2201LZJE-HO-C6-N_2015.05.

Compound 2-stage Screw Compressor

2016 C Instruction Manual

**

2016LLC / 2016LMC / 2016LSC

2016MMC/ 2016MSC / 2016SSC

CAUTION
Before operating, servicing, or inspecting this product, read this manual thoroughly to
fully understand the contents.
Keep this Instruction Manual in a safe, designated place for future reference whenever
the manual is needed.
Specifications of this product and contents of this manual are subject to change without
prior notice due to technical improvements, and the like.
 2201LZJE-HO-C6-N_2015.05.
Preface

Preface

Thank you for purchasing the compound 2-stage screw compressor 2016**C
(hereinafter referred to as "this product").
This Instruction Manual (hereinafter referred to as "this manual") provides safety information and
operation and maintenance procedures, so that users correctly understand how to handle this product
and, as a result, can use it safely and efficiently. This manual is applicable to the following models:
2016LLC-*B*-51, 2016LMC-*B*-51, 20162LSC-*B*-51, 2016MMC-*B-51, 2016MSC-*B*-51, 2016SSC-*B*-51
2016LLC-*B*-61, 2016LMC-*B*-61, 20162LSC-*B*-61, 2016MMC-*B-61, 2016MSC-*B*-61、2016SSC-*B*-61
* -51 (-61) may not be written. For more information, see 2.2 "Model designation of the compressor"
in this manual Chapter 2.

Before installing or using this product, make sure to read this manual.
Keep this manual in a safe place near this product for quick reference.

Revision History
Title Document No. First edition issue date

2016**C Instruction Manual 2201LZJE-HO-C6-N_2015.05. Dec. 16, 2013

Revision
Issue date Major Contents of revisions Created / approved by:
No.
- Jun. 30,1974 Issuance of 2016C first edition S. Yamamoto
- Oct.01,1983 Newly issued as 1612**C/2016**C edition. S. Yamamoto
- Jun. 30, 1993 Revision of 1612**C/2016**C S. Yamamoto
(correction of errors, etc.)
- Jun. 30,1996 Reviewed pursuant to the Product Liability Law, Ikehara / Shozu
established June 1994
00 Dec. 16, 2013 Overall review associated with reissue as Ikehara, / Hirao
electronic document, document No. change
01 May 01, 2015 Modified the constitution of Chapter 4 and Ikehara / Muta
Chapter 5. Correction of describing, etc.

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Warranty and Disclaimer

Warranty and Disclaimer

Warranty
MAYEKAWA shall repair or replace parts of this product for no charge if any failure resulting from
defects in design or manufacture occurs, under normal use with the purpose and method that are in
accordance with the specifications of this product and this manual, within the warranty period.
The warranty period is "12 months from factory shipment of this product". If there is a separate
agreement, that agreement shall prevail in principle.
MAYEKAWA is not liable for production or man-made disaster compensation due to malfunction or
damage of this product.

Disclaimer of Warranty
Although MAYEKAWA warrants the clauses mentioned above, the following clauses are exempted.

 Malfunction or damage of this product caused by natural disaster, or other accidental forces
(such as fire, thunderbolt, windstorm, intense rainfall, flood, tidal wave, earthquake, land
subsidence, etc.).
 Malfunction or damage caused by misusage described below.
 Malfunctions, damage, or deterioration of this product due to abnormal or improper use
(including improperly storing this product outdoors or under too hot/humid conditions,
unexpected inspections, tests, operations, too frequent liquid flow-back operation*, and
too frequent start-stop cycles, etc.).
 Malfunction or damage caused by devices or equipments not provided by MAYEKAWA
including operation control methods of those devices.
 Malfunction or damage caused by refrigerants, gases, or refrigerant oils, and operating
conditions (design conditions) not approved for this product.
 Malfunction or damage caused by maintenance or inspection not recommended by
MAYEKAWA.
 Malfunction or damage caused by parts that are not genuine.
 Malfunction or damage caused by remodeling the product without approval of
MAYEKAWA.
 Malfunction or damage caused by unexpected misusage

"Liquid flow-back operation" is ･･･

Normally, while the compressor sucks in the refrigerant liquid only after vaporizing it in the
evaporator, it may directly sucks it in because of the faulty adjustment or failure of the
expansion valve. We call this state of compressor operation "liquid flow-back operation".
No compressor can compress a liquid. The compressor may be damaged should the liquid be
sucked in.

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Important Information

Important Information

Intended Use of This Product

This product is a general-purpose screw compressor for refrigeration, cold storage and various gases
compression. Do not use this product for any other purposes that are not intended for or which depart
from the specifications. For specifications of this product, refer to "2.3 Compressor Specifications".
Please perform the maintenance items described in this manual by using safe and assured procedures.

Important Information for Safe Use of This Product

Although MAYEKAWA has paid a lot of attention to safety measures for this product, all hazards
including potential hazards caused by human errors, or due to environmental conditions can not be
anticipated.
As there are too many items to be strictly observed or prohibited when using this product, it is
impossible to inform all of them through this manual or warning labels. Therefore, when operating this
product, pay extreme caution on personnel safety as well as on items described in this manual.
Important rules for safety work with this product that apply to all workers including managers and
supervisors are listed below.
Please read this manual before using this product. Fully understand the instructions provided there,
and be sure to perform the safety procedures described in this manual.
 Operation, maintenance, and inspection of this product should be performed by qualified
personnel educated about the fundamentals of this product and trained about hazards
involved and measures to avoid danger.
 Do not allow any person other than those educated on the fundamental expertise of this
product and trained about hazards involved and measures to avoid dangers to approach this
product while it is operating or during maintenance.
 Observe all related federal/national and local codes and regulations.
 To prevent accidents, do not carry out any operation or maintenance other than those
described in this manual. Do not use this product for any purpose other than intended.
 Replace the parts with genuine parts.
 Not only workers but also managers should actively participate safety and health activities in
the workplace to prevent accidents.
 When closing or opening a valve during work, make sure to apply lockout/tagout to prevent
the valve from being accidentally closed or opened during the work.

[Lockout] To lock with a key in order to keep people, except the workers involved, from
operating the product.
Lockout means disconnecting or keeping disconnected machines and devices by locking their
energy (power) sources. Lockout is not just simply turning off the power switches to stop the supply
of power, but includes immobilizing them with a key or similar device to keep any blocked switches
from being operated.
Lockout devices are devices such as keys, covers, and latches, to immobilize switches, valves,
opening and closing levers, etc., with a state of being locked.

[Tagout] To prevent any inappropriate work by hanging tag plates indicating "work in
progress".
Tagout means to clearly indicate, by hanging tag plates, that a device is in lockout and that
operation of the device is prohibited. Tag plates forbidding operation, starting, opening, etc. are
warnings clearly stating to not operate energy (power) sources, and are not for stopping blocking
devices.

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Important Information

Observe the following precautions when performing maintenance work on electrical control.
 Electrical maintenance of the product must be performed by certified/qualified personnel and
only those educated about the electrical control of the product.
 Before servicing or inspecting the electrical equipment or devices, turn "OFF" the motor main
power and control power, and perform lockout/tagout to prevent the power from being turned
on during work.
Even when the motor main power and control power are turned "OFF", this product may be turned on if
the power is supplied from outside the package unit in which this product is used. Make sure the power
supply on the power source side is shut off, and perform lockout/tagout to prevent this product from
being turned on during work.

About This Manual

 This product may be modified without prior notice. Therefore, the appearance of actual
machine may differ from the descriptions in this manual. If you have any questions, contact
our sales offices or service centers. For each sight of MAYEKAWA, refer to "Contact
Information" in this manual or following URL. http://www.mayekawa.com/about/network/
 This manual is in English. If any other language is required, it is the customers responsibility
to prepare a manual for safety education and operation instructions.
 This manual is copyrighted. Drawings and technical references including this manual shall not,
in whole or part, be copied, photocopied, or reproduced into any electronic medium or
machine-readable form without prior permission from MAYEKAWA.
 Photographs or drawings included in this manual may differ from the appearance of actual
product.
 If this manual is lost or damaged, immediately request our local sales offices or service
centers for a new manual. Using this product without the manual may result in safety issues.
 If you resell this product, never fail to attach this manual to this product.

Construction of This Manual

Chapter/Section Title Details
Preface Describes the outline of this manual and how to use it.
Describes what MAYEKAWA warrants and what are covered by
Warranties and Disclaimer
the warranties. Warranty exemption is stated as disclaimer.
Describes important information related to this product and this
Important Information
manual.
Describes workers' safety information, safety measures taken for
1. Safety this product, and administrative control on industrial safety which
is required when handling this product.
2. Compressor Specifications and Describes main components of this product and their functions,
Structure specifications and operating limits.
3. Installation Describes procedures for installing this product.
4. Compressor and Package Unit Describes precautions for using this product.
Operation
Describes inspection locations & frequency and assembly &
5. Maintenance and Inspection
disassembly of this product.
Regarding major troubles that may occur during use of this
6. Troubleshooting product, describes how this product will act as well as what
actions should be taken when a trouble may occur.
7. Related Documents Shows materials such as exploded drawings and parts list.
Provides contact information for our sales offices and service
Contact Information centers which is to be used for purposes such as
genuine parts ordering.

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Table of Contents

Table of Contents
Preface .................................................................................................................... ⅰ
Revision History ..................................................................................................... ⅰ
Warranty and Disclaimer ....................................................................................... ⅱ
Important Information ............................................................................................ ⅲ
Intended Use of This Product ........................................................................................... ⅲ
Important Information for Safe Use of This Product .......................................................... ⅲ
About This Manual ............................................................................................................. ⅳ
Construction of This Manual .............................................................................................. ⅳ
Table of Contents ................................................................................................... ⅴ

Chapter 1 Safety
1.1 Strict Requirements and Prohibitions........................................................ 1-1
1.1.1 Strict Requirements (Do’s)................................................................................... 1-1
1.1.1.1 Do’s on Operation ........................................................................................ 1-1
1.1.1.2 Do’s on Maintenance ................................................................................... 1-1
1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power ................................. 1-1
1.1.1.4 Do’s about Personal Protective Gear .......................................................... 1-2
1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances.......................... 1-2
1.1.1.6 Do’s about Handling Emergency Situations ................................................ 1-2
1.1.1.7 Do’s about Waste Oil, Fluid, and Materials ................................................. 1-2
1.1.1.8 Other Do’s.................................................................................................... 1-2
1.1.2 Prohibitions (Don’ts) ......................................................................................... 1-3
1.2 Warnings ....................................................................................................... 1-3
1.3 Residual Risks ............................................................................................. 1-4
1.4 Safety Devices .............................................................................................. 1-6
1.4.1 Emergency Stop Button ....................................................................................... 1-6
1.4.2 Breakers of Motor Main Power and Control Power
(with Lockout/Tagout Mechanism) ...................................................................... 1-6
1.4.3 Compressor Protective Devices .......................................................................... 1-7

Chapter 2 Compressor Specifications and Structure

2.1 Overview of the 2016**C ............................................................. 2-1
2.2 Model Designation of the Compressor ................................................... 2-1
2.3 Compressor Specifications ........................................................................ 2-2
2.3.1 Standard Specifications ....................................................................................... 2-2
2.3.2 Operation Limits ................................................................................................... 2-4
2.3.3 Outer Dimensions ................................................................................................ 2-4
2.4 Structure of Compressor .......................................................................... 2-10
2.4.1 Sectional View ................................................................................................... 2-10

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2.5 Mechanisms ............................................................................................... 2-11

2.5.1 Basics of the Screw Compressor ...................................................................... 2-11
2.5.2 Suction Process ................................................................................................. 2-11
2.5.3 Compression Process........................................................................................ 2-12
2.5.4 Discharge Process............................................................................................. 2-12
2.5.5 About Volume Ratio (Vi) .................................................................................... 2-12
2.5.6 Capacity Control Mechanism ............................................................................. 2-14
2.5.7 Bearings and Balance Piston ............................................................................ 2-14
2.5.8 Shaft Seal .......................................................................................................... 2-14
2.6 Gas and Oil Flow ........................................................................................ 2-15

Chapter 3 Installation
3.1 General Precautions for Installation .......................................................... 3-1
3.2 Installation Works ........................................................................................ 3-1
3.2.1 Unpacking ............................................................................................................ 3-1
3.2.2 Storage ................................................................................................................ 3-1
3.2.3 Transportation ...................................................................................................... 3-1
3.2.4 Preparation for Installation ................................................................................... 3-4
3.2.5 Installation ............................................................................................................ 3-5
3.2.5.1 Installation.................................................................................................... 3-5
3.2.5.2 Shaft Alignment between the Compressor and Driving Machine ................ 3-5
3.2.5.3 Piping Connection ....................................................................................... 3-6
3.2.5.4 Equipment and Devices for Protection of the Compressor ......................... 3-6
3.2.6 Airtightness Test .................................................................................................. 3-7
3.2.7 Lubricating Oil Charge ......................................................................................... 3-7
3.2.7.1 Initial Charge of Lubricating Oil ................................................................... 3-7
3.2.7.2 Additional Charge of Lubricating Oil ............................................................ 3-7
3.2.8 Charge of Refrigerant .......................................................................................... 3-7
3.2.9 Check after Installation ........................................................................................ 3-7

Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil) ................................................................. 4-1
4.1.1 Precautions for Selecting the Lubricating Oil....................................................... 4-1
4.1.2 Recommended Lubricating Oils .......................................................................... 4-1
4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant .......................... 4-1
4.1.2.2 Oils for systems using Hydrofluorocarbon (HFC) refrigerants .................... 4-2
4.1.3 Change of Lubricating Oil Brand ......................................................................... 4-3
4.1.4 Precautions for Handling lubricating Oil .............................................................. 4-4
4.1.4.1 Precautions for Handling Polyalkylene Glycol (PAG) .................................. 4-4
4.1.4.2 Precautions for Handling Polyolester (POE) Oil .......................................... 4-4
4.1.5 Lubricating Oil Management Criteria ................................................................... 4-5
4.1.6 Lubricating Oil Replacement Timing .................................................................... 4-6

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4.1.6.1 After Starting the Initial Operation ............................................................... 4-6

4.1.6.2 During Normal Operation............................................................................. 4-6
4.2 Precautions for Operation ........................................................................... 4-7
4.2.1 Prevention of Liquid Flow-back Operation........................................................... 4-7
4.2.2 Purging of Non-Condensable Gases ................................................................... 4-7
4.3 When Stopping the Compressor for a Long Time .................................... 4-8

Chapter 5 Maintenance and Inspection

5.1 Precautions for Maintenance and Inspection............................................ 5-1
5.2 Maintenance and Inspection List................................................................ 5-3
5.2.1 Daily Management ............................................................................................... 5-3
5.2.2 Periodic Inspection .............................................................................................. 5-5
5.2.3 Guidelines for the Timing of Compressor Overhaul ............................................ 5-6
5.3 Compressor Disassembly Preparation ...................................................... 5-7
5.3.1 Disassembly Tools and Workplace ..................................................................... 5-7
5.3.2 Replacement Parts .............................................................................................. 5-7
5.3.3 Refrigerant Gas Recovery ................................................................................. 5-10
5.3.4 Removal of Connections to the Unit .................................................................. 5-11
5.3.5 Removal and Lifting the Compressor ................................................................ 5-12
5.3.6 Draining Oil from the Compressor ..................................................................... 5-12
5.4 Disassembly and Inspection ..................................................................... 5-13
5.4.1 Shaft Seal Block ................................................................................................ 5-15
5.4.1.1 Disassembly .............................................................................................. 5-15
5.4.1.2 Inspection .................................................................................................. 5-16
5.4.2 Unloader Indicator ............................................................................................. 5-18
5.4.2.1 Disassembly .............................................................................................. 5-18
5.4.2.2 Inspection .................................................................................................. 5-20
5.4.3 Unloader Cover .................................................................................................. 5-21
5.4.3.1 Disassembly .............................................................................................. 5-21
5.4.3.2 Inspection .................................................................................................. 5-22
5.4.4 Unloader Piston and Unloader Cylinder ............................................................ 5-22
5.4.4.1 Disassembly .............................................................................................. 5-22
5.4.4.2 Inspection .................................................................................................. 5-23
5.4.5 Bearing Cover .................................................................................................... 5-24
5.4.5.1 Disassembly .............................................................................................. 5-24
5.4.6 Separating High-stage and Low-stage .............................................................. 5-25
5.4.6.1 Disassembly .............................................................................................. 5-25
5.4.7 Gear Coupling .................................................................................................... 5-25
5.4.7.1 Disassembly .............................................................................................. 5-26
5.4.7.2 Inspection .................................................................................................. 5-26
5.4.8 Balance Piston Cover ........................................................................................ 5-27
5.4.9 Balance Piston ................................................................................................... 5-27
5.4.9.1 Disassembly .............................................................................................. 5-27

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5.4.9.2 Inspection .................................................................................................. 5-28

5.4.10 High-stage Suction Cover and Side Bearings ................................................... 5-29
5.4.10.1 Disassembly .............................................................................................. 5-29
5.4.10.2 Inspection .................................................................................................. 5-30
5.4.11 Low-stage Suction Cover and Side Bearings .................................................... 5-31
5.4.11.1 Disassembly .............................................................................................. 5-31
5.4.11.2 Inspection .................................................................................................. 5-31
5.4.12 Thrust Bearing Block ......................................................................................... 5-32
5.4.12.1 Disassembly of the High-stage Thrust Bearing Block ............................... 5-32
5.4.12.2 Disassembly of the Low-stage Thrust Bearing Block ................................ 5-33
5.4.12.3 Inspection (High-stage and Low-stage) ..................................................... 5-33
5.4.13 High-stage Rotors and Main Rotor Casing ........................................................ 5-35
5.4.13.1 Disassembly .............................................................................................. 5-35
5.4.13.2 Inspection .................................................................................................. 5-35
5.4.14 Low-stage Rotors and Main Rotor Casing......................................................... 5-36
5.4.15 High-stage Bearing Head and Main Bearings ................................................... 5-37
5.4.15.1 Disassembly .............................................................................................. 5-37
5.4.16 Low-stage Bearing Head and Main Bearings .................................................... 5-38
5.5 Reassembly ................................................................................................ 5-39
5.5.1 Unloader Slide Valve and Guide Block.............................................................. 5-41
5.5.2 Bearing Head and Main Bearings ...................................................................... 5-42
5.5.3 Bearing Head and Main Rotor Casing ............................................................... 5-43
5.5.4 Installing Rotors ................................................................................................. 5-44
5.5.5 Suction Cover and Side Bearings ...................................................................... 5-45
5.5.6 Balance Piston Sleeve ....................................................................................... 5-46
5.5.7 Installing Suction Cover ..................................................................................... 5-47
5.5.8 Thrust Bearing Block ......................................................................................... 5-49
5.5.8.1 End Clearance Measurement .................................................................... 5-51
5.5.8.2 Procedure for End Clearance Adjustment ................................................. 5-53
5.5.8.3 Tightening after Finishing the End Clearance Adjustment ........................ 5-52
5.5.9 Bearing Cover .................................................................................................... 5-54
5.5.10 Coupling High-stage and Low-stage Blocks ...................................................... 5-55
5.5.11 Balance Piston Cover and High-stage Unloader Cylinder................................. 5-57
5.5.12 Low-stage Unloader Cylinder ............................................................................ 5-59
5.5.13 Shaft Seal Block ................................................................................................ 5-61
5.5.13 Unloader Cover .................................................................................................. 5-64
5.5.15 Unloader Indicator ............................................................................................. 5-65
5.5.15.1 Potentiometer ............................................................................................ 5-65
5.5.15.2 Micro-switches and Micro-switch Cam ...................................................... 5-66
5.5.15.3 Reassembly ............................................................................................... 5-66

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Chapter 6 Troubleshooting
01: Compressor does not start up ................................................................................ 6-1
02: Compressor stops immediately after startup.......................................................... 6-1
03: Unusually low pressure (decrease of suction pressure) ........................................ 6-2
04: Low oil pressure (low lubricating oil supply pressure) ............................................ 6-2
05: Intermediate pressure is unusually high................................................................. 6-3
06: Unusually high pressure (abnormal discharge pressure) ...................................... 6-4
07: Discharge temperature is abnormally high............................................................. 6-5
08: Leak from mechanical seal..................................................................................... 6-6
09: Squeaking of mechanical seal................................................................................ 6-7
10: Capacity control position is indicated incorrectly.................................................... 6-7
11: Capacity control malfunction .................................................................................. 6-8
12: Compressor generates abnormal vibration and/or sound ...................................... 6-9

Chapter 7 Related Documents

7.1 Development Views, Assembly Sectional Views ...................................... 7-1
7.2 Parts Configuration Table ......................................................................... 7-13
7.3 Tightening Torques for Bolts and Nuts ................................................... 7-20
7.4 About the O-rings Used............................................................................. 7-22
7.4.1 List of O-rings Used ........................................................................................... 7-22
7.4.2 O-ring Materials Used for Screw Compressor ................................................... 7-22
7.5 Tools for Disassembly............................................................................... 7-23

Contact Information
Sales Offices in Japan ........................................................................................... Contact-1
Manufacturing Bases in Japan............................................................................... Contact-1
Global Network....................................................................................................... Contact-2
NORTH AMERICA ........................................................................................................ Contact-2
EUROPE and AFRICA .................................................................................................. Contact-2
ASIA PACIFIC ............................................................................................................... Contact-3
LATIN AMERICA ........................................................................................................... Contact-5

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Chapter 1 Safety

Chapter 1 Safety
1.1 Strict Requirements and Prohibitions
1.1.1 Strict Requirements (Do’s)
1.1.1.1 Do’s on Operation
 Make sure to install safety and protective devices on the package unit.
 Regularly inspect the safety and protective devices if they function properly.
 If the safety or protective devices do not work properly or if this product operates abnormally,
immediately stop the operation and report to the supervisor. Obtain his/her approval and
direction before restarting this product.
 If this product stops for unknown reasons, immediately inform your supervisor of it. Obtain
his/her approval before restarting the compressor.
 Some types of refrigerants emit bad smell or toxic gases when they leak. Make sure to
ventilate the air during operation.
 For the properties of refrigerant and lubricating oil (corrosiveness, decomposability or toxicity),
be sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.
 When stopping the operation of this product, close the suction and discharge side shut-off
valves and turn "OFF" the motor (main power), heater power, and control power.

1.1.1.2 Do’s on Maintenance

 Prepare work procedures based on a work schedule. Be sure to perform danger forecasting
before starting the work.
 Before performing the work together with at least one other person, thoroughly confirm each
other's work details and procedures to acknowledge the other worker's movement.
 When troubleshooting during operation or before performing setup, cleaning, maintenance, or
inspection of this product, always turn OFF the main power to the motor and control power and
other devices. Also, lock and tag out them to prevent the power from being supplied
erroneously during operation.
 When troubleshooting during operation or before performing setup, cleaning, maintenance, or
inspection of this product, confirm that the pressure inside this product and the package unit is
at atmospheric pressure.
 Some refrigerants in use generate bad smell or toxic gases, or may cause deficiency of
oxygen. Before starting work, measure oxygen concentration in the work area as necessary.
Ventilate the area well. Be sure to keep the area well ventilated until the work is finished.
 For the properties of refrigerant and lubricating oil (corrosiveness, decomposability or toxicity),
be sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.
 After using tools always restore to designated place and never leave tools in the package unit.

1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power

 Attach lockout/tagout mechanism to the main breakers of motor main power and control power.
Lockout/tagout after power off is a very effective means to secure safety. It can prevent the
power source from being turned on by accident by two or more workers which may cause
injury to other worker(s).

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 2201LZJE-HO-C6-N_2015.05.
Chapter 1 Safety

 If there are any possibilities of danger during works (especially during cleaning, maintenance
and inspection, and troubleshooting), turn "OFF" the motor main power and control power, and
perform lockout/tagout.
 In the following situations, workers may neglect to perform power source shutoff or
lockout/tagout. Clearly notify the workers of the necessity of lockout/tagout.
 It is assumed that workers do not perform lockout/tagout before starting work because it is
troublesome, and only turn "OFF" the main motor and control power.
 It is assumed that workers only turn off the main motor and control power and do not
lockout/tagout the main motor and control power, because they judge that there is no
danger.

1.1.1.4 Do’s about Personal Protective Gear

 Prepare and use protective gear complying with the safety standards of the regulations.
 Check the function of each protective gear before using.
 Wear designated clothes such as work outfits, with their cuffs tightly closed.
 Do not wear any neckties or jewelry as there is a risk of being entangled by a movable part or
rotating part. Put on a helmet as your hair may get entangled.
 Do not have anything in your pocket to prevent objects from falling into the package unit..

1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances

 Obtain the Safety Data Sheet (SDS) from manufacturers of hazardous and toxic substances.
Check the SDS and follow the handling instructions recommended by the manufacturers to
handle and store those substances.

1.1.1.6 Do’s about Handling Emergency Situations

 Formulate an emergency action plan complying with the regulations, and post it on a safe
place.

1.1.1.7 Do’s about Waste Oil, Fluid, and Materials

 Disposing of refrigerant and oil used for this product are subject to a number of regulations for
the environmental protection purposes. Follow the local, state, federal acts and regulations
and your company's rules when disposing of such waste oil, fluid and materials.

1.1.1.8 Other Do’s

 Clean the floor around the entire package unit.
Provide a safety passage.
 Walk only on the areas set up as a work floor. Also, do not leave tools and cleaning solutions
in that area.
 If water or oil is spilled on this product or the floor, immediately wipe it off to prevent workers
from slipping and getting injured.

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Chapter 1 Safety

1.1.2 Prohibitions (Don’ts)

 Do not remove or relocate any safety device, including electrical interfaces.
 Do not disable any safety device by short-circuiting or bypassing without any permission.
 Do not leave this product unsafe and unattended, by removing a safety cover or some other
measures.
 Do not touch, clean or lubricate any part of this product which is moving.
 Do not touch relays or electric systems such as terminal block with bare hands when turning
on the power.

1.2 Warnings
The warning messages described in this manual warn dangerous situations that may arise during work
by using the following four categories.
Neglecting such warnings may cause accidents, resulting in personal injury or even death.
Also, this product or its auxiliary equipment may be heavily damaged. Therefore, be sure to always
observe the instructions of the warnings.

Table 1-1 Warning Symbols and their Meanings

Symbol Meaning
Indicates a hazardous situation which, if not avoided, could very likely cause serious
injury or death.
Indicates a potentially hazardous situation which, if not avoided, may cause serious injury
or death.
Indicates a potentially hazardous situation which, if not avoided, may cause minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.

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Chapter 1 Safety

1.3 Residual Risks

The following information assumes that this product is operated or inspected/maintained while being
used in general refrigerating/cold storage/gas compression package units.
Note that all hazardous sources cannot be predicted for the applications mentioned.
Devise appropriate countermeasures for hazardous sources in your systems.

Table 1-2 Hazardous Sources

Countermeasures in
Countermeasures in
Hazardous sources Predicted hazard cleaning, inspection,
operation
and parts exchange
A Motor and  Caught in due to contact  Install coupling cover  Turn off motor main
compressor coupling and prohibit opening. power and control power,
Refer to Figure 1-1  Keep away. and conduct
lockout/tagout.
B Motor terminals  Electric shock caused by  Keep away.  Turn off motor main
contact with live wires or  Do not open terminal power and control power,
electrical leakage boxes. and conduct
 Do not touch terminal lockout/tagout.
boxes.
C Compressor  Frostbite due to contact  Keep away and do not  Wear protective gear.
low-stage side  Contact with or inhalation touch.  Work under room
suction casing of hazardous substances  Wear protective gear. temperature.
Refer to Figure 1-1 generated by leakage of  Detect gas leakage.
refrigerant or the like
D Compressor  Burn injury due to contact  Keep away and do not  Wear protective gear
intermediate piping  Contact with or inhalation touch  Work in temperatures
(low-stage discharge of hazardous substances  Wear protective gear below 40 °C
port to high stage generated by leakage or  Gas leakage detection
suction port) spout of refrigerant or the
Refer to Figure 1-1 like
E Compressor  Burn injury due to contact  Keep away and do not  Wear protective gear.
high-stage side  Contact with or inhalation touch.  Work at a temperature of
discharge casing and of hazardous substances  Wear protective gear. not higher than 40°C.
discharge piping generated by leakage or  Detect gas leakage.
Refer to Figure 1-1 spout of refrigerant or the
like
F Check valves/service  Contact with or inhalation  Sufficient ventilation  Sufficient ventilation
valves and joints on of hazardous substances  Indicate valve  Wear protective gear.
each section of the generated by mishandling open/close state.  Tagout for controlled
package unit or leakage  Keep away and do not valve
 Frostbite or burn due to touch.
contact  Wear protective gear.
G Solenoid  Electric shock caused by  Install protective cover  Turn off each breaker and
valves/motor contact with live wires or on terminals, and the control power, and
operated valves on electrical leakage prohibit opening. conduct lockout/tagout.
each section of the  Pinched due to contact  Keep away and do not  Wear protective gear.
package unit with driving part touch.
 Wear protective gear.
H Electric components  Electric shock caused by  Install protective cover  Turn off each breaker and
in each section of the contact with live wires or on terminals, and the control power, and
package unit (oil electrical leakage prohibit opening. conduct lockout/tagout.
heater, protective  Pinched due to contact  Keep away and do not  Wear protective gear.
switch, etc.) with driving part touch.
 Wear protective gear.
I Package unit oil  Contact with hazardous  Sufficient ventilation  Sufficient ventilation
drains substances generated by  Keep away and do not  Wear protective gear.
leakage or spout touch.  Work at a temperature of
 Burn caused by contact  Wear protective gear. not higher than 40°C.
with high-temperature
fluid
J Noises  Damage caused by noise  Wear protective gear. —

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Chapter 1 Safety

C
A

E
D D
C

A
Figure 1-1 Locations of Hazardous Sources (compressor)

E
Photo 001 Locations of Hazardous Sources (Compressor)

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Chapter 1 Safety

1.4 Safety Devices

For safe use and protection of this product, make sure to attach safety devices to this product in
accordance with the regulations and the following instructions.
Safety devices cannot be kept in normal condition unless inspected and maintained at regular intervals.
Their maintenance and inspection need to be performed as an important part of the
maintenance/inspection work project. Provide users of this product with necessary information on the
safety devices, for example, types of the safety devices, installation position, function, and inspection
method of safety related devices.

 Check the safety devices after turning on the power and before operation of the
compressor. If they do not operate normally, immediately take repair or replace
safeties before starting compressor.

1.4.1 Emergency Stop Button

 Overview/Function/Purpose
The emergency stop buttons are used to stop the compressor operation immediately if an
emergency occurs in this product.

 Installation Positions
On the control board and in the operation control room

 Stop/Restoration Methods
The operating procedures for the emergency stop button, i.e., how to stop the operation and
restore the normal operating condition, must be clearly defined and the information provided to the
user of this product.

 Inspection Method/Cycle
The emergency stop buttons must be tested before commissioning and must also be periodically
re-tested after that. The inspection procedures and the inspection interval for the emergency stop
button must be clearly defined and the information provided to the user of this product.

1.4.2 Breakers of Motor Main Power and Control Power

(with Lockout/Tagout Mechanism)
 Overview/Function/Purpose
Turn off the main motor and control power, and if there is any possibility of danger during work
(especially during cleaning, maintenance, inspection, or troubleshooting), lockout/tagout devices
must be used on the breakers of the main motor and control powers to prevent injuries to workers in
case the power is turned on accidentally during work.

 Methods of Performing and Releasing Lockout/Tagout

Make sure to clearly notify methods of performing and releasing lockout/tagout referring to the
regulations created by Occupational Safety & Health Administration (OSHA) or local governing
body.

 Inspection Method/Cycle
The inspection procedures and the inspection interval for the lockout/tagout devices, must be
clearly defined and the information provided to the user of this product.

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Chapter 1 Safety

1.4.3 Compressor Protective Devices

 Be sure to adjust the set values and check operation of the protective devices at
the commissioning.

 Overview/Function/Purpose
These protective devices are used to protect this product.
 Protecting from discharge temperature rise (DT)
This device stops the compressor operation when the discharge temperature of the
compressor exceeds the set value.
Install a temperature sensing port to the discharge pipe.

 Protecting from oil temperature rise (OT)

This device stops the compressor operation when the oil temperature of the compressor
exceeds the set value.
Install a temperature sensing port to the package unit's oil supply pipe (after the oil cooler).

 Protecting from high pressure (HP)

This device stops the compressor operation when the discharge pressure abnormally rises
due to mishandling of the compressor or stoppage of cooling water supply to the condenser.
This device prevents explosion of the equipment and components.
Install a pressure sensing port to the discharge pipe.

 Protecting from intermediate pressure (IP)

This device controls the compressor appropriately when the intermediate pressure exceeds
the set value. In some cases, this device stops the compressor operation.
Install a pressure output port to the package unit's intermediate gas pipe (or compressor's
intermediate gas pressure output port).

