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mycom J-Series Instruction Manual

Screw compressor
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Screw Compressor
J-Series Instruction Manual
Before operating, maintaining, or inspecting this product, read the manual thoroughly and fully
understand the contents.
Keep the operation manual in a safe, designated place for future reference whenever the need
arises.
Specifications of this product are subject to change without prior notice.
170JS-V/170JM-V/170JL-V
220JS-V/220JM-V/220JL-V
280JS-V/280JM-V/280JL-V
CAUTION
3–14–15 Botan Koto-ku, Tokyo 135-8482, Japan
2205B0JE-DA-J-N_2014.05.

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  • Page 1 2205B0JE-DA-J-N_2014.05. Screw Compressor J-Series Instruction Manual 170JS-V/170JM-V/170JL-V 220JS-V/220JM-V/220JL-V 280JS-V/280JM-V/280JL-V CAUTION Before operating, maintaining, or inspecting this product, read the manual thoroughly and fully understand the contents. Keep the operation manual in a safe, designated place for future reference whenever the need arises.
  • Page 2 Preface Preface Thank you for purchasing this J-series/screw compressor (hereinafter indicated as "this product"). This instruction manual (hereinafter indicated as "this manual") describes safety information, operational and maintenance procedures in detail for safe and effective use of this product、and applies to the following types.
  • Page 3  Malfunction or damage caused by parts that are not MAYEKAWA genuine.  Malfunction or damage caused by remodeling the product without the approval of MAYEKAWA.  Direct or indirect production warranty or all other related warranties that arose due to malfunction or damage of this product. Screw Compressor J-series...
  • Page 4 “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. Screw Compressor J-series...
  • Page 5 Describes documents such as illustrated parts breakdown and 7. Related Documents parts list. Describes tips for design, manufacturing, and installation of the Appendix compressor package. Describes contact information for our local sales offices or service Contact Information centers, which are for ordering genuine parts. Screw Compressor J-series...

  • Page 6: Table Of Contents

    (Use of Lockout/Tagout Devices) ..............1-10 1.4.3 Compressor Protection Devices ..............1-11 Structure and Specifications of the Compressor Features of the J-Series Screw Compressor ..........2-1 Model Designation of the Compressor ............2-1 Compressor Specifications ................ 2-2 2.3.1 Specifications ....................2-2 2.3.2...
  • Page 7 Lubricant (Refrigerant Oil) ................4-2 4.2.1 Precautions for Selecting the Lubricant ............4-2 4.2.2 Recommended Lubricant ................. 4-2 4.2.3 Change of Lubricant Brand ................4-4 4.2.4 Precautions for Handling Lubricant ..............4-4 4.2.4.1 Precautions for Handling Polyalkylene Glycol (PAG) ........4-4 Screw Compressor J-series...
  • Page 8 5.4.11.1 Common Precautions for Removal/Installation ......... 5-38 5.4.11.2 Precautions for Removal ................5-38 5.4.11.3 Precautions for Installation ................ 5-39 5.4.12 Unloader Cylinder ................... 5-42 5.4.12.1 Common Precautions for Removal/Installation ......... 5-43 5.4.12.2 Precautions for Removal ................5-43 Screw Compressor J-series...
  • Page 9 Unloader Slide Valve Guide ................5-72 5.4.24 Adjustment of End Clearance ................. 5-73 5.4.25 Inspection for Runout Male Rotor Shaft ............5-75 5.4.26 Inspection for Runout of Seal Cover Mount Face (Bearing Cover) ....5-75 Troubleshooting Table 6.1 Troubleshooting ....................6-1 Screw Compressor J-series viii...
  • Page 10 Compressor Package Appendix 1.1 Precautions for Design of the Compressor Package ........... Appendix 1-1 Appendix 1.2 Tips for Compressor Package Manufacturing ..Appendix 1-6 Appendix 1.3 Tips for Compressor Package Installation ....Appendix 1-6 Contact Information Screw Compressor J-series...

