Maintenance — Shimadzu GC-2025
This page covers all user-level maintenance tasks for the Shimadzu GC-2025. Service engineer tasks (internal repairs, battery replacement) should only be performed by qualified Shimadzu personnel.
Maintenance Schedule Overview
Inspection & Replacement Schedule
| Task | Frequency | Parts Needed | Notes |
|---|---|---|---|
| Inspect Glass Insert | Before analysis series | None | Check for dirt, silica wool position |
| Replace Glass Insert | Every 100 injections | Glass insert + silica wool | Or if dirty/ghost peaks |
| Replace Septum | Every 100 injections | Septa (various types) | Or 50 for thick needles |
| Replace O-Ring | With glass insert replacement | Fluoride rubber O-ring | Or if carrier gas leak |
| Inspect/Replace Ferrule | As needed | Graphite ferrule (0.5 or 0.8) | If compressed, leaking, or ghost peaks |
| Re-condition Column | After long non-use | None | Or if ghost peaks/high noise |
| Replace Split/Purge Traps | Every 6 months | Trap (SPLIT/PURGE) | More often for high-BP compounds |
| Regenerate/Replace Molecular Sieve | When saturated | Molecular sieve filter | If unstable baseline/high noise |
| Rinse/Replace FID Jet & Igniter | As needed | FID Jet | If ignition fails or poor peaks |
| Inspect Door Switch | Every 6 months | None | If powered continuously |
| Clean GC Exterior | As needed | Cloth + neutral detergent | When dirty |
| Backup System Database | Periodically | None | After settings changes |
📋 From manual
Preparation for Injection Port Maintenance
⚠️ Before replacing septum, glass insert, or O-ring:
- Press SYSTEM key
- Select Maint INJ
- Injection port and oven temperatures will drop
- Carrier gas stops when temp < 50 °C
- Wait for message: “GC is ready for maintenance”
📋 From manual
Glass Insert Maintenance
When to Replace:
- Every 100 injections (default warning limit)
- If dirty or contaminated
- If ghost peaks appear — see 6. Ghost Peaks
- If tailing occurs — see 2. Poor Peak Shape
Parts Required:
- Glass insert for split: P/N 221-41444 or S221-41444-01
- Glass insert for splitless: P/N 221-48335-01 or S221-48335-01
- Deactivated insert with wool (5 pcs): P/N S221-48876-03
- Silica wool: P/N 221-48600 or S221-48600
For the difference in wool packing between split and splitless modes, see Hardware Differences.
📋 From manual
Glass Insert & O-Ring Replacement (Detailed)
| Step | Action | Important Notes |
|---|---|---|
| 1 | Hold septum nut, loosen/remove glass insert nut | — |
| 2 | Lift septum nut assembly straight up, move aside | Avoid breaking glass |
| 3 | Use tweezers to lift glass insert out | If O-ring stuck, gently turn with tweezers first |
| 4 | Remove old O-ring | — |
| 5 | Place new fluoride O-ring ~4 mm from top of insert | — |
| 6 | Insert glass insert, push down until touching bottom | Positions O-ring perfectly at 3 mm from top |
| 7 | Move septum nut back over insert | — |
| 8 | Tighten insert nut by hand, then 1/3 to 1/2 turn with wrench | — |
⚠️ Warning: Never attempt to remove/install while hot (>50 °C). Can seize and damage threads permanently.