 Protecting from suction pressure drop (LP)

This device stops the compressor operation when the suction pressure becomes below the
set value.
Install a pressure sensing port to the suction pipe.

 Protecting from oil pressure (OP)

This device stops the compressor operation when lubricating oil supply is not sufficient, the oil
filter is clogged, the refrigerant is mixed into the lubricating oil, and oil supply pressure
difference (from discharge pressure) becomes below the set value.
This device is to protect the compressor from wear and burnout.
Install a pressure sensing port to the package unit's oil supply pipe (after the oil pump) and the
discharge pipe.

 Protecting from motor overcurrent (OCR)

This device controls the compressor appropriately when the current exceeds the set value. In
some cases, this device stops the compressor operation.
This device is normally installed in the compressor operation controller.

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Chapter 1 Safety

 Connection Positions and Settings

Specify the connection position and setting for each compressor protective device, and make sure
to provide users of this product with them.
Make sure that the set values do not exceed the operating limits shown in Chapter 2, section 2.3.2
and Table 2-2 of this manual.

 Inspection Method/Cycle
Compressor protective devices require operation tests and confirmation of the settings calibration
before test run as well as at regular intervals.
Specify the inspection methods/intervals of the compressor protection devices, and make sure to
provide users of this product with such information.

 In the operation test, check that alarms and protective devices operate normally
by using devices such as pressure tester. Do not operate the compressor with all
the valves closed, or in any other dangerous conditions.
 If the protection from oil pressure (OP), high pressure (HP) activates, do not
restart operation until the cause of activation is removed.

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Chapter 2 Compressor Specifications and Structure

Chapter 2 Compressor Specifications and Structure

2.1 Overview of the 2016**C

The 2016**C model is the earliest model in the compound 2-stage screw compressor
C-series which started production in 1974 as well as 1612**C model..
The 2-stage compression system, which has hitherto required two units of standard-type screw
compressor for its embodiment, can now be realized by a single unit of compound 2-stage screw
compressor.
Generally, screw compressors use oil injection to keep discharge temperature at a low level during
operation without loss of volumetric efficiency even at high compression ratios. It can, therefore, be
operated with a single-stage compression system even at evaporative temperatures near -40 °C.
However, for normal use at low temperatures, a 2-stage compression system is applied in order to
improve kW/RT (ratio of power consumption versus cooling ability). If the 2-stage compression system
is configured with standard-type screw compressors, at least two screw compressor units need to be
installed, one on the high-stage and the other on the low-stage, which inevitably requires double
installation of the entire system including machinery, motors, utilities, etc.
This 2-stage screw compressor is produced to solve this problem. It is a single unit that has two
single-stage compressor units combined into one.
The 2016**C model has a capacity control mechanism for startup load reduction on the high-stage, and
a capacity control mechanism for coping with load change on the low-stage.
In addition, there are three specification types in rotor length for the low-stage and the high-stage each.
Moreover, customer is able to select each low-stage and high-stage volume ratio from two
specifications. Employing these combinations of each specification, 2016**C is providing a high
versatility that can satisfy a wide range of operation conditions required by different applications at the
load side.

2.2 Model Designation of the Compressor

This manual describes 2016**C-*B*-51 and 2016**C-*B*-61 models.
The meaning of the type designation, which is engraved on the MODEL column of the compressor
nameplate, is as follows.

*2016**C-*B*-51/61
5: Power frequency (6: 60Hz)
1: Indicates that it is a motor directly connected type.
* Unless specifically specified, machines manufactured in
September, 2010 or after do not have this indication engraved
on their nameplate.
Vi (volume ratio) specified for the high-stage discharge port,
standard value of which is L or M
Means a booster (low-stage machine)
Vi (volume ratio) specified for the low-stage discharge port, standard
value of which is L or M
Stands for Compound (compound 2-stage machine)
Specifications of high-stage rotor length, which is L, M or S
Specifications of low-stage rotor length, which is L, M or S
High-stage rotor diameter of 160
Low-stage rotor diameter of 200
Indicates working fluid
(Example: N = Ammonia, F= Fluorocarbon, P = Propane, HE = Helium)

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2.3 Compressor Specifications

2.3.1 Standard Specifications
Table 2-1 2016**C Standard Specifications
2016
Items
LLC LMC LSC MMC MSC SSC
Product mass kg 1180 1140 1100 1090 1050 1000
Low-stage swept volume
m3/h 1460/1210 1460/1210 1460/1210 1220/1020 1220/1020 975/810
@3550 min-1 /2950 min-1
High-stage swept volume
m3/h 749/622 624/519 499/415 624/519 499/415 499/415
@3550 min-1 /2950 min-1
Refrigerant - Ammonia, Hydrofluorocarbon, etc.

Design pressure MPa 2.6

Capacity control (Actual
% 10 to 100
load)
Rotation direction - Counterclockwise viewed from motor
Low-stage
suction - JIS 20K 150A (6")
flange
Low-stage
discharge - JIS 20K 100A (4")
flange
High-stage
suction - JIS 20K 100A (4")
flange
High-stage
discharge - JIS 20K 80A (3")
flange
Connected Journal
pipe size lubrication - JIS 20K 25A (1")
(low-stage)
Journal
lubrication - JIS 20K 20A (3/4")
(high-stage)
Oil injection
- JIS 20K 15A (1/2")
lubrication
Low-stage
capacity - Load: Rc1/4, Unload: Rc3/8
control
High-stage
capacity - Load: Rc3/8, Unload: Rc1/4
control

 Unless otherwise noted, the pressure unit MPa represents the gauge pressure
in this manual.
 For limits of working temperature and pressure, see "2.3.2 Operation Limits" in
next Section

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2.3.2 Operation Limits

Table 2-2 Operation Limits of 2016**C

Items Operation Limits

Maximum discharge pressure MPa 1.96
Minimum suction pressure MPa −0.080
Maximum intermediate pressure MPa 0.588
Minimum intermediate pressure - > Suction pressure
Oil supply pressure
･ Maximum journal lubrication pressure MPa Discharge pressure + 0.39
Discharge pressure +0.049 and
･ Minimum journal lubrication pressure MPa
Suction pressure +0.49
･ Minimum oil injection lubrication pressure MPa Suction pressure +0.49
Maximum Suction temperature °C 85
Minimum suction temperature °C −60
Maximum low-stage discharge temperature °C 90
Maximum high-stage discharge temperature °C 100
Maximum oil supply temperature °C 60
Minimum oil supply temperature °C 30
Maximum male rotor rotation speed min-1 3600
Minimum male rotor rotation speed min-1 1450
Note : Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual.

 If operation at partial load, which is not greater than 30 % of the indicated load, is
continued for a long time except when starting up the machine, abnormal noises
or vibration may be generated. So avoid such operation.
 Repeated startup and stop in a short period is harmful not for the startup devices
and electric machinery but also for the compressor itself. For information on the
start/stop limitations, refer to each instruction manual. Wait at least 15 minutes
after stopping the compressor before restarting it.

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Chapter 2 Compressor Specifications and Structure

2.3.3 Outer Dimensions

Figure 2-1 Outer Dimensions 2016LLC

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Chapter 2 Compressor Specifications and Structure

Figure 2-2 Outer Dimensions 2016LMC

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Figure 2-3 Outer Dimensions 2016LSC

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Figure 2-4 Outer Dimensions 2016MMC

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Figure 2-5 Outer Dimensions 2016MSC

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Figure 2-6 Outer Dimensions 2016SSC

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Chapter 2 Compressor Specifications and Structure

2.4 Structure of Compressor

 For names of each part of the compressor, refer to Section 7.1 "Development Views, Assembly
Sectional Views ", and Section 7.2 "Parts Configuration Table" in this manual.

2.4.1 Sectional View

High-stage capacity Suction port
control mechanism
Low-stage
capacity control
mechanism

High-stage suction port Discharge port Low-stage

discharge port

Shaft seal block

Low-stage
High-stage compressor compressor
Figure 2-7 2016**C Screw Compressor Sectional View
The 2016**C model, a compound 2-stage compressor, consists of two compressors, (i) a low-stage
compressor which suctions gas, working fluid, from the refrigerating unit and compresses (pressure-raises)
the gas and (ii) an high-stage compressor which furthermore compresses the gas that has been
pressure-raised by the low-stage compressor and sends the resulting gas to the refrigerating system side.
In each casing (low-stage, high-stage), two screw rotors are supported on both ends by bearings. They are
meshed with each other in a joint assembly. These two screw rotors are a set of a male rotor having 4
protruding lobe profiles (M rotor) and a female rotor having 6 concave lobe profiles (F rotor). They conduct
compressing according to the mechanism explained below.
The standard compressor's M rotor is driven by a 2-pole motor; it operates at 3000 mini-1 (50 Hz) or 3600
mini-1 (60 Hz). F rotor operates at 2000 mini-1 (50 Hz) or 2400 mini-1 (60 Hz), conforming to the operation of
M rotor.
* The actual speed of a motor is less than its calculated speed (synchronous speed). This difference is
caused by slipping of the motor rotor.
The shaft of the low-stage compressor's M rotor which is linked with the motor has a shaft seal block that
keeps gas and lubricating oil from escaping from inside the compressor.
For high efficient operation, the 2016**C model has a capacity control mechanism for coping with load
change on the low-stage, and a capacity control mechanism for reducing startup load on the high-stage.

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2.5 Mechanisms

2.5.1 Basics of the Screw Compressor

The screw compressor is categorized as a positive displacement rotary compressor.
As shown in Figure 2-8, the refrigerant (gas) is continuously compressed by the 3-dimensional spaces
that are formed by a pair of male and female screw rotors (with different sectional profiles) and the
casing, as the spaces change continuously.
The rotor having 4 protruding lobe profiles is called a male or M rotor, and the rotor having 6 concave
lobe profiles is called a female or F rotor. In this manual, they are referred to as M rotor and F rotor.
The compressor is driven by the motor connected to the shaft of the M rotor.

Figure 2-8 Compressor Mechanism

2.5.2 Suction Process

As shown in Figure 2-9, the rotors with different lobe profiles are engaged. As the rotors turn, the
volume between the M and F rotor lobe profiles and the compressor casing gradually increases starting
from the suction side.
As the rotation continues, at a certain point when the volume reaches its maximum, the rotors isolate
the gas (volume), which is enclosed by the rotors and the compressor casing, from the suction port and
then continues rotation.

Figure 2-9 Suction Process

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Chapter 2 Compressor Specifications and Structure

2.5.3 Compression Process

As the rotors rotate further, the volume between the rotor lobes decreases while the sealing line moves
toward the discharge side, which compresses the trapped refrigerant gas.

Figure 2-10 Compression Process

Figure 2-11 Discharge Process

2.5.4 Discharge Process
The volume between the rotor lobes decreases to a level predetermined by the discharge port. With the
rotations of the rotors, the compressed refrigerant gas is pushed out to the discharge port.

2.5.5 About Volume Ratio (Vi)

Volume ratios (Vi) of C-series screw
compressors are indicated in performance tables
or catalogs by using port symbols L and M.
The volume ratio represented by each symbol is
as follows:
L=2.63, M=3.65.

Which volume ratio (L or M) should be used is

decided according to operating conditions. If the
compressor is used with a volume ratio that does
not match operating conditions, operation will go
inefficiently wasting the power.
The relationship between volume ratios and
generally used compression ratios is as follows:

Figure 2-12 Volume Ratio

(Vi) κ = πi = Pd/Ps κ= Cp/Cv of refrigerant gas

Vi = Design volume ratio πi = Design compression ratio

As Vi is affected by the constant of the refrigerant gas, its value that corresponds to the compression
ratio will change depending on the refrigerant gas.

(A) Properly adapted Vi to load condition

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Chapter 2 Compressor Specifications and Structure

Both the required compression ratio and Vi are low. Both the required compression ratio and Vi are high.

(B) Improperly adapted Vi to load condition

Vi is too low compared to the required compression ratio. Vi is too high compared to the required compression ratio.

Figure 2-13 Relationship between Volume ratio (Vi) and Operation Conditions

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2.5.6 Capacity Control Mechanism

The capacity control mechanism, by moving a slide valve, lets suction gas (immediately before
compressed) bypass and advance to the suction side, to help shorten the rotor portion used for
compression. The slide valve is located at the bottom of the casing in which the rotors mesh together,
and is constructed to move parallel to the rotor shaft. This movement is changed by a cam mechanism
into rotation movement. Its position (namely, capacity control ratio) is indicated externally and, at the
same time, fed back to the automatic control circuit by changing the electric resistance.

Figure 2-15 Slide Valve in the

Main Rotor Casing

Figure 2-14 Capacity Control Mechanism

The 2016**C model has a capacity control mechanism (indicated load: 20 % to 100 %) for startup load
reduction on the high-stage unit, and another one (indicated load: 0 % to 100 %) for coping with load
change on the low-stage.

2.5.7 Bearing and Balance Piston

For the load acting on the rotor perpendicular to the shaft, sleeve-type white metal-lined bearings are
used. For the load acting along the shaft direction, face-to-face combination type of angular contact ball
bearings are used.
Special care is taken to cope with the load acting along the shaft direction. Because the M rotor is a
kind of helical gear and also because the thrust load produced by discharge pressure is larger than that
for F rotor, the load applied onto the M rotor is reduced by using not only a thrust bearing but also a
balance piston that applies pressure from the opposing direction.

2.5.8 Shaft Seal

To prevent refrigerant gas and oil leakage, a reliable mechanical seal assembly is used for the shaft
seal of the M rotor.
Mechanical seal assembly is mainly composed of "rotating ring" installed on the rotor shaft and
"stationary ring" installed in the seal cover. Rotating ring rotates with the shaft, and slides each other
with the stationary ring while maintaining a micron class gap. The sliding each other place is called as
the sliding surface.
For example, the BBSE (Balance Bellow Single Seal) which is currently used as standard seal,
employs a stationary ring (mating ring) made of special cast iron, a rotating ring made from carbon, and
O-rings for the packing.

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2.6 Gas and Oil Flow

The compression process of the screw compressor is
as described in the preceding paragraphs.
Gas of the compound 2-stage screw compressor
2016**C is sent from the evaporator, and passes
through the strainer and check valve. It is drawn in
from the upper central area (1) of the compressor,
compressed at the lower (2), and then discharged at (3).
(3) and (4) are connected with a pipe.
At the mid point of the pipe, that gas is mixed with
the gas from liquid cooler which was used for supercooling.
Lubricating oil injected at the low-stage is, while kept mixed
with gas, suctioned from (4) into the high-stage.
Figure 2-16 Gas Flow
After being compressed at (5), the gas mixed with lubricating
oil is discharged from (6), and is sent from the oil separator to the condenser.
Even if without intermediate gas cooling, oil provides cooling effect.
So, the high-stage discharge temperature is maintained at a temperature not higher than 90 °C.

 Oil Supply Route

As shown in Figure 2-17, lubricant is split into five flows. After completing each role, the oil is mixed with
discharge gas and leaves the compressor. In standard configuration, oil injection is not performed at
the high-stage.

Figure 2-17 2016**C Oil Supply Route

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Chapter 3 Installation

Chapter 3 Installation
3.1 General Precautions for Installation

 This chapter (Installation) assumes that the compressor is installed to a standard refrigeration /
cold storage/gas compression package unit.
If the package unit you are actually using is not the standard type refrigeration/cold storage/gas
compression package unit, prepare a proper installation manual by referring to the description in
this chapter and paying due consideration to safety, before installing the compressor.
If there are any questions, please contact our local sales offices or service centers.

 In some cases, it may be required that installation is performed by qualified personnel. Make
sure that the work is performed by qualified personnel in compliance with local laws,
ordinances and other regulations/requirements.
 Before installing the compressor, please read this chapter and related documents attentively
and fully understand their contents.
 Electrical works should be performed only by electrical engineers.

3.2 Installation Works

3.2.1 Unpacking
Check that there are no abnormalities such as damage on the compressor.

 If there are abnormalities or deficient parts on the compressor, please contact our sales offices
or service centers immediately.
 Unnecessary packing materials should be discarded according to the laws and ordinances, or
your company's rules.

3.2.2 Storage
If you need to store the compressor before installation, perform the followings:
 Store it indoors.
 Infuse nitrogen gas into the compressor and seal it. (Pressure: Approximately 0.15 Mpa )

3.2.3 Transportation

 Dropping of the lifted compressor may cause death or serious injury to the
worker. Do not stand under the lifted compressor.

1. For lifting the compressor within the safety limit, use lifting equipment and tools appropriate for the
mass of compressor.
2. Secure sufficient space for safe lifting.

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3. Always check the wire ropes before using them. Thoroughly check the wire ropes for problems
such as kinks, knots and broken strands. Do not perform lifting before checking the wire ropes. If
you cannot make a correct evaluation or judgment, entrust an expert to check.
4. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate
shackles and hooks. Use the eye bolts only for lifting the compressor. Refer to Figure 3-1 and
Photo 002 in next page.
Do not use the eye bolts when lifting the compressor together with additive equipment.

 The compressor eye bolts must not be used for lifting the package unit. To lift the
package unit, use the lifting chains provided around the base or other lifting
means provided on the base.

5. Check path of compressor installation to make sure it is free of obstacles in consideration of the
compressor size.
6. Before lifting, check that the hook is located above the gravity center of the compressor.
7. Direct all the workers to stay clear of the work site before lifting.
8. Before lifting the compressor, alert all workers in area of dangers during lifting process by signal
(such as calling at the beginning of the work or making a signal by hand). Do not lift the
compressor unless the signals (such as calling out or hand signals) are completely understood by
the workers at site.
9. Slowly reel up the wire ropes until immediately before the compressor leaves the ground.
10. Then, reel up the wire ropes a little further until the compressor is slightly up away from the ground.
Check that the compressor is not tilted. If the compressor is tilted, return the compressor to the
ground and correct the tilt by adjusting the wire ropes. After that, restart the lifting operation.
11. Be sure to lift up the compressor slowly. If it is lifted rapidly, it may damage the lifting tools such as
wire ropes or a part of the compressor.
12. When the lifting work starts, observe to see if wire ropes and lifting tools are normal. Be sure that
the compressor is not tilted.
13. When moving the lifted compressor, always use guiding ropes.
14. When moving the compressor, turn away workers from the movement direction and check safety.
15. Do not lift the compressor above the safety passage unless absolutely necessary.
16. Do not lower the compressor on the safety passage. Always keep the safety passage free of
obstacles.
17. Remove any obstacles before lowering the compressor onto the ground. The compressor should
not be tilted or unstable.
18. Before lowering the compressor, announce to the workers around the working area in advance.
19. When lowering the compressor onto two or more blocks, align the tops of blocks so that the
compressor becomes stable horizontally on them.
20. Slowly lower the lifted compressor so that it is not damaged by shock.

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 Outer Dimensions, Mass and Lifting Position

2016LLC 2016LMC 2016LSC 2016MMC 2016MSC 2016SSC

Product mass (kg) 1180 1140 1100 1090 1050 1000
L (mm) 1980.5 1913.5 1842.5 1858.5 1787.5 1730.5
Figure 3-1 Outer Dimensions, Mass and Lifting Position of Compressor

Photo 002 Lifting Position

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3.2.4 Preparation for Installation

 Installation Space
Secure sufficient working space for easy operation, cleaning, maintenance, and inspection.

 Illumination
Prepare illumination devices which allow easy operation, cleaning, maintenance, and inspection.

 Ventilation
If natural ventilation is insufficient, install ventilation fans according to the relevant regulations.

 Piping
Table 3-1 List of Connecting Pipes (Compressor)
Item Dimensions Remarks
Suction gas inlet JIS 20K 150A (6") See Figure 3-2.
Low-stage gas outlet JIS 20K 100A (4") See Figure 3-2.
High-stage gas inlet JIS 20K 100A (4") See Figure 3-2.
High-stage discharge gas outlet JIS 20K 80A (3") See Figure 3-2.
Lubrication oil supply port for low-stage
JIS 20K 25A (1"）
bearing (journal)
Lubrication oil supply port for low-stage
Rc1/4
capacity control (load)
Lubrication oil supply port for low-stage
Rc3/8
capacity control (unload)
Oil supply port for oil injection JIS 20K 15A (1/2"）
Lubrication oil supply port for high-stage
JIS 20K 20A (3/4"）
bearing (journal)
Lubrication oil supply port for high-stage
Rc3/8
capacity control (load)
Lubrication oil supply port for high-stage
Rc1/4
capacity control (unload)

D t g C N-h y
15A □ 74 5 43 70 4-M12 × P1.75 25
20A □ 84 5 51 75 4-M12 × P1.75 25
25A □100 5 61 90 4-M16 × P2 25
80A 200 5 121 160 8-M20 × P2.5 35
100A 225 5 146 185 8-M20 × P2.5 35
150A 305 5 216 260 12-M22 × P2.5 34

Figure 3-2 JIS 20K Flange Dimensions of Compressor (mm)

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3.2.5 Installation
3.2.5.1 Installation
Check that the surface of the package unit, where the compressor is to be installed, is even and
horizontal. If it is uneven and non-horizontal, tightening the bolts may lead to compressor deformation,
which may prevent normal operation.

3.2.5.2 Shaft Alignment between Compressor and Driving Machine

 Turn off the main power and control power of the driving machine before shaft alignment
work between the compressor and the driving machine. Be careful so that the power of
instruments does not turn on during shaft alignment work. If the power turns on during
shaft alignment work, the driving machine starts moving and there is a risk of being
entangled with the rotating shaft.
 At the time of turning ON/OFF each electric power breaker, make sure to prevent
electric shock.

 For shaft alignment work between the compressor and driving machine, use designated
tools in normal condition. If a worn or damaged tool or a tool unsuitable for the work is
used, there is a risk of being injured.

In the case shaft alignment between the compressor and the driving machine, be sure that the
deviations within the range shown in the Table 3–2. However, if alignment tolerance of the driving
machine side is more stringent than Table 3-2, please adjust to the request within the allowable value of
the driving machine side.
Table 3–2 Tolerance of Misalignment

Tolerance
Offset 6/100 mm
Angularity 3/100 mm (reference: Φ100 mm)

The Figure 3–3 and 3–4 show how to measure offset and angularity when performing the centering of
the shafts of the driving machine and this product using a dedicated hub, a dial gauge and a magnet
stand.

Figure 3-3 Measurement of Offset Figure 3-4 Measurement of Angularity

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3.2.5.3 Piping Connection

 Refrigerant Piping
Observe the following when connecting the refrigerant piping to the compressor.
 The compressor is one of the few devices installed within the package unit that have moving
components. These moving components are adversely affected by foreign substances within
the system (scale, dust, spatter, etc.). Therefore, when connecting the piping, do not allow any
of such foreign substances to enter inside.
 Some compressors (mainly those for export) are charged with nitrogen gas to prevent rust. Be
sure to release the pressure before starting piping work.
 Be sure not to allow moisture to enter the piping. There is a high probability that it will cause
trouble after the start of operation. Be sure to assemble piping when it is dry.
 Cover flanges are attached to the compressor's low-stage gas outlet and high-stage gas inlet.
After installation, be sure to attach piping (intermediate piping) that links the both connection
ports.
 Improper piping may cause operating problems such as oil not returning to the compressor or
liquid flow-backs.
 When connecting the piping to the compressor, use piping that is the same size as the
compressor connection port. If the pipe size of the piping is smaller than the compressor
connection port, the flow of lubricating oil or refrigerant will be obstructed leading to problems.
 Do not let the mass of the piping connected to the compressor applied onto flanges or joints.
Be sure to prepare proper supports for piping.

3.2.5.4 Equipment and Devices for Protection of the Compressor

 Oil Filter
According to the requirements of the use of the package unit or the standard to apply, install an oil
filter of appropriate filtration precision in the lubrication system of the compressor.
In the case of general applications such as closed-cycle refrigeration systems, we recommend to
use an oil filter with beta ratio in the range of β20 ≥ 150 that conforms to requirements of NAS 1638
class 8 or ISO 4406 17/15/13.
When the package unit requires API 619 4th/5th edition conformity, use an oil filter with beta ratio in
the range of β10≥200.
The oil filter may be clogged just after commissioning. We recommend installing two oil filters in
parallel. This will enable replacement of either filter during operation.

 Oil Heater for Oil Separator

To preserve the temperature of the lubricating oil before starting the compressor, install an oil
heater on the oil separator. Make sure to install a protection function (thermostat, etc.) to prevent
overheating.

 Suction Strainer
When compatible (inter-soluble) oil is used, the mesh size of suction strainer should be not less
than 200 meshes. When incompatible (non- inter-soluble) oil is used, it should be not less than 100
meshes.
For details about compatible and incompatible oils, refer to Section 4.1 "Lubricating Oil (Refrigerant
Oil)" in this manual Chapter 4.
During commissioning, small particles and scale may come from the system. We recommend to
install a finer filter temporarily.

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 Compressor Protective Devices (Safety Devices)

To protect the compressor, install the protective devices as indicated in Section 1.4.3 "Compressor
Protective Devices" in this manual Chapter 1.

3.2.6 Airtightness Test

Perform an airtightness test on the package unit before starting commissioning. To prevent water entry
in the package unit, use nitrogen gas or dry air for the airtightness test.

3.2.7 Lubricating Oil Charge

 TO select the lubricating oil to be used, refer to Section 4.1 "Lubricating Oil
(Refrigerant Oil)" in this manual.
 When refilling lubricating oil, ensure that it is clean and does not contain foreign
matters.
 Be careful that air and water are not mixed in when refilling.
 To ensure that the lubricating oil does not absorb air moisture, keep it indoors in
an airtight container until use.

3.2.7.1 Initial Charge of Lubricating Oil

Depending on the package unit configuration and operating condition, specify the procedure, method
and amount of the initial charge of lubricating oil, and make sure to provide users of this product with
such information.
In determining the procedure and work procedure of the initial charge of lubricating oil, please care oil is
to be filled in the oil filter and oil cooler always.

3.2.7.2 Additional Charge of Lubricating Oil

Specify the procedure of the additional filling of lubricating oil based on the configuration of the package
unit, and make sure to provide users of this product with the information.

3.2.8 Charge of Refrigerant

Depending on the use working fluid and equipment configuration of your package unit, specify the work
procedure that considered safety enough, and conduct the refrigerant initial filling work accordingly.
In addition, specify the procedure of the additional filling of refrigerant, make sure to provide users of
this product with the information.

3.2.9 Check after Installation

Depending on the package unit to which this product is installed, formulate the necessary confirmation
items and methods for package unit after installation and conduct them accordingly before the
commissioning. In addition, make sure to record and keep the results of your confirmation.

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Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil)
Lubrication management is very significant to keep the compressor in a good operating condition.
Take the following notes when managing lubricating oil.

4.1.1 Precautions for Selecting the Lubricating Oil

 Selection of the lubricating oil should depend on the type of the refrigerant, the type of the
evaporator used with the compressor, and the conditions under which the compressor is
operated. Also to be considered when selecting lubricating oil are the properties of the oil that
include not only the viscosity but also such characteristics as compatibility in refrigerant,
separability from refrigerant, low temperature fluidity, high temperature thermal stability, etc.
We therefore recommend contacting our sales offices or service centers for choice of a
specified brand for your system.
 Lubricating oil used for compressors must have a viscosity appropriate for lubricating the
bearings and other components in the compressors. The viscosity to be considered in this case
should be the viscosity the oil shows at the oil inlet of the compressor. The viscosity of the
lubricating oil significantly changes depending on the type of the refrigerant used in combination
with the lubricating oil. If the refrigerant dissolves in the lubricating oil (or the lubricating oil and
refrigerant are compatible), the viscosity of the lubricating oil drops to a level remarkably below
the level required for operation of the compressor under some operating conditions. On the
contrary, if the refrigerant does not dissolve in the lubricating oil (or the lubricating oil and
refrigerant are incompatible), the viscosity may become too high when the supply oil
temperature is low. For this reason, the lubricating oil must be selected such that it is supplied to
the compressor with an appropriate viscosity (kinematic viscosity of 13 to 40 mm2/s) in the
operating state.
 The circulation of the lubricating oil for the entire system must be considered. After lubricating
and cooling each part of the compressor, the lubricating oil is discharged with refrigerant gas.
Most of the oil which is discharged from this compressor is trapped by the oil separator and is
cycled to the compressor. A small quantity of refrigerant oil goes to the condenser and the
evaporator. The lubricating oil is required to have sufficient fluidity and stability inside each part
in the refrigerating cycle where temperatures differ.
 Note that some lubricating oils cannot be used depending on the combination with the
refrigerant. The following caution is an example case that is required especially attention.

 Be careful since polyolester synthetic oil (POE) must not be used with ammonia
refrigerant.

4.1.2 Recommended Lubricating Oils

When selecting lubricating oil, not only compatibility with refrigerant but also effects on O-rings must be
considered. To prevent compressor malfunctions, we recommend the lubricating oil described below.

4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant

 Polyalkylene Glycols (PAG) Based Synthetic Oil (compatible oil)
Brand Kinematic viscosity (40°C) mm2/s Manufacturer Type
JOMO Freol PN46 46 JX Nippon Oil and Energy Corporation PAG

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 Mineral oils (incompatible oils)

Kinematic viscosity
Brand Manufacturer Type
(40°C) mm2/s
SUNISO 3GS 30 Sun Oil Naphthene
SUNISO 4GS 55 Sun Oil base
REFOIL NS 3GS 30 Nippon Oil
GARGOYLE ARCTIC C HEAVY 46 Exxon Mobil
GARGOYLE ARCTIC 300 68 Exxon Mobil
CAPELLA WF46 46 Texaco
CAPELLA WF68 64 Texaco
CP-1009-32 34 CPI Hydrotreated
CP-1009-68 69 CPI paraffinic base
REFLO 46A 46 Petro Canada
REFLO 68A 58 Petro Canada
CAPELLA PREMIUM 67 Texaco
RHT-68 68 Kluber
REFLO XL 59 Petro Canada

 Synthetic oils (incompatible oils)

Kinematic viscosity
Brand Manufacturer Type
(40°C) mm2/s
Acemire 300 59 Acemire AB
Mycold AB68 53 BVA
ZERICE S46 46 Exxon Mobil
ZERICE S68 68 Exxon Mobil
BERREL FREEZE 46S 46 Matsumura Oil Co., Ltd.
CP-4700-32 31 CPI
CP-4700-68 56 CPI
Gold-Cold 300 53 Golden West
GARGOYLE ARCTIC NH68 64 Exxon Mobil PAO+AB
REFLO SYNTHETIC 68A 62 Petro Canada
Gargoyle arctic SHC 224 Note 30 Exxon Mobil PAO
Gargoyle arctic SHC 226(E) Note 68 Exxon Mobil

Note: Use only a seal of the standard BBSE type.

4.1.2.2 Oils for systems using Hydrofluorocarbon (HFC) refrigerants

 Polyolester synthetic oil (POE) for R404A, R507A and R410A (compatible synthetic
oil)
Brand Kinematic viscosity (40°C) mm2/s Manufacturer Type
SUNISO SL-68S 67 Sun Oil POE
EMKARATE RL68H 72 Lubrizol

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 Polyolester Synthetic Oil (POE) for R134a (Incompatible synthetic oil)

Brand Kinematic viscosity (40°C) mm2/s Manufacturer Type
JOMO Freol α100 107 JX Nippon Oil and POE
Energy Corporation

 When using lubricating oil of a brand not described in this section, or when using
lubricating oil along with refrigerants or gases not described in this section,
please contact us.

4.1.3 Change of Lubricating oil Brand

When changing the lubricating oil brand in currently use for some reason, attention must be paid to the
following points.

 The change of lubricating oil brand may cause problems in operating conditions and
the compressor. When changing the lubricating oil brand in use, make sure to
contact us because appropriate steps must be surely followed.
 Package unit composition differs depending on the characteristics of lubricating oil
(compatible/incompatible with refrigerant). As a general rule, changing compatible oil
to incompatible oil or vice versa is not allowed.

 Lubricating oil contains various additives to fulfill necessary lubricating conditions. Types of
additives and their mixing ratio depend on each oil brand. We, therefore, recommend to avoid
mixed use of different brands of lubricating oil. If mixed brands of lubricating oil are used, the
different additives in the lubricating oil may react with each other and produce foreign
substances like slurry.
 If it is necessary to change the brand of lubricating oil, collect as much as oil as possible from
the compressor as well as from the condenser, evaporator, and all other refrigerating unit
components before charging the new lubricating oil. After 100 to 200 hours of operation, replace
the oil again.
 If lubricating oil manufacturers differ, contact both of them and inquire whether the changing is
appropriate. The same confirmation is required for changing the brand even if it is of the same
manufacturer.
 There is no problem in changing the viscosity level within the same brand. However, make sure
that the viscosity grade will not cause problems during operation (Example ： SUNISO
3GS→SUNISO 4GS).

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4.1.4 Precautions for Handling lubricating oil

 When refilling lubricating oil, ensure that it is clean and does not contain foreign matters.
 Be careful that air and water are not mixed in when refilling.
 To ensure that the lubricating oil does not absorb air moisture, keep it indoors in an airtight
container until use.

