelubricate the lubrication oil circuit via the oil charge

valve mounted on top of the oil pump housing
Remove oil filling plug and fill the oil suction filter
with oil
Refit the oil filling plug with new aluminium ring
Connect oil filling pump pre-lubrication stop valve
and fill the oil discharge filter, shaft seal and

crankshaft with oil to lubricate the oil circuit
- 70-
SIM2010/v002
4. REASSEMBLING
4.15 COUPLING
Fig. 4.15-1
Fig. 4.15-3 To avoid rotation, use an auxilairy bolt (1) and a wrench
Fig. 4.15-2 Slide the coupling half on the compressor shaft and place
the bolts
SIM2010/v002
- 71-
4. REASSEMBLING
Fig. 4.15-4 Tighten the bolts in opposing sequence to the torque given
- 72-
SIM2010/v002
5. MISCELLANEOUS
5. MISCELLANEOUS
5.1
TABLE OF TORQUES FOR BOLTS AND

NUTS GRASSO 5HP
Table 5.1-1
Refer to Grasso information sheet 00.86.005-v002 and to

Grasso 5HP partslist manual;
Position
Dims
Item description
Item number
Quality
Torque in
Nm
Assembly cover
M12x35
Hexagon headed bolt
0110635
8.8
86
Sight glass
M6x16
Hexagon headed bolt
0110316
8.8
Head cover
M12x110
Hexagon headed bolt
0189611
12.9
140
Bearing cover
M12X35
Hexagon headed bolt
0110635
8.8
86
Shaft seal housing
M12X45
Hexagon headed bolt
0110645
8.8
86
Shaft seal
M4x...
Hexagon socket head screw
316 ST
2-2.9
Oil pump housing
M12x50
Hexagon headed bolt
0110650
8.8
86
Oil pump housing
M12x90
Hexagon headed bolt
0110651
8.8
86
Oil pump housing
M12x80
Hexagon headed bolt
0110652
8.8
86
10
Pump element
M6x20
Hexagon headed bolt
0110320
8.8
11
Oil filter
M10x80
Hexagon headed bolt
0110581
8.8
50
12
Suction flange
M12
Hexagon nut
0115610
86
13
Suction filter flange
M12
Hexagon nut
0110610
86
14
Pressure flange
M12
Hexagon nut
0110610
86
15
Bearing cover
M10x40
Hexagon headed bolt
0110540
8.8
50
16
Cylindrical roller bearing
M10x55
0104555
8.8
50
17
Connecting rod
MF12x1.5
Hexagon nut
0145605
34-44
18
Valve central
M12x25
Stud
0151665
8.8
86
19
Valve central
M12
Hexagon nut
0145600
86
20
Valve
M5x35
0106240
8.8
21
Valve screw
M10x76
0176572
CrMo4
40
22
Valve screw nut
M10
Hexagon nut
0145500
30
23
Flange cap. control
M10x40
0104540
8.8
50
24
Flange cap. control
M5x10
0123010
12.9
25
Relief valve
M10x55
0104555
8.8
50
26
Sealing plug
G1/8
Plug G10
0136108
ST
20
27
Sealing plug
G1/4
Plug G13
0136134
ST
40
28
Sealing plug
G1/2
Plug G21
0136821
ST
60
29
Sealing plug
G3/4
Plug G27
0136827
ST
120
30
Oil regulator
G1
Plug G33
1241132
ST
200
31
Oil heater pipe
G1
Pipe
0385136
ST
200
5.2
WEAR LIMITS AND TOLERANCES

GRASSO 5HP
to be replaced, but moreover the condition of the part;

have the honing or grinding tracks of precision machined
butting or running faces not been worn off irregularly,
are there any visible discolouring of material, has the
Not only do the wear limits determine whether a part is

SIM2010/v002
- 73-
5. MISCELLANEOUS
roundness remained correct and are there any signs of

glazing of grind. All these wear factors make a part
virtually unserviceable, even if this part remains within its
wear limits.
Table 5.2-1 Wear limits and tolerances
Item
Description of part
Ref.
Limits (mm)
Remarks
Main bearing bush pump side
Main bearing bush driving side
11.46.759
Max. internal diameter 65+0.110
When fitted
Bearing bush small end of the

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

rod
11.44.336
When fitted
Crankshaft (main bearing and

crankshaft journal)
22.95.xxx
Min. external diameter 65-0.057
Crankshaft (axial play)
22.95.xxx
11.48.165
No play
Cylinder liner
23.94.086
Gudgeon pin
24.94.026
Max. internal diameter 26-0.007
Piston rings
20.94.020
max. gap 1.0
10
Piston / valve clearance
0.46 .. 0.89
11
Control pressure piston rings
09.70.056
09.70.040
Wear 75% of the circumference
12
Control pressure piston housing
23.94.xxx
max. 56.06
13
Bearing bush
27.36.500
Max. diameter 40.07
14
Spring valve lifting housing
11.31.133
Min. 60, Max. 64
15
Die spring
11.35.431
Min. 37.5, Max. 38.1
- 74-
Measured in non-scored part of

cylinder liner
SIM2010/v002
5. MISCELLANEOUS
5.3
REQUIRED SERVICE TOOLS AND

MATERIALS
Description
Grasso special tool kit TA
In order to properly carry out the disassembly, inspection

and assembly procedures described in this manual, the
service engineer should possess the following tools,
measuring equipment and aids.
Centre punch
Circlip pliers
Hammer (steel)
Table 5.3-1
Hammer (soft)
-Spanners:
Description
Ring spanners and socket
spanners (metric):
8-10 (2x)
-13-14-17-19-24-27-30-32-36-41
Hexagon socket head