  • Page 11: Safety

    Safety Data Sheets (SDS) of the refrigerants and refrigerant oils and follow their instructions.  After working on the machine, always store the tools used at the specified places and make sure that no tools are left in or around the machine. Screw Compressor J-series 1.1 Observation/Prevention...

  • Page 12: Do's On Lockout/Tagout After Shutting Off The Power

     Disposal of refrigerant and waste oil from the compressor are subject to a number of regulations for environmental protection purposes. Follow the local, state or federal acts and regulations as well as your company's rules, when disposing of such waste oil, fluid and materials. Screw Compressor J-series 1.1 Observation/Prevention...

  • Page 13: Other Do's

     Do not touch, clean, or lubricate any part of the compressor especially moving parts when the compressor is operating.  Do not touch relays or electric systems such as terminal block with bare hands when turning on the power. Screw Compressor J-series 1.1 Observation/Prevention...

  • Page 14: Warnings

     If the safety labels are damaged or missing, purchase and affix new labels to their proper positions according to this manual.  Inform our service centers of the product name and safety label number when placing a purchase order for safety labels. Screw Compressor J-series 1.2 Warnings...
  • Page 15 2205B0JE-DA-J-N_2014.05. 1 Safety  Types of Safety Labels Table 1-2 Safety Label S af et y l a b e l Remarks Screw Compressor J-series 1.2 Warnings...
  • Page 16 The figure below shows the affixing positions of safety labels. The numbers in the figure correspond to the ones in Table1-2 Safety Label. Figure 1-1 Safety Label Locations (170J/220J) Figure 1-2 Safety Label Locations (280J) Screw Compressor J-series 1.2 Warnings...

  • Page 17: Residual Risks

    Keep away and do not control power Trapping caused by touch Wear protective gear contact with a drive Wear protective gear part Screw Compressor J-series 1.3 Residual Risks...
  • Page 18 Work in temperatures and blowoff Wear protective gear below 40 °C Burn caused by contacting with high temperature fluid J Noises Hearing disabilities Wear protective gear — caused by noises Screw Compressor J-series 1.3 Residual Risks...
  • Page 19 2205B0JE-DA-J-N_2014.05. 1 Safety Figure 1-3 Hazardous Sources (170J/220J) Figure 1-4 Hazardous Sources (280J) Screw Compressor J-series 1.3 Residual Risks...

  • Page 20: Safety Devices

    (OSHA) and other authorities, make sure to clearly indicate methods of performing and releasing lockout/tagout and provide users of this compressor with the necessary information.  Inspection Method/Cycle For inspection procedures and the inspection cycle of the lockout/tagout devices, refer to the unit instruction manual. Screw Compressor J-series 1.4 Safety Devices 1-10...

  • Page 21: Compressor Protection Devices

     Protection from motor over-current This function controls the unloader of compressor when current exceeds the set value (upper limit). In some cases, it stops the compressor. The current value is monitored by the CP4 controller. Screw Compressor J-series 1.4 Safety Devices 1-11...
  • Page 22  If oil pressure, abnormal high pressure or, oil filter differential pressure protection functions operate, eliminate the cause before re-starting the compressor. Screw Compressor J-series 1.4 Safety Devices 1-12...

  • Page 23: Structure And Specifications Of The Compressor

    ’s original technology and special high-load capacity thrust ball bearings. The J-series achieves an improvement of reliability because the design pressure is higher than the standard model, O-rings are used for sealing between casing and the bellows type mechanical seal are adopted for shaft seal.

  • Page 24: Compressor Specifications

    Note 1: In this manual unless otherwise noted, pressure units MPa represents the gauge pressure. Note 2: The connection flanges of the compressor conform to ANSI CLASS 300. Note 3: The weight excluding the motor spacer is the weight of the compressor. Screw Compressor J-series 2.3 Compressor Specifications...
  • Page 25 Note 1: In this manual unless otherwise noted, pressure units MPa represents the gauge pressure. Note 2: The connection flanges of the compressor conform to ANSI CLASS 300. Note 3: The weight excluding the motor spacer is the weight of the compressor. Screw Compressor J-series 2.3 Compressor Specifications...
  • Page 26 3.2.5.3 in this manual Chapter 3) Note 1: In this manual unless otherwise noted, pressure units MPa represents the gauge pressure. Note 2: The connection flanges of the compressor conform to ANSI CLASS 300. Screw Compressor J-series 2.3 Compressor Specifications...