4.1.4.1 Precautions for Handling Polyalkylene Glycol (PAG)

PAG oil is much more hygroscopic than mineral oils and any moisture mixed in the oil may lead to rust,
corrosion and wear within the package. When handling PAG oil, pay special attention to the following
points.

 Do not perform oil charging in rainy weather or at a place with high humidity to prevent
absorbing moisture.
 Before charging, remove as much moisture as possible from the system by exhausting it with
a vacuum pump for a sufficient length of time and leaving the system in vacuum condition
overnight.
 Do not open the lid of pail (oil container) until just before charging. Once the can is opened,
finish the oil charge as quickly as possible. (Finish the charge of a single can of oil within 15
minutes.)
 Cover any gaps between the pail opening and the charge hose so that foreign substances or
moisture cannot enter. A more effective way is to substitute any space inside the pail with
nitrogen gas .
 Always charge all oil from the pail. Even if some oil remains, do not use it subsequently.
 If any oil drops on a painted surface, wipe it away as soon as possible. Otherwise the paint
may come off.

4.1.4.2 Precautions for Handling Polyolester (POE) Oil

This type of oil has high hygroscopicity as polyalkylene glycol, and also exhibits hydrolyzability under
high temperature environments. Moisture entry must be avoided. Therefore, special attention must be
paid as with PAG when handling POE.
 Finish the charging in as short a time as possible after opening the pail to minimize exposure
to air.
 Make sure that all oil in a pail is used in a single charging. Any remaining oil must be stored
indoors with the can lid closed tightly. Do not attempt to store it for a long time.
 Because POE can hydrolyze, make sure to perform an oil analysis regularly in the package to
see if any abnormal conditions are present.

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4.1.5 Lubricating Oil Management Criteria

Lubricating oils that are managed by the criteria are classified into the following categories:

(1) Synthetic oils: Polyalkylene glycols (PAG)

(2) Mineral oils: Naphthenic base oils and paraffinic base oils
(3) Synthetic oils: Alkylbenzene (AB) and Polyalphaolefine (PAO)
(4) Synthetic oils: Polyolesters (POE)

 Oil sampling and analysis is recommended every six months.

 If the following control criteria are not satisfied, replace the oil.
◆ Note that the water content of PAG shall be excluded from the above oil replacement criteria.
Refer to the Note *1 in the following table.

The analysis items and the criteria are shown in the following tables. Please note that these
management criteria may be changed without notice.

Table 4-1 Synthetic Oil (PAG)

Item Criteria
(a) Color phase ASTM color scale: 4.0 or less
(b) Total acid number (TAN) 0.1 mg KOH/g or less
(c) Kinematic viscosity Within ±10 % from that of fresh oil
(d) Water content 2000 mass ppm or less Note1
(e) Degree of contamination Degree of contamination measured by mass method (Millipore value)
shall be 15 mg/100 mL or less

Table 4-2 Mineral Oil and Synthetic Oil (AB, PAO)

Item Criteria
(a) Color phase ASTM color scale: 6.0 or less
(b) Total acid number (TAN) 0.3 mg KOH/g or less
(c) Kinematic viscosity Within ±15 % from that of fresh oil
(d) Water content 100 mass ppm or less
(e) Degree of contamination Degree of contamination measured by mass method (Millipore value)
shall be 15 mg/100 mL or less

Table 4-3 Synthetic Oil (POE)

Item Criteria
(a) Color phase ASTM color scale: 4.0 or less
(b) Total acid number (TAN) 0.2 mg KOH/g or less
(c) Kinematic viscosity Within ±10 % from that of fresh oil
(d) Water content 200 mass ppm or less
(e) Degree of contamination Degree of contamination measured by mass method (Millipore value)
shall be 15 mg/100 mL or less

Note 1: Synthetic oils (compatible with ammonia) are so highly hygroscopic that they can absorb
moisture at the time of sampling. In addition, the ammonia content they have absorbed may
be detected as the water content at the time of the analysis, making it difficult to precisely
measure the water content. Thus, use the criterion value only as a reference.

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4.1.6 Lubricating Oil Replacement Timing

4.1.6.1 After Starting the Initial Operation
As the oil can easily be contaminated and degraded relatively quickly during the initial operation due to
scales and deposits remaining in piping and vessels, be sure to sample and analyze the oil after 500
hours of operation.
If it is found as a result of the analysis that the criteria given in Tables 4-1 to 4-3 are not satisfied, the oil
must be replaced.

4.1.6.2 During Normal Operation

Lubricating oils will degrade gradually as the system is operated over time.
The rate of degradation depends on the operating condition, type of oil and amount of foreign matters
and moisture contained in the oil.
The lubricating oil must be sampled and analyzed every six months. If it is found as a result of the
analysis that the control criteria given in Tables 4-1 to 4-3 are not satisfied, the oil must be replaced.
If the oil filters are frequently clogged or the oil color quickly becomes darker and unclear, replace the
oil after removing the cause of the problem.

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4.2 Precautions for Operation

If the package unit is used in the refrigeration cycle, please keep in mind the contents of this section in
particular.

4.2.1 Prevention of Liquid Flow-back

Liquid flow-back is a phenomenon where refrigerant that did not completely evaporate with the gas
reaches the compressor. Liquid flow-back may cause insufficient lubrication of the compressor,
abnormal vibrations and noises, and abnormal foaming of lubricating oil (too much oil loss). To prevent
liquid flow-back, properly adjust the expansion valve of each liquid cooler. For details, refer to Chapter 6
"Troubleshooting" in this manual.

4.2.2 Purging of Non-Condensable Gases

 Some types of refrigerants emit bad smells or toxic gases. Make sure to ventilate
the air during work.

If there is a leak on the low-pressure side of the refrigeration cycle, air may enter the package unit.
If non-condensable gas like air enters the package unit, the condensing pressure rises and the energy
consumption increases. This leads to uneconomical operation.
Follow the procedure below to check for non-condensable gases.
1. When the compressor is stopped, allow the cooling water to flow to the condenser for at least 15
minutes. Check the condensing pressure by using the pressure gauge of the compressor.
2. Check the cooling water temperature.
3. Compare the condensing pressure checked in step 1 above with the refrigerant saturation
pressure that depends on the cooling water temperature (as shown in the table below).

Table 4-1 Typical Refrigerant Temperature and Saturation Pressure

Pressure MPa
Temperature °C
Ammonia R404A R507A R410A R134a
0 0.328 0.509 0.523 0.699 0.192
4 0.396 0.590 0.606 0.807 0.237
8 0.472 0.678 0.696 0.924 0.287
12 0.557 0.775 0.795 1.053 0.342
16 0.652 0.881 0.903 1.193 0.403
20 0.756 0.996 1.021 1.346 0.471
24 0.871 1.121 1.148 1.513 0.545
28 0.998 1.256 1.286 1.693 0.626
32 1.137 1.401 1.435 1.887 0.714
36 1.289 1.559 1.595 2.098 0.811
40 1.454 1.728 1.768 2.324 0.916
■ Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual.

4. When the pressure inside the condenser and the refrigerant saturation pressure that depends on
the cooling water temperature are approximately equivalent, non-condensable gases do not exist.
When the pressure inside the condenser is 0.05 MPa or more higher than the refrigerant
saturation pressure that depends on the cooling water temperature, there is a possibility of
non-condensable gases entering the unit. In that case, purge the non-condensable gases from
the condenser.

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4.3 When Stopping the Compressor for a Long Time

When stopping the compressor for a long period of time, make sure to perform the following steps.
 Turn off the motor main power.
 Turn off the heater power and control panel power.
 Close the suction and discharge side shut-off valves.

If the operation stop period is 1 month or longer, perform the following checks.

 Operate the oil pump for 10 seconds per week.

After that, rotate the compressor shaft (10 rotations or more).
 Measure the package unit pressure once per month.
 Check for refrigerant leakage once per month.

When restarting the compressor after an operation stop period of 1 year or longer, check the system for
refrigerant leak and analyze the lubricating oil.
If it is found as a result of the analysis that the control criteria given in this Chapter, Section 4.1.5 Tables
4-1 to 4-3 are not satisfied, the oil must be replaced.
Also check the motor insulation resistance.
Supply power to the oil heater at least 1 day before operation start.
Before starting the operation, confirm that the refrigerant is not condensed in the package unit by
checking the package temperature and pressure.

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Chapter 5 Maintenance and Inspection

Chapter 5 Maintenance and Inspection

5.1 Precautions for Maintenance and Inspection
When reading this Section, also refer to Section 1.1 in this manual Chapter 1.

 When entering the machine room for maintenance services, ensure that sufficient
ventilation has been started and measure the oxygen concentration so that there is
no risk of oxygen deficiency. The ventilation must be continued steadily until the
work is completed.
 For performing the inspection work, be sure to prepare safety shoes, protective
glasses, gas mask and other proper protective equipment and do not fail to use
them whenever they are required.
 After stopping the machine and before working on a regular inspection or overhaul,
be sure to shut off the main motor power, control power, and other power to each
equipment and valve. After they are shut off, be sure to make the switches
inoperable by others. Also, be sure to attach notification tags to prohibit operation
(lock-out/tag-out).
 When any manual stop valve has been closed, be sure to make the valve
inoperable by others and put a notification tag to prohibit the operation (tag-out).
 When the compressor is to be overhauled, check that the internal pressure of this
product is at the atmospheric pressure before starting the work.
 When using lifting devices, e.g. a crane, etc. and/or lifting tools, ensure that they
can sufficiently withstand the load.
 When lifting a heavy load object, do not allow anyone’s body to put under it.
 The work to turn each power supply ON/OFF or operate a lifting unit must be
exclusively performed by qualified personnel.
 When using electric tools, ensure that they are properly managed in accordance
with each instruction manual. Especially before using and while using, be sure to
follow the care instructions on the safety of each instruction manual.

 Be sure to use only genuine parts for replacement. Using parts that are
not genuine can cause damage to this product or other devices during operation.
 Do not convert or modify this product or its components without prior permission
from MAYEKAWA. Otherwise, it can lead to an unexpected accident.
 Exercise sufficient care for handling a heavy load, and use such a lifting device as a
crane or work with an adequate number of personnel commensurate with the
magnitude of the weight. Also, be sure to use stud bolts (safety retention bolts) and
other support tools for the work. Neglecting the above warning can lead to low back
pain of the worker or injury due to dropping of the parts.
 If two or more people are to work together, be sure to clearly define the work
procedures to
 share a common understanding among all workers before performing the work.
 Not only the work to turn each power supply ON/OFF or operate a lifting device, but
also any type of work requiring qualification must be exclusively performed by
qualified personnel.

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 When checking the operation data of units and executing other daily maintenance
services, pay particular attention to avoid touching the area heated to a high
temperature causing skin burns or inadvertently moving the handle of a valve
leading to an erroneous operation.
 In the disassembly/inspection workplace, secure a sufficient space for temporary
storage of the removed parts and tools, replacement parts, and for the
disassembling work as well as safety passages, and then put up necessary off-limit
signs.
 In the workplace, secure a sufficient space and refrain from putting tools directly on
the floor or from haphazardly laying wires.
 Keep the floor clean all the time. Leaving the floor smeared with oil and the like
causes it to be slippery and may result in the fall and injury of personnel. Thus, do
not leave it but wipe it off right away.
 Make sure that the temperature of the high temperature sections such as head
covers and discharge lines has been cooled down to normal ambient temperature,
before working on them.
 When disassembling and reassembling the compressor, use the specified tools
properly. Before starting to use those tools, gain the full understanding of their
characteristics and the method for use.
 During the maintenance service, keep the tools clean all the time. Using those tools
smeared with oil increases the risk of slip and fall, leading to an injury. Also during
the service, there is a risk of foreign matters intruding inside the compressor to
cause its damage.
 Parts are slippery with oil. Fully watch out for the risk of any object falling down.
Pay attention to any parts falling down, which could lead to personal injury.

 Before disassembly, inspections, and handling of the compressor, sufficiently

understand the disassembly and assembly procedures.
This manual is not intended to provide complete disassembly and assembly
procedures for the compressor. Instead, it describes only the important points in
relation to the maintenance service of the compressor.
 If complete disassembly and assembly of the compressor are required, please
contact your nearest sales office or service center of MAYEKAWA.
 When removing a part, be careful not to damage it.
 Place the removed parts on a clean workbench in an orderly manner.
 For cleaning parts, use kerosene and/or machine parts cleaner.
 Washed parts shall be dried by compressed air or wiped up using clean cloth. Do
not use synthetic textiles or woolen textiles to prevent fibers from attaching the
parts.
 When separating the assembled compressor casings, sometimes it is difficult to
separate them due to the gasket stuck. In such a case, never hammer in a screw
driver or flat chisel into the gap. Screw jack bolts using the screw holes to separate
the casing each other. When some gap is observed between them, use a scraper
to remove one side of the gasket from the surface.
 Removed bolts from each part should be classified into each used section to
prevent confusion.

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5.2 Maintenance and Inspection List

5.2.1 Daily Management

As daily management, check the items listed in Table 5-1 "Daily Inspection Items" and record the
results.
Logging these operation data on a daily basis aid in finding out any abnormal conditions of the
compressor. This is significantly effective in preventing compressor failures.
It is particularly important to check whether the temperature/pressure correlations related to the
refrigerant evaporation and condensation is proper. This makes it possible to quickly find out problems
in the compressor or the system.
If a failure or accident should occur in the compressor or the system, the operation logbook will help
determine the cause and take prompt and proper actions.

Table 5-1 Daily Inspection Items

Inspection Items Inspection Contents Check Points and Actions
Operating hours hr Total operating hours  Judgment of periodic
Compressor

maintenance timing
Suction pressure MPa Difference from the set value  Contamination on the cooling
Note 1
of evaporation temperature pipe surface
equivalent pressure  Temperature, flow rate, etc. of
the object to be cooled
Intermediate pressure MPa Pressure difference from  If it is too high， check high-
rated operation (normal stage. If it is too low, check
value) low-stage.
Discharge pressure Mpa Difference from cooling water  Contamination on condenser
temperature equivalent cooling pipes
condensing pressure  Non-condensable gases mixed
into the system
 Quantity, temperature, etc. of
cooling water
Oil supply pressure MPa Difference from discharge  Whether differential pressure is
pressure decreasing
 Operation with liquid flow-back
 Whether compressor parts are
worn
Oil filter pressure loss MPa Pressure difference between  Contamination of lubricating oil
oil filter inlet and outlet  Clogging of oil filter element
Suction temperature °C Whether within upper and  Temperature, flow rate, etc. of
lower limits the object to be cooled

Degree of superheat °C Whether degree of  Adjust expansion valve

for suction superheat is proper  Insufficient refrigerant flow
Intermediate °C Whether within upper and  Adjust intermediate expansion
temperature lower limits valve
Discharge °C Whether within upper limit  Non-condensable gases mixed
temperature into the system
 Oil supply temperature,
insufficient oil supply
 Compressor failure

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Inspection Items Inspection Contents Check Points and Actions

Oil supply °C Whether within upper and  Contamination on cooling pipes
Compressor

temperature lower limits of oil cooler

Capacity control % Whether operation is normal  Damage to solenoid valve coil
Indicated load  Improper adjustment of manual
control valve of
electromagnetic assembly
Leak from ml Leak per hour  Mechanical seal failure
mechanical seal
Noise and vibration Abnormal noise/vibration  Compressor failure
Motor current A Whether it is higher than the  Compressor/Motor failure
Others

current at test run

Oil level of oil - Oil level  Oil loss
separator  Replenish oil
Fluid level in the - Fluid level  Replenish refrigerant
receiver
Check for refrigerant - leak or not  Inside the machine room and in
leak the facility on the load side
Note 1 : Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this
manual.

 Daily Maintenance Items

1. Lubricating oil level
When the oil level in the oil separator reaches the lower limit, charge lubricating oil.
2. Replacing oil filter element
When the differential pressure between the inlet and outlet ports of the oil filter exceeds 0.1 MPa,
replace the filter element. During the period of initial operation, the pressure difference between
the inlet and outlet ports of the oil filter can quickly become large
3. Cleaning of suction strainer
When the compressor operating hours exceeds 500, check the suction strainer. If a temporary
filter is installed for the initial stage of operation, remove it.
At the beginning of the operation or after periodical check, the differential pressure between the
front and back of the suction strainer may increase quickly. If the differential pressure becomes
large, check and clean the suction strainer.
4. Lubricating oil leak rate from mechanical seal
If much oil leaks from the mechanical seal, determine the leak rate per hour. The following table
shows guidelines for allowable leak rate and the rate at which inspection must be done.
If any problem (damage, etc.) is found in mechanical seal, replace the mechanical seal.

Table 5-2 Guideline for Leak from Mechanical Seal

2016**C
Allowable leak rate ≤ 3 ml/hr
Rate at which inspection must be done ≥ 9 ml/hr
Note: The specifications above are just guidelines. They are not guaranteed values.

5. Contamination on the cooling water side of the cooling pipes of condenser and oil cooler
Clogging and contamination of the cooling pipe is largely affected by the quality of cooling water.
When the oil temperature and discharge pressure gradually rise during the initial stage of
operation, inspect and clean the cooling water side of oil cooler and condenser even when the
time has not yet come at which inspection must be done.

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5.2.2 Periodic Inspection

Conduct inspection for the following items according to the specified intervals.
In addition, observe relevant laws and regulations on the inspections and recording of the results that
are provided for other related items such as any safety devices (e.g. gas leak detectors), or other utility
(gas/electricity) protection devices that constitute the cooling package unit together with the
compressor.
Table 5-3 Periodical Inspection Items

Item Inspection interval and Content Remarks

Pressure gauges/ Yearly inspection
pressure sensors
Thermometers/ Yearly inspection
temperature sensors

Protection devices and Yearly inspection

safety valves
Suction strainer Inspect after 500 hours from the start If the differential pressure between
of operation. the front and back of the suction
Yearly inspection and cleaning strainer increases, check and clean
the suction strainer.
Lubricating oil Analyze lubricating oil after 500 hours Replace the oil if the analysis result
from the start of operation. does not satisfy the control criteria
Analyze oil every 6 months. given in Section 4.1.5 "Lubricating
oil Management Criteria".
Oil filter element Yearly replacement Replace the filter element if the
differential pressure between the
inlet and outlet ports of the oil filter
exceeds 0.1 MPa.
Cooling water side of oil Yearly inspection Clean if excessively contaminated.
cooler
Cooling water side of Yearly inspection Clean if excessively contaminated.
condenser
Mechanical seal Inspection every year or every 8000 To be replaced if any abnormality is
hours of operation Note* found
If it is difficult to stop equipment
except for scheduled inspections,
replace the part at each inspection.

Coupling Inspection every year or every 8000

hours of operation Note*

Note*: The inspection shall be performed according to the operating period or operating hours,
whichever comes first.

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5.2.3 Guidelines for the Timing of Compressor Overhaul

The compressor overhaul interval is largely affected by the compressor operating conditions, type and
status of refrigerant and oil, and the system/equipment in which the compressor is operated.
The table below shows the recommended interval of overhaul, as a guideline.

Table 5-4 Guidelines for the Timing of Overhaul Based on the Conditions of Use
(standard package)
Application
Category of operating condition Guideline for the overhaul timing
example
Cold storage and
Relatively stable operating condition Every 5 years or 40,000 operating hours
refrigeration

Relatively variable operating condition Ice maker/chiller Every 4 years or 30,000 operating hours

Frequently started/stopped, and

Heat pump Every 3 years or 20,000 operating hours
relatively variable operating conditions

Note 1: The above guidelines are only applicable when the compressor is operated within the operation
limits specified separately.
(Refer to Section 2.3.2 "Operation Limits" in this manual.)
Note 2: The above guidelines are only applicable when the compressor undergoes daily and periodical
inspections specified separately.
(Refer to Section 5.2.1 "Daily Management" in this manual.)
Note 3: Inspect the compressor at the intervals of specified period or operating hours, whichever comes
first.
Note 4: The above guidelines do not constitute any warranty.

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5.3 Compressor Disassembly Preparation

Although screw compressors are very reliable machines it is still necessary to disassemble and inspect
parts after a certain period of operation.
This chapter 5 describes the essential points of disassembly methods, where to inspect on parts, and
reassembly procedure of the compound 2-stage screw compressor 2016**C.
In principle, overhauling of the screw compressor that require complete disassembly should be
performed in the maintenance factory.
If you must do the overhaul work at the installation site due to unavoidable reasons, use the methods
described in the following paragraphs.
However, please note that regular overhaul work requires removal of the compressor from the base
frame. And then, the compressor should be placed on a work bench which has properly size area to
disassembling the compressor.

When moving the compressor from the unit base to the workbench, be sure to follow the instructions
given in Chapter 3, Section 3.1 "General Installation Precautions" and Section 3.2.3 "Transportation" in
this manual.

Note that some parts name given in the text of this manual is followed by a number enclosed in square
brackets [ ], which indicates the part identification number given in assembly sectional views and/or
parts configuration table.

5.3.1 Disassembly Tools and Work Place

Prepare necessary disassembly tools for the compressor by referring to Section 7.5 "Disassembly
Tools" in this manual Chapter 7.
In addition, prepare other necessary tools and materials including general hand tools, GC (green
carbonite) grinding stones, sandpapers of #80 to #100, about #400 to #800 sandpapers, parts cleaner,
lubricating oil, oilcan, empty can to receive drain oil, waste, etc.
If the overhaul work is to be done with the compressor removed from the installation base, prepare the
work bench whose size is at least around 1.5 times the length and the width of the compressor..
In addition, a special stand for the compressor is required in order to safely perform the
removal/fastening of bolts and plugs on the bottom side of the compressor. Refer to Section 5.3.5 of
this chapter.
To the extent possible, choose a dry and clean workplace free from sand or dust. Note that a sufficient
space is required around the compressor. In addition, it is necessary a temporary storage place for
disassembled parts .

5.3.2 Replacement Parts

Prepare genuine replacement parts.
Parts listed in Table 5-5, we recommend to be replaced on the occasion of each compressor overhaul.
When ordering any part, inform its (a) model name, (b) serial number, (c) part name, (d) code No. and
(e) quantity required to our sales offices or service centers. Especially when the (b) serial number of the
compressor is not identified, it will be difficult to decide the required parts because we can not specify
the design and manufacturing specifications. So, make sure to inform the (b) serial number to us.

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Table 5-5 Replacement Parts of 2016**C Overhauling

P/N Part Name Code No. Remarks Q’ty.
6-1 Gasket, Suction Cover (1) CS00600-200N 1
6-2 Gasket, Suction Cover (2) CS00600-160N 1
9 O-ring JIS B 2401 P30 PA11-030 1
12-1 Gasket, Bearing Head (1) CS01200-200N 1
12-2 Gasket, Bearing Head (2) CS01200-160N 1
17-1 Gasket, Bearing Cover (1) CS01700-2016C1N 1
17-2 Gasket, Bearing Cover (2) CS01700-2016C2N 1
23 Gasket, Balance Piston Cover CS02300-160N 1
27-1 Main Bearing (1) with O-ring CS0270-ERT 2
27-2 Main Bearing (2) with O-ring CS0270-DRT 2
28-1 Side Bearing (1) with O-ring CS0280-ERT 2
28-2 Side Bearing (2) with O-ring CS0280-DRT 2
30 Balance Piston CS03000-160 To be replaced if any 1
33 Balance Piston Sleeve CS03300-160 abnormality is found. 1
35 O-ring JIS B 2401 G95 PA12-095 1
38-1 Thrust Bearing (1) CS03800-200P 2
38-2 Thrust Bearing (2) CS03800-160P 2
39-1 Lock Nut (1) AN13 NG31-013 To be replaced if any 2
39-2 Lock Nut (2) AN12 NG31-012 abnormality is found. 2
40-1 Lock Washer (1) AW13 NG32-013 2
40-2 Lock Washer (2) AW12 NG32-012 2
49 O-ring JIS B 2401 G115 PA12-115 1
50 Oil Seal CS05010-200VD 1
52 Gasket, Seal Cover CS05200-200N 1
59 O-ring JIS B 2401 P20 PA11-020 1
63 O-ring JIS B 2401 G125 PA12-125 2
65 O-ring JIS B 2401 P100 PA11-100 2
66 Cap Seal BE-100 CS06600-160 2
68-1 Guide Pin (1) NE2505-012 To be replaced if any 1
68-2 Guide Pin (2) NE2503-008 abnormality is found. 1
69-1 Lock Nut (1) AN07 NG31-007 To be replaced if any 1
69-2 Lock Nut (2) AN05 NG31-005 abnormality is found. 1
70-1 Lock Washer (1) AW07 NG32-007 1
70-2 Lock Washer (2) AW05 NG32-005 1
73-1 O-ring JIS B 2401 G30 PA12-030 1
73-2 O-ring JIS B 2401 P21 PA11-021 1
75 O-ring JIS B 2401 G110 PA12-110 2
78 Ball Bearing, Indicator Cam #6000 CS07800-200 2
79 Snap ring C type External S10 NG12-010 2
82 V-ring, Indicator Cam VH10 NBR CS08200-200B 2
86 O-ring JIS B 2401 P21 PA11-021 1
89-1 O-ring JIS B 2401 P20 PA11-020 2

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P/N Part Name Code No. Remarks Q’ty.

89-2 O-ring, Guide Block Stem (1) PA11-016 JIS B 2401 P16 2
93-1 Gasket, Suction Flange (1) CS71200-150N JIS 20K 150A(6") 1
93-2 Gasket, Suction Flange (2) CS71200-100N JIS 20K 100A(4") 1
96-1 Gasket, Discharge Flange (1) CS71200-100N JIS 20K 100A(4") 1
96-2 Gasket, Discharge Flange (2) CS71200-080N JIS 20K 80A(3") 1
100 Mechanical Seal Assembly BBS-E CS10002-200EBS 1
125-1 Micro-switch Set(1) CS1259-C To be replaced if any 1
125-2 Micro-switch (2) CS12500-200 abnormality is found. 2
129 Potentiometer (1) 1612K with Wire CS1299-J To be replaced if any 1
129 Potentiometer (2) 200-1k with Wire CS1299-E10 abnormality is found. 1
Gear Coupling Assembly (Current To be replaced if any
CS1519-K abnormality is found. 1
Type)
To be replaced if any
159 Knurled Cup Point Socket Set Screw NA83608-015 1
abnormality is found.
To be replaced if any
160 Lock Nut AN10, Drive Hub NG31-010 1
abnormality is found.
161 Lock Washer AW10 NG32-010 1
163 O-ring JIS B 2401 G25 PA12-025 1
165 O-ring JIS B 2401 G25 PA12-025 1
197 O-ring JIS B 2401 P40 PA11-040 1
To be replaced if any
202 Bevel Gear (2) 1612LSC(φ6) CS20100-1612C6 abnormality is found. 2

216-1 Gasket, Lubricating Oil Inlet Flange (1) CS71200-025N JIS 20K 25A (1") 1
216-2 Gasket, Lubricating Oil Inlet Flange (2) CS71200-020N JIS 20K 20A (3/4") 1
219 Gasket, Oil Injection Inlet Flange CS71200-015N JIS 20K 15A (1/2") 1
237-1 Tortional Slip Washer (1) CS23700-200 2
237-2 Tortional Slip Washer (2) CS23700-160 2
421 O-ring JIS B 2401 G30 PA12-030 1(*SC)
2(LLC,LMC)
421 O-ring JIS B 2401 P30 PA11-030 1(MMC)
432-1 O-ring (Old JIS W 1516 G22) PA62-022 AS568A-244 4
432-2 O-ring JIS B 2401 G85 PA12-085 4
433-1 O-ring (Old JIS W 1516 G22) PA62-022 AS568A-244 4
433-2 O-ring JIS B 2401 G85 PA12-085 4
528 Oil Seal Sleeve with O-ring CS52809-200VD 1
702 O-ring JIS B 2401 G100 PA12-100 1(MMC,MSC)
744 O-ring JIS B 2401 G60 PA12-060 1

In case of replacing the main/side bearings of No.27 and No.28, it is not necessary to prepare the
O-rings of No.432 and No.433 because the main/side bearings have the O-rings.

● The part code of the O-ring is the one assigned to NBR which is standard material.
When the material of the O-ring is other than NBR, a different part code is used for
each material.
If you are using O-rings made from other than the standard material, please contact
us when placing an order.

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5.3.3 Refrigerant Gas Recovery

At the time the compressor operation is stopped, the pressure inside the compressor is still high. As
such, it is necessary to lower the pressure down to the atmospheric pressure before starting the
disassembly process. To do this, there are the following methods for example. Perform your recovery
work in an appropriate manner considering site conditions, requirements of regulatory laws and
regulations.

 By using the bypass valve, release the high pressure gas in the package unit to the low pressure
side.
 If there is another compressor unit to which a permanent bypass line is connected, operate the
other compressor and lower the pressure through the bypass
line.
 Operate the refrigerating system, and close the fluid supply master valve to turn the gas into liquid,
and recover the liquid at the receiver.
 By using a refrigerant recovery machine, recover the liquefied refrigerant in the receiver.

In using either method, prepare a working flow sheet of the system beforehand. Check the valves to be
controlled during the recovery work, according to the method to be used, by comparing them with the
ones in the flow sheet, and clearly note the valves to be operated, other connected devices, and tubes
on the flow sheet.
Two flow sheets must be prepared: one at the foreman and the other for posting in the workplace.
In addition, prepare a work procedure document for the refrigerant recovery work to reflect the actual
conditions of the workplace, and sufficiently share the work details among all the coworkers through
checking and confirmation before actually starting the work.
The gas mask and other protective gears required at each stage of refrigerant recovery work must be
prepared before starting the work.

 Before the work, be sure to check and communicate the work details and procedure
among all coworkers, and carry out hazard prediction activities based on the
information shared. Neglecting to do this will increase the risk of on-the-job
accidents and injuries to a considerable level..
 After closing (opening) a valve for work, conduct lockout/tagout to prevent it
from being handled accidentally during work.

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5.3.4 Removing Parts Connected to the Unit

 If refrigerant gas or a mixture of refrigerant and oil remains in the compressor,

refrigerant gas may blow off when the closed circuit is opened. This may result in
injury such as frostbite or loss of vision. Be sure to confirm that there is no
residual pressure before opening any pipe connections.

When removing the compressor from the mounting base frame, the following parts must be
disconnected beforehand:
(1) Coupling that is connecting the compressor and driving machine;
(2) Compressor's suction pipe flange and discharge pipe flange (if the suction strainer is connected
directly with the compressor, remove the strainer, too), and the intermediate pipe connecting
low-stage discharge port and high-stage suction port;
(3) Compressor's lubrication piping
(journal lubrication (2 sets), oil injection (1 set) and capacity control loading/unloading (2 sets for
each));
(4) Electric wiring for operating capacity control
(Depending on the situation of the workplace, unloader indicator assembly may be removed, with
the wiring left as it is. Refer to Section 5.4.2. and Section 5.5.15 in this chapter);
(5) Bolts for mounting the compressor (leg bolts); and

When removing oil lines from the compressor, there is possibility of gas and oil blowing out caused by
residual pressure. And any residual oil in the pipe will flow out. To be prepared for this, either check the
amount of oil outflow by slightly loosening the pipe joint or drain the oil from the oil temperature gauge at
the supply header before removing the pipe.
Work carefully in particular when disassembling the unloader cylinder block since there is residual
pressure and oil fills in the unloader cylinder. Moreover, prepare a larger volume container than the
unloader cylinder volume to receive oil flowing out.
For easy reconnection, disconnected electric wires should be properly marked for identification. Any
wrong reconnection may result in a startup failure or inability to operate the capacity control mechanism.

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5.3.5 Compressor Removing and Lifting

 The work to lift up or move the compressor must be performed by a qualified operator.
 Make sure that the lifting equipment and wires have sufficient load capacity for the
compressor before starting the compressor lifting work.
 Never try to perform disassembly or assembly while the compressor is lifted in the air.

As the suction pipe is located immediately above the compressor, lift up or partially remove the pipe
such that it will not interfere with the lifting device.
For the lifting positions of the compressor, refer to Photo 002 or Figure 3-1 in page 3-3 of Chapter 3 in
this manual, and/or Photo 003 shown below.
If the planned overhaul work includes separation between low-stage and high-stage blocks of the
compressor, place the compressor on a special stand as shown in Photo 004 and then remove eight
or more hexagon head cap screws around the bottom flange part. Never try to remove these bolts
while the compressor is lifted in the air. Note that these bolts cannot be removed once the
compressor is placed on the work bench.

Photo 003 Lifting the Compressor Photo 004 Lower-side Bolts for
Fastening Rotor Casing

5.3.6 Removing Oil from Inside the Compressor

Remove oil in advance, since a large quantity of oil remains inside the compressor.
There is plug [10] under suction covers [5-1] [5-2] and plug [15] under bearing head [11-1].
Most of the oil will flow out of these plug holes. Remove the remaining oil as it appears, while
disassembling the compressor on the work bench.
Oil mainly resides inside a) unloader cylinders [60-1] [60-2], b) balance piston cover [22] , c) seal cover
[51] and d) suction covers [5-1] [5-2].
Prepare a receiving tray and waste cloth for oil that will spill during disassembly.