📋 From manual
Septum Replacement
When to Replace:
- Every 100 injections (standard guideline)
- Every 50 injections if using thick needles
- If visible damage or leakage
Available Types:
| Type | Part Number |
|---|---|
| Silicon rubber septa (20 pcs) | 201-35584 or S201-35584 |
| High temperature septa (20 pcs) | S221-48398-91 |
| LL long-life septa (20 pcs) | S221-48972-91 |
| Thermogreen LB-2 (10 pcs) | S221-35507-01 |
Septum Replacement (Detailed)
| Step | Action | Important Notes |
|---|---|---|
| 1 | Set column inlet pressure to 0 kPa | Prevents pressure shift that dislodges glass wool |
| 2 | Remove septum nut, needle guide, old septum | — |
| 3 | Use tweezers to handle new septum | ⚠️ Never touch with bare hands (causes ghost peaks) |
| 4 | Insert new septum, replace needle guide and nut | — |
| 5 | Tighten septum nut by hand fully | — |
| 6 | Loosen by half turn | Or tighten until touching nut below, then loosen half turn (autosampler) |
📋 From manual
Graphite Ferrule Inspection/Replacement
When to Replace:
- When installing new column
- If fully compressed
- If tightening doesn’t stop a leak
- If baseline drifts during temperature ramps
- If ghost peaks occur
Parts:
| Type | Part Number |
|---|---|
| Graphite ferrule 0.5 (10 pcs) | 221-32126-05 or S221-32126-05 |
| Graphite ferrule 0.8 (10 pcs) | S221-32126-08 |
Graphite Ferrule Replacement (Detailed)
| Step | Action |
|---|---|
| 1 | Remove wire from new ferrule, slide onto column |
| 2 | Pull column through insertion jig until 10 mm protrudes |
| 3 | Tighten column nut to fasten ferrule at this position |
| 4 | Clip column end flush with jig using capillary cutter |
| 5 | Remove loose graphite dust with tweezers |
| 6 | Position ferrule: 34 mm from tip (injection port) or 69 mm from tip (FID detector) |
Ferrule Reconditioning: If contaminated but not physically degraded, hold in blue gas burner flame for 1–2 seconds until red hot. Use heat-resistant pliers.
📋 From manual
Column Conditioning Procedure
When Needed:
- After long periods of non-use
- If ghost peaks present
- If baseline noise is high
Procedure:
- Disconnect detector end of column
- Set carrier gas to normal analysis flow rate
- Heavily reduce split ratio to conserve gas
- Set oven temp ~30 °C higher than normal operating temp
- ⚠️ Never exceed column manufacturer’s max temperature (high heat + trace oxygen destroys liquid phase permanently)
- Bake for several hours
- Cool and reconnect to detector
- Verify performance with test injection
📋 From manual
Split/Purge Trap Replacement
When to Replace:
- Every 6 months (guideline)
- More frequently if analyzing high-boiling point compounds
- If clogged
Parts:
- Trap (SPLIT): P/N 221-42559-92 or S221-42559-92
- Trap (PURGE): P/N 221-42559-92 or S221-42559-92
Procedure:
- Stop carrier gas flow completely
- Remove panel from INJ/DET unit
- Replace one trap at a time (prevents mixing flow lines)
- Disconnect blank nuts from new trap
- Install into flow line matching codes:
- S = Split flow line
- P = Septum Purge flow line
- C = Carrier gas inlet
📋 From manual
Molecular Sieve Filter Regeneration
When to Regenerate/Replace:
- If baseline is unstable
- If noise is significant
- If filter is saturated
Parts: Molecular sieve filter: P/N 221-34121-94 or S221-34121-94
Regeneration Procedure
| Step | Action |
|---|---|
| 1 | Stop carrier gas, remove panel, remove filter |
| 2 | Connect filter to standalone gas supply |
| 3 | Flow N₂ or He in reverse direction at 10–20 mL/min |
| 4 | Bake at 300 °C for 3–4 hours |
| 5 | Immediately reinstall to prevent air contamination |
Replacement Procedure
- Remove old filter
- Install new filter
- Leak check
- Verify baseline
📋 From manual
FID Component Replacement (Igniter & Jet)
When to Service:
- If ignition fails — see 5. FID Ignition Failure
- If flame goes out frequently
- If peaks aren’t detected
- If peak shape is abnormal
Parts:
| Part | Part Number |
|---|---|