  • Page 27: Operation Limits

    , Propane and Propylene Note 1: Pressure unit [MPa] in the table 2-4 means gauge pressure. Note 2: The J-series compressors must be used within the allowable operation range defined in the table 2-4 and next page, Figure2-1.  When using J series in the explosion-proof area, use certainly in the condition with the maximum suction temperature of equal to or less than 50 °C, the maximum lubrication...
  • Page 28 2 Structure and Specifications of the Compressor Operation range Operation range (Pressurized lubrication by oil pump) (Lubrication supplied by differential pressure) Figure 2-1 Operation Limits Chart NOTE1: The pressure values in the operation limit chart are absolute values [MPa (A)]. Screw Compressor J-series 2.3 Compressor Specifications...

  • Page 29: Outer Dimensions

    2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor 2.3.3 Outer Dimensions  Outer dimensions of the 170J and 220J-series (Standard Specification) Figure 2-1 Outer Dimensions of the 170J and 220J-Series (Standard Specification) Screw Compressor J-series 2.3 Compressor Specifications...
  • Page 30 12：Unloader indicator connect PF 3/4 13：Vi-sensor connect connector 14：The leg hole for securing the 4-φ19 4-φ23 compressor 1358 1413 1485 1680 1752 1845 71.5 92(F rotor side) 86（M rotor side） -0.043 -0.052 +0.012 +0.012 -0.007 -0.007 Screw Compressor J-series 2.3 Compressor Specifications...
  • Page 31 Unit: mm 1 7 0 J 2 2 0 J I t e m NEMA NEMA 44*D 50*D FF-500 FF-600 44*D 50*D FF-600 FF-740 8-M20 8-M16 8-M20 8-M20 2-φ19 2-φ23 457.2 457.2 558.8 558.8 Screw Compressor J-series 2.3 Compressor Specifications...
  • Page 32 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor  Outer dimensions of the 170J and 220J-series (Explosion Proof) Figure 2-4 Outer Dimensions of the 170J and 220J-Series (Explosion-proof) Screw Compressor J-series 2.3 Compressor Specifications 2-10...
  • Page 33 PF 3/4 13：Vi-sensor connect connector 14：The leg hole for securing the 4-φ19 4-φ23 compressor 1358 1413 1485 1680 1752 1845 71.5 92(F rotor side) 86（M rotor side） -0.043 -0.052 +0.012 +0.012 -0.007 -0.007 Screw Compressor J-series 2.3 Compressor Specifications 2-11...
  • Page 34 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor  Outer dimensions of the 280J-series Figure 2-5 Outer Dimensions of the 280J-series Screw Compressor J-series 2.3 Compressor Specifications 2-12...
  • Page 35 10-2：Vi control decrease（H→L） Rc1/2 11：Capacity control oil return Rc1/2 12：Unloader indicator connect PF 3/4 13：Vi-sensor connect connector 14：The leg hole for securing the 4-φ33 compressor 2112 2205 2328 112(M rotor side) -0.052 +0.011 -0.011 Screw Compressor J-series 2.3 Compressor Specifications 2-13...

  • Page 36: Structure Of The Compressor

     For the names and locations of the compressor components, refer to "7.1 Development View and Configuration Table of the Parts" in this manual chapter 7. Figure 2-6 Structure of Compressor (170JM-V) Screw Compressor J-series 2.4 Structure of the Compressor 2-14...