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5.4 Disassembly and Inspection

Generally compressors are disassembled in the order shown in Figure 5-1 Illustrated
Disassembly Sequence but the order in the figure is just an example and the actual order may
differ according to individual situations.
For instance when overhauling it is no problem to start separation of high-stage part from
low-stage part after removing the compressor from the unit frame and putting it on the work bench
prepared beforehand.
In addition it is often the case that the disassembly of unloader cover/unloader cylinder part from
mechanical seal part is performed in the reverse order of shown in the Figure 5-1.
Shown in the steps in the Figure 5-1, ① through ⑤ ,⑩ and ⑪, you can disassemble the
compressor with the compressor attached on its frame.
When conducting steps ⑦ through ⑳, perform each step after removing the compressor and
placing it on the work bench.
When conducting steps ⑦ through ⑳, the compressor should be removed from its frame and placed
on a work bench prepared in advance.
When disassembling high-stage or low-stage side only, start from step ⑦ and disassemble necessary
parts only.
Parts which have no problem should be left as they are. Do not disassemble such parts unless during
periodical inspection.
Since it is difficult to completely eliminate the risks of performing inaccurate work at the field,
disassemble the minimum required parts only.

Table 5-6 Disassembly Sequence of 2016**C (example)

Disassembly Sequence
Part to Be Disassembled
(Refer to Figure 5-1)
(1) Shaft seal block ①－②
(2) Unloader indicator ③
(3) Unloader cylinder cover ③－④
(4) Unloader piston and unloader cylinder ④
(5) Bearing cover ⑤
(7) Separating high-stage and low-stage. ⑦

High-stage parts
(8) Gear coupling ⑦－⑧
(9) Thrust bearing ⑦－⑧－⑨
(10) Balance piston cover ⑩－⑪
(11) Balance piston ⑩－⑪
(12) Suction cover and side bearings ⑩－⑪－⑫
(13) Rotors and main rotor casing ⑬－⑭
(14) Bearing head and main bearing ⑭

Low-stage parts
(15) Bearing head, thrust bearings, etc. ⑮
(16) Gear coupling ⑯
(17) Suction cover and side bearings ⑰
(18) Rotors and main rotor casing ⑱－⑲
(19) Bearing head and main bearings ⑲
(20) Unloader slide valve and guide block ⑲

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Figure 5-1 Illustrated Disassembly Sequence (example)

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5.4.1 Shaft Seal Block

P/N Part Name

101 Mating ring
Stationary
102 Insert lock pin
rings
103 O-ring
109 Seal collar
Rotating
111 Seal collar set screw
rings
112 O-ring
528 Oil seal sleeve
529 Sleeve set screw for oil seal
744 O-ring
48 Oil seal retainer
49 O-ring
50 Oil seal
Photo 005 20 Spring pin
Figure 5-2 Details of BBSE Type Mechanical Seal Assembly and Rerated Parts

5.4.1.1 Disassembly
a) Of the eight hexagon socket head cap screws [53] securing the seal cover [51], remove six screws
leaving two diagonally opposite screws.
b) Loosen the remaining two screws alternately and evenly, a little at a time. After loosened to some
extent, the seal cover of the mechanical seal will be raised slightly by the force of the inside spring,
creating a gap under the cover. The gap will not be created if the gasket is sticking to both surfaces.
In this case, free the cover by screwing the M8 eye bolts into the jacking screw holes in the seal
cover to separate it.
c) Use a container to catch the oil that will flow out through the gap.
d) Pull out the seal cover, while keeping it parallel with the shaft (rotor shaft). The mating ring is
attached inside the seal cover by using an O-ring. Be careful not to let the mating ring and the shaft
damaged by contact.
e) Remove the O-ring [49] from between the seal cover and oil seal retainer [48].

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Photo 006 Removing Seal Cover Photo 007 Seal Cover and Mating Ring

f) After removing the seal cover, wipe clean and inspect the shaft surface. If there are scratches, use
fine sandpaper to smooth them over. This is done to prevent damage to the internal O-ring when
pulling out the mechanical seal.
g) Loosen the set screws [111] securing the seal collar [109] by turning them approximately three times
(Photo 008).
Do not remove the set screws completely, but leave them so that their ends are below the surface of
the seal collar. These screws are located in two places 90 degrees apart from each other.

Photo 008 Loosening the Seal Collar Set Screws Photo 009 Oil Seal Retainer

h) Pull out the seal collar with your fingers. While pulling out, make sure that the ends of the set screws
do not touch the shaft surface. Axial-direction scratches on the shaft can cause leaks.
i) By removing the two set screws [529], pull out the oil seal sleeve [528].
j) Screw two M8 eye bolts into the screw holes in the oil seal retainer [48] and pull out the oil seal
retainer while keeping it at a right angle against the shaft.
k) Remove the oil seal [50] that is attached into the oil seal retainer.

5.4.1.2 Inspection
a) Mechanical seal should be replaced if any defect is found during inspection. Actually, however, it is
sometimes difficult to find out defects on the sliding surface only through visual inspection. In such
circumstances, MAYEKAWA recommends to replace it with a new one in the same manner as with
O-rings or gaskets.
Also, if it is difficult to stop the compressor operation except for scheduled inspections, we
recommend to replace the mechanical seal assembly with a new one at every inspection of this
block.

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The contact between the sliding surfaces of the mating ring and seal collar must be checked even
when replacing the seal. If there are obvious traces of uneven contact or damage, find out the cause
(degradation over time, problems such as heating operation, etc.) and take necessary actions.

b) Replace the O-rings every time the mechanical seal assembly is inspected because they normally
swell and deform over time.
A total of four O-rings are used for the sealing section. They are located between the seal cover and
oil seal retainer [49]; between the mating ring and seal cover [103]; between the seal collar and
shaft [112]; and between the shaft and oil seal sleeve [744].
c) Inspect the oil seal sleeve for wear in its section rubbing against the oil seal lip.
If wear is evident, replace both the oil seal [50] and oil seal sleeve [528] with new parts. Since the oil
seal is made of a special material, only a genuine oil seal must be used for replacement.
<About the O-rings attached to oil seal sleeve [744]>
In the design modification applied in March, 2010, O-ring [744] is attached to the inner diameter of
the oil seal sleeve.
d) Replace the seal cover gasket with a new one.

Photo 010 Oil Seal Retainer and Oil Seal Sleeve attached with O-ring

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5.4.2 Unloader Indicator

As the 2016**C model has a capacity control mechanism also on the high-stage, it has two
separately-placed indicators. Normally, the low-stage capacity control only is used during operation.
The high-stage capacity control mechanism is used to reduce the startup load.
As various control methods are employed depending on the system, refer to the separate electrical
control schematic diagram (provided for each plant).

Figure 5-3 2016**C Low-stage Unloader Indicator Block (same as 1612C Low-stage)

5.4.2.1 Disassembly
 When removing wiring only
When removing the compressor, the wiring of the unloader indicator has to be pulled out. As the
indicator has a terminal board for wiring, remove the cover from the indicator. Follow the procedure
below. After the wiring is removed, attach the cover again for protection.

[Low-stage]
a) Loosen the hexagon socket head cap screws [212] fastening the indicator glass [141]. Do not
by mistake loosen the crosshead screw [210] on the same surface.
Remove assemblies [141], [202 to 207], [210] and [211].
b) Remove hexagon socket head cap screws [147A] [147B] (two each) that fasten the indicator
cover [146]. Then the cover gets removable.
c) There is a terminal block. Remove the plastic plate on the surface, and loosen the screws.

[High-stage]
a) Remove three hexagon socket head cap screws [147] that fasten the indicator cover [146].
Then the cover gets removable.
b) The indicator cover comes off with glass [141] and indicator glass spacer [142] attached. The
glass and the spacer are pasted together, however, take care not to drop them as they may
come apart.
c) Remove the wiring.

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Figure 5-4 2016**C High-stage Unloader Indicator (Standard type, High-stage Dial Plate)

Photo 011 Removing Low-stage Indicator Cover Photo 012 Loosening Low-stage
Micro-switch Cam Set Screw

Photo 013 Removing High-stage Indicator Cover Photo 014 Loosening High-stage
Micro-switch Cam Set Screw

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 When removing entire unloader indicator assembly, with the wiring left as it is
The indicator is an assembly. Unless it needs to be disassembled, remove it as a assembly unit
and do not disassemble it into smaller parts.
[High-stage/Low-stage]
a) As a result of the disassembly process conducted above, (i) the internal potentiometer,
(ii) micro-switch and (iii) micro-switch base plate [121] attached with micro-switch cam get
removable.
b) Remove hexagon socket head cap screws [122].
c) Loosen the micro-switch cam set screw [128].
d) Now, the assembly can be pulled out as it is if pulled out in the axial direction.

Photo 015 Loosening the Screws Photo 016 Removing High-stage Indicator
Securing High-stage Micro-switch Base Plate

Photo 017 Removing Low-stage Indicator Photo 018 Removing Low-stage

Indicator Cover

Photo 019 Removing Low-stage Indicator Pointer Photo 020 Low-stage Indicator Inside

5.4.2.2 Inspection
Inspection and adjustment of the unloader indicator is often done after its removal as part of indicator
assembly. The inspection and adjustment is done after the compressor, which was disassembled and
inspected, is reassembled and restored to the package unit frame. So, for information on inspection,
refer to Section 5.5.14 "Unloader Indicator" in this chapter.

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5.4.3 Unloader Cover

The unloader cover [74-1] [74-2] is mounted with the indicator cam [77-1] [77-2], which converts the
Indicator Cam , and their mounting parts.

5.4.3.1 Disassembly

Photo 021 Loosening Bolts of Photo 022 Removing Unloader Cover

Unloader Cover

a) Remove the hexagon socket head cap screws [76] used to attach the unloader cover.
b) The indicator cam [77], which is attached to the unloader cover, is fit to the inner side of the
unloader push rod [67] which is inside the unloader cylinder. The guide pin [68] at the tip end of the
push rod is engaged with the spiral groove of the indicator cam. So the unloader cover can be
pulled out straight as it is (Photo 022).
If the unloader cover should be bent obliquely, the shaft of the indicator cam will also be bent. So
take care.

Photo 023 Main Body of Unloader Cover Photo 024 Sealed Portion of Indicator Cam

c) If the indicator cam does not move properly, check the spiral groove of the indicator cam, bearing
and guide pin. Disassembly sequence is as shown below.
c-1) The bearing gland [80] that holds the indicator cam is secured to the cylinder side of the
unloader cover. Remove the three hexagon socket head cap screws [81] that are securing the
bearing gland.
c-2) Now, the indicator cam can be pulled out as it is, together (attached to its shaft) with its ball
bearing [78] and external snap ring [79] securing the bearing.
c-3) The spring retainer [84], spring [83] and V-rings [82] are attached, in this order, to the inside of
the unloader cylinder cover.
The outer diameter of the Teflon V-rings is attached tightly to the holes of the unloader cover.
These V-rings, once removed, cannot be reused because their tongue portion gets damaged.
So be careful.

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Photo 025 V-ring (Black part is NBR/FKM.)

5.4.3.2 Inspection
a) Check the packing portion of the indicator cam shaft for any flaw. If the refrigerant leaks without any
flaw observed in this part, it should be due to a defect of the V-ring or installing the V-ring without
sufficient oil. In this case, replace the V-ring.
b) Check the spiral groove of the indicator cam. If defect such as damage or wear is found, replace it
with a new one.

5.4.4 Unloader Piston and Unloader Cylinder

5.4.4.1 Disassembly
a) Pull out the unloader piston [64] to the utmost front
position.
b) Then, unbend the rotation stopper tooth of the lock
washer [70] and loosen the lock nut [69].
c) As the unloader piston has two screw holes, screw
in two M8 eye bolts and pull out the piston with the
eye bolts.
d) The low-stage unloader cylinder [60-1] is, together
with the bearing cover [16], attached to the
low-stage bearing head [11-1] by using eight long
bolts [62-1]. Photo 026 Unbending the Lock
Remove those bolts [62-1], and pull out the unloader Washer Tooth
cylinder.

Photo 027 Removing Lock Nut Photo 028 Removing Low-stage

Unloader Cylinder

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e) The high-stage unloader cylinder [60-2] is, fastened by using two hexagon socket head cap screws
[61] and six hexagon socket head cap screws [62-2]. Pull out the unloader cylinder in the same way
as described in b) above. If, after disassembly of the cylinder portion, further process of
disassembly has to be done, leave the two screws [61] fastened as they are and remove the bolts
[62-2] and bolts [24] that fasten the balance piston cover, so that the unloader cylinder can be
removed as a unit, combined with the balance piston cover. At this moment, there is oil accumulated
at the balance piston and side bearings. So pay attention to the oil that will flow out when removing
the balance piston cover. When the gasket [23] is stuck, remove it by tapping the balance piston
cover with a hammer.

Photo 029 Removing High-stage Unloader Cylinder

5.4.4.2 Inspection
a) Be sure to replace the cap seal [66], which is attached to the outer circumference of the unloader
piston [64], as well as the O-ring [65].
b) The unloader cylinder often has damage or oil refuse stuck to its inner surface. Clean it thoroughly,
and smoothen its surface by using fine sandpaper (#400 or finer).

Photo 030 Removing the Cap Seal of the Unloader Piston

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5.4.5 Bearing Cover

The bearing cover [16] should be removed when pulling out the low-stage thrust bearings or rotors for
inspection.

5.4.5.1 Disassembly
a) Remove all the hexagon socket head cap screws [18-1]. The bearing cover remains attached to the
bearing head [11-1] with alignment pins [19-1].
b) Screw holes are provided in symmetric positions. Screw the two bolts that have been removed[18-1]
into the right and left holes. This will cause the bearing cover to separate from the bearing head.
When a small gap is created, peel up one side of the gasket [17-1] by using a scraper
c) Screw the bolts further, until the cover comes off the alignment pins.

 At this time, be sure to support the bearing cover. Otherwise, it may fall over or
fall down, causing the shaft (rotor shaft) to get damaged. Protect in advance the
shaft with a cloth, or the like.

Photo 031 Removing Bearing Cover Photo 032 After the Bearing Cover is Removed

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5.4.6 Separating High-stage and Low-stage

Separate the high-stage and low-stage when pulling out the high-stage thrust bearings or rotors of each
stage. Structurally, they can be separated at the initial step of disassembly.

5.4.6.1 Disassembly
a) As explained in Section 5.3.5 of this chapter, put the compressor on a special table and remove the
bolts from the lower side. Then, remove the remaining hexagon socket head cap screws [18-2].
At this moment, the high-stage of the compressor is spaced apart the work bench. Brace the
high-stage with a rectangular piece of wood or the like to prevent it from falling when disassembled.
As the screws [18-2] of the 2016**C model are 5 mm longer than other screws, they cannot be used
for other purposes. Distinguish these from others.
b) Drive alignment pins [19-2] into suction cover [5-1].
c) The bearing head [11-2] and suction cover are stuck together by gasket [17-2]. Screw in screws
[18-2] (which have been removed) into the holes on the bearing head, to separate the suction cover
evenly by pushing.
Do not drive a screwdriver or chisel into the gap.
d) The power transmission gear couplings [151 to 161] are attached to the inside of M rotor shaft.
Move the main body in parallel with the shaft to separate the drive side and the driven side in the
direction of the shaft.

Photo 033 Separating High-stage and Low-stage Photo 034 Low-stage After Separation

5.4.7 Gear Coupling

The gear coupling, which is used as a power transmission means, is divided into the high-stage and the
low-stage blocks, with each block attached to the corresponding M rotor shaft, and these two blocks are
directly connected by a drive sleeve.

Gear coupling mechanism of 2016**C models

In March 1982, the coupling method was changed from the initial type (coupling hub is directly
connected using hexagon head screws) to the method using coupling hub and sleeve. This method
was used for a long time.
However, the anti-falling method of the drive sleeve was modified in October 2010 as the design
modification. While the old couplings have stoppers on both outer ends of the drive sleeve, the
stoppers are placed on the inside of the drive sleeve after the design modification (compatible with the
old type).
After this design modification, the drive sleeve stopper [154] and snap ring [155] are no more used.
* Date on which design was changed: The new method was applied first to assembly in Oct. 19. 2010.
"Model: N2016SSC-LBM Serial number: 2023130".

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Gear coupling assembly comprising Gear coupling assembly comprising

151, 152, 153, 154*2, 155*2 and 159. 151, 152, 153 and 159.

Figure 5-5 Former Method Figure 5-6 New Method

(Used Until Design Change in Oct. 2010) (Used After Design Change in Oct. 2010)

5.4.7.1 Disassembly
a) Drive sleeve [151] can be removed with hands when the high-stage and low-stage are separated.
b) On the high-stage (driven) side, loosen the set screw [159] of the key [157] attached on the driven
hub [153], and then remove the driven hub. As it is clearance-fitted, it can be removed easily.
c) On the low-stage side, unbend the lock washer tooth [161] and loosen the lock nut [160] to remove
the drive hub [152].
d) Two screw holes are provided on the drive hub. Screw in M8 eye bolts, and pull out the drive hub.
As it is clearance-fitted, it can be removed easily.

For the set screw [159], MAYEKAWA recommends a knurled cup point locking screw with an
anti-loosening coating on the screw.

Photo 035 Removing the Driven Hub Photo 036 Current Parts of Gear Coupling

5.4.7.2 Inspection
Check the hub and sleeve for possible deformation of the gear teeth and wear on each tooth flank.
If any defect is found, replace the whole gear coupling assembly. Also, investigate cause(s) of the
defect.

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5.4.8 Balance Piston Cover

Disassemble this part when pulling out the rotor or when inspecting the side bearing [28-2] or balance
piston.
The balance piston cover [22] is removed, combined together with the unloader cylinder [60-2]. If the
unloader cylinder is pulled out and disassembled further, follow the procedure below.
a) Loosen all of the hexagon socket head cap screws [24] by turning them three or four times, and tap
the side face of the cover with a soft hammer, to release the balance piston cover gasket [23] that is
stuck.
b) In this state, drain the oil from the balance piston and side bearing block inside the suction cover.
When the oil has been drained, remove all the screws except for the one on the upper side. While
holding down the balance piston cover, remove the remaining screw and remove the balance piston
cover.

5.4.9 Balance Piston

When the screw compressor is operated, the thrust load applied to the M rotor is large and the M rotor
rotates very fast compared with the F rotor. Therefore, the life of thrust bearing on the M rotor would
normally be much shorter than that of those attached on the F rotor.
To reduce the thrust bearing load on the M rotor, a hydraulic piston is installed at the end of the
high-stage M rotor shaft in order to cancel the thrust load.
* Note that balance piston is not used on the low-stage, because the low pressure conditions is lower
than high-stage, the service life difference of the bearings is not so significant compared to the
high-stage.

Photo 037 Balance Piston and Snap ring

5.4.9.1 Disassembly
a) By using external snap ring pliers, remove
the snap ring [32] which retains the balance
piston [30] on the shaft.
Screw in two M8 eye bolts, and pull out the
balance
piston.
It is not necessary to remove the balance
piston key [31] fitted in the rotor shaft.

Photo 038 Removing Snap ring

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Photo 039 Pulling Out Balance Piston Photo 040 Loosening Set Screws Used for
Stopping Rotation of Balance Piston Sleeve

b) Then, retract the hexagon socket head cap set screws [34] which are used for locking rotation of the
balance piston sleeve [33].
Two set screws are used. Loosen the F rotor-side set screw, and get the balance piston-side set
screw under the suction cover.
c) By using internal snap ring pliers, remove the snap ring [37] which retains the balance piston sleeve.
As the snap ring is pushed out by the force of the inner O-ring [35], it can be removed easily by
pushing in lightly.
d) Pull out the balance piston sleeve. As the outer diameter of the sleeve is clearance-fitted with the
suction cover, it can be pulled out easily.
Remove the balance piston sleeve, O-ring and O-ring spacer [36].
e) The snap ring [29] attached inside the O-ring spacer need not be removed, except when removing
the side bearing [28].

5.4.9.2 Inspection
Although there are signs of wear on the inner surface of the balance piston sleeve, this is not a problem.
They result from the fact that the gap between the balance piston and the piston sleeve is smaller than
the gap between the rotor shaft and the bearings.
These wears will not develop further, because a large gap is created around the outer circumference of
the balance piston sleeve in order to prevent the bearing load from being applied to the balance piston.
However, you should still carefully check the condition because when the side bearing is significantly
worn, the balance piston may also be worn.

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5.4.10 High-stage Suction Cover and Side Bearings

If the work sequence is such that the thrust bearing block is disassembled first and then the suction
cover is removed, there is a risk that, when the suction cover is separated from the main rotor casing,
the rotor may also be pull out and dropped. As such, in the procedure described in this manual, the
suction cover is removed first, and then the thrust bearing is disassembled.

 In this procedure to remove the suction cover before disassembling the thrust bearing
block, it is necessary to sufficiently loosen the lock nut that are securing the thrust
bearing while the rotor is supported by both the main and side bearings, in order not to
damage the rotor during the disassembly process.

5.4.10.1 Disassembly
a) Remove the hexagon head bolts [45-2] and the conical spring washers [46-2] that are used to fasten
the thrust bearing gland [43-2], and then remove the gland.
In case of a former model which uses a rotation stopper fitting instead of a conical spring washer,
extend the claw bent plate of the rotation stopper and remove it from the hexagon head blot [46-2],
and then remove the hexagon head bolt and the thrust bearing gland.
b) Unbend the rotation stopper tooth of the lock washer [40-2] holding the lock nut [39-2] which retains
the inner race of thrust bearing [38-2] on the rotor shaft and loosen the lock nut using a lock nut
wrench.
c) As the height of the high-stage main rotor casing is low, the casing is installed like a bridge to
connect between the suction cover and the bearing head. As such, the main rotor casing will be
supported only by one side (i.e., overhang) when the suction cover is removed. To avoid this, either
place squared timbers or use a lifting device to properly support the main rotor casing.
d) Loosen and remove the hexagon socket head cap screws [2-2] that fasten the high-stage suction
cover [5-2] and high-stage main rotor casing [1-2].
e) The suction cover gasket [6-2] is stuck to the flange surface. Screw two hexagon socket head cap
screws [2-2] (which have been removed) into the threaded holes on the main rotor casing flange, to
push the suction cover evenly.
When a small gap is created, peel up one side of the gasket by using a scraper (Do not drive a
screwdriver or chisel into the gap).
f) At the position where the alignment pins can be disengaged, pull out the suction cover all at once in
parallel with the rotor axis.

Photo 041 Pulling Out Suction Cover

d) The side bearing [28-2] is press fit from the balance piston cover side of the suction cover.
Release the snap ring [29-2], and push it out from the rotor side.

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5.4.10.2 Inspection

a) Check the oil inlet path to the balance piston part of the suction cover by spraying air or the like.
b) We recommend unconditional exchange of the side bearings on the occasion of the compressor
overhaul, but for confirmation of the compressor condition and system operating condition, carefully
check the sliding part metal surface of the side bearings.
If the metal surface is turned gray or any foreign matter is embedded, also carefully check the wear
of the rotor shaft.
c) The inside surface of the main rotor casing should have no problems because sufficient clearance is
provided. However, if any trace of scraping by the end of the rotor is found, it should be determined
that the thrust bearing is defective. It is also necessary to check the operational condition, such as
whether the system is operated for a long time with a high intermediate pressure.
d) The high-stage suction cover of 2016**C has a hole for the unloader push rod to pass through,.
Check the O-ring [9] in there, and replace it.

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5.4.11 Low-stage Suction Cover and Side Bearings

Similarly to the case of the high-stage, the lock nut fastening the thrust bearing should be loosened
before removing the suction cover.

5.4.11.1 Disassembly
a) Remove the hexagon head bolts [45-1] fastening the thrust bearing gland [43-1]. As conical spring
washers [46-1] are used together, be careful not to lose them.
b) Unbend the tooth of the lock washer [40-1] to preventing the lock nut rotation, and loosen the lock
nut [39-1].
c) The oil injection pipe [85] that supplies lubricating oil for injection to the unloader slide valve is
located at the lower area of the low-stage suction cover. Since the oil injection pipe is retained by
the oil injection pipe gland [164], unscrew four hexagon socket head cap screws [166] and remove
the oil injection pipe gland.

Photo 042 Removal of Oil Injection Pipe Retainer Photo 043 Pulling Out Oil Injection Pipe

d) There are M16 threaded hole on the head of the oil injection pipe. Screw the bolts [2-1] which has
been removed, and pull out the pipe.
e) Remove all the hexagon socket head cap screws [2-1]. Then, drive alignment pins [3-1] into the
main rotor casing [1-1].
f) Screw hexagon socket head cap screws [2-1] into the two screw holes on the main rotor casing
flange, to push the suction cover flange evenly.
g) When some gap is observed between them, use a
scraper to remove one side of the gasket [6-1] from the
body.
h) When a gap gets spread to a full length of the jacking
screws, release the engagement of the rotor shaft and
side bearing by sliding on the work bench parallel with
the rotor axis.
i) Remove the snap ring [29-1] and push out the side
bearing [28-1] from the main rotor casing side.

Photo 044 Removing the Snap ring

5.4.11.2 Inspection
Inspect the suction cover and side bearings in the same way as for the high-stage.

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5.4.12 Thrust Bearings Block

Thrust bearing is a face-to-face angular contact ball
bearing. This bearing only receives thrust load and
does not receive the radial load perpendicular to the
shaft because there is a gap between the outer ring of
the thrust bearing and the bearing head. Apart from
receiving the thrust load, the bearing has the important
role of securing the position of the gap between the
rotor and the discharge side of the bearing head. This
gap (end clearance) is significantly linked with
performance.

Photo 045 Thrust Bearing

P/N Part name Qty.

38-2 Thrust bearing (2) 2
39-2 Lock nut (2) 2
40-2 Lock washer (2) 2
41-2 Thrust bearing outer race spacer (2) 2
42-2 Thrust bearing alignment spacer (2) 2
43-2 Thrust bearing gland (2) 2
45-2 Hexagon head bolt, M10×30 8
46-2 Conical spring washer for M10 8
237-2 Torsional slip washer for 160*** 2
250-2 Thrust washer 160*** 2
Figure 5-7 Thrust Bearing Block (High-stage / Low-stage)

5.4.12.1 Disassembly of High-stage Thrust Bearing Block

a) Remove the lock nut [39-2] that has been loosened. Then, remove the torsional slip washer [237-2],
lock washer [40-2], and thrust washer [250-2].
b) The clearance fit is applied to two gaps between the outer race of the thrust bearing and the bearing
head, between the inner race of the thrust bearing and the rotor shaft
Prepare a 1 or 2 mm diameter aluminum wire, make the tip of the wire flat by hammering, and
slightly bend the tip to make a hook. Then, insert the tip of the wire between the outer race and the
ball retainer of the thrust bearing [38-2] to hook and pull out the bearing. In this way, the bearing can
be easily removed.
c) The whole thrust bearing will be removed helped by the surface tension of the oil on the side face.
If you have failed to remove the whole bearing at once, put the components in the order of the
removal.
d) Attached to the inside of the thrust bearing are; thrust bearing outer race spacer [41-2] for the
bearing head-side outer ring, and the thrust bearing alignment spacer [42-2] for the rotor shaft side
inner race. To identify where to set, the thrust bearing outer race spacers and thrust bearing
alignment spacers have a stamped mark of "M" or "F" which means "for M rotor" or "for F rotor".
The bearing glands, thrust washers, thrust bearings, thrust bearing outer race spacers and thrust
bearing alignment spacers, which have been removed, should be divided into two groups (M rotor
group and F rotor group).
You must be very careful because if an assembly error is made to result in a wrong combination of
parts after failing to neatly arranging and separating the parts, it can lead to performance
degradation and/or dragging accident due to overheating caused by being too narrow end
clearance, for example.

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Photo 046 Pulling Out Thrust Bearing Photo 047 Stamp Marks on Outer race Spacer
and Alignment Spacer

5.4.12.2 Disassembly of Low-stage Thrust Bearing Block

a) Remove the lock nut [39-1] that has been loosened. Then, remove the torsional slip washer [237-1],
lock washer [40-1], and thrust washer [250-1].
b) Similarly to the case of the high-stage, remove the thrust bearing [38-1], thrust bearing outer race
spacer [41-1], and the thrust bearing alignment spacer [42-1].

Photo 048 Thrust Bearing Glands are Just Removed Photo 049Bearings are Just Removed

5.4.12.3 Inspection (High-stage and Low-stage)

a) The thrust bearing is normal if the bearing balls are found fully glossy after the thrust bearing has
been fully washed and cleaned. It is abnormal if the ball surface has tarnish streaky pattern.
b) Support the inner race with your hand and rotate the outer race. If you feel abnormal vibration on the
hand, the rolling contact surface of the inner or outer race or some balls may be in an abnormal
condition. So, carefully check the conditions. You could feel some irregular click even with a small
foreign matter that has entered during the removal process. In such a case, it should return to the
normal condition when high pressure air is used to blow out the foreign matters after washing and
cleaning the unit. If the bearing is determined to be defective, it must be replaced with new ones.
c) If the inner race and outer race can be easily separated, the wear is considered excessive. If so, you
cannot reuse the bearing.
d) After washing the bearing, you should be able to hear a clattering sound when the bearing is rotated
by hand. Such a sound is due to the motion of the ball within the backlash or play, or the gap
between the retainer and the ball. Such a sound will not be heard if the bearing is held horizontal
and turned. If some lubricating oil is applied after washing the bearing, the sound should not be
heard when the bearing is turned. If you can still hear the sound, the bearing is abnormal.

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e) If any abnormality is seen in the thrust bearing in the above inspection, replace with new ones.
In addition, carefully check the reason whether due to mere aging or any problem with the operating
condition and/or lubricating mechanism.
f the compressor has been operated for more than 20,000 hours without replacing the thrust bearing,
it is recommended to replace the bearing with a new one for safely continuing the operation until the
next overhaul, even if no abnormality is found in the above described inspection.

 Since a bearing is a combination of specifically designed parts, even if a bearing

with the same number is found in a bearing manufacturer's catalog, the accuracy
or material may not be identical. Replace the parts with genuine
parts. Parts other than genuine parts are not covered by the warranty.

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5.4.13 High-stage Rotors and Main Rotor Casing

5.4.13.1 Disassembly
a) Either the M rotor or F rotor may be removed first. However, as the M rotor is longer, it is easier to
remove the M rotor first. When pulling out the M rotor (or F rotor) first, pull out about 2/3 of the full
length of the rotor by holding the shaft upward and turning it in the CW (or CCW) direction.
When approximately two thirds of the rotor has been pulled out, draw the rest out slowly while
attaching the other hand to the outer circumference of the rotor.

 You should carefully note that the rotor must be rotated in the specified direction
while pulling it out. If the M (F) rotor is not turned during the pulling out process,
the F (M) rotor can also be pulled out together.

Photo 050 Pulling Out M Rotor Photo 051 Pulling Out F Rotor

b) Do not place the pulled-out rotor directly on the floor. Cover the floor with wooden pieces or the like
as a cushion. Otherwise, use V-blocks to support the shaft to prevent blemishing of the outer
surface.
c) Pull out the F rotor in the same way. Take care not to get the main bearing damaged with the edge
of rotor shaft during removal.

5.4.13.2 Inspection
a) No abnormality should be observed on the surface of the rotor lobes under normal operations.
Regarding the contact surface of the teeth, black luster should be seen on the root area of the M
rotor lobes and on the tip area of the F rotor lobes.
In other cases, when the suction gas or oil is contaminated by fine dust, there may be fine linear
scratches on the shaft surface, in the direction perpendicular to the shaft axis. If any such flaw is
found, use a fine sand paper or grindstone to smooth the surface.
b) In case of ammonia refrigerant or gas compressor, the non-contact surface of the rotor may be
discolored by rust or deposits. Use sand papers or others to finish the surface according to the
degree of the problem.
c) Then, check the bearing areas of the rotor shaft. Two types of finishing are used: one is the
induction hardening (polish finishing) for the standard specification, and the other is the hard
chrome plating (polish finishing), as a special specification. The most suitable finish is selected
according to the type of refrigerant and operation conditions.
Very little wear will be present unless the compressor is operated for a long time using dirty oil or
any hard matter is buried in the metal of the inner circumference of the bearing.

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d) Check the portion of the shaft on which the thrust bearing is mounted for any trace to show that the
inner race of the bearing has rotated.
If the lock nut that fastens the inner race of the thrust bearing is loosened, or if the bearing is
abnormally worn, the inner race will become rotate. If any trace of rotation is seen, correct the
problem. Depending on the degree of the rotation trace, it might be necessary to replace the rotors
with new ones.
e) Check the inner surface of the main rotor casing.
There is a narrow clearance between the periphery of the rotor and the main rotor casing. Any slight
flaw present on the tip of the rotor teeth or on the inner surface of the main rotor casing, due to small
foreign matters, will not be a problem.
If there is any trace to show that the tips of the rotor teeth have hit the inner surface of the main rotor
casing, it is an abnormal condition. In such a case, the possible cause is that the main bearing
and/or side bearing is worn out. Take proper actions by finding the cause of the problem, such as
contamination of the lubricating oil or entrance of foreign matters.