spanners (metric):
8-13-10-17
Torque spanners (metric)
19-24-30-36
Pin-face wrench (metric) for

shaft seal
M4
Pair of pliers
Outside micrometer of
50-100 mm
for measuring piston clearance
Polishing paper
Polishing (compound) paste
Misc:
Inside micrometer of 50-100

mm
Outside micrometer of 0-50
mm
Remove split pin valve-lifting

mechanism
Loctite
Lead or tin soldering wire 2
mm
Inside micrometer of 0-50

mm
-Measuring equipment:
various service activities
Vacuum pump
(two) Screwdrivers (small)
e.g. for removing shaft seal
Screwdiver (large)
removing key
Abrasive linen
Silicon grease
Wire brush
Piston ring pliers
Depth micrometer of 0-50

mm
Grease
Vernier gauge of 10"
Self-made (crankshaft)
auxiliary tool
Feeling gauges of 0.05-1.00

mm
Auxiliary tools for shaft seal
Magnetic gauge with

extended plunger
Oil drip tray
removing and inserting

crankshaft
Steel strip
support buffer spring
Tube brush 10 mm
cleaning crankshaft oil

passageways
Bar 6 mm
cleaning crankshaft oil

passageways
Compressed air device
cleaning e.g. crankshaft oil

passageways
Hydraulic press
Heater approx. 80 C
SIM2010/v002
removing and inserting

connecting rod bearings
- 75-
5. MISCELLANEOUS
5.4
FITTING INSTRUCTIONS FOR PIPE

COUPLINGS AND DOUBLE LOCKING
RING
Fig. 5.4-1 Pipe couplings
Fig. 5.4-2 Double locking ring
A) Preparation
Saw off the pipe at right angles.
Deburr and clean the pipe end.
Oil thread, taper and clamping sleeve (facilitates
fitting).
In bends, the minimum length of the straight pipe
end must be twice the height of the union nut.

A = Coupling threaded piece
B = clamping sleeve
C = Union nut
D = Pipe
B)
Fitting
Slide union nut and clamping sleeve on the pipe
(mind the assembling sequence).

Press pipe against stop and tighten union nut by
hand.
Tighten a further half a turn (clamping sleeve is about
to grip).
Slack the union nut and retract pipe from stop by 2 3 mm.
Tighten 3/4 - 1 turn (ridges now penetrate into pipe).
On reassembly, only tighten up the union nut.
- 76-
SIM2010/v002
5. MISCELLANEOUS
SIM2010/v002
- 77-

Sim 5HP

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Reciprocating Compressors for industrial refrigeration

Series Grasso 5HP

Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP

This manual must be carefully read and understood prior

Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP

REPAIR AND OVERHAUL

EVACUATION/DRYING THE REFRIGERATING SYSTEM

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

EVACUATION OF REFRIGERANT BEFORE SERVICING

LEAK-TIGHTNESS AFTER SERVICING

EVACUATION AFTER SERVICING

START-UP AFTER SERVICING

DISMANTLING SUCTION GAS FILTER

DISMANTLING OVERFLOW VALVE

REMOVING CYLINDER HEAD

REMOVING DISCHARGE VALVE AND SUCTION VALVE ASSEMBLY

REMOVING PISTON/CONNECTING ROD ASSEMBLY

DISMANTLING ROTARY SHAFT SEAL

REMOVING OIL DISCHARGE FILTER ELEMENT

REMOVING OIL PUMP ASSEMBLY

INSPECTION AND PREASSEMBLY

BACK PRESSURE INDEPENDENT RELIEF VALVE

LUBRICATING OIL PRESSURE REGULATOR

CAPACITY CONTROL MECHANISM

INSPECTION DISCHARGE VALVES

INSPECTION SUCTION VALVES

INSPECTION PISTONS AND CONNECTING RODS

PRE ASSEMBLING PISTON AND CONNECTING ROD

INSPECTION CYLINDER LINER

OIL PUMP AND FILTERS

DISASSEMBLING OIL PUMP

REMOVING PUMP ELEMENT/BEARING ASSEMBLY

INSERTING OIL PUMP ELEMENT

OIL FILTER HOUSING

PRE ASSEMBLING BEARING COVERS

ROTARY SHAFT SEAL

Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP

CRANKSHAFT AND MAIN BEARINGS

OIL PUMP ASSEMBLY

OIL DISCHARGE FILTER

OIL SUCTION FILTER

OIL LUBRICATION PRESSURE REGULATOR

CYLINDER LINER, PISTON AND CONNECTING ROD

DETERMINING PISTON CLEARANCE

SUCTION VALVES AND DISCHARGE ASSEMBLE

ROTARY SHAFT SEAL

CRANKCASE SERVICE COVERS

PRESSURE RELIEF VALVE ASSEMBLY

OIL FILLING AND PRE LUBRICATION

TABLE OF TORQUES FOR BOLTS AND NUTS GRASSO 5HP

WEAR LIMITS AND TOLERANCES GRASSO 5HP

REQUIRED SERVICE TOOLS AND MATERIALS

FITTING INSTRUCTIONS FOR PIPE COUPLINGS AND DOUBLE LOCKING RING

Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP

Indicates an IMPORTANT note or procedure to which

5) Service & Maintenance Schedules

1) Product Information (PI)

6) Instructions for accessories

Grassos technical manuals includes generic

3) Service Instruction Manual (SIM)

Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP

Reciprocating Compressors for industrial refrigeration / Series Grasso 5HP

General info SIM