  • Page 37: Sectional View

    2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor 2.4.1 Sectional View Figure 2-7 Sectional View of the 170J-Series (1/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-15...
  • Page 38 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor Figure 2-8 Sectional View of the 170J-Series (2/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-16...
  • Page 39 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor 794 ASSY [ Liquid Injection Port ] [ Economizer Port ] Figure 2-9 Sectional View of the 170J-Series (3/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-17...
  • Page 40 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor Figure 2-10 Sectional View of the 220J-Series (1/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-18...
  • Page 41 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor Figure 2-11 Sectional View of the 220J-Series (2/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-19...
  • Page 42 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor 794 ASSY [ Liquid Injection Port ] [ Economizer Port ] Figure 2-12 Sectional View of the 220J-Series (3/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-20...
  • Page 43 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor Figure 2-13 Sectional View of the 280J-Series (1/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-21...
  • Page 44 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor Figure 2-14 Sectional View of the 280J-Series (2/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-22...
  • Page 45 2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor 794 ASSY [ Liquid Injection Port ] [ Economizer Port ] Figure 2-15 Sectional View of the 280J-Series (3/3) Screw Compressor J-series 2.4 Structure of the Compressor 2-23...

  • Page 46: Mechanisms

    (The flange motor is not available for the 280J-series.) The newly developed J profile optimizes the rotor profile and mating, thereby improving the compressor efficiency significantly. Figure 2-17 J Profile Screw Compressor J-series 2.5 Mechanisms 2-24...

  • Page 47: Suction Process

    The volume between rotor lobes decrease to a predetermined value at the discharge port. As the rotors further rotate, the compressed gas is pushed out from the discharge port to the outlet of the compressor. （Refer to Figure 2-20) Figure 2-19 Compression Process Figure 2-20 Discharge Process Screw Compressor J-series 2.5 Mechanisms 2-25...

  • Page 48: Oil Flow

    2205B0JE-DA-J-N_2014.05. 2 Structure and Specifications of the Compressor Oil Flow Figure 2-21 Oil Flow (170J/220J-Series) Figure 2-22 Oil Flow (280J-Series) Screw Compressor J-series 2.6 Oil Flow 2-26...

  • Page 49: Capacity Control Characteristics

    2 Structure and Specifications of the Compressor Capacity Control Characteristics The J-series can vary capacity continuously using the slide valve capacity control structure. This control system offers a wide capacity control range with high efficiency by hydraulic control. Example of Capacity Characteristics...

  • Page 50: Variable Vi Control

    Vi is the ratio of the volume between rotor lobes and casing after completion of suction and the volume when discharge port starts to open. The J-series basically adopts three Vi values of 2.50, 3.50, and 5.0 which are called ‘L port’, ‘M port’, and ‘H port’ respectively.

  • Page 51: Reasons For Adjusting Vi According To Operating Conditions

    Vi is decreased. The position of the variable Vi slide valve can be detected by the Vi position sensor. The J-series can always control Vi to an optimum value with a specified controller according to measured operating conditions (such as suction and discharge pressure).

  • Page 52: Fixed Vi Mode

    2.8.3.2 Fixed Vi Mode The J-series also allows for fixed Vi if the operating conditions are stable and the automatic variable Vi control is not necessary. Note, however, a specified controller is required to adjust the variable Vi slide valve to the desired Vi value.

  • Page 53: Solenoid Valve

    Table 2-13 Specifications of the Coil for SXL6-4BL Allowable voltage Rated voltage Lead wire color Frequency Effective power fluctuation 110-127 V AC 12-19 W Blue 50 Hz +10—－15 % 12-15 W 220-240 V AC Screw Compressor J-series 2.9 Solenoid Valve 2-31...
  • Page 54 Note 1: If it is not possible to adjust capacity or variable Vi control because a hunting occurred and the unloader slide valve or the Vi slide valve move too fast, carry out the appropriate adjustment by decreasing the openings of RV (*) valves. Screw Compressor J-series 2.9 Solenoid Valve 2-32...

  • Page 55: Explosion Proof For 170J/220J-Series, Also 280J-Series

    Table 2-15 Recommended Specifications of the solenoid valves for the J-series Item...

  • Page 56: Installation

    3 Installation Precautions for Installation Basically the J-series is delivered as a standard package consisted of the compressor. Figure 3-1 Appearance of the Package  This chapter 3 is based on the assumption that the compressor is installed to standard packages for the purpose of refrigeration, cold storage, and air conditioning.