Photo 052 High-stage Rotor Casing

5.4.14 Low-stage Rotors and Main Rotor Casing

Take care because the low-stage rotors are heavy.

Perform the work similarly to the case of the high-stage unit. The work should be very carefully
performed as the low-stage rotors are heavier than the high-stage rotors.
Also perform the inspection work similarly to the case of the high-stage unit.
Since the low-stage M rotor is installed with a mechanical seal, do the work very carefully not to
damage the shaft. It is recommended to apply a protective tape on the shaft surface.

Photo 053 Low-stage Rotor Casing

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5.4.15 High-stage Bearing Head and Main Bearings

On the rotor mounting side of the bearing head [11-2], there is a gas discharge port as determined by
the operating conditions of the compressor. This discharge port affects the performance of the
compressor.
In addition, the bearing head has the main bearing that supports one end of the rotor.

5.4.15.1 Disassembly
a) Place a support like a squared timber or the like under the rotor casing.
Remove all the hexagon socket head cap screws [2-2] that fasten the main rotor casing and bearing
head. Drive alignment pins [3-2] into the rotor casing.
b) Screw two hexagon head cap screws [2-2] into the jacking threaded holes of the main rotor casing
flange to push the bearing head evenly.
c) When some gap is observe, use a scraper to remove one side of the gasket [12-2] from the body.
d) The main bearing [27-2] is lightly press fit to the bearing head.
To take out the main bearing, remove the snap ring [29-2] and tap the rotor side by using internal
snap ring pliers.
Then, either use a plastic block or other suitable element to push the bearing from the main rotor
casing side or use a special tool to pull out the bearing. For the details of the special tool, refer to
Section 5.5.2 in this chapter.
e) The unloader slide valve assembly is installed into the high-stage of the 2016**C. Draw it toward the
bearing head and out. If no specific abnormality is found, no further disassembly is required.
f) The guide block stem [88-2] is screwed from bottom of the main rotor casing, and the guide block
[87-2] is engaged from the top. To replace the O-rings [89-2], remove the guide block stem.

Photo 054 After Removal of Main Bearings

5.4.15.2 Inspection

a) We recommend as well as the side bearings, unconditional exchange of the main bearings on the
occasion of the compressor overhaul, but for confirmation of the compressor condition and system
operating condition, carefully check the sliding part metal surface of the main bearings.
If the metal surface is gray or any foreign matter is buried, also carefully check the wear of the rotor
shaft.

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b) Check the condition of the surface of the bearing head on the rotor side, where the discharge port is.
Properly mend the surface if any flaw is observed. If the entire surface has significant flaws, either
the thrust bearing is defective or the end clearance adjustment is poor.
If oil compression has been caused during the operation, carefully and thoroughly check the area of
the discharge port in particular. If the continued use is in doubt at all, perform the penetrant testing
(color check) to determine if it can be used or not.
c) With the unloader slide valve mounted in position, check the step height between the slide valve
and the main rotor casing surfaces.Generally Usually, the surface of the slide valve should be lower
than the surface of the main rotor casing.
If the top surface of the slide valve has a trace of hitting the rotor, the probable cause is that the slide
valve is worn or the rotor shaft/bearing is worn. Please contact our sales offices or service centers.
d) Check the properness of the guide pin [68-2] at the tip of the unloader push rod [67-2] that engages
with the indicator cam [77-2].

5.4.16 Low-stage Bearing Head and Main Bearings

Perform the disassembly and inspection work for the low-stage bearing head and main bearings in
the same way as with the high-stage.

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5.5 Reassembly

 During the reassembly work, be very careful in selecting the correct replacement
O-rings of the specified standard, not to make a mistake regarding the size,
material, for fixed use, for sliding use, etc. Using a wrong O-ring can lead to oil
leak or other problems.
 Some gaskets are not symmetrically shaped. In such a case, be careful not to
misplace the gasket. If the gasket is misplaced, it can lead to a significant
problem such as blocking any oil supply route on the casing.

After completing the disassembly and inspection procedures, start the assembly process.
First, read again Section 5.1 "Precautions for Maintenance and Inspection" in this Chapter 5.

Before starting the assembly, check the replacement parts once again.
Like gaskets, all O-rings that have been removed during the compressor disassembly must be replaced
with new ones.
The reassembly sequence is mostly the reverse of the disassembly sequence. First of all, clean the
work bench and the tools to be used.
Immediately prior to the assembly, use washing agent (e.g., kerosene, parts cleaner) oil to clean the
parts to be assembled, dry them with compressed air, and sufficiently apply lubricating oil, etc. For this,
prepare a sufficient amount of clean lubricating oil for the reassembly. Also, apply oil on both sides of
the gasket.
Because the assembly procedure is mostly similar between the high-stage and low-stage sides, the
following sections provide explanations that are commonly used for both stages. For this purpose, the
part number given in the common explanations will omit the distinction between high-stage and
low-stage by means of a hyphenated suffix (the suffix of [**-1] for low-stage and [**-2] for high-stage
part number will be omitted).
Please fully understand the details in this Section 5.5 for correct assembly work.

Table 5-7 Standard Tightening Torque for Hexagon Socket Head Cap Screws
Torque Unit M6 M8 M10 M12 M14 M16 M20 M24
N·m 10 25 50 90 140 240 450 750
kgf·cm 100 250 500 900 1400 2400 4500 7500
When fastening the hexagon socket head cap screws, use the tightening torque specified in the above
table.

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Figure 5-8 Illustrated Assembly Sequence (example)

* The circled numbers in the figure do not correspond to
the paragraph numbers used in the steps below.

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5.5.1 Unloader Slide Valve and Guide Block

a) First, tightly screw the guide block stem [88] into the bottom of the main rotor casing, and then
mount the guide block [87 inside the main rotor casing.
b) If the slide valve assembly has been disassembled, first make sure that the alignment position
between the slide valves [54] and [55] is accurately reproduced and then tighten the hexagon
socket head cap screws [58] with spring washers [267] at the specified torque. The outer diameter
of the spring washers used here is less than normal spring washers for hexagon socket head cap
screws. So, be careful not to mix up with other washers.
c) After using a grind stone or fine sand paper to lightly finish the circumference of the unloader slide
valve assembly, mount the assembly in the main rotor casing. Then, slowly push-in the push rod
while aligning the groove of the slide valve with the guide block.
d) After it is assembled, hold the unloader push rod and move it for several times to check that it
moves smoothly. Then, carefully check the joint with the main rotor casing that there is no step
between them.
If there is a step, check it by reversing the orientation of the guide block first. If the step is still
present, it should be due to imperfect assembling, and it must be reassembled.
* Regarding the unevenness between the unloader slide valve and the main rotor casing, there is no
problem if the slide valve is slightly lower than the casing.

 If the unloader slide valve is higher than the main rotor casing, there is a problem
in assembly. Do not leave the problem as it is. Be sure to reassemble. If used
without correcting it, the outer periphery of the rotor may hit against the slide
valve, which will cause a severe damage accident.

e) The low-stage slide valve assembly has an oil injection pipe guide [168] on the opposite side of the
push rod. Do not forget to install the O-ring [59] (Photo 056).

Photo 055 Guide Block Stem Inside Casing Photo 056 O-ring for Oil Injection Pipe Guide

Photo 057 High-stage Rotor Casing

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5.5.2 Bearing Head and Main Bearings

Photo 058 Attaching Main Bearing Photo 059 Securing with Snap ring
(High-stage) (Low-stage)

The main bearing (O-ring type) [27] is installed by a light press fit.

a) Align the notch on the main bearing with the spring pin [14] that is driven in into the bearing head
[11], and then push it in with a pad. For the alignment, it is convenient to use a tool such as a guide
bar (Photo 058).
b) After the bearing has been inserted, install the snap ring [29] to retain the bearing in position (Photo
059). Securely install the snap ring to be fully seated in the ring groove, by pushing the snap ring
with a guide bar or the like, or by lightly hitting the guide bar with a hammer while placing the guide
bar on the snap ring.

When press fitting, using a weight jig and a plastic spacer indicated in the Figure 5-9 makes
attaching bearing works easier. The plastic spacer should be just the right size of the bearing inner
diameter and hit the spacer inside with the weight jig.

Figure 5-9 Spacer and Weight Jig (example) for press fitting a Bearing

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5.5.3 Bearing Head and Main Rotor Casing

 Since the bearing head gasket [12] is not formed symmetric laterally, pay
attention to the installation direction.
 If you place the bearing head gasket by just hanging it on the stud bolts, the gasket
will protrude into the inside of the rotor casing when the casing is assembled. Apply
sufficient amount of oil, etc. to the gasket to make it fully attached to the surface to
prevent protruding upon the assembly.

Photo 060 Fastening Low-stage Assembly with Bolts Photo 061 High-stage Assembly

a) In case of assembling the low-stage, fit the unloader push rod [67-1] in the hole of bearing head
[11-1]. Then, slide the bearing head or main rotor casing to let them mate together.
b) Loosely tighten two bolts in symmetrical positions. Next, drive in the alignment pins [3-1] to fix the
position, and then screw bolts in opposing positions, and then fasten the bolts evenly in turn.
c) After fastening the bolts, check that the bearing head gasket is not protruding toward the inside of
the casing.
d) Also, move the slide valve back and forth to check that it works normally.

 Make sure to check for protrusion of the bearing head gasket after assembling the
bearing head and rotor casing. If this work is not performed, measurements may be
incorrect due to the gasket becoming stuck between the end of the rotor and the
surface of the bearing head when adjusting end clearance. Also, performance may
deteriorate by operating the compressor after confirming the incorrect end
clearance.

e) Since the full height of the high-stage main rotor casing is lower than that of the bearing head, both
centers will not be aligned when they are placed on the work bench. Therefore, either use a
pedestal as used in the disassembly process or lift the rotor casing using a crane or other device to
align the centers.
The assembly procedure after mating the both casing flanges is same as the high-stage.
f) The bottom bolts that cannot be fastened on the work bench should be fastened during final
assembly, placed on the special stand which was used during disassembly.

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5.5.4 Installing Rotors

Note on the rotor profile of 2016**C
The rotor profile has been changed from the A profile to O profile from the production in November
1993.
The most significant difference is the existence of the edge on the lobe tip. Edged A-profile has been
changed to the edgeless O-profile.

Make the rotor sufficiently adjusted. By using fine sandpaper, remove over any damage on the shaft
surface of the bearing and seal.
Both the M and F rotors have certain engagement positions which are indicated by engravings.
To facilitate the alignment when attaching to the main rotor casing, numbers are engraved on the
discharge-side lobe peak of the M rotor and the suction-side lobe peak of the F rotor, respectively.

Photo 062 M Rotor Mating Mark Photo 063 F Rotor Mating Marks

a) Sufficiently lubricate the main bearing inside the bearing head as well as the bearing portion of the
rotor shaft.
b) While it is easier to mate the markings if the F rotor is first installed into the casing, it is not a mistake
to install the M rotor first.
c) Regardless of which rotor is installed first, engage the M rotor lobe, which has engraved mark 1,
between the F rotor lobes having engraved marks 1 and 2. As factors, such as mating of lobes,
balance, etc., should be considered, be sure to mate the lobe profiles as instructed.

Photo 064 Attaching F Rotor Photo 065 Attaching M Rotor

 In this state, the rotor's outer periphery is in contact with the main rotor casing.
Do not rotate it much. Letting it rotate may cause its tooth tips to get worn.

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5.5.5 Suction Cover and Side Bearings

a) The side bearing (O-ring type) [28] is dimensioned in such a way that it is lightly press fit to the
suction cover [5].
Align the notch of the bearing with the positioning pin[8]which is driven into the suction cover, and
press fit the bearing. During the press fit, check the position of the pin and the notch. If the position
is misaligned, pull the bearing out once and then press fit it again.
When the assembly is finished, secure the side bearing by using the snap ring [29] (Photo 067,
069).

Photo 066 Attaching Side Bearing Photo 067 Securing with Snap ring
(Low-stage) (Low-stage)

Photo 068 Attaching Side Bearing Photo 069 Securing with Snap ring
(High-stage) (High-stage)

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5.5.6 Balance Piston Sleeve

Attach the balance piston sleeve to the high-stage suction cover, by the procedure below.

a) After attaching the internal snap ring [37, attach the O-ring spacer [36].
b) The size of the O-ring [35] for balance piston sleeve is rather small. Extend it slightly all over with
your hands before attaching it.
c) Install the balance piston sleeve [33].
d) Screw two set screws [34] for preventing rotation of the balance piston sleeve (Photo 073), and then
attach the internal snap ring [37] to retain the balance piston sleeve (Photo 075).

Photo 070 Attaching O-ring Spacer (High-stage) Photo 071 O-ring for Balance Piston Sleeve

Photo 072 Attaching Balance Piston Sleeve Photo 073 Screwing Set Screws for Stopping
Rotation

Photo 074 Two Set Screws Have Been Screwed Photo 075 Attaching Snap ring

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5.5.7 Installing Suction Cover

a) The suction cover gaskets [6-1] [6-2] are not formed symmetric laterally. Apply oil on both sides of
the gasket, and attach it to the main rotor casing side while carefully checking the position of oil
supply holes. Lubricate the side bearing sufficiently too.

Photo 076 Installing Low-stage Suction Cover Photo 077 Installing High-stage Suction Cover

b) On the high-stage, pass the unloader push rod through the hole on the lower area of the suction
cover.
Slide the suction cover on the work bench, and move it to the assembly position. When fitting the
side bearing and the rotor shaft, be careful not to let the end of the rotor shaft damage the metal on
the inner surface of the side bearing.
c) When the rotor shaft fits in the side bearing, push the suction cover parallel with the shaft axis to the
main rotor casing for assembly.
d) When the suction cover is pushed until it contacts the flange surface, fasten several hexagon socket
head cap screws [2] lightly, and drive two alignment pins into the suction cover for positioning.
e) Then, fasten the bolts [2] evenly. The bottom bolts that cannot be fastened on the work bench
should be fastened during final assembly, placed on the special stand which was used during
disassembly.
f) Rotate the M rotor shaft with your hand, and check the rotors mating condition.
g) On the low-stage, attach the O-ring [86] to the oil injection pipe [85].
Screw the hexagon socket had cap screw M16 into the threaded hole of the oil injection pipe as
same as disassembly way, and push it into the suction cover.
h) Then install the oil injection pipe gland [164] attached the O-ring [165], and fasten it by four hexagon
socket head cap screws [166] (Photo 079).

Photo 078 Driving In Alignment Pin for Positioning Photo 079 Oil Injection Pipe Retainer

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i) Move the push rod with your hand, and check that the unloader slide valve is working smoothly.
j) While holding the M rotor shaft with your hand, move it in the axial direction and check that there is
allowance in the axial direction.
k) To the high-stage, attach the balance piston [30] and secure it with the external snap ring [32].
Check that the snap ring fits well in the groove.

080 Attaching the Balance Piston Photo 081 Attaching the Snap ring

k) Attach the load capacity adjustment spacer (spacer for 20 % load) [420] to the high-stage push rod.

Photo 082 Attaching Load Capacity Adjustment Spacer

(Spacer for 20 % Load)

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5.5.8 Thrust Bearing Block

Thrust bearing is a component of the screw compressor that is playing the most important role.
This component's assembly/adjustment quality could affect the compressor performance or cause
problems. Be very careful when assembling/adjusting this block.

[High-stage] [Low-stage]

Figure 5-10 Thrust Bearing Block

Table 5-8 Parts List of Thrust Bearing Block

P/N Part name Qty.
42-1, 42-2 Thrust bearing alignment spacer (1), (2) Two for each
41-1, 41-2 Thrust bearing outer race spacer (1), (2) Two for each
38-1, 38-2 Thrust bearing (1), (2) Two sets for each
250-1, 250-2 Thrust washer (1), (2) Two for each
40-1, 40-2 Lock washer (1), (2) Two for each
237-1, 237-2 Torsional slip washer (1), (2) Two for each
39-1, 39-2 Lock nut (1), (2) Two for each
43-1, 43-2 Thrust bearing gland (1), (2) Two for each
46-1, 46-2 Conical spring washer (1), (2) Eight for each
45-1, 45-2 Hexagon head bolt (1), (2) Eight for each

 When assembling the disassembled thrust bearing without replacing any parts,
check the M and F engravings on the thrust bearing outer race spacer and thrust
bearing alignment spacer, and reassemble them in the same way as before
disassembly. This is essential to control the end clearance of the rotor discharge
side.
 Even when assembling the same bearing, dimensions may become incorrect if
flakes of paint or dirt are caught between spacers and alignment spacers.
 Regarding the direction of thrust bearing assembly, there may or may not be a
V-shaped mark for assembly on the outer periphery of the bearing. Follow the
instructions below for each case of assembling.

a) The procedure for assembling this block is described in Figure 5-10. The important points are
explained below.
If there is a V-shaped mark for assembly on the outer periphery of the thrust bearing, assemble with
the pointed end of the mark on the inner side of the machine, as there is a slight directional
difference that affects end clearance adjustment.

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If there is no V-shaped mark, assembly direction does not affect end clearance adjustment.
However, to clarify the difference between the inner side and outer side of the machine, assemble
the thrust bearing with the bearing number engravings on the outer side. Then, put down a
V-shaped mark on the side which is to be attached to the inner side of the machine, by using blue
whetstone.

Photo 083 Thrust Bearing Assembly Mark Photo 084 Attaching Thrust Bearing

b) After installing the thrust bearing, attach the thrust washer, lock washer and torsional slip washer.
Fasten the lock nut with the specified torque or tightening angle range (see Section 7.3 "Tightening
Torques for Bolts and Nuts" in this manual Chapter 7), so that the inner race of the thrust bearing is
fit in the rotor shaft.

Tightening the lock nut while keeping the setting position between the lock nut wrench hooks
and the lock nut grooves may cause to make the rotor run-out to enlarge due to uneven
tightening forces.
Change the setting position between the lock nut wrench hooks and lock nut grooves about four
times when fastening the lock nut.

d) Turn the M rotor shaft by hand, to make sure that rotation of rotors is smooth.

 Since the inner race of the thrust bearing is clearance-fitted for ease of access at
the assembly site and is secured by the tightening force of the nut alone, the
tightening work is very important!
 If the thrust bearing has been replaced, the difference between the bearing inner
race and outer race surfaces is different even when it is within standard values.
Therefore, if the thrust bearing alignment spacer hitherto used lacks required
thickness, fully tightening the nut from the start may lead to a noticeable
reduction in the life of bearing, due to a lack of end clearance between the rotor
and the bearing head discharge end face, and also due to indentations on the
contact surface formed by ball pressure. To avoid this, rotate the rotor while
tightening the locknut lightly. Tighten the inner race, while checking that there is
enough clearance for the outer race. If the rotor does not rotate smoothly, the
thickness of the thrust bearing alignment spacer is insufficient.

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5.5.8.1 End Clearance Measurement

At this point (i.e., after the thrust bearing block has been fully assembled), measure the clearance
between the bearing head end face and the rotor end face on the discharge side. This clearance is
called as the end clearance.
In particular, this measurement must be made when the thrust bearing has been replaced. Even if the
same bearing is used, the measurement should be made for verification.
If the measured clearance does not satisfy the range specified in Table 5-9, proper adjustment must be
made.

Table 5-9 Specified Range of End Clearance (Unit : mm)

Model of the Low-stage
High-stage
compressor S M L
2016**C 0.04 to 0.05 0.26 to 0.30 0.28 to 0.32 0.31 to 0.35
■ End clearance of 2016**C is the same as A-profile rotor and O-profile rotor.

Photo 085 Pushing Rotor from Suction Side Photo 0868 End Clearance Measurement

a) Push the rotor to the discharge side while the thrust bearing inner race is secured to the rotor shaft.
Push the rotor from the suction side to the discharge side by using a jig (Teflon). Alternatively, by
using a chamfered part of the lock nut, pull out the rotor with the edge of a flat blade screwdriver as
shown in Figure 5-10.
b) When the rotor has been pushed to the discharge side, prepare to install the thrust bearing gland.
Attach a dial gauge on the suction side axial end of the rotor, and match the needle to 0.

Figure 5-11 Preparation for End Clearance Measurement

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c) Fasten the bearing gland by tightening the four bolts (without conical spring washer inserted) evenly
and gradually to the specified torque. Tightening each bolt to the specified torque at once will lead
to uneven tightening. Tighten bolts in turn and in several steps.
d) Then, read the dial gauge measurement. This value is the actual end clearance.
If the end clearance is outside the specified value, perform the adjustment work described in the
next section. If the end clearance is within the specified value, turn the M rotor shaft by hand and
confirm the smooth turning without uneven tightening. And then perform the measurement of the
run-out of the rotor shaft described in next section (3).

Table 5-10 Tightening Torques for Thrust Bearing Glands

Tightening
Model of the torque
compressor
N·m kgf·cm
High-stage 40 400
2016**C
Low-stage 50 500

Photo 087 Fastening with Bearing Gland

Figure 5-12 End Clearance Adjustment [Ⅱ]

5.5.8.2 Procedure for End Clearance Adjustment

(1) When end clearance is smaller than the specified value
To deal with this, insert shim material (thrust adjustment liner) of required thickness (difference in
thickness from the specified value) between the thrust bearing alignment spacer [42] and thrust
bearing inner race.
* The thrust adjustment liner is not shown in the sectional view and development view, but available
from us. Place an order together with a model name.

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Or using a highly accurate surface grinding machine or asking professional service vendors to
grind, grind the surface of thrust bearing outer race spacer [41] by the difference from the specified
value. After grinding the flat surface, measure the whole circumference of the saucer by using a
micrometer, and check that the thickness is even.

(2) When end clearance is larger than the specified value

As the end clearance is excessive, remove shim material (thrust adjustment liner) of a thickness
equal to the difference between the measured value and the specified value if the shim material is
used between thrust bearing alignment spacer and thrust bearing inner race.
Or if the shim material is not used between thrust bearing alignment spacer and thrust bearing inner
race, or even if used but insufficient thickness, grind the surface of thrust bearing alignment
spacer[42] by the difference between the measured value and the specified value or ask
professional vendors to do so.
After grinding the flat surface, measure the whole circumference of the spacer by using a
micrometer, and check that the thickness is even.

(3) Rotor axial runout measurement

When the end clearance has been adjusted to within the
specified range, place a dial gauge on the mechanical
seal attachment part of the low-stage M rotor shaft.
Measure axial runout by turning the rotor shaft.
The tolerance for axial runout is 0.03 mm or less for all
models.
Runout occurs when the thrust bearing alignment spacer
and saucer are not parallel or when the thrust bearing
mark is not at the correct side. And it occurs if fastening
the lock nut performed without changing the position of
the lock nut wrench (i.e., the uneven fastening of the lock
Photo 088 Measuring Runout of Shaft
nut).
Moreover small particles of dirt trapped between parts
may cause excessive runout.
If axial the rotor runout is over the tolerance, even if the end clearance is within the specified
range, disassemble and adjust the relative positions of the spacer, alignment spacer and thrust
bearing.
This is important because it affects the life of the mechanical seal and its performance.

5.5.8.3 Tightening after End Clearance Adjustment

a) Bend the lock washer claw to the notch of the lock nut which is tightening the thrust bearing inner
race, to prevent rotation.
b) Remove the hexagon head bolts that are tightening thrust bearing gland [43] one by one. Insert
conical spring washers [46] as rotation stoppers, and tighten to the specified torque again.

Conical spring washer has been adopted instead of the plate type lock washer from October, 2001.
When using the conical spring washers for the compressors produced before this modification, the
hexagon head bolt heads may interfere with the low-stage bearing cover inner face.
In case of overhauling the compressor produced before October, 2011, do not change the lock
washer [46] to the conical spring washer.

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5.5.9 Bearing Cover

a) Before installing the bearing cover [16], confirm once again that the lock washer teeth of the thrust
bearing block bended as a rotating stopper and that all the hexagon head bolts for holding the thrust
bearing gland have conical spring washer inserted.
b) For ensuring the safety, screw two stud bolts in the upper bolt holes on the flange of the low-stage
bearing head [11-1].
c) Apply oil to the bearing head flange surface and the both surfaces of the bearing cover gasket
(1)[17-1]. Hang the gasket on those stud bolts in such that it is put on the flange surface.

 The bearing cover gasket is not symmetric because there is a hole for lubricating oil
line to the mechanical seal block in the left (seal) side.
Be careful that do not mistake the direction of the gasket when attaching onto the
bearing head flange surface. Mistaken the direction of the gasket causes the
lubrication failure to the mechanical shaft seal block.

d) Attach O-ring [197] to the part where the push rod goes through bearing cover [16].
e) Attach lifting tools to the eye bolt of the bearing cover [16]. Install the bearing cover taking care not
to let it touch the M rotor shaft or push rod. After it is hung on the stud bolts, the lifting tools can be
removed (Photo 090).
f) Align the alignment pins with the hole. Tap the flanged part of the bearing cover alternately with a
soft hammer to install the cover in position. When it becomes possible to screw in bolts, screw in
two or three bolts. Evenly narrow the gap until the mating surfaces come in contact, and then tighten
the other bolts.

Photo 089 Stud Bots and Gasket Photo 090 Installing Bearing Cover

Photo 091 Tightening Bearing Cover

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5.5.10 Coupling High-stage and Low-stage Blocks

Figure 5-13 Assembly Drawing of Gear Coupling

a) On the high-stage, attach the driven hub [153] of the gear coupling, and fasten the M8 set screw
[159] for securing the driven hub key [157]. This set screw is knurled and provided with
anti-loosening.
b) On the low-stage, attach the drive hub [152], lock washer [161] and lock nut [160] in this order.
Fasten the lock nut with the specified torque or tightening angle range (refer to Chapter 7 Section
7.3 "Tightening Torques for Bolts and Nuts" in this manual).
Align the lock washer tooth with the notch of the lock nut, and bend it.
c) Set the driven sleeve onto the low-stage drive hub.

Photo 092 Tightening the Set Screw Photo 093 Setting Driven Sleeve onto Low-stage
for Securing Driven Hub

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d) Screw stud bolts into two of the upper holes provided in

the low-stage suction cover flange surface which is to be
attached to the high-stage.
e) Apply sufficient oil to the both surfaces of the bearing
cover gasket (2) [17-2]. Attach the gasket on the flange
surface over the stud bolts.
f) Lift the high-stage by using lifting tools until it is slightly off
the work bench, and move it toward the low-stage.
At this moment, on the low-stage, slightly move the M
rotor shaft in both directions, so that the gear coupling
assembly will fit smoothly.
g) After the gear coupling is engaged, press the high-stage Photo 094 Attaching the Gasket onto
block parallel with the rotor shaft. For both upper and the Low-Stage Flange Surface
lower side, gradually and evenly tighten, temporarily,
the hexagon socket head cap screws [18-2] that are
set in the bolt holes, each hole located one hole apart from the left or right alignment pin, until the
high-stage and low-stage flange surfaces come into contact.
h) After the flange surfaces come into contact, slightly loosen the four hexagon socket head cap
screws, which have been temporarily tightened, and then drive in the left and right alignment pins.
i) Tighten the hexagon socket head cap screws to the specified torque (240 N·m). The lower bolts
should be tightened on the special stand, which was used during disassembly.
j) Turn the low-stage M rotor (use of a jig for rotating the rotor is helpful), and check that it rotates
properly.

Photo 095 Attaching High-stage and Low-stage

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5.5.11 Balance Piston Cover and High-stage Unloader Cylinder

The 2016**C model has the unloader cylinder [60-2] also on the high-stage. To facilitate the assembly
work, attach the unloader cylinder [60-2] to the balance piston cover [60-2] first, and then attach the
united body to the high-stage suction cover [5-2].
The balance piston cover and unloader cylinder are often omitted from disassembly unless specifically
needed. Accordingly, steps a) through d) below shall apply when they have been disassembled.

a) Attach the O-ring [63] to the O-ring groove provided on the surface of the balance piston cover
where the unloader cylinder is to be installed (Photo 96).

According to the design change on October 1996, the

place O-ring [63] is attached has been changed from
the opening with chamfered to the current position
indicated in photo098. At the same time the same
design modification was applied to low-stage bearing
cover. Refer to the next Section 5.5.12 in this chapter.

Photo 096

b) Align the balance piston cover with the unloader cylinder. A gasket cannot be inserted between the
aligning flange surfaces of the balance piston cover and unloader cylinder. So, as shown in Photo
101, thinly and evenly apply special synthetic rubber liquid gasket onto the mating flange surface of
the unloader cylinder at the inner radius from the center positions of the bolt holes.
c) As O-ring is inserted, attach the balance piston cover while tapping its flange surface with a soft
hammer (as shown in Photo 98).
d) When mating the both flange surfaces, also align the bolt holes. Fasten the two hexagon socket
head cap screws [61], one at the position shown in Photo 103 and the other at the position spaced
two bolt holes apart from it.

Photo 097 Photo 98 Photo 99

e) Fit the O-ring [73-2] in the O-ring groove at the end of the unloader push rod [67-2] where the
unloader piston is to be attached.

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f) Attach the O-ring [65] without lubricating oil to the unloader piston[64-2], and then attach the cap
seal [66] on them. Lightly making a mountain fold in the circumferential direction of the cap seal will
facilitate the work. Use of a small and smooth spatula-shaped tool (as shown in Photo 100) will aid
the assembly.
g) Attach the unloader piston, which has the O-ring and cap seal attached, to the unloader cylinder.
The unloader piston has a surface which has threaded holes for eye bolts and another surface
without such holes. First, while exchanging these surfaces alternately several times using the
chamfer of the unloader cylinder, press the unloader piston lightly with the palm to settle the cap
seal. Finally, apply lubricating oil to the unloader cylinder, then, push and install the unloader piston
with its surface having threaded holes faced to the unloader cylinder cover as shown in Photo 102.
After attaching, check that the cap seal is not broken or pinched.

Photo 100 Photo 101 First Fit in Photo 102

Reverse Direction

h) Push the unloader piston into around the midst of

the unloader cylinder. With the unloader push rod
[67-2] pulled toward you, install the balance piston
cover with gasket attached (as shown in Photo 102),
onto the high-stage suction cover (Photo 103).
If you push the piston into the push rod and
temporarily tighten it with the lock nut [69-2], the
work that follows will be easier.
i) Align the flange surfaces, and tighten the hexagon
socket head cap screws to the specified torque (50
N·m).
j) Pull the piston toward you by using eye bolts, and Photo 103
remove the temporarily tightened lock nut. As shown
in Photo 106, attach the lock washer [70-2] and lock nut [69-2] to the push rod, and fasten the lock
nut to the specified torque of 80 N·m (Photo 105).
To stop rotation, bend the lock washer tooth aligned with the notch of the lock nut (Photo 106).
Lastly, check the movement of the piston by using eye bolts.

Photo 104 Photo 105 Photo 106

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5.5.12 Low-stage Unloader Cylinder

The low-stage unloader cylinder may be installed immediately after installing the bearing cover (refer to
Section 5.5.9 "Bearing cover" in this manual), or after attaching the mechanical seal (refer to the
description below). The contents of and points for this work are almost the same as the previous
section.
a) Attach the O-ring [73-1] in the O-ring groove at the end of the unloader push rod [67-1] where the
unloader piston is to be attached.
b) Attach the O-ring [65] and cap seal [66] to the unloader piston [64-1].
c) Attach the unloader piston, which has the O-ring and cap seal attached, to the unloader cylinder
[60-1] (Photo 109).
d) Attach the O-ring to the O-ring groove provided on the portion of the bearing cover [16] where the
unloader cylinder is to be attached (Photo 108).
* According to the design change on October 1996, the place O-ring [63] is attached has been
changed from the opening with chamfered to the current position indicated in Figure 5-14.

Figure 5-14 Change of The O-ring position for Bearing cover

e) Attach the unloader cylinder to the bearing cover (Photo 109), and fasten the eight hexagon socket
head cap screws [62-1] to the specified torque (50 N·m).

Photo 107 Photo 108 Photo 109

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f) Attach the lock washer [70-1] and lock nut [69-1] to the unloader push rod, and fasten the lock nut to
the specified torque of 120 N·m (Photo 110).
To stop rotation, align the lock washer tooth with the notch of the lock nut in the tightening direction,
and bend the tooth (Photo 111). Lastly, check the movement of the unloader piston by using eye
bolts.

Photo 110 Photo 111

 For the 2016MSC and 2016MMC, be sure to install the unloader piston spacer
[423] with the O-ring [702] to the low-stage unloader cylinder (refer to Chapter 7,
Figure 7-9 and Figure 7-11 in this manual).