| Standard jet (0.3 mm ID) | S221-48258-91 |
| Jet for water analysis (0.8 mm ID) | S221-49373-91 |
| FID collector | S221-72322-91 |
| Igniter | S221-41847-93 |
⚠️ Safety First:
- Stop hydrogen supply
- Extinguish flame
- Ensure detector temp < 50 °C
- Turn off FID power
- Remove column
Procedure:
| Step | Action |
|---|---|
| 1 | Loosen and remove two collector screws |
| 2 | Lift collector straight up, detach cables |
| 3 | Lift high-voltage plate up |
| 4 | Pull high-voltage cable and spring out horizontally |
| 5 | Use hexnut screwdriver to remove FID jet |
| 6 | Insert new jet, tighten securely |
| 7 | Reinstall high-voltage unit |
| 8 | Connect new igniter cable (if replacing) |
| 9 | Place collector back, tighten screws |
📋 From manual
Consumables Inventory
Injection Port Consumables
| Part | Part Number | Typical Lifetime |
|---|---|---|
| Silicon rubber septa (20 pcs) | 201-35584 or S201-35584 | 100 injections |
| High temp septa (20 pcs) | S221-48398-91 | 100 injections |
| LL long-life septa (20 pcs) | S221-48972-91 | 100 injections |
| Thermogreen LB-2 (10 pcs) | S221-35507-01 | 100 injections |
| Glass insert (split) | 221-41444 or S221-41444-01 | 100 injections (or when dirty) |
| Glass insert (splitless) | 221-48335-01 or S221-48335-01 | 100 injections (or when dirty) |
| Deactivated insert w/ wool (5 pcs) | S221-48876-03 | When contaminated |
| Glass wool (2g) | 221-48600 or S221-48600 | With insert replacement |
| Fluoride O-ring (5 pcs) | 036-11203-84 or S036-11203-84 | With insert replacement |
Column & Detector Consumables
| Part | Part Number | Typical Lifetime |
|---|---|---|
| Graphite ferrule 0.5 (10 pcs) | 221-32126-05 or S221-32126-05 | When compressed or leaking |
| Graphite ferrule 0.8 (10 pcs) | S221-32126-08 | When compressed or leaking |
| FID jet standard (0.3 mm) | S221-48258-91 | If clogged or ignition issues |
| FID jet water analysis (0.8 mm) | S221-49373-91 | If clogged or damaged |
| FID collector | S221-72322-91 | If heavily contaminated |
| FID igniter | S221-41847-93 | If filament broken |
Gas Flow & Maintenance Parts
| Part | Part Number | Typical Lifetime |
|---|---|---|
| Trap (SPLIT) | 221-42559-92 or S221-42559-92 | Every 6 months |
| Trap (PURGE) | 221-42559-92 or S221-42559-92 | Every 6 months |
| Molecular sieve filter | 221-34121-94 or S221-34121-94 | When saturated |
| Aluminum gaskets (100 pcs) | 201-35183 | When damaged |
| Aluminum gaskets (500 pcs) | S201-35183-84 | When damaged |
📋 From manual
Service Engineer Tasks
⚠️ The following tasks must only be performed by qualified Shimadzu service personnel:
- CPU backup battery replacement (approx. every 5 years)
- Internal hardware repairs
- Circuit board diagnostics
- Removing side covers
- Advanced detector troubleshooting
📋 From manual
Maintenance Log Template
═══════════════════════════════════════════════════════
GC-2025 MAINTENANCE LOG
═══════════════════════════════════════════════════════
Date: _______________ Technician: _______________
TASK PERFORMED:
[ ] Glass insert replaced
[ ] Septum replaced
[ ] O-ring replaced
[ ] Ferrule replaced
[ ] Column re-conditioned
[ ] Traps replaced (SPLIT/PURGE)
[ ] Molecular sieve regenerated/replaced
[ ] FID jet cleaned/replaced
[ ] FID igniter replaced
[ ] FID collector replaced
[ ] Other: ________________________________
PARTS USED:
Part Name: _______________ P/N: _______________
Part Name: _______________ P/N: _______________
INJECTION COUNT SINCE LAST SERVICE:
Glass Insert: _______
Septum: _______
OBSERVATIONS/ISSUES:
_________________________________________________
_________________________________________________
NEXT SERVICE DUE:
_________________________________________________
Signature: _______________ Date: _______________
═══════════════════════════════════════════════════════
See Also
- Overview — Instrument specifications
- Quick_Start_Guide — Operation procedures
- Troubleshooting — Problem solving
- References — Technical documents