  • Page 57: Installation Work

    (such as calling at the beginning of the work or making a signal with hand). Remove all nonessential workers from area until lift is complete. Do not lift the compressor unless the signals are completely understood by the all personal working together. Screw Compressor J-series 3.2 Installation Work...

  • Page 58: Preparation For Installation

    Prepare lighting for easy operation, cleaning, maintenance, and inspection.  Ventilation If natural ventilation is insufficient, install ventilation fans according to the regulations.  Piping Refer to "2.3.2 Outer Dimensions" in this manual chapter 2. Screw Compressor J-series 3.2 Installation Work...

  • Page 59: Installation

    Remove the crane used to lift the compressor and check for any gaps between the base of package and the feet of the compressor. If there are any gaps, adjust the compressor height using shims and then fix the compressor to the base with bolts. Screw Compressor J-series 3.2 Installation Work...

  • Page 60: Piping

     When performing welding work, make sure to disconnect wiring described below. If welding work is performed with wiring connected, the compressor parts may be damaged. 1) Wirings of the capacity control and potentiometer for Vi changing 2) Wirings of the solenoid valves for 170J/220J Screw Compressor J-series 3.2 Installation Work...

  • Page 61: Equipment And Devices For Protection Of The Compressor

    When an economizer or liquid injection is used, install a filter of 100μm or finer in the line.  Compressor Protection Functions (Safety Device) The J-series has a specified controller which must be used to protect the compressor with the controller's protection functions.

  • Page 62: Pressure Test (Leak Test)

    Thoroughly vacuum the compressor and oil separator to 40 Torr. Make sure that the unloader and variable Vi solenoid valves are opened to vacuum the cylinders. Close the oil separator outlet valve in the oil supply line. Also close the oil injection regulating valve. Screw Compressor J-series 3.2 Installation Work...

  • Page 63: Additional Charge Of Lubricant Procedure

    For further details on refrigerant charging works, refer to the package or refrigeration unit instruction manual. 3.2.9 Check after Installation Perform the checks after compressor installation according to the check list in the package instruction manual. Screw Compressor J-series 3.2 Installation Work...

  • Page 64: Documents Related To Installation

    2205B0JE-DA-J-N_2014.05. 3 Installation Documents Related to Installation  Lifting Positions/Gravity Center Positions/Lifted View Figure 3-5 Center of Gravity and Lifting Points (170J) Screw Compressor J-series 3.3 Documents Related to Installation...
  • Page 65 2205B0JE-DA-J-N_2014.05. 3 Installation Figure 3-6 Center of Gravity and Lifting Points (220J) Screw Compressor J-series 3.3 Documents Related to Installation 3-10...
  • Page 66 2205B0JE-DA-J-N_2014.05. 3 Installation Figure 3-7 Center of Gravity and Lifting Points (280J) Screw Compressor J-series 3.3 Documents Related to Installation 3-11...
  • Page 67 2205B0JE-DA-J-N_2014.05. 3 Installation Figure 3-8 Compressor being Lifted Screw Compressor J-series 3.3 Documents Related to Installation 3-12...

  • Page 68: Compressor And Package Operation

    With these steps, the initial adjustment for the unloader slide valve and the variable Vi slide valve is completed. Screw Compressor J-series 4.1 Adjustment before Test Operation...

  • Page 69: Lubricant (Refrigerant Oil)

    Recommended Lubricant When selecting lubricant, not only the refrigerant but also O-rings in use must be considered. We therefore recommend using the following brands of lubricant for the J-series compressors to prevent any operating problems.  Recommended Lubricant for Ammonia Refrigerant...
  • Page 70 Note 1: Using inter-soluble oil, a case to use in liquid injection is excluded as for the recommended viscosity.  The lubricants listed above are adaptable to the J-series. We do not recommend using any of them with our other compressors.