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5.5.13 Shaft Seal Block

The standard mechanical seal assemblies used in the current shaft seal of standard
screw compressors are of the BBSE (balance bellows single) type.
In addition, the BOS (balance O-ring single) type mechanical seal assembly may be used depending
on the specifications of the customer.

Figure 5-15 BBSE Type Mechanical Seal Assembly and Related Parts

a) Before assembly, clean the portion where the rotor shaft seal will be installed.
b) In particular, recheck immediately before assembly that the axial stepped portion where the axial
seal will be mounted is free of damage.
c) Attach the oil seal [50] to the oil seal retainer [48].
The installation orientation of the oil seal has been reversed in November 2002 as a design change.
While the oil seal had been installed with the oil seal lip facing the direction of the atmosphere, the
direction was reversed. This is because excessively high pressure should be avoided by helping the
escape of oil from the seal box.
Using a Teflon block or the like as a pad, lightly hit the pad to push the oil seal evenly into the
retainer until it is fully seated. Once the oil seal is fully inserted, you can easily sense it as the hitting
sound as well as the response will change.
After assembly, check that the step formed at the boundary
between the oil seal and the retainer is even. See from the
opposite side, and confirm that they are evenly assembled.
d) Insert the O-ring [744] in the inner periphery of the oil seal
sleeve [528], which should then be attached to the oil seal
retainer with oil seal inserted (Photo 112).

Photo 112

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e) Install the oil seal retainer, which has oil seal and sleeve attached, along the rotor shaft by using two
standard M8 eye bolts (as shown in Photo 113). At this time, ensure that the retainer's oil hole is on
the upper side of the rotor shaft, and accurately align the rotation stop spring pin [20], which has
been screwed to the bearing cover, with the notch of the oil seal retainer.
After assembly, try to slightly turn the retainer's eye bolts to check that they are secure. If they are
properly aligned, the retainer will not rotate.
f) Secure the oil seal sleeve to the rotor shaft by using two set screws [529] (Photo 114).

Photo 113 Photo 114

g) Then, insert the O-ring [49] for the oil seal retainer (Photo
115).

 You should be particularly careful on this point,

as the O-ring for the oil seal retainer [49] is often
forgotten to be installed.

h) Install the seal collar [109], which has the O-ring [112] Photo 115
attached to its inner periphery, to the rotor shaft. Before
assembly, apply sufficient lubricating oil onto the rotor shaft and wash away dirt.
Push in the seal collar, carefully not to damage the O-ring [112] by the step on the rotor shaft (Photo
116). After installing the seal collar, push it by hand and check it’s normal movement in the axial
direction.
i) Fasten the seal collar on the rotor shaft by screwing the two seal collar set screws [111] at the
countersinks on the rotor shaft (Photo 117).
Failing to fasten the screws at the countersink positions will damage the rotor shaft, and it can
cause a leakage.

Photo 116 Photo 117

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j) Attach the O-ring [103] for mating ring and mating ring [101] to seal cover [51] (Photo 118).
k) Apply oil to the seal cover gasket [52], align the gasket oil hole with the oil hole on the seal cover
flange surface, and affix the gasket.
* With the standard internal oil supply type compressors, the bearing cover and the seal cover are
connected by an oil supply hole. Oil flows from the notch in the seal cover through the groove to
the upper side of the seal cover, and then flows through the drilled oil supply hole to the upper
sliding surface of the mechanical seal.
m) Install the seal cover with the gasket, so that the oil drop pipe of the seal cover is on the bottom side
At this time, assemble it carefully, either at a right angle or by delaying the upper side slightly, while
paying attention not to cause the mating ring inside the seal cover hit against the rotor shaft (Photo
119).

Photo 118 Photo 119

n) The seal ring and the mating ring sliding surface will come into
contact midway through attachment. At this moment, check the
dimensions between the seal cover gasket and the bearing
cover flange surface by using a taper gauge (Photo 120). This
value is called "fastening margin" for seal.
It is used when checking the sliding face pressure between the
rotating ring and stationary ring of the seal.
In case of BBSE-type seal of the 2016**C, make sure that this
value is in the range of 2 to 3 mm.
.
o) When the seal fastening margin is proper, push the seal cover
firmly into the bearing cover. Since there is repulsion force of the
seal bellows, keep it pushed firmly and tighten the two hexagon Photo 120
socket head cap screws [53] (for tightening the seal cover)
evenly at positions 180 degrees apart. When there is no gap
between the flange surface and the gasket, tighten all of the
remaining bolts to the specified torque (50 N·m).
p) After fastening the seal cover, remove the plug on the top of the
seal cover, and supply oil approx. 200 mL into the seal cover
while rotating the rotor shaft (Photo 121).
This oil refilling work is very important to maintain the
airtightness in the shaft seal block when vacuuming after
compressor overhauling.
After the refilling work, make sure to attach the removed plug on
the seal cover.

Photo 121

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5.5.14 Unloader Cover

Figure 5-16 Unloader Cover Block

a) Attach eye bolts to the unloader piston, and move it back and forth. Check once again that it
functions properly. During this manual check, pay attention not to let the piston reach the utmost
front position.

 With some model (2016MSC), the slide valve may come off the guide block if you
pull the low-stage unloader piston excessively toward you.

b) Attach the ball bearing [78] to the shaft of the indicator cam [77]. When fitting, push the inner race of
the bearing. Pushing the outer ring may damage the bearing.
Push the bearing to the stepped portion of the indicator cam and retain the bearing with the external
snap ring.
c) Apply sufficient oil to the unloader cover [74], and attach the V-ring set [82]. One of the V-rings in a
set is made of rubber (dark color) to improve sealing performance. As shown in Figure 5-16, it is set
at the second position viewed from the outer side of the machine.
Set the V-ring in such a way that its ridge faces the machine's outer side and the lip faces the inner
side.
d) Install the spring [83] and spring retainer [84] into position. Then insert the shaft of the indicator cam,
which has been assembled in step b) above, into the V-ring. Fasten the bearing to the unloader
cover by using the bearing gland [80].
e) After making sure that the indicator cam rotates smoothly, attach the O-ring [75] to the unloader
cylinder cover.
f) Attach the unloader cover to the unloader cylinder [60]. Push the unloader cover in such a way that
the guide pin [68] of the unloader push rod [67] just fits to the spiral groove of the indicator cam.
Secure the unloader cover with the hexagon socket head cap screws [76], with its hole for supplying
unloader working oil facing upward.

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5.5.15 Unloader Indicator

The unloader indicator contains micro-switches, a micro-switch cam and a potentiometer. Either of
them detects the rotational volume change of the shaft of the indicator cam, which converts the axial
positional change of the unloader slide valve into circumferential positional change, and sends it as
electric signals to the control side of the package unit or refrigerating system.
For confirmation after inspection/adjustment or parts replacement, they need to be linked with the
control side. So, even during an overhaul which is conducted with the compressor carried out of the
installation site, this portion is often removed from the compressor as an indicator assembly so that
inspection/adjustment or parts replacement can be conducted at the site.

 When removing or inspecting/adjusting the indicator assembly, be sure to turn

off the control power and conduct lockout/tagout. Failure to turn off the power
supply could cause an electric shock.

The 2016**C model has, on its high-stage, an indicator which is designed for the standard-type
single-stage compressor (however, the dial face and micro-switch cam are exclusively designed for the
2016**C high- stage). On the low-stage, it has an indicator designed for the low-stage of 2-stage
compressor, which, additively, has bevel gears for changing the indicator dial needle and dial from axial
direction to lateral direction. The basic functions and inspection procedures are common to both. So,
the following explanation is given based on the standard-type high-stage unloader indicator.

5.5.15.1 Potentiometer
The potentiometer of the standard-type indicator is of the full rotation type. It senses the continuously
variable position (indicated load of 0 % to 100 %) of the unloader slide valve, and feeds the sensed
position as electric signals to the control side of the package unit or refrigerating system.
While the expected service life of the potentiometer will significantly vary depending on the installation
environment of the compressor (e.g. corrosive gas atmosphere, moisture, or the like.) and operational
conditions (e.g. frequent partial load operations, frequent start/stop operation, vibration, etc.), the
potentiometer is a consumable part that requires regular replacement according to the situation.
 Disassembly
a) Turn off the control power and conduct lockout/tagout. After that, remove the indicator cover
[146], indicator glass [141] and indicator glass spacer [142].
b) Remove the philips screw [140] securing the indicator dial needle [139] to the shaft.
c) Remove the indicator dial screws [138] securing the indicator dial [137] to the dial supports.
d) Remove the electric wiring of the potentiometer. To avoid future assembly errors, put markings
to indicate positional relationship of wiring by using different colors of tape or the like, and take
a note.
e) The potentiometer set-plate [130] is fitted between the potentiometer support arms [1] [134]
and arms [2] [135]. Loosen and remove the arms [2] by turning them counterclockwise while
holding the arms [1].
f) When the right and left support arms are removed, the potentiometer [129] can be removed
together with the potentiometer set-plate.
g) The potentiometer is secured to the potentiometer set-plate with three philips screws.
 Inspection
a) On the terminal block, check whether or not the lead wires of the potentiometer are loose.
b) Check for defects such as cracks in the welded portion of the potentiometer lead wires.
c) Rotate the axis of the potentiometer with hand, and check with a circuit tester whether the
resistance value changes smoothly.
 Reassembly
To reassemble the unloader indicator, follow the disassembly procedure in reverse.

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5.5.15.2 Micro-switch and Micro-switch Cam

The standard-type unloader indicator has two micro-switches and one micro-switch cam, for sensing
that the unloader slide valve is at the 0 % position or the 100 % position of capacity control (indicated
load). If, for any reason, their assembly gets loose or the micro-switch(es) gets faulty, proper sensing
will be disabled, which will cause trouble in operation control of the compressor.

 Disassembly
a) Turn off the control power and conduct lockout/tagout. After that, remove the indicator cover
[146], indicator glass [141] and indicator glass spacer [142].
b) Remove the philips screw [140] securing the indicator dial needle [139] to the shaft.
c) Remove the indicator dial screws [138] securing the indicator dial [137] to the dial supports.
d) Remove the electric wiring of the micro-switch. To avoid future assembly errors, put markings
to indicate positional relationship of wiring by using different colors of tape or the like, and take
a note.
e) The micro-switch [125] is secured with two long philips screws [126]. The micro-switch can be
removed by loosening these screws. Do not remove these screws except when the
micro-switch needs to be replaced. Leave them as they are when conducting inspections or
positional adjustments.
f) The micro-switch on the right is for sensing the no-load (0 %) position and the micro-switch on
the left is for sensing the full-load (100 %) position.
Under the left micro-switch, the micro-switch base plate [123] is secured with different philips
screws [124] on the micro-switch mounting frame. This is to use the cam which is outside the
micro-switch cam [127].

 Inspection
a) In a normal state where the compressor's capacity control oil pressure pipe is not opened, pull
the unloader piston to the no-load position/full-load position by using the manual capacity
control circuit, in order to check, through the control circuit (operation check of related relays
and/or contacts), whether the micro-switch senses the 0% /100% position of the micro-switch
cam.
b) Turn off the control power, and conduct lockout/tagout. After that, remove the indicator glass
and check for looseness of the philips screw for securing the micro-switch [126].
c) Check for looseness of the set screw for securing the micro-switch cam [127].
d) Check that the wiring of the micro-switch has been removed. After that, turn the switch on and
off and check whether it works properly by using a tester.
e) When the compressor's capacity control oil pressure pipe is opened due to overhaul or the like,
pull the unloader piston to the no-load position/full-load position by using nitrogen gas or
compressed air pressure, in order to check whether the micro-switch senses the 0 %/100 %
position of the micro-switch cam.
f) In addition, conduct appearance check to find out any traces of water entry inside the indicator,
defects in the switch terminal such as corrosion, wear in the switch roller or micro-switch cam,
etc.

5.5.15.3 Reassembly
To reassemble, follow the inspection procedure in reverse. Lastly, position the indicator dial needle
correctly by following the procedure below.

a) When the compressor's capacity control oil pressure pipe is opened due to overhaul or the like,
pull the unloader piston to the no-load position by using nitrogen gas or compressed air
pressure. Then, align the indicator dial needle to the start point of the semicircular range drawn
on the dial face, and fix it. Next, move the unloader piston to the full-load position, and check
that the indicator dial needle points at the end point of the range drawn on the dial face.

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b) In a normal state where the capacity control oil pressure pipe is not opened, move the unloader
piston by using a manual capacity control circuit. When the control power is turned on, keep the
indicator cover attached to avoid electrical shock. After the position of the piston is determined,
turn off the control power and conduct lockout/tagout. After that, remove the indicator cover and
fix the indicator dial needle.

Figure 5-17 2016**C Standard-type High-stage Unloader Indicator

Table 5-11 Unloader Indicator Components (Standard type)

No. Part name Qty. No. Part name Qty.
121 Micro-switch base plate 1 136 Potentiometer mounting screw 3
122 Hexagon socket head cap screw 3 137 Indicator dial 1
123 Micro-switch set plate 1 138 Indicator dial screw 2
124 Philips screw 2 139 Indicator dial needle 1
125 Micro-switch 2 140 Philips Screw 1
126 Philips screw 4 141 Indicator glass 1
127 Micro-switch cam 1 142 Indicator glass spacer 1
128 Set screw 1 143 Electric wiring connector 1
129 Potentiometer 1 144 Connector support 1
130 Potentiometer set- plate 1 145 Hexagon socket head cap screw 2
131 Philips screw 3 146 Indicator cover (2) 1
132 Terminal block 1 147 Hexagon socket head cap screw 3
133 Philips screw 2 148 Plug 1
134 Potentiometer support arm [1] 2 214 Spring pin 1
135 Potentiometer support arm [2] 2 265-2 Spring washer 7

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No.1 switch for

full-load (100%)

No.2 switch for

no-load (0%)

Table 5-18 Assembly Drawing of Unloader Indicator (Standard type)

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Chapter 6 Troubleshooting
Table 6-1 describes typical trouble symptoms of compressors, their causes and actions to be taken.
The explanations of this Chapter are assumed that the compressor is used in the general refrigeration
cycle.

Table 6-1 Troubleshooting

01: Compressor does not start up

Direct cause Root cause Action
Power source is off. Mostly caused by forgetting to Use a check sheet for post-inspection
turn on after inspection. actions and implement finger pointing
and call check to prevent forgetting.
Main motor failure Mostly caused by activation of Refer to the operation manual of the
overload protection circuit. motor for details including other
causes and actions.
"Micro-switch and Micro-switch failure Replace.
micro-switch cam" of the
indicator do not sense Loosening of micro-switch or Adjust the position of the cam and
capacity control of 0%. micro-switch cam set screw switch, and tighten them.
due to vibration. Use thread locking agent when
necessary.
When compressor's vibration is
unusually high, see Item No. 12
"Compressor generates abnormal
vibration and/or sound".
Defective capacity control Improper adjustment of oil flow Readjust.
oil supply line control valve (throttled
excessively).
Leak/clogging in piping or Remove cause, and check oil for
solenoid valve contamination/replace oil.
Oil pressure not detected Failure of oil pressure Identify defective devices, investigate
protection device, pressure causes of failure and take necessary
sensor, relay, etc. actions.
Then, replace failed device(s).
Pressure pipe is clogged. Remove clogging, and check oil for
contamination/replace oil.
Cooling water circulation Failure of devices such as Identify defective devices, investigate
is not confirmed. cooling water pump and causes of failure and take necessary
related circuits actions.
Then, replace failed device(s).
Circulation route is clogged. Remove the clogging.
Failure of magnet, relay, Aging degradation Replace with new one.
etc. in compressor startup
circuit Poor installation environment Replace ventilation fans, etc. if
defective.
Improve temperature, humidity and
ventilation at the installation site.

02: Compressor stops immediately after startup

Direct cause Root cause Action
Low pressure protection Insufficient refrigerant flow To correct insufficient refrigerant,
circuit activates.  Insufficient refrigerant check leak, stop leak and then add
refrigerant.
* Also pay attention to moisture
entering into the system.

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02: Compressor stops immediately after startup (continued)

Direct cause Root cause Action
Low pressure protection Insufficient refrigerant flow To correct insufficient liquid supply,
circuit activates.  Insufficient liquid supply inspect expansion valve and liquid
supply strainer. Take necessary
actions.
In addition, inspect devices and
parameters (set values) of the
expansion valve aperture adjusting
mechanism, and take necessary
actions.
Heat exchange failure in heat If there are any problem (insufficiency)
exchanger in heat exchange, such as
malfunction of defrosting, investigate
the cause and take necessary
actions.
In case of malfunction of pressure
control valve, replace the valve or
remove the cause.
Failure of low pressure Identify defective devices, investigate
protection device, pressure causes of failure and take necessary
sensor, relay, etc. actions.
Then, replace failed device(s).
Motor overload Motor overload that occurs just after startup is mostly caused not by the
refrigeration cycle but by the motor. Refer to the instruction manual of
the motor.

03: Unusually low pressure (decrease of suction pressure)

Direct cause Root cause Action
Refer to direct cause, Same as left Same as left
"Low pressure protection
circuit activates", in Item
02 above.

04: Low oil pressure (low lubricating oil supply pressure)

Direct cause Root cause Action
Oil filter element is Contamination of lubricating oil Remove clogging, and check oil for
clogged. contamination/replace oil.
* Pressure difference
between the outlet port Internal defects of compressor Check for oil contamination and
and inlet port is large. conduct vibration/noise diagnosis.
Overhaul compressor if necessary.
Insufficient oil in oil Oil heater is not functioning, Inspect oil heater alone, inspect
separator. refrigerant dissolves relays, etc. on related circuits, and
excessively when the machine replace parts as necessary.
is stopped, and oil loss occurs
at startup.

Insufficient oil return due to Correct insufficient refrigerant

insufficient refrigerant circulation, and return oil from
circulation load-side heat exchanger.
* Supply lubricating oil temporarily.
Troubles such as clogging in oil Remove causes of the trouble, and
return passage restore the system.

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04: Low oil pressure (continued)

Direct cause Root cause Action
Insufficient oil in oil Extensive oil leak Inspect machine room and around the
separator. compressor, and take necessary
actions.
Check if there is oil floating in cooling
water system.
→If there is, check for oil leak from
heat transmission tube of oil cooler
and take necessary actions.
If piping is damaged due to excessive
vibration, take measures to reduce
vibration (including measures for
resonance vibration).
Oil pressure detection Failure of oil pressure Identify defective devices, investigate
function is defective. protection device, pressure causes of failure and take necessary
sensor, relay, etc. actions.
Then, replace failed device(s).
Pressure pipe is clogged. Remove clogging, and check oil for
contamination/replace oil.

05: Intermediate pressure is unusually high.

Direct cause Root cause Action
High suction pressure Heat load on load side is Inspect the conditions on load side
higher than design value. (warehousing volume,
opening/closing of doors, etc.), and
take necessary measures.
Malfunction of suction pressure In case of pressure sensing failure,
control mechanism replace the pressure sensor.
* In some cases, pressure pick-up
position is improper. → Change the
position.
If there is a problem in device(s) on
the control circuit, find the defective
device(s) and replace it.
If parameter (set value) on the control
circuit is improper, optimize it.
In case of malfunction of pressure
control valve, replace the valve or
remove the cause.
Malfunction of compressor's See Item No. 11 "Capacity control
capacity control malfunction".

Liquid flow-back from Failure or internal leakage of Repair or replace.

intermediate liquid cooler. intermediate liquid supply
expansion valve
There is problem in Malfunction of capacity control See Item No. 11 "Capacity control
compressor's high-stage. on compressor's high- stage malfunction".

Excessive wear or sliding Overhaul compressor and replace

damage of the part(s) on parts.
compressor's high- stage Replace the whole quantity of
lubricating oil.

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06: Unusually high pressure (abnormal discharge pressure)

Direct cause Root cause Action
Heat exchange failure in Heat transmission tubes and/or Clean and wash.
condenser (heat fins are contaminated or Depending on the contamination
exchanger) blocked. level, use chemical cleaning.
Failure or water dripping in fan Identify defective devices, investigate
motor, thermo switch, water causes of failure and take necessary
spraying pipes, cooling water actions.
pumps, etc. Then, replace failed device(s).

Faulty adjustment of cooling In case of manually adjusted valve,

water/brine readjust the valve.
When an automatic control valve
(including wax valve) is used,
investigate the cause and take
necessary actions.
Other causes of insufficient Inspect filters installed on the
flow of cooling water, etc. circulation route for clogging and
contamination, and take necessary
actions.
Inspect for leaks in circulation routes,
and take necessary actions.
Inspect water supply
routes/mechanisms, and take
necessary actions.
If frozen, take measures such as
improvement of heat insulation or
increase of temperature.
Deficiency in heat exchanger If the symptom is caused by change in
performance operating conditions, re-examine the
conditions for improvement.
If the symptom is caused by change in
installation environment, improve the
environment if possible.
In either case, if improvement
measure is difficult to be made, add
more heat exchangers or increase
their sizes.
Non-condensable gases Leak on low pressure side Perform a leak check, and take
mixed into the system * There are also cases where necessary measures.
the symptom was caused by Air-purge the heat exchanger.
corrosion in suction
temperature gauge protection
Refrigerant is excessive. In some cases, insufficient Properly adjust the refrigerant charge.
cooling is judged as caused by
insufficient refrigerant and, as
a result, refrigerant is charged
repeatedly.

Capacity of heat changer is If the symptom is caused by change in

insufficient. operating conditions, re-examine the
conditions for improvement.
If improvement is difficult, add heat
exchangers or increase their sizes.

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06: Unusually high pressure (continued)

Direct cause Root cause Action
Discharge pressure Failure of high pressure Identify defective devices, investigate
detection function is protection device, pressure causes of failure and take necessary
defective. sensor, relay, etc. actions.
Then, replace failed device(s).
clogging of pressure pipe Remove clogging, and check oil for
contamination/replace oil.
Outlet shut-off valve of oil Operator forgot to restore after Open the valve or perform emergent
separator is closed. shut down operation. stop.
Human error Be sure to conduct tagout while
handling valves.
Be sure to check valves before
starting the compressor.

07: Discharge temperature is abnormally high.

Direct cause Root cause Action
Overheated during Insufficient refrigerant flow See the causes listed in item 02
operation above.
Heat load on load side is Inspect the conditions on load side
higher than design value. (warehousing volume,
opening/closing of doors, etc.), and
take necessary measures.
Failure of low pressure Identify defective devices, investigate
protection device, pressure causes of failure and take necessary
sensor, relay, etc. actions.
Then, replace failed device(s).
Non-condensable gases Leak on low pressure side Perform a leak check, and take
mixed into the system necessary measures.
Air-purge the heat exchanger.
Oil supply temperature is Heat exchange failure in oil For water-cooling system, see "Heat
high. cooler exchange failure in heat exchanger" in
06 above.
For liquid cooling system, check liquid
supply expansion valve, temperature
sensor and related
relays/wiring/terminals, and take
necessary actions.
Oil temperature rise protection Check temperature protection device,
feature does not function. temperature sensor and related
relays/wiring/terminals, and take
necessary actions.
Defective discharge Failure of temperature Identify defective devices, investigate
temperature protection device, temperature causes of failure and take necessary
detection/protection sensor, relay, etc. actions.
feature. Then, replace failed device(s).

Insufficient oil supply See "Low oil pressure" in Item Same as left
04 above.

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Chapter 6 Troubleshooting

08: Leak from mechanical seal

Direct cause Root cause Action
Initial leak after In some cases, immediately In case of initial leak, although leak
replacement until sliding after replacement, the amount might increase temporarily, it
surfaces settle compressor-specific operating will decrease gradually. Check that
conditions and the pressure leak does not increase continuously.
receiving conditions of Duration of initial leak depends on
machined sliding surface is design/operating conditions. It is
unstable. approximately 200 hours, as a rough
indication.
Sliding surface is Started and stopped too many If heat load is less than the level set
roughened due to times. by the equipment's design conditions,
overheating. * In case of standard review the operating conditions and
equipment, "four or more set control such that equipment is
times per hour" is considered started/stopped less frequently.
"frequent/too many". In case of capacity control
malfunction, see "Capacity control
malfunction" in item No. 11.
Excessive refrigerant solved In case of liquid flow-back, remove the
into the lubricating oil, resulting cause(s).
in decreased viscosity of oil. If oil heater or devices on its control
circuit are defective, replace the
defective part.
Overheated operation See the causes in item 02,
"Insufficient refrigerant flow".

Oil supply temperature is high. See the causes in item 07, "Oil supply
temperature is high".

Machine is stopped for a User-specific conditions, such If machine is sometimes stopped

long time. as intermittent heat load longer than a week, take either of the
(No oil film on sliding following measures: (i) Manually
surfaces) operate oil pump alone and turn the
rotor shaft of the compressor.
(ii) Attach an oil pot for supply oil to
the seal cover.
Deteriorated part(s) Hardened O-ring If deteriorated over time, replace.
For other specific causes, see the
causes/action for symptom
"Overheating of sliding surface".
Swelled O-ring In case of liquid flow-back, remove the
* This occurs when the cause(s).
lubricating oil of refrigerating If oil heater or devices on its control
machine contains large circuit are defective, replace the
amount of refrigerant. defective part.
Deteriorated seal ring/mating If deteriorated over time, replace.
ring For other specific causes, see the
causes/action for symptom
"Overheating of sliding surface".
Incompatibility of Unsuitable lubricating oil was If possible, review the operating
lubricating oil and selected, or operating conditions.
operating conditions (such conditions have changed after If not, see "4-1 Lubricating Oil
as working temperature installation of the equipment. (Refrigerant Oil)" to select suitable
range or refrigerant) lubricating oil and replace the whole
quantity.

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08: Leak from mechanical seal (continued)

Direct cause Root cause Action
Poor contact of sliding Foreign matter attached to Replace the whole quantity of
surfaces sliding surfaces, due to lubricating oil.
contaminated lubricating oil. Install bypass filter to oil supply line.
Faulty assembly of parts Disassemble, replace parts and
Human error reassemble.
Use assembly check sheet to ensure
confirmation.

09: Squeaking of mechanical seal

Direct cause Root cause Action
During initial period after As the sliding surfaces are very Squeaking itself does not cause leak
exchange for new hard and dense, they need from seal or deterioration in sealing
mechanical seal, squeaks time to fit together. function.
may be heard from sliding Normally, squeaking is heard for
surfaces until they fit several dozens of hours, however, it
together. may last longer in rare cases.
→In this case, contact our service
center.

10: Capacity control position is indicated incorrectly

Direct cause Root cause Action
Inaccurate reading of Screw for securing indicator Manually operate the compressor's
compressor indicator needle is loose. capacity control to indicate 0%
gauge. position, and tighten the screw again.
Indicator's bevel gears are If deteriorated over time, replace.
worn. If the wear is caused by excessive
vibration of the compressor, take
measures to reduce vibration and
then replace the bevel gears.
Inaccurate reading of The cam groove of Often caused by continued operation
capacity control indicator compressor's indicator cam is with load on a certain point.
on the control panel. worn. →Replace the indicator cam.
* The currently shipped indicator cam
has its grooved portion
strengthened.
The guide pin of the Currently, this pin is also improved in
compressor push rod is worn. resistivity against wear. If the indicator
cam is replaced with the improved
version, replace the pin with the
countermeasure part.
Failure of potentiometer If the part is deteriorated over time or
loaded at a certain point during
operation for a long time, replace it.
If the wear is caused by excessive
vibration of the compressor, take
measures to reduce vibration and
then replace the potentiometer.
Improper zero span adjustment Readjust.
of E/E positioner

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Chapter 6 Troubleshooting

10: Capacity control position is indicated incorrectly (continued)

Direct cause Root cause Action
Inaccurate reading of E/E positioner or/and indicator If deteriorated over time, replace.
capacity control indicator is faulty. If there are specific causes such as
on the control panel. surge current, remove the cause or
take proper action.
Loosened terminals or Tighten the terminals if loosened.
defective wires Replace defective wires.

11: Capacity control malfunction

Direct cause Root cause Action
↑ See the causes for Same as left Same as left
"Inaccurate reading of
capacity control indicator
on the control panel".
"Micro-switches and Micro-switch failure Replace.
micro-switch cam" of the Loosening of micro-switch or Adjust the position of the cam and
indicator do not sense micro-switch cam screw due to switch, and tighten them.
"100%" position and/or vibration. Use thread locking agent when
"0%" position. necessary.
When compressor's vibration is
unusually high, see Item No. 12
"Compressor generates abnormal
vibration and/or sound".
Failure of capacity control Mostly caused by coil burnout. If deteriorated over time, replace.
solenoid valve or related If the symptom is caused by wet with
relays water, etc., remove the cause(s) and
then replace defective part(s).
For details, refer to the instruction
manual of solenoid valve.
Internal leakage of Oil compression due to If the symptom is caused by long
capacity control solenoid temperature rise inside duration of low-load operation, review
valve unloader cylinder and improve the operating method.
Arrange inline check valve and oil
bypass route on the capacity control
oil supply line.
Defective capacity control Improper adjustment of oil flow Readjust.
oil supply line control valve
Leak/clogging in solenoid valve Remove cause, and check oil for
gland or oil supply piping contamination/replace oil.
Unloader piston does not Damage on the cap seal of the Check oil for contamination/replace
move. piston oil.
(Though this is one of the Replace O-ring, cap seal, etc.
causes of "Defective Cap seal is pinched. Replace O-ring, cap seal, etc.
capacity control oil supply Cap seal is worn. Check oil for contamination/replace
line", it is listed separately oil. Replace O-ring, cap seal, etc.
here.) There is residual refrigerant Stop the compressor. By operating the
gas inside unloader cylinder. oil pump, repeat load/unload
operation to purge refrigerant gas
from unloader cylinder.
In case of liquid flow-back, remove the
cause(s).
If oil heater or devices on its control
circuit are defective, replace the
defective part.

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12: Compressor generates abnormal vibration and/or sound.

Direct cause Root cause Action
Shaft poorly aligned with If the shaft vibration value of Conduct shaft alignment again.
motor axial direction is high, it may be If this occurs frequently in monocoque
caused by this. unit, perform hot alignment (operate
the compressor at rated speed to raise
the temperature and make adjustment
before it cools down).
M rotor shaft runout Lock nuts and/or thrust bearing If lock nuts are not loose and parts
excessively. glands are tightened unevenly. such as thrust bearing are free of
defects, tighten the glands evenly.
Thrust bearing glands get Lock washer tooth not bended, or
loosened. thrust bearing rolling elements (balls)
are worn.
→ Check the thrust bearing. If any
defect is found, replace it, and then
reassemble it after adjusting end
clearance and checking shaft runout.
Rotor dynamic balance is If no other causes are found for
disturbed. abnormal vibration, or if on-site
overhaul only has been repeatedly
performed for a long time, this may be
the cause.
→ Overhaul the compressor at a place
where a dynamic balance
measurement/adjustment system is
available, such as the MAYEKAWA
Moriya Factory.
Oil compression Continuous low-load operation During low-load operation, lubricating
with capacity control not oil is difficult to be discharged. As a
greater than 30% result, oil that stays between the
engaged rotors increases and gets
compressed.
→ Avoid continuous low-load
operation as far as possible.
* Especially when the fluid is light gas
(He, NH3, etc.), continuous operation
of merely 10 minutes can cause bad
effect. The maximum limit should be
30 minutes even for fluorocarbon
fluids.
Liquid flow-back during Refrigerant liquefies and stays There are many probable causes,
startup inside upstream piping when such as a leak inside liquid supply
* Loud abnormal noise at equipment is stopped. solenoid valve on the load side,
startup. insufficient heat exchange (refrigerant
* If this is heard, the evaporation) in heat exchanger, or
compressor may get trapping due to mis-piping in the piping
damaged instantaneously. line.
→ Identify the cause(s) and take
necessary measures. Then overhaul
and inspect the compressor.

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12: Compressor generates abnormal vibration and/or sound (continued)

Direct cause Root cause Action
Liquid flow-back during Aperture of liquid In case of temperature-type expansion valve,
operation supply expansion check the condition of temperature sensitive
* Notable frosting on the valve is large cylinder and capillary tube. If any defect is found,
suction side. take necessary actions.
* In many cases, If orifice gets unsuitable due to the change in
flow-back of mist operating conditions, replace the orifice with
(steam) rather than proper size one(s).
liquid occurs.
* Sometimes, gas-liquid In case of electronic expansion valve, check
separator devices attached on the expansion valve aperture
(accumulator) is control mechanism (circuit) such as temperature
attached to prevent sensor, converter, controller (overheating
this symptom. regulator). If any of them is found defective,
replace it.
* See also the causes in In the same way as with temperature-type
item 02, "Insufficient expansion valve, if orifice gets unsuitable due to
refrigerant flow" the change in operating conditions, replace the
orifice with proper size one(s).
Rapid change from Set control parameters so as to prevent rapid
no-load operation to changes.
full-load operation Otherwise, make adjustment by throttling the
aperture of the capacity control increase-side oil
quantity adjusting valve.

Expansion valve Avoid rapid change in heat load that exceeds the
aperture control cannot set value of follow-up range of "heat exchanger on
keep up with rapid load side (evaporator)" and "expansion valve".
change in heat load on For details, refer to the instruction manuals
the load side. related to devices/control on load side.

Heat exchange failure In case of frosting (icing), conduct manual

in heat exchanger on defrosting.
load side Set defrosting interval shorter.
・Related to defrosting If a device which is specific to the defrosting type
fails, remove the cause(s) and replace the
device(s).
If a piping route which is specific to the defrosting
type gets blocked, remove the cause(s) and take
necessary actions.
* Especially when handling hot gas defrosting
systems, thoroughly read and understand the
contents of the instruction manuals for the units
associated with devices/control on the load side.
Heat exchange failure If ventilation around the heat exchanger is
in heat exchanger on obstructed for any reason such as piled up load,
load side improve the conditions.
・Load side conditions * Ensure the flow of heating medium through the
heat exchanger on the load side.
Heat exchange failure Check for any blocked heat transmission tubes or
in heat exchanger on fan motor(s) failure. If any problem is found, take
load side necessary actions.
・Heat exchanger
conditions

Compound 2-stage Screw Compressor 2016**C

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Chapter 6 Troubleshooting

12: Compressor generates abnormal vibration and/or sound (continued)

Direct cause Root cause Action
Foreign substances Welding spatter, etc. Check suction strainer and/or oil filters. Replace
entering the flowing from upstream element if defective.
compressor side Overhaul the compressor.
Tools and/or waste Collect foreign substances and identify their
cloth left uncollected sources. Then take necessary actions.
after overhauling
Damaged thrust Deterioration over time The time for replacement depends largely on
bearings. (operated beyond operating conditions (low pressure or high
recommended time of intermediate pressure will make the life shorter,
replacement) etc.) and/or oil management conditions. In case of
a typical refrigeration application which basically
operates in a stable continuous mode, inspect and
replace them every 40,000 hours or 5 years,
whichever comes first.
For details, see Chapter 5, Section 5.2.3 in this
manual.
Operation with liquid Refer to causes of "Liquid flow-back during
flow-back startup" and "Liquid flow-back during operation" in
item 12.
Entry of foreign Refer to causes of "Foreign substances entering
substances the compressor" above.
Excessive thrust stress Re-examine operating conditions, and improve if
other than above possible.
・High suction If difficult to improve, review maintenance interval.
pressure/intermediate
pressure exceeding
the level set by
operating conditions
Faulty assembly Tighten lock nuts by using specified torque or
* Lock nuts tightened torque angle (see Chapter 7, "7.3 Tightening
insufficiently, lock Torques for Bolts and Nuts" in this manual).
washer tooth not
bended, rotation Be sure to record data on the assembly check
stopper not set to sheet to prevent omission of work steps.
thrust bearing gland,
gland not assembled,
etc.
Resonance vibration This occurs when the In many cases, this symptom is caused by change
frequency of vibration in installation environment (such as change in
comes close to the piping routes or additive installation of devices in
natural frequency of the machine room, oil level change, etc.)
any component in the →If occurrence of resonance vibration is a
entire vibrating system, suspected, contact our service centers.
including pipes and
supports.

Compound 2-stage Screw Compressor 2016**C

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 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Chapter 7 Related Documents

7.1 Development Views, Assembly Sectional Views

Figure 7-1 2016**C Development View (Low-stage)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-1
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-2 2016**C Development View (High-stage)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-2
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-3 2016LLC Assembly Sectional View (Vertical)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-3
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-4 2016LLC Assembly Sectional View (Horizontal)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-4
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-5 2016LMC Assembly Sectional View (Vertical)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-5
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-6 2016LMC Assembly Sectional View (Horizontal)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-6
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-7 2016LSC Assembly Sectional View (Vertical)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-7
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-8 2016LSC Assembly Sectional View (Horizontal)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-8
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-9 2016MSC Assembly Sectional View (Vertical)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-9
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-10 2016MSC Assembly Sectional View (Horizontal)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-10
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-11 2016SSC Assembly Sectional View (Vertical)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-11
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

Figure 7-12 2016SSC Assembly Sectional View (Horizontal)

Compound 2-stage Screw Compressor 2016**C 7.1 Development Views, Assembly Sectional Views
7-12
 2201LZJE-HO-C6-N_2015.05.
Chapter 7 Related Documents

7.2 Parts Configuration Table

Table 7-1 Parts Configuration Table
Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
1-1 Main Rotor Casing (1) CS00100-200L 200L** 1 1 1 - - -
1-1 Main Rotor Casing (1) CS00100-200M 200M** - - - 1 1 -
1-1 Main Rotor Casing (1) CS00100-200S 200S** - - - - - 1
1-2 Main Rotor Casing (2) CS00100-160L 160L** 1 - - - - -
1-2 Main Rotor Casing (2) CS00100-160M 160M** - 1 - 1 - -
1-2 Main Rotor Casing (2) CS00100-160S 160S** - - 1 - 1 1
Hexagon Socket Head
2-1 NB35416-050 M16×50 50 50 50 50 50 50
Cap Screw
Hexagon Socket Head
2-2 NB35412-040 M12×40 52 52 52 52 52 52
Cap Screw
3-1 Alignment Pin NE2016-055 Φ16×55 4 4 4 4 4 4
3-2 Alignment Pin NE2013-040 Φ13×40 4 4 4 4 4 4
4-1 Eye Bolt NB600-020 M20 1 1 1 1 1 1
4-2 Eye Bolt NB600-016 M16 1 1 1 1 1 1
5-1 Suction Cover (1) CS00500-2016C1 2016**C 1 1 1 1 1 1
5-2 Suction Cover (2) CS00500-2016C2 2016**C 1 1 1 1 1 1
Gasket, Suction Cover
6-1 CS00600-200N 200*** 1 1 1 1 1 1
(1)
Gasket, Suction Cover
6-2 CS00600-160N 160*** 1 1 1 1 1 1
(2)
7 Eye Bolt NB600-012 M12 2 2 2 2 2 2
8-1 Spring Pin (1) NE3206-012 Φ6×12 2 2 2 2 2 2
8-2 Spring Pin (2) NE3204-010 Φ4×10 2 2 2 2 2 2
9 O-ring PA11-030 JIS B 2401 P30 1 1 1 1 1 1
10-1A Plug NF06-010 R3/8 1 1 1 1 1 1
10-1B Plug NF06-015 R1/2 1 1 1 1 1 1
10-2A Plug NF06-008 R1/4 1 1 1 1 1 1
10-2B Plug NF06-008 R1/4 1 1 1 1 1 1
10-2C Plug NF06-010 R3/8 1 1 1 1 1 1
11-1 Bearing Head (1) CS01100-2016C1 2016**C 1 1 1 1 1 1
11-2 Bearing Head (2) CS01100-2016C2 2016**C 1 1 1 1 1 1
Gasket, Bearing Head
12-1 CS01200-200N 200*** 1 1 1 1 1 1
(1)
Gasket, Bearing Head
12-2 CS01200-160N 160*** 1 1 1 1 1 1
(2)
13 Eye Bolt NB600-024 M24 2 2 2 2 2 2
14-1 Spring Pin NE320G-012 Φ6×12 2 2 2 2 2 2
14-2 Spring Pin NE3204-010 Φ4×10 2 2 2 2 2 2
15-1A Plug NF06-015 R1/2 1 1 1 1 1 1
15-1B Plug NF06-010 R3/8 1 1 1 1 1 1
16 Bearing Cover CS01600-2016C 2016**C 1 1 1 1 1 1
Gasket, Bearing Cover
17-1 CS01700-2016C1N 2016**C 1 1 1 1 1 1
(1)
Gasket, Bearing Cover
17-2 CS01700-2016C2N 2016**C 1 1 1 1 1 1
(2)
Hexagon Socket Head
18-1 NB35416-050 M16×50 18 18 18 18 18 18
Cap Screw
Hexagon Socket Head
18-2 NB35416-055 M16×55 25 25 25 25 25 25
Cap Screw

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Chapter 7 Related Documents

Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
19-1 Alignment Pin NE2010-050 Φ10×50 2 2 2 2 2 2
19-2 Alignment Pin NE2016-055 Φ16×55 2 2 2 2 2 2
20 Spring Pin NE3203-010 Φ3×10 1 1 1 1 1 1
21 Plug NF06-004 R1/8 1 1 1 1 1 1
22 Balance Piston Cover CS02202-160VD 160*** 1 1 1 1 1 1
Gasket, Balance
23 CS02300-160N 160*** 1 1 1 1 1 1
Piston Cover
Hexagon Socket Head
24 NB35410-025 M10×25 11 11 11 1 11 11
Cap Screw
25-1 Male Rotor (1)
CS02520-2016LC1 2016L*C 1 1 1 - - -
26-1 Female Rotor (1)
25-1 Male Rotor (1)
CS02520-2016MC1 2016M*C - - - 1 1 -
26-1 Female Rotor (1)
25-1 Male Rotor (1)
CS02520-2016SC1 2016S*C - - - - - 1
26-1 Female Rotor (1)
25-2 Male Rotor (2)
CS02520-2016LC2 2016*LC 1 - - - - -
26-2 Female Rotor (2)
25-2 Male Rotor (2)
CS02520-2016MC2 2016*MC - 1 - 1 - -
26-2 Female Rotor (2)
25-2 Male Rotor (2)
CS02520-2016SC2 2016*SC - 1 -- 1 1-
26-2 Female Rotor (2)
27-1 Main bearing (1) CS0270-ERT 200*** 2 2 2 2 2 2
27-2 Main bearing (2) CS0270-DRT 160*** 2 2 2 2 2 2
28-1 Side bearing (1) CS0280-ERT 200*** 2 2 2 2 2 2
28-2 Side bearing (2) CS0280-DRT 160*** 2 2 2 2 2 2
29-1 Stop Ring (1) NG11-130 H130 4 4 4 4 4 4
29-2 Stop Ring (2) NG11-102 H102 4 4 4 4 4 4
30 Balance Piston CS03000-160 160*** 1 1 1 1 1 1
31 Key, Balance Piston CS03100-160 160*** 1 1 1 1 1 1
32 Stop Ring NG12-050 S50 1 1 1 1 1 1
Sleeve, Balance
33 CS03300-160 160*** 1 1 1 1 1 1
Piston
34 Set Screw NA83606-015 M6×15 2 2 2 2 2 2
35 O-ring PA12-095 JIS B 2401 G95 1 1 1 1 1 1
36 Spacer, O-ring CS03600-160 160*** 1 1 1 1 1 1
37 Stop Ring NG11-102 H102 2 2 2 2 2 2
38-1 Thrust Bearing (1) CS03800-200P 7313B 2 2 2 2 2 2
38-2 Thrust Bearing (2) CS03800-160P 7212B 2 2 2 2 2 2
39-1 Lock Nut (1) NG31-013 AN13 2 2 2 2 2 2
39-2 Lock Nut (2) NG31-012 AN12 2 2 2 2 2 2
40-1 Lock Washer (1) NG32-013 AW13 2 2 2 2 2 2
40-2 Lock Washer (2) NG32-012 AW12 2 2 2 2 2 2
Spacer, Thrust Bearing
41-1 CS04100-200 200*** 2 2 2 2 2 2
(1)
Spacer, Thrust Bearing
41-2 CS04100-160 160*** 2 2 2 2 2 2
(2)
Spacer,
42-1 CS04200B200 200*** 2 2 2 2 2 2
Thrust Alignment (1)
Spacer,
42-2 CS04200-160 160*** 2 2 2 2 2 2
Thrust Alignment (2)

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
Thrust Bearing Gland
43-1 CS04300-200S 200*** 2 2 2 2 2 2
(1)
Thrust Bearing Gland
43-2 CS043002016C2B 2016**C 2 2 2 2 2 2
(2)
45-1 Hexagon Head Bolt NB111012-035 M12×35 8 8 8 8 8 8
45-2 Hexagon Head Bolt NB111010-030 M10×30 8 8 8 8 8 8
46-1 Lock Washer (1) ND150-012 200*** 8 8 8 8 8 8
46-2 Lock Washer (2) ND150-010 160*** 8 8 8 8 8 8
48 Retainer, Oil Seal CS04800-200VDS 200*** 1 1 1 1 1 1
49 O-ring PA12-115 JIS B 2401 G115 1 1 1 1 1 1
50 Oil Seal CS05010-200VD SA1J 65×85×12 1 1 1 1 1 1
51 Seal Cover CS05100-200 200*** 1 1 1 1 1 1
52 Gasket, Seal Cover CS05200-200N 200*** 1 1 1 1 1 1
Hexagon Socket Head
53 NB35410-025 M10×25 8 8 8 8 8 8
Cap Screw
Unloader Slide Valve
54-1 CS05400-2016**** 2016LSC 1 1 1 - - -
(1-1) (L port)
Unloader Slide Valve
54-1 2016LSC 1 1 1 - - -
(1-1) (M port)
Unloader Slide Valve
54-1 2016MSC - - - 1 1 -
(1-1) (L port)
Unloader Slide Valve
54-1 2016MSC - - - 1 1 -
(1-1) (M port)
Unloader Slide Valve
54-1 2016SSC - - - - - 1
(1-1) (L port)
Unloader Slide Valve
54-1 2016SSC - - - - - 1
(1-1) (M port)
Unloader Slide Valve
54-2 2016*SC - - 1 - 1 1
(1-2) (L port)
Unloader Slide Valve
54-2 2016*SC - - 1 - 1 1
(1-2) (M port)
Unloader Slide Valve
54-2 2016MSC - - - - 1 -
(1-2) (H port)
Unloader Slide Valve
54-2 2016LLC 1 - - - - -
(1-2) (L port)
Unloader Slide Valve
54-2 2016*LC 1 - - - - -
(1-2) (M port)
Unloader Slide Valve
54-2 2016LMC - 1 - 1 - -
(1-2) (L port)
Unloader Slide Valve
54-2 2016*MC - 1 - 1 - -
(1-2) (M port)
Unloader Slide Valve
55-1 200L** 1 1 1 - - -
(2-1)
Unloader Slide Valve
55-1 200M** - - - 1 1 -
(2-1)
Unloader Slide Valve
55-1 200S** - - - - - 1
(2-1)
Unloader Slide Valve
55-2 160L** 1 - - - - -
(2-2)
Unloader Slide Valve
55-2 160M** - 1 - 1 - -
(2-2)
Unloader Slide Valve
55-2 160S** - - 1 - 1 1
(2-2)
Hexagon Socket Head
58-1 NB35410-030 M10×30 4 4 4 4 4 4
Cap Screw
Hexagon Socket Head
58-2 NB35408-025 M8×25 4 4 4 4 4 4
Cap Screw
59 O-ring PA11-020 JIS B 2401 P20 1 1 1 1 1 1
60-1 Unloader Cylinder CS06000-2016C 2016LSC 1 1 1 1 1 1

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Chapter 7 Related Documents

Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
60-2 Unloader Cylinder CS06000-160L 160L** 1 - - - - -
60-2 Unloader Cylinder CS06000-160M 160M** - 1 - 1 - -
60-2 Unloader Cylinder CS06000-160S 160S** - - 1 - 1 1
Hexagon Socket Head
61 NB35410-025 M10×25 2 2 2 2 2 2
Cap Screw
Hexagon Socket Head
62-1 NB35410-110 M10×110 8 8 8 8 8 8
Cap Screw
Hexagon Socket Head
62-2 NB35410-065 M10×65 6 6 6 6 6 6
Cap Screw
63 O-ring PA12-125 JIS B 2401 G125 2 2 2 2 2 2
64-1 Unloader Piston (1) CS06400-2016T 2016LSC 1 1 1 1 1 1
64-2 Unloader Piston (2) CS06400-160T 160*** 1 1 1 1 1 1
65 O-ring PA11-100 JIS B 2401 P100 2 2 2 2 2 2
66 Cap Seal CS06600-160 BE100 2 2 2 2 2 2
Push Rod, Unloader
67-1 CS06700-2016C1 2016LSC 1 1 1 1 1 -
Slide Valve (1)
Push Rod, Unloader
67-1 CS06700-2016SSC 2016SSC - - - - - 1
Slide Valve (1)
Push Rod, Unloader
67-2 CS06700-2016C2 2016LSC - - 1 - 1 1
Slide Valve (2)
Push Rod, Unloader
67-2 CS06700-2016LLC 2016LLC 1 - - - - -
Slide Valve (2)
Push Rod, Unloader
67-2 CS06700-2016LMC 2016LMC - 1 - 1 - -
Slide Valve (2)
68-1 Guide Pin NE2505-012 Φ5×12 1 1 1 1 1 1
68-2 Guide Pin NE2503-008 Φ3×8 1 1 1 1 1 1
69-1 Lock Nut (1) NG31-007 AN07 1 1 1 1 1 1
69-2 Lock Nut (2) NG31-005 AN05 1 1 1 1 1 1
70-1 Lock Washer (1) NG32-007 AW07 1 1 1 1 1 1
70-2 Lock Washer (2) NG32-005 AW05 1 1 1 1 1 1
71-1 Lock Nut (1) NG31-007 AN07 1 1 1 1 1 1
71-2 Lock Nut (2) NG31-005 AN05 1 1 1 1 1 1
72-1 Lock Washer (1) NG32-007 AW07 1 1 1 1 1 1
72-2 Lock Washer (2) NG32-005 AW05 1 1 1 1 1 1
73-1 O-ring PA12-030 JIS B 2401 G30 1 1 1 1 1 1
73-2 O-ring PA11-021 JIS B 2401 P21 1 1 1 1 1 1
74-1 Unloader Cover (1) CS07400-2016S 2016LSC 1 1 1 - - 1
74-1 Unloader Cover (1) CS07400-2016MSC 2016MSC - - - 1 1 -
74-2 Unloader Cover (2) CS07400-160S 160*** 1 1 1 1 1 1
75 O-ring PA12-110 JIS B 2401 G110 2 2 2 2 2 2
Hexagon Socket Head
76-1 NB35408-030 M8×30 8 8 8 8 8 8
Cap Screw
Hexagon Socket Head
76-2 NB35408-025 M8×25 8 8 8 8 8 8
Cap Screw
77-1 Indicator Cam (1) CS07700-2016C 2016LSC 1 1 1 - - -
77-1 Indicator Cam (1) CS07700-2016MSC 2016MSC - - - 1 1 -
77-1 Indicator Cam (1) CS07700-2016SSC 2016SSC - - - - - 1
77-2 Indicator Cam (2) CS07700-160L 160L** 1 - - - - -
77-2 Indicator Cam (2) CS07700-160M 160M** - 1 - 1 - -
77-2 Indicator Cam (2) CS07700-160S 160S** - - 1 - 1 1
78 Ball Bearing CS07800-200 #6000 2 2 2 2 2 2

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Chapter 7 Related Documents

Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
79 Stop Ring NG12-010 S10 2 2 2 2 2 2
80 Bearing Gland CS08000-200 200*** 2 2 2 2 2 2
Hexagon Socket Head
81 NB35406-015 M6×15 6 6 6 6 6 6
Cap Screw
82 V-ring CS08200-200B 20×10×12 2 2 2 2 2 2
83 Spring CS08300-200 200*** 2 2 2 2 2 2
Retainer, Indicator
84 CS08400-200 200*** 2 2 2 2 2 2
Cam Spring
85 Oil Injection Pipe CS08500-200LUK 200LU* 1 1 1 - - -
85 Oil Injection Pipe CS08500-2016MSC 2016MSC - - - 1 1 -
85 Oil Injection Pipe CS08500-2016SSK 2016SSC - - - - - 1
86 O-ring PA11-021 JIS B 2401 P21 1 1 1 1 1 1
87-1 Guide Block (1) CS08700-200 200*** 1 1 1 1 1 1
87-2 Guide Block (2) CS08700-160 160*** 1 1 1 1 1 1
88-1 Stem, Guide Block (1) 200&250*** 1 1 1 1 1 1
88-2 Stem, Guide Block (2) 160*** 1 1 1 1 1 1
89-1 O-ring PA11-020 JIS B 2401 P20 2 2 2 2 2 2
89-2 O-ring PA11-016 JIS B 2401 P16 2 2 2 2 2 2
91 Shaft key (1) CS09100-200 200*** 1 1 1 1 1 1
92-1 Suction Flange (1) CS71300-150 JIS 20K 150A(6") 1 1 1 1 1 1
92-2 Suction Flange (2) CS71300-100 JIS 20K 100A(4") 1 1 1 1 1 1
Gasket, Suction
93-1 CS71200-150N JIS 20K 150A(6") 1 1 1 1 1 1
Flange (1)
Gasket, Suction
93-2 CS71200-100N JIS 20K 100A(4") 1 1 1 1 1 1
Flange (2)
94-1 Hexagon Head Bolt NB12022-055 M22×55 12 12 12 12 12 12
94-2 Hexagon Head Bolt NB12020-055 M20×55 8 8 8 8 8 8
95-1 Discharge Flange (1) CS71300-100 JIS 20K 100A(4") 1 1 1 1 1 1
95-2 Discharge Flange (2) CS71300-080 JIS 20K 80A(3") 1 1 1 1 1 1
Gasket, Discharge
96-1 CS71200-100N JIS 20K 100A(4") 1 1 1 1 1 1
Flange (1)
Gasket, Discharge
96-2 CS71200-080N JIS 20K 80A(3") 1 1 1 1 1 1
Flange (2)
97-1 Hexagon Head Bolt NB12020-055 M20×55 8 8 8 8 8 8
97-2 Hexagon Head Bolt NB12020-055 M20×55 8 8 8 8 8 8
Mechanical Seal
100 CS10002-200EBS BBS-E 1 1 1 1 1 1
Assembly (BBSE)
Unloader Indicator
120-1 CS12000-1612F 1612LSC 1 1 1 1 1 1
Assembly (1)
Unloader Indicator
120-2 CS12000-200F 200*** 20-100 % 1 1 1 1 1 1
Assembly (2)
151 Driven Sleeve CS15100-2016 1 1 1 1 1 1
152 Drive Hub 1 1 1 1 1 1
153 Driven Hub 1 1 1 1 1 1
154 Stopper, Driven Sleeve CS15400-2016C 2 2 2 2 2 2
155 Stop Ring FRS-90 4 4 4 4 4 4
157 Key, Driven Hub CS15700-2016C 1 1 1 1 1 1
158 Key, Drive Hub CS15800-2016C 1 1 1 1 1 1
M8×15 knurled
159 Set Screw NA83608-015 1 1 1 1 1 1
with anti-loosening
160 Lock Nut NG31-010 AN10 1 1 1 1 1 1
161 Lock Washer NG32-010 AW10 1 1 1 1 1 1

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
Hexagon Socket Head
162 NB35406-045 M8×45 5 5 5 5 5 5
Cap Screw
163 O-ring PA12-025 JIS B 2401 G25 1 1 1 1 1 1
Retainer, Oil Injection
164 CS16400-2016C 1 1 1 1 1 1
Pipe
165 O-ring PA12-025 JIS B 2401 G25 1 1 1 1 1 1
Hexagon Socket Head
166 NB35408-030 M8×30 4 4 4 4 4 4
Cap Screw
Pipe Guide, Oil
168 CS16800-2016 1 1 1 1 1 1
Injection
197 O-ring PA11-040 JIS B 2401 P40 1 1 1 1 1 1
Flange, Lubrication Oil
215-1 CS71300-025 JIS 20K 25A(1") 1 1 1 1 1 1
Supply (1)
Flange, Lubrication Oil
215-2 CS71300-020 JIS 20K 20A(3/4") 1 1 1 1 1 1
Supply (2)
Gasket, Lubrication Oil
216-1 CS71200-025N JIS 20K 25A 1 1 1 1 1 1
Supply Flange (1)
Gasket, Lubrication Oil
216-2 CS71200-020N JIS 20K 20A 1 1 1 1 1 1
Supply Flange (2)
217-1 Hexagon Head Bolt NB111016-045 M16×45 4 4 4 4 4 4
217-2 Hexagon Head Bolt NB111012-035 M12×35 4 4 4 4 4 4
Flange, Injection Oil
218 CS71300-015 JIS 20K 15A(1/2") 1 1 1 1 1 1
Supply
Gasket, Injection Oil
219 CS71200-015N JIS 20K 15A 1 1 1 1 1 1
Supply Flange
220 Hexagon Head Bolt NB111012-035 M12×35 4 4 4 4 4 4
Torsional Slip Washer
237-1 CS23700-200 200*** 2 2 2 2 2 2
(1)
Torsional Slip Washer
237-2 CS23700-160 160*** 2 2 2 2 2 2
(2)
Special Spring Washer
245 for Hexagon Socket ND330-08 M8 5 5 5 5 5 5
Head Cap Screw
250-1 Thrust Washer (1) CS25000-200 200*** 2 2 2 2 2 2
250-2 Thrust Washer (2) CS25000-160 160*** 2 2 2 2 2 2
Special Spring Washer
267-1 for Hexagon Socket ND330-10 M10 4 4 4 4 4 4
Head Cap Screw
Special Spring Washer
267-2 for Hexagon Socket ND330-08 M8 4 4 4 4 4 4
Head Cap Screw
For 2016*LC(2)
420 Unload Spacer CS42000-160L20 1 - - - - -
20 % load
For 2016*MC(2)
420 Unload Spacer CS42000-160M20 - 1 - 1 - -
20 % load
For 2016*SC(2)
420 Unload Spacer CS42000-160S20 - - 1 - 1 1
20 % load
421 O-ring PA12-030 JIS B 2401 G30 - - 1 - 1 1
421 O-ring PA11-030 JIS B 2401 P30 2 2 - 1 - -
Used for MSC
423 Unload spacer - - - 1 1 -
low-stage only.
Hexagon Socket Head
424 NB35406-020 M6×20 Note 1 - - - 3 3 -
Cap Screw
AS568A-244
432-1 O-ring PA62-022 4 4 4 4 4 4
(JIS W1516 G22)
432-2 O-ring PA12085 JISB2401 1A G85 4 4 4 4 4 4
AS568A-244
433-1 O-ring PA62022 4 4 4 4 4 4
(JIS W1516 G22)

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Chapter 7 Related Documents

Q’ty.
P/N Part name Code No. Remarks
LLC LMC LSC MMC MSC SSC
433-2 O-ring PA12-085 JIS B 2401 G85 4 4 4 4 4 4
528 Sleeve, Oil Seal CS52809-200VD 200V** with O-ring 1 1 1 1 1 1
529 Set Screw NA83606-008 M6×8 2 2 2 2 2 2
605-1 Plug NF06-008 R3/4 1 1 1 1 1 1
605-2 Plug NF06-015 R1/2 1 1 1 1 1 1
607 Plug NF06-004 R1/8 1 1 1 1 1 1
JIS B 2401 G100
702 O-ring PA12-100 - - - 1 1 -
Note 1
744 O-ring PA12-060 JISB2401 1A G60 1 1 1 1 1 1
- O-ring Set CS7109-0K 2016C NBR
- O-ring Set CS7109-5K 2016C FPM
- Gasket Set CS7118-0K 2016C
Lock Nut and Washer
- CS8009-K 2016C
Set

 The part code of the O-ring except for "O-ring set 2016C FKM" is the one
assigned to NBR which is standard material. When the material of the O-ring is
other than NBR, a different part code is used for each material.
If you are using O-rings made from other than the standard material, please
contact MAYEKAWA when placing an order.

Note 1: The hexagon socket head cap screw (No. 424) is used to fasten the unload spacer (No. 423),
which is for the exclusive use of the MSC low-stage, to the unloader cover (No. 74-1). In April
2007, this spacer and the explosion proof type unloader piston spacer were standardized
according to the design change. As a result, the use of this part is discontinued. One piece of
O-ring (No.702) (JIS B 2401 G100) is used instead of this part. According to this design
change, the use of the MSC unloader cover (1) with bolt hole for spacer is also discontinued.
The MSC unloader cover and the LSC unloader cover are shared/standardized.

Compound 2-stage Screw Compressor 2016**C 7.2 Parts Configuration Table

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Chapter 7 Related Documents

7.3 Tightening Torques for Bolts and Nuts

Table 7-2 List of Tightening Torques
 Hexagon socket head cap screw
Tightening
P/N What is tightened torque Q’ty. Size
N·m kgf·cm
Main Rotor Casing (1) to
2-1 240 2400 50 M16×50
Suction Cover (1) and Bearing Head (1)

Main Rotor Casing (2) to

2-2 90 900 52 M12×40
Suction Cover (2) and Bearing Head (2)

18-1 Bearing Cover to Bearing Head (1) 240 2400 18 M16×50

18-2 Bearing Head (2) to Suction Cover (1) 240 2400 25 M16×55

24 Balance Piston Cover to Suction Cover (2) 50 500 11 M10×25

53 Seal Cover to Bearing Cover 50 500 8 M10×25

58-1 For Securing Unloader Slide Valve 50 500 4 M10×30

58-2 For Securing Unloader Slide Valve 25 250 4 M8×25

61 Unloader Cylinder (2) to Balance Piston Cover 50 500 2 M10×25

Unloader Cylinder (1) to
62-1 50 500 8 M10×110
Bearing Cover and Bearing Head (1)
Unloader Cylinder (2) to
62-2 50 500 6 M10×65
Balance Piston Cover and Suction Cover
76-1 Unloader Cylinder Cover (1) to Unloader Cylinder (1) 25 250 8 M8×30

76-2 Unloader Cylinder Cover (2) to Unloader Cylinder (2) 25 250 8 M8×25

81 Bearing Gland 10 100 6 M6×15

162 Push Rod, Unloader Slide Valve (1) 25 250 5 M8×45

166 Retainer, Oil Injection Pipe 25 250 4 M8×30

 Hexagon Head Bolt

Tightening
P/N What is tightened torque Q’ty. Size
N·m kgf·cm
45-1 Thrust Bearing Gland (1) 50 500 8 M12×35

45-2 Thrust Bearing Gland (2) 40 400 8 M10×30

94-1 Suction Flange (1) JIS20K 150A 240 2400 12 M22×55

94-2 Suction Flange (intermediate pipe) (2) JIS20K 100A 180 1800 8 M20×55

97-1 Discharge Flange (intermediate pipe) (1) JIS20K 100A 180 1800 8 M20×55

97-2 Discharge Flange (2) JIS20K 80A 120 1200 8 M16×55

Compound 2-stage Screw Compressor 2016**C 7.3 Tightening Torques for Bolts and Nuts
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Chapter 7 Related Documents

 Lock Nut

Tightening torque (N·m)

P/N What is tightened Q’ty. Size
Standard Maximum

39-1 Thrust Bearing (1) Note 1 522 653 2 AN13

39-2 Thrust Bearing (2) Note 1 408 510 2 AN12
69-1 Unloader Piston (1) 120 - 1 AN07
69-2 Unloader Piston (2) 80 - 1 AN05
71-1 Unloader Slide Valve (1-1) 79 99 1 AN07
71-2 Unloader Slide Valve (1-2) 28 35 1 AN05
160 Gear Coupling Drive Hub Note 1 238 297 1 AN10

Note 1: When tightening a lock nut, if it is difficult to use a torque wrench, manage the tightening
torque of the lock nut controlling the tightening angle range as explained below.
 Tightening Angle Range of Lock Nuts for Rotors
a) After tightening the lock nut by hand, further tighten the lock nut by using a lock nut wrench
until the rotor starts to turn. Take care not to over-tighten.
b) Put a mark on the lock nut at the right side edge of the rotor groove where the stopper tongue
of the lock washer fits in, as shown in Figure 7-9.
c) From this marking position, tighten the lock nut in such a way that rotation can be stopped
within the tightening angle range shown in Table 7-3 (2016**C【39-1】,【39-2】and【160】:
30° to 40°(first time tightening), 20° to 30°(second time tightening). When measuring the
angle, use an angle gauge which is set to the diameter of rotor shaft.

Table 7-3 Tightening Angles Specified

for Lock Nuts of Rotor
Model Angle range
2016**C First time tightening 30° to 40°
Low-stage
Rotor groove (slot) High-stage Second time tightening 20° to 30°
Marking
where stopper tongue of
the lock washer fits * When tightening lock nut, tightening start position differs
between the first time tightening and the tightening for
the second time or after. Therefore, angle ranges are
specified also for the second time tightening.