  • Page 71: Change Of Lubricant Brand

     Always charge all oil from the bale can. 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. Screw Compressor J-series 4.2 Lubricant (Refrigerant Oil)

  • Page 72: Precautions For Handling Polyolester (Poe) Oil

    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. Screw Compressor J-series 4.2 Lubricant (Refrigerant Oil)

  • Page 73: Precautions For Operation

    Measure the pressure of the condenser and compare it with the refrigerant saturation pressure depending on the cooling water temperature. If the condenser pressure is higher than the refrigerant saturation pressure by 0.05 MPa or more, purge any non-condensable gases. Screw Compressor J-series 4.3 Precautions for Operation...

  • Page 74: Action For Stopping The Compressor For Long Period Of Time

    Supply power to the oil heater for at least 1 hour before operation starts. And before starting the operation, confirm that the refrigerant is not condensed in the package by checking the package temperature and pressure (especially the suction pipe). Screw Compressor J-series 4.4 Action for Stopping the Compressor for Long Period of Time...

  • Page 75: Maintenance And Inspection

     When turning on and off the power supplies, take care to avoid any electric shock hazard.  Any electric works requiring some expert qualifications must be performed by a qualified person. Screw Compressor J-series 5.1 Precautions for Maintenance and Inspection...

  • Page 76: Maintenance List

    If any compressor/system failure or operating accident occurs, the operating log book will help the cause to be clear and take appropriate measures promptly. Figure 5-1 Controller Display Screen (Example) Screw Compressor J-series 5.2 Maintenance List...
  • Page 77  Check for refrigerant leak or not The machine room and the load leak side facilities Note 1 : Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual. Screw Compressor J-series 5.2 Maintenance List...
  • Page 78 If the oil temperature and discharge pressure increase gradually in an initial period of operation, inspect and clean the cooling water side of the oil cooler and condenser even when the inspection time has not come. Screw Compressor J-series 5.2 Maintenance List...

  • Page 79: Periodical Inspection

    Coupling Annually or every 8,000 operating hours * Note*: Inspect the machine per period or operating hours, whichever is shorter. Screw Compressor J-series 5.2 Maintenance List...

  • Page 80: Guidelines For Compressor Overhaul Frequency

    (See "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. Screw Compressor J-series 5.2 Maintenance List...

  • Page 81: Replacement Parts Of The Compressor In Overhauling

    JIS B 2401 P155 561 O-ring JIS B 2401 P12 657 O-ring JIS B 2401 G100 713 O-ring JIS B 2401 P12 714 O-ring JIS B 2401 P6 717 O-ring JIS B 2401 G25 Screw Compressor J-series 5.2 Maintenance List...
  • Page 82 To be replaced if Balance piston sleeve there is any damage. JIS B 2804 H120 Retaining ring To be replaced if 29-1 C type - Internal there is any damage. Screw Compressor J-series 5.2 Maintenance List...
  • Page 83 M damage. To be replaced if Thrust bearing outer race 41-2 there is any spacer, F damage. To be replaced if Thrust bearing alignment 42-1 there is any spacer, M damage. Screw Compressor J-series 5.2 Maintenance List...
  • Page 84 Reusable if not damaged: If there is no damage or abnormality in visual inspection, the part can be used continuously. To be replaced if there is any damage: Replace the part if any damage or abnormality is found in visual inspection. Screw Compressor J-series 5.2 Maintenance List 5-10...
  • Page 85 JIS B 2401 P12 657 O-ring JIS B 2401 G120 713 O-ring JIS B 2401 P12 714 O-ring JIS B 2401 P6 717 O-ring JIS B 2401 G25 728-4 O-ring JIS B 2401 G45 Screw Compressor J-series 5.2 Maintenance List 5-11...
  • Page 86 528 Sleeve, oil seal damaged. Reusable if not 712 Vi position sensor rod damaged. To be replaced if Balance piston there is any damage. To be replaced if Balance piston sleeve there is any damage. Screw Compressor J-series 5.2 Maintenance List 5-12...
  • Page 87 To be replaced if M rotor there is any damage. To be replaced if F rotor there is any damage. To be replaced if Thrust bearing outer race 41-1 there is any spacer, M damage. Screw Compressor J-series 5.2 Maintenance List 5-13...
  • Page 88 Reusable if not damaged: If there is no damage or abnormality in visual inspection, the part can be used continuously. To be replaced if there is any damage: Replace the part if any damage or abnormality is found in visual inspection. Screw Compressor J-series 5.2 Maintenance List 5-14...
  • Page 89 JIS B 2401 G140 657 O-ring JIS B 2401 G120 713 O-ring JIS B 2401 P12 714 O-ring JIS B 2401 P6 717 O-ring JIS B 2401 G25 728-4 O-ring JIS B 2401 G65 Screw Compressor J-series 5.2 Maintenance List 5-15...
  • Page 90 JIS B 2804 S80 To be replaced if Retaining ring there is any C type - External damage. JISB2804 S10 To be replaced if Retaining ring there is any C type - External damage . Screw Compressor J-series 5.2 Maintenance List 5-16...
  • Page 91 Reusable if not damaged: If there is no damage or abnormality in visual inspection, the part can be used continuously. To be replaced if there is any damage: Replace the part if any damage or abnormality is found in visual inspection. Screw Compressor J-series 5.2 Maintenance List 5-17...

  • Page 92: Management Of Lubricant

    In addition, ammonia dissolved in the lubricant may be detected as water when it is analyzed, thereby preventing correct measurement of water content. Therefore, the management standards above should be construed as guidelines. Screw Compressor J-series 5.3 Management of Lubricant 5-18...

  • Page 93: Replacement Interval For Lubricant

    5-8 to 5-10, replace the lubricant. However, if the oil filter is clogging frequently or the oil becomes black and opaque, replace the oil after confirming and eliminating the cause. Screw Compressor J-series 5.3 Management of Lubricant 5-19...

  • Page 94: Disassembly And Assembly Of The Compressor

    Operate the refrigerating unit, close the fluid supply master valve, and collect the liquefied gas in the receiver.  By using a refrigerant recovery machine, recover the liquefied refrigerant in the receiver. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-20...

  • Page 95: Removing The Compressor

    Pull out the parallel pin between motor spacer and compressor, and remove the bolts. Using lifting equipment, remove the compressor from the motor spacer. Put place the lifting compressor on a work bench like the right photograph. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-21...

  • Page 96: Removing Oil From Inside The Compressor

    Figure 5-2 Positions of Drain Plugs Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-22...

  • Page 97: Common Work Items

     When the size of the retaining ring pliers is different, the retaining ring may jump out, causing injuries. Always retaining ring pliers of appropriate size and wear protective goggles.  Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-23...
  • Page 98 Notice that the lock nut for the unloader push rod is harder to screw in because it is high friction locking devices. To assemble the nut, use a locknut wrench.  Use liquid gasket (for example, HERME SEAL) or silicon grease for the suction adapter tightening bolts. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-24...

  • Page 99: Position Sensor

    Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Note: For the details about the Vi position sensor, separately, refer to the special instruction manual. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-25...

  • Page 100: Common Precautions For Removal/Installation

    Make sure that all necessary O-rings are attached. (In particular, part No. 714)  Vi position sensor rod housing gland Install the Vi position sensor rod housing gland of the groove facing down. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-26...

  • Page 101: Seal Cover

    Retaining ring C type internal Seal cover (H100) Sleeve, shower flushing Remove the parts in the order of numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-27...
  • Page 102 (H120/ H140) Sleeve, shower flushing Shaft seal cover Remove the parts in the order of numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-28...

  • Page 103: Common Precautions For Removal/Installation

    Using eyebolts (M8), remove the seal cover.  Shower flushing sleeve Using eyebolts (M8), remove the shower flashing sleeve.  Mechanical seal assembly (mating ring) Remove the mechanical seal mating ring from the seal cover. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-29...

  • Page 104: Precautions For Installation

    Lubricate the seal ring of the male rotor shaft with lubricant. Lubricate the mating ring of the seal cover assembly with lubricant.  Shaft key Check for damages. If anything wrong is found, replace the key. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-30...

  • Page 105: Bearing Cover

    Retainer for oil seal — Bush, P14 type O-ring Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-31...

  • Page 106: Common Precautions For Removal/Installation

     The spring pin (3 dia. x 8/3 dia. x 10) attached to the bearing cover may not be pulled out during a regular service. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-32...

  • Page 107: Precautions For Installation

     Mechanical seal assembly Install the mechanical seal ring by aligning the hexagon socket set screw positions and the drilled holes of the male rotor shaft. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-33...

  • Page 108: Unloader Indicator/Capacity Control Solenoid Valve

    According to the design modification notification as of January 2014, J series unloader indicators have all changed to explosion-proof type which is newly designed. For details of this new unloader indicators refer to their instruction manual provided separately. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-34...

  • Page 109: Precautions For Removal

     Capacity control solenoid valve/variable Vi solenoid valve  Install the capacity control solenoid valve and variable Vi solenoid valve, after assembling all other parts of the unloader cylinder and the variable Vi cylinder. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-35...

  • Page 110: Unloader Cover

    Unloader spacer Retainer assembly, O-ring — O-ring (P32/P44) Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-36...
  • Page 111 — Unloader spacer Retainer, O-ring O-ring (P58) Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-37...

  • Page 112: Common Precautions For Removal/Installation

    Hold the hexagon socket head cap screws (M10, for 170J) or eye bolts (M8, for 220J/280J), pull out the unloader cylinder cover horizontally and remove. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-38...

  • Page 113: Precautions For Installation

     Pull the push rod towards yourself so that the push rod can be inserted into the internal face of the unloader piston, before inserting the unloader piston into the unloader cylinder. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor...
  • Page 114  Locknut (FU nut) (only for 170J)  The FU nut has a high friction locking device. Turn the FU nut with a locknut wrench when tightening the FU nut. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-40...
  • Page 115 Check that the cam rotates smoothly by moving the unloader cover assembly back and forth horizontally. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-41...

  • Page 116: Unloader Cylinder

    325-1 Partition plate, unloader cylinder Unloader cylinder Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-42...

  • Page 117: Common Precautions For Removal/Installation

     Pull the unloader cylinder straight and horizontally not to damage the unloader slide valve push rod.  Unloader cylinder partition plate Using eyebolts (M8), remove the unloader cylinder partition plate. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-43...

  • Page 118: Precautions For Installation

    For the upper two bolts, the size is M12×70 for 170J, M16×90 for 220J, or M20×110 for 280J. Other screws are of M12×110 for 170J, M160×140 for 220J, M20×170 for 280J. Pay attention to the size difference. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-44...

  • Page 119: Cylinder

    O-ring (P130/P170) O-ring (WG36/G200) 63-1 Piston, Vi Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-45...
  • Page 120 Vi piston assembly — — — — Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-46...

  • Page 121: Common Precautions For Removal/Installation

     Vi cylinder Lubricate the inner face of Vi cylinder with lubricant. Install the Vi cylinder to the Vi piston and push the Vi cylinder into the balance piston cover. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-47...

  • Page 122: Balance Piston Cover

    Back-up ring for O-ring Partition plate, suction cover O-ring (P52/P65/P85) Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-48...

  • Page 123: Common Precautions For Removal/Installation

    Ensure that the joint of backup ring mates, and the O-ring fits between the two back-up rings. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-49...

  • Page 124: Suction Cover

    7.4 design modification information (No.C0956-02) in the chapter 7. If you require information about the suction cover (balance piston) before this design modification, refer to the instruction manual(No.2202B0-JJ-DA-J-N_2012.01.). Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-50...
  • Page 125 Retaining ring C type internal Balance piston (H120/None) Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-51...

  • Page 126: Common Precautions For Removal/Installation

     Balance piston Using eyebolts (M8), remove the balance piston with the balance piston sleeve.  Balance piston sleeve Using eyebolts (M8), remove the balance piston sleeve. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-52...

  • Page 127: Precautions For Installation

     Balance piston cover inner cover (male rotor side) Install the balance piston inner cover into the suction cover aligning the spring pin (6 dia.×12) the cutout on the detent hole of the balance piston sleeve Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-53...

  • Page 128