Figure 7-9 Position where mark is put

Photo 122 Angle Gauge (example)

Compound 2-stage Screw Compressor 2016**C 7.3 Tightening Torques for Bolts and Nuts
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7.4 About the O-rings Used

7.4.1 List of O-rings Used
Table 7-4 List of O-rings Used
Location nominal
P/N
attached place description in functional aspect symbols

9 Suction Cover (2) Push Rod P30

35 Sleeve, Balance Piston same as left G95
49 Oil Seal Retainer same as left G115
59 Pipe Guide, Oil Injection Oil Injection Pipe P20
63 Bearing Cover, Balance Piston Cover Unloader Cylinder (1), (2) G125
65 Unloader Piston (1), (2) same as left P100
73-1 Unloader Push Rod (1) Unloader Piston (1) G30
73-2 Unloader Push Rod (2) Unloader Piston (2) P21
75 Unloader Cylinder Cover (1), (2) same as left G110
86 Oil Injection Pipe same as left P21
89-1 Stem, Guide block (1) same as left P20
89-2 Stem, Guide block (2) same as left P16
163 Unloader Slide Valve (1) same as left G25
165 Gland, Oil Injection Pipe same as left G25
197 Bearing Cover Push Rod, Unloader Slide Valve (1) P40
421 Unload Spacer 2016*SC (2) same as left G30
421 Unload Spacer 2016*LC (2), *MC (2) same as left P30
432-1 Main Bearing (1) same as left AS568A-244
432-2 Main Bearing (2) same as left G85
433-1 Side Bearing (1) same as left AS568A-244
433-2 Side Bearing (2) same as left G85
702 Unloader Spacer (used for MSC low-stage only) same as left G100
744 Sleeve, Oil Seal same as left G60

■ Designation codes are based on JIS B 2401 except AS568A-244.

■ Attached place means parts which they have grooves or with taper cutting for attaching O-ring.

7.4.2 O-ring Materials Used for Screw Compressor

Table 7-5 List of O-ring Materials Used for Screw Compressor

(excluding mechanical seal)
Working fluid O-ring material
Ammonia
NBR
Hydrofluorocarbon (HFC)
FKM
CO2
HNBR
Trifluoromethane (R23)
Propane
Propylene
FKM
Natural gas
City gas
Helium

Compound 2-stage Screw Compressor 2016**C 7.4 About the O-rings Used
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7.5 Tools for Disassembly

Table 7-6 List of Tools for Disassembly

Parts Center
Tool name Illustration size, etc.;
Code No.

Ratchet wrench 1/4” SG261-08

Adjustable wrench 250mm SG231-250

Screwdriver Philips SG112-075

Screwdriver Flat blade SG111-075

Stop ring pliers External (for shaft) SG311-03

Stop ring pliers Internal (for groove) SG312-04

Eye bolt M8 two-peace-set UHT0016

Across flats 2mm SG241-02
3mm SG241-03
4mm SG241-04
5mm SG241-05
Allen wrench key 6mm SG241-06
8mm SG241-08
10mm SG241-10
12mm SG241-12
14mm SG241-14
AN-05 SAS111-05
AN-07 SAS111-07
Lock nut wrench AN-10(L) SAS112-10
AN-12 SAS111-12
AN-13 SAS111-13
5-25N･m -
Torque wrench
for assembly 20-100N･m SG132-0900
40-280N･m SG132-2800

Compound 2-stage Screw Compressor 2016**C 7.5 Tools for Disassembly

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 Contact Information_2015.04.

Contact Information

Sales Offices/Service Centers

 Sales Offices in Japan (as of April 21, 2015)

Description Location Phone/Fax

Head Office 3–14–15 BOTAN KOTO-KU, TOKYO 135-8482 TEL: 03-3642-8181

FAX: 03-3643-7094
Hokkaido 2-5-1, 3-JYO NIJYUUYONKEN NISHI-KU, TEL: 011-631-2052
Branch SAPPORO-CITY, HOKKAIDO 063-0803 FAX: 011-631-2053
Tohoku 8-72, ROKUTYONO-MEMINAMI-MACHI, TEL: 022-288-5001
Branch WAKABAYASHI-KU, SENDAI-CITY, MIYAGI 984-0013 FAX: 022-288-5155
Kanto 3–14–15 BOTAN, KOTO-KU, TOKYO 135-8482 TEL: 03-3642-8968
Branch FAX: 03-3641-8468
Chubu 2-9-6, MARUNOUCHI, NAKA-KU, NAGOYA CITY, AICHI 460-0002 TEL: 052-218-3307
Branch FAX: 052-218-3308
Kansai 1-4-27, EBIE, FUKUSHIMA-KU, OSAKA CITY, OSAKA 553-0001 TEL: 06-4795-6000
Branch FAX: 06-4795-6033
Chugoku 2-3-40, TAKAYADAI, HIGASHIHIROSHIMA CITY, TEL: 082-491-1830
Branch HIROSHIMA 739-2117 FAX: 082-491-1838
Shikoku 410-1, OTAKAMI-MACHI, TAKAMATSU-CITY, KAGAWA 761-2117 TEL: 087-868-3400
Branch FAX: 087-868-3399
Kyushu FUKUOKA-FUJILAND-BUILD. 10F, 2-3, NAKASHIMA-MACHI, TEL: 092-262-0016
Branch NAKASU, HAKATA-KU, FUKUOKA CITY, FUKUOKA 810-0802 FAX: 092-262-0115

 Manufacturing Bases in Japan (as of April 21, 2015)

Description Location Phone/Fax

Moriya Plant 2000, TATSUZAWA MORIYA-CITY, IBARAKI 302-0118 TEL: 0297-48-1361

FAX: 0297-48-5269
Higashi- 2-3-40, TAKAYADAI, HIGASHIHIROSHIMA CITY, TEL: 082-491-1828
Hiroshima HIROSHIMA 739-2117 FAX: 082-491-1838
Plant

Sales Offices/Service Centers

Contact -1
 Contact Information_2015.04.

 Global Network (as of April 21, 2015)

Telephone and
Description Location
facsimile No.

NORTH AMERICA
MAYEKAWA CANADA INC. 12180 RIVERSIDE WAY, TEL: (1) 604-270-1544
(VANCOUVER OFFICE) RICHMOND, B.C., V6W 1K5, CANADA FAX: (1) 604-270-9870

MAYEKAWA CANADA INC. 1745 BONHILL ROAD, TEL: (1) 905-564-0664

(TORONTO OFFICE) UNIT #6&7 MISSISSAUGA, FAX: (1) 905-564-7614
ONTARIO, L5T 1C1, CANADA
MAYEKAWA CANADA INC. 4525 6A STREET N.E., CALGARY, TEL: (1) 403-250-1554
(CALGARY OFFICE) ALBERTA, T2E 4B2, CANADA FAX: (1) 403-250-1504
MAYEKAWA U.S.A. INC. 1850 JARVICE AVENUE, ELK GROVE TEL: (1) 773-516-5070
(CHICAGO OFFICE) VILLAGE, FAX: (1) 773-516-5071
IL 60007, U.S.A.
MAYEKAWA U.S.A. INC. 250 WEST NYACK ROAD,SUITE TEL: (1) 914-301-9770
(NEW YORK OFFICE) 230,WEST NYACK, FAX: (1) 914-332-0400
NY 10994, U.S.A.
MAYEKAWA U.S.A. INC. 130 SMART PARK DRIVE, LEBANON, TEL: (1) 615-773-2859
(HEAD QUARTERS) TN 37090, U.S.A. FAX: (1) 615-444-1995
(NASHVILLE PLANT)
MAYEKAWA U.S.A. INC. 19475 GRAMERCY PLACE, TEL: (1) 310-328-1362
(LA OFFICE) TORRANCE, CA 90501, U.S.A. FAX: (1) 310-782-6759
MAYEKAWA U.S.A. INC. 2615 W CASINO ROAD, UNIT-3D, TEL: (1) 425-645-9400
(SEATTLE OFFICE) EVERETT, WA 98204, U.S.A. FAX: (1) 425-353-3344
MAYEKAWA U.S.A. INC. 1272 CENTER COURT DR, SUITE 106, TEL: (1) 626-598-5030
(COVINA OFFICE) COVINA, CA 91724, U.S.A. FAX: (1) -
MAYEKAWA U.S.A.INC. 1219 SAFARI, SAN ANTONIO, TEL: (1) 210-599-4536
(SAN ANTONIO OFFICE) TX 78216, U.S.A. FAX: (1) 210-599-4538
MAYEKAWA U.S.A. INC. 3395 FARMTRAIL ROAD YORK, TEL: (1) 717-779-0138
(YORK OFFICE) PA 17406, U.S.A. FAX: (1) 717-779-0109
MAYEKAWA U.S.A. INC. 19475 GRAMERCY PLACE, TEL: (1) 310-328-6279
CHEMICAL PROCESS DIVISION TORRANCE, CA 90501, U.S.A. FAX: (1) 310-328-8487
(LA OFFICE & ANUFACTURING)
MAYEKAWA U.S.A. INC. 3222 PASADENA FREEWAY TEL: (1) 281-447-2599
CHEMICAL PROCESS DIVISION PASADENA, FAX: (1) 281-447-6623
(HUSTON SERVICE OFFICE) TX 77503, U.S.A.
MAYEKAWA U.S.A. INC. 1770 ST. JAMES PLACE, SUITE 408, TEL: (1) 832-547-2320
CHEMICAL PROCESS DIVISION HOUSTON, TX 77056, U.S.A.
(HUSTON SALES &
ENGINEERING OFFICE)

EUROPE and AFRICA

N.V.MAYEKAWA EUROPE S.A. LEUVENSESTEENWEG 605, TEL: (32) 2-757-9075
(HEAD OFFICE, FACTORY) 1930 ZAVENTEM, BELGIUM FAX: (32) 2-757-9023

MAYEKAWA DEUTSCHLAND UNTER-BOHNHOF-STRASSE 38A, TEL:(49) 89-5527-989-0

GMBH D-82110 GERMERING, FAX:(49)89-5527-989-19
DEUTSCHLAND
MAYEKAWA DEUTSCHLAND WEIDESTRASSE 122A, 22083 TEL:(49)40-2788-9149-0
GMBH (HUMBURG OFFICE) HAMBURG, DEUTSCHLAND FAX:(49)40-2788-9149-9
N.V.MAYEKAWA EUROPE 16 OAKHURST GARDENS, TEL: (44) 1322-433558
S.A.(UK) BEXLEYHEATH, FAX: (44) 1322-433164
KENT DA7 5JP, UNITED KINGDOM

Sales Offices/Service Centers

Contact -2
 Contact Information_2015.04.

Telephone and
Description Location
facsimile No.
MAYEKAWA. S.L. CALLE MONTEVIDEO 5, NAVE 13 TEL: (34) 91-830-0392
POL. INDUSTRIAL CAMPORROSO FAX: (34) 91-830-0397
28806 ALCALA DE HENARES,
MADRID, SPAIN
MAYEKAWA FRANCAISE SARL 9, RUE MICHAEL FARADAY, 78180 TEL: (33) 1-30-58-26-00
MONTIGNY-LE-BRETONNEUX, FAX: (33) 1-30-58-19-37
FRANCE
N.V. MAYEKAWA EUROPE KOROVY VAL ST., 7, OFFICE 228, TEL: (7) 499-230-01-76
MOSCOW REPRESENTATIVE 119049, MOSCOW,RUSSIA FAX: (7) 499-230-21-12
OFFICE
MAYEKAWA-SVEDAN SP. Z 0.0. UL. DRUSKIENNICKA 8/10, 60-476 TEL: (48) 61-842-0738
(MPL) POZNAN, POLAND FAX: (48) 61-848-5837

MAYEKAWA INTERTEC AG ROSENBERGSTRASSE 31, CH-6300 TEL: (41) 41-726-8626

ZUG, SWITZERLAND FAX: (41) 41-726-8620
MAYEKAWA INTERTEC AG P.O.BOX 341 TEL: (20) 22-503-2925
- EGYPT NEW CAIRO - 5th SETTLEMENT, FAX: (20) 22-503-2801
NORTH 90th St. THE 47th BUILDING -
4th FLOOR, OFFICE 419, EGYPT

MAYEKAWA INTERTECH AG ALI & SONS BUSINESS CENTER TEL: (971) 2-5102-451
- ABU DHABI OFFICE No.201 FAX: (971) 2-5102-571
ALI KHALFAN RASHED AL MUTAWA
AL DHAHIRI BLDG. PLOT No.29, AL
AIN ROAD, UMM AL NAR, ABU DHABI
U.A.E. P.O. BOX 129865
MAYEKAWA MIDDLE EAST FZCO P.O.BOX 61349, PBU: RA08-UC05, TEL: (971) 4-888-6363
JEBEL ALI FREE ZONE, DUBAI, U.A.E. FAX: (971) 4-888-6373
MAYEKAWA TURKEY SOGUTMA ISTANBUL DUNYA TICARET MERKEZI TEL: (90) 212-4653631
SANAYI VE TICARET LIMITED A-2 BLOK KAT 10 No:325 YESILKOY FAX: (90) 212-4653635
SIRKETI 34149, ISTANBUL, TURKEY

N.V. MAYEKAWA EUROPE S.A. 24,KAMEN ANDREEV STR. 1303, TEL: (359) 2-8910130
（BULGARIA） SOFIA, BULGARIA FAX: (359) 2-8910131

MAYEKAWA ITALIA S.R.L. VIA RICCARDO LOMBARDI 19/12, TEL: (39) 02-4892-9159
（MILANO OFFICE） 20153 MILANO, ITALY FAX: (39) 02-453-1728

MAYEKAWA ITALIA S.R.L. VIA PRADAZZO 7,40012 CALDERARA TEL: (39) 051-726-364
（BOLOGNA OFFICE） DI RENO, FAX: (39) 051-726-804
BOLOGNA, ITALY

MAYEKAWA SOUTH AFRICA (PTY) WEST END, UNIT 3 PRIME PARK, TEL: (27) 21-551-1434
LTD. PRINTERS WAY, MONTAGUE FAX: (27) 86-546-3618
(CAPE TOWN OFFICE) GARDENS 7441, REPUBLIC OF
SOUTH AFRICA

ASIA PACIFIC
MAYEKAWA AUSTRALIA UNIT 2, 44 MCCAULEY STREET TEL: (61) 2-9695-7000
PTY.LTD. MATRAVILLE NSW 2036, AUSTRALIA FAX: (61) 2-9695-7001

MAYEKAWA AUSTRALIA PTY. UNIT 2, 30 TUI STREET, OTAHUHU, TEL: (64) 9-276-2305
LTD.(NEW ZEALAND OFFICE) AUCKLAND 2024, NEW ZEALAND FAX: (64) 9-276-2306

MAYEKAWA INDIA PVT.LTD. 545, 1st FLOOR, SECTOR-20,VILLAGE TEL: (91) 12-4651-0181
(GURGAON OFFICE) DUNDAHERA FAX: (91) 12-4651-0188
GURAGAON-122016, HARYANA,
INDIA

Sales Offices/Service Centers

Contact -3
 Contact Information_2015.04.

Telephone and
Description Location
facsimile No.
P.T.MAYEKAWA INDONESIA GRAHA PRATAMA BUILDING, 9TH TEL: (62) 21-8370-9484
FLOOR JL. M.T. HARYONO KAV.15 FAX: (62) 21-8370-9483
JAKARTA 12810, INDONESIA

P.T.MAYEKAWA INDONESIA JL. SUTRISNO No.274 MEDAN-20215, TEL: (62) 61-7323627

(MEDAN OFFICE) INDONESIA FAX: (62) 61-7358848

P.T.MAYEKAWA INDONESIA BUMI MANDIARI BUILDING, 7TH TEL: (62) 31-531-6613

(SURABAYA OFFICE) FLOOR SUITE 702B, JL. JEND. FAX: (62) 31-532-4341
BASUKI RACHMAT No. 129-137,
SURABAYA-INDONESIA

MAYEKAWA (M) SDN. BHD. No.3, JALAN PJU 3/50, SUNWAY TEL: (60) 3-78051406
DAMANSARA TECHNOLOGY PARK, FAX: (60) 3-78051409
47810 PETALING JAYA, SELANGOR,
MALAYSIA
MAYEKAWA PHILIPPINES CORP. 4/F UNIT A AND B SUNTREE TOWER, TEL: (63) 2-706-0473
13 MERALCO AVENUE, SAN FAX: (63) 2-706-0475
ANTONIO, ORTIGAS CENTER, PASIG
CITY 1605, PHILIPPINES
MAYEKAWA PHILIPPINES CORP. ROOM 4, LEAH DAPROZA BUILDING TEL: (63) 83-552-3282
(GENARAL SANTOS OFFICE) FISCAL DAPROZA AVENUE FAX: (63) 83-301-2698
GENERAL SANTOS CITY 9500,
PHILIPPINES
MAYEKAWA SINGAPORE 6 TAGORE LANE SINGAPORE 787470 TEL: (65) 6451-1565
PTE.LTD. FAX: (65) 6451-4932

MAYEKAWA (TAIWAN) CO., LTD. No.2-1,XINZHAN RD.,QIANZHEN TEL: (886) 7-821-0886

(KAOHSIUNG OFFICE) DIST., FAX: (886) 7-821-4688
KAOHSIUNG CITY,80672
TAIWAN , ROC
MAYEKAWA (TAIWAN) CO., LTD. 1F., NO.2, SHIN JANN ROAD, TEL: (886) 7-812-7709
(CHEMICAL DEPARTMENT) CHIEN CHEN DIST., KAOHSIUNG, FAX: (886) 7-812-9019
TAIWAN 80672, ROC

MAYEKAWA (TAIWAN) CO., LTD. 8F, NO, 421, SUNG-SHAN ROAD, TEL: (886) 2-2727-9711
(TAIPEI HEAD OFFICE) TAIPEI, TAIWAN 11083, REP. OF FAX: (886) 2-2759-8484
CHINA

MAYEKAWA (TAIWAN) CO., LTD. NO. 80-2, SEC.3, HUANJUNG RD., TEL: (886) 4-2251-4128
(TAICHUNG BRANCH) TAICHUNG, TAIWAN, 40755, FAX: (886) 4-2251-4129
REP. OF CHINA
MAYEKAWA CHINA INDUSTRIES ROOM 3001, NANZHENG BUILDING, TEL: (86) 21-5234-1988
CO., LTD. NO.580 WEST NANJING RD., FAX: (86) 21-5234-1788
(SHANGHAI BRANCH) 200041 SHANGHAI, P.R. CHINA
MAYEKAWA CHINA MFG.CO., LTD. 201700 PLANT 1, NO.39, WEST TEL: (86) 21-6920-7718
XIQING ROAD, FAX: (86) 21-6920-7719
QINGPU, SHANHAI, P.R. CHINA

MAYEKAWA CHINA MFG.CO., LTD. RM.1205, TIANLHEFULI BUSINESS TEL: (86) 20-8527-6161
(GUANGZHOU BRANCH) MANSION, No.4, HUA TING RD, FAX: (86) 20-8527-6165
GUANGZHOU, 510610, CHINA

MAYEKAWA CHINA MFG. CO., ROOM 601, FULIN BUILDING TEL: (86) 532-8602-6169
LTD. (QINGDAO BRANCH) NO.87 SOUTH FUZHOU ROAD, FAX: (86) 532-8602-6269
SOUTH DISTRICT, QINGDAO CITY,
266071, CHINA

Sales Offices/Service Centers

Contact -4
 Contact Information_2015.04.

Telephone and
Description Location
facsimile No.
MAYEKAWA CHINA MFG. CO., RM.A13-5, No.1 BUILDING, AREA A , TEL: (86) 411-8753-9620
LTD. (DALIAN BRANCH) WUCAI CITY, DALIAN ECO-TECH FAX: (86)411-8757-9620
DEVELOPMENT ZONE, 116100,
DALIAN, P. R. CHINA
MAYEKAWA (THAILAND) CO., 2/3 MOO 14, 3RD FLOOR TEL: (66) 2-751-9610
LTD. BANGNA TOWER BLDG., TOWER A, FAX: (66) 2-751-9565
MAYEKAWA HOLDING BANGNA-TRAD RD, K.M.6.5,
(THAILAND)CO., LTD. BANGKAEW BANGPLEE,
SAMUTPRAKARN 10540, THAILAND

MAYEKAWA (THAILAND) CO., LTD. 1/7 TRANG-PALIAN RD., MUANG, TEL: (66) 75-224-784
(TRANG BRANCH) TRANG 92000, THALAND FAX: (66) 75-224-351

MAYEKAWA VIETNAM ONE ROOM 305, 3FL, TUOI TRE TOWER, TEL: (84) 8-3997-5284
MEMBER CO., LTD. 60A HOANG VAN THU, WARD 9, FAX: (84) 8-3997-5287
PHU NHUAN DIST., HO CHI MINH
CITY,
VIETNAM

MYCOM KOREA CO., LTD. 2F, 345, CHEONGRA-RO , TEL: (82) 2-796-1766
(HEAD OFFICE) YONGSAN-KU, FAX: (82) 2-798-7715
SEOUL, 140-710, REP.OF KOREA
MYCOM KOREA CO., LTD. 19, BANGYE-RO, UICHANG-KU, TEL: (82) 55-294-8678
CHANGWON FACTORY CHANGWON-SI, FAX: (82) 55-299-7678
GYEONGSANGNAM-DO 641-847,
REP.OF KOREA
MYCOM KOREA CO., LTD. 5F, 26, JUNGANG-DAERO, JUNG-GU, TEL: (82) 51-242-3737
(BUSAN BRANCH) BUSAN 600-714, REP.OF KOREA FAX: (82) 51-243-8542

LATIN AMERICA
MAYEKAWA ARGENTINA S.A. DR. JOSE VALENTIN GOMEZ 151, TEL: (54) 11-4627-6660
(BUENOS AIRES OFFICE) LOT42, HAEDO-PARTIDO DE MORON, FAX: (54) 11-4628-1511
BUENOS AIRES, CP B1706FMA,
ARGENTINA
MAYEKAWA ARGENTINA S.A. OFICINA PTO. MADRYN LEOPOLDO TEL: (54) 2965-475414
(PUERTO MADRYN OFFICE) LUGONES 45 FAX: (54) 2965-475414
(U9129KDA)-PUERTO MADRYN PCIA
DE CHUBUT REPUBLICA ARGENTINA
MYCOM PERU S.A.C. CALLE LUIS PASTEUR 1490, TEL: (51) 1-205-5400
LINCE, LIMA, PERU FAX: (51) 1-222-1543

MAYEKAWA CHILE S.A.C.el. CORDILLERA No.331, MODULO D14, TEL: (56) 2-739-0202
(SANTIAGO OFFICE) FLEX CENTER, PUERTO VESPUCIO, FAX: (56) 2-739-2700
QUILICURA, SANTIAGO, CHILE
MAYEKAWA CHILE S.A.C.el. ANIBAL PINTO No.215, OFICINA 403, TEL: (56) 41-223547
(CONCEPCION OFFICE) CONCEPCION, CHILE FAX: (56) 41-212443

MAYEKAWA CHILE S.A.C.el. BERNARDINO 1057 MODULO 6, TEL: (56) 65-257570

(PUERTO MONTT OFFICE) PARQUE INDUSTRIAL SAN ANDRES FAX: (56) 65-288073
PUERTO MONTT, CHILE
MAYEKAWA ECUADOR S.A. CALLE 15B Y AV. GUILLERMO TEL: (593)4-262-9108
PAREJA C.C.STEFANY LOCAL #4, TEL: (593)4-262-6407
CALLA.LA GARZOTA 1 MZ.28 SOLOR FAX: -
13, GUAYAQUIL, ECUADOR
MAYEKAWA COLOMBIA S.A.S TRANSVERSAL 93 NO.53-48 TEL: (57) 1-430-9980
INTERIOR 37, PAQUE INDUSTRIAL EL TEL: (57) 1-224-3028
DORADO, BOGOTA, COLOMBIA FAX: (57) 1-437-0988

Sales Offices/Service Centers

Contact -5
 Contact Information_2015.04.

Telephone and
Description Location
facsimile No.
MAYEKAWA COLOMBIA S.A.S. DIRECCION CR 43B No. 8 SUR 10 TEL: (57) 4-313-4343
(MEDELLIN OFFICE) OFICINA 404 EDF. OVIEDO FAX: (57) 4-313-4343
MEDELLIN, COLOMBIA
MAYEKAWA DO BRASIL RUA LICATEM 250, BLOCO B/C, TEL: (55) 11-4654-8000
EQIPAMENTOS INDUSTRIAIS JARDIM PEROVA-ARUJA-SP FAX: (55) 11-4654-8002
LTDA. CEP:07428-280, BRASIL
MAYEKAWA DO BRASIL LTDA. RUA DR. JOSE PEROBA, 275 - SALA TEL: (55) 71-3341-0737
(BAHIA BRANCH) 902 EDIFICIO METROPOLIS - BAIRRO FAX: —
STIEPE, SALVADOR –
BA,CEP:41770-235, BRASIL
MAYEKAWA DO BRASIL AV. NEREU RAMOS, 75D, SALA 503A, TEL: (55) 49-3324-0681
EQIPAMENTOS INDUSTRIAIS EDIFICIO CENTRO PROFISSIONAL FAX: (55) 49-3322-4241
LTDA. (CHAPECO BRANCH) CEP:89801-023 C.P.:177
CHAPECO-SC, BRASIL
MAYEKAWA DO BRASIL AVENIDA ISSAC POVOAS, 586 – SALA TEL: (55) 65-3023-7559
EQIPAMENTOS INDUSTRIAIS 405 EDIFICIO WALL STREET - FAX: —
LTDA. (CUIABA BRANCH) CENTRO CUIABA-MT, CEP 78055-560,
BRASIL
MAYEKAWA DO BRASIL RUA XV DE NOVEMBRO, 2175 6 TEL: (55) 41-3383-1518
EQIPAMENTOS INDUSTRIAIS ANDAR SALA 30 SHOPPING CELLI FAX: (55) 41-3383-1987
LTDA. (CURITIBA BRANCH) CEP:83005-000
SAO JOSE DOS PINHAIS-PR, BRASIL
MAYEKAWA DO BRASIL RUA C, 255 – QUADRA 588 – LOTE 4/8 TEL: (55) 62-3093-5062
EQIPAMENTOS INDUSTRIAIS SALA 104 – CENTRO EMPRESARIAL FAX: —
LTDA. (GOIANIA BRANCH) SEBBA GOIANIA-GO, CEP 74280-010,
BRASIL
MAYEKAWA DO BRASIL AV. FRANCISCO DE CHAGAS TEL: (55) 17-3227-0235
EQIPAMENTOS INDUSTRIAIS OLIVEIRA, FAX: (55) 17-3227-3120
LTDA. (OESTE PAULISTA 344 JARDIM PINHEIRO SAO JOSE DO
BRANCH) RIO PRETO-SP, CEP 15091-330,
BRASIL
MAYEKAWA DO BRASIL RUA AGENOR LOPES, 292 SALA 305 TEL: (55) 81-3342-7670
EQIPAMENTOS INDUSTRIAIS CEP:51021-110 BOA VIAGEM FAX: —
LTDA. (RECIFE BRANCH) RECIFE-PE, BRASIL

MAYEKAWA DO BRASIL RUA MUCK, 298 – SALA 601 EDIFICIO TEL: (55) 51-3429-1860
EQIPAMENTOS INDUSTRIAIS SANTA HELENA CEP:92010-250 FAX: (55) 51-3477-5212
LTDA. CANOAS-RS, BRASIL
(RIO GRANDE DO SUL BRANCH)
MAYEKAWA DO BRASIL AV. GOVERNADOR CARLOS TEL: —
EQIPAMENTOS INDUSTRIAIS LINDENBERG, 873/107 CENTRO FAX: —
LTDA. (LINHARES BRANCH) CEP:29900-020 LINHARES-ES,
BRASIL
MAYEKAWA DO BRASIL RUA PROFESSOR MARIETA TEL: (55) 22-2772-6069
EQIPAMENTOS INDUSTRIAIS PEIXOTO, FAX: (55) 22-2759-3112
LTDA. (MACAE) 62 CENTRO - MACAE – RJ,
CEP 27910-250, BRASIL

MAYEKAWA DO BRASIL AV.LUIZ CARLOS PRESTES, TEL: (55) 21-2431-3600

EQIPAMENTOS INDUSTRIAIS 350-SALA 313-EDIFICIO BARRA FAX: (55) 21-2430-8882
LTDA. TRADE II,
(RIO DE JANEIRO BRANCH) BARRA DA TIJUCA, RIO DE
JANEIRO-RJ
CEP:22775-055, BRASIL

MYCOM CENTROAMERICA S.A BODEGA #63, CONDOMINIO TEL: (506) 2441-4464

COMERCIAL TIERRA DOS, EL FAX: (506) 2441-4465
CACIQUE DE RIO SEGUNDO,
ALAJUELA, COSTA RICA

Sales Offices/Service Centers

Contact -6
 Contact Information_2015.04.

Telephone and
Description Location
facsimile No.
MYCOM VENEZUELA CALLE LOS MANGOS, TEL: (58) 212-216-6026
SALES & SERVICES,C.A. EDIFICIO SELEMAR, PISO 8, FAX: (58) 212-216-0608
(CARACAS OFFICE) SABANA GRANDE, CARACAS,
VENEZUELA
MYCOM VENEZUELA AV.INTERCOMUNAL TURMERO, TEL: (58) 243-269-4913
SALES & SERVICE, C.A. EDF.TECHOMAT METROPOLITANO, FAX: (58) 243-269-3952
(MARACAY OFFICE) PISO 1, OFICINA 3, MARACAY,
EDO.ARAGUA, VENEZUELA

MYCOM VENEZUELA CALLE 148,CENTRO EMPRESARIAL TEL: (58) 261-418-1760

SALES & SERVICE, C.A. SAN FRANCISCO NIVEL 1 LOCAL 5 Y FAX: -
(MARACAIBO OFFICE) 6, ZONA INDUSTRIAL IIETAPA,SAN
FRANCISCO
EDO.ZUILIA, VENEZUELA

MYCOM VENEZUELA AV. MUNICIPAL DE PTO. LA CRUZ, TEL: (58) 261-765-1059

SALES & SERVICE, C.A. EDIF. LOCAL NRO.57, PLANTA ALTA,
(BARCELONA OFFICE) MUNICIPIO SOTILLO, PUERTO LA
CRUZ, VENEZUELA

MYCOM CHEMICAL PROCESS CALLE 148,CENTRO EMPRESARIAL TEL: (58) 261-418-1760

CORP. DE VENEZUELA S.A. SAN FRANCISCO NIVEL 1 LOCAL 5 Y FAX: -
6, ZONA INDUSTRIAL IIETAPA,SAN
FRANCISCO EDO.ZUILIA,
VENEZUELA

MAYEKAWA DE MEXICO, AV.DE LOS 50MTS.NO.381, TEL: (52) 77-73-19-0925

S.A. DE C.V. CIVAC. JIUTEPEC MORELOS, FAX: (52) 77-73-20-5762
(CUERNAVACA OFFICE) C.P.62578, MEXICO
MAYEKAWA DE MEXICO, AV.COYOACAN #945 COL .DEL VALLE TEL: (52) 55-5062-0870
S.A. DE C.V. DEL. BENITO JUAREZ C.P.03100, FAX: (52) 55-5062-0898
(MEXICO CITY OFFICE) MEXICO,
D.F. MEXICO
MAYEKAWA DE MEXICO, SANTA MARIA No.3086, COL. TEL: (52) 3336-15-5765
S.A. DE C.V. VALLARTA SAN LUCAS FAX: (52) 3336-15-1307
(GUADALAJARA OFFICE) GUADALAJARA, JALISCO, C.P.44690,
MEXICO

MAYEKAWA DE MEXICO, AV.CHAPULTEPEC NO.2233 OTE. TEL: (52) 81-8347-3085

S.A. DE C.V. FRACC, FAX: (52) 81-8347-5830
(MONTERREY OFFICE) BUENOS AIRES MONTERREY N.L.
C.P.64800, MEXICO
MAYEKAWA DE MEXICO, CALLE FRAY TORIBIO DE TEL: (52) 662-216-2047
S.A. DE C.V. BENAVENTE #38 COL. LOS ARCOS FAX: (52) 662-216-2047
(HERMOSILLO OFFICE) CD. HERMOSILLO, SONORA,
C.P.83250, MEXICO
MAYEKAWA DE MEXICO, CALLE AGUSTIN ZARAGOZA NO.219 TEL: (52) 462-624-9353
S.A. DE C.V. LOCAL-2 COL.DEPORTIVA, C.P.36612, FAX: (52) 462-624-9264
(IRAPUATO OFFICE) IRAPUATO, GTO. MEXICO
MAYEKAWA DE MEXICO, AV. NICOLAS BRAVO 1572, LOCAL 1 TEL: (52) 66-7715-4199
S.A. DE C.V. COL.MORELOS CULIACAN, SINALOA, FAX: (52) 66-7715-4150
(CULIACAN OFFICE) C.P.80170, MEXICO
MAYEKAWA DE MEXICO, CERRADA DE RIO AMATAN 106-A COL. TEL: (52) 993-315-4025
S.A. DE C.V. CASA BLANCA PRIMERA SECCION,
(VILLAHERMOSA OFFICE) VILLAHERMOSA, TABASCO,
C.P.86060, MEXICO

Sales Offices/Service Centers

Contact -7
 2201LZJE-HO-C6-N_2015.05.

MAYEKAWA MFG. CO., LTD.

3-14-15 Botan, Koto-ku, Tokyo 135-8482
TEL : 03-3642-8181
URL : http://www.mayekawa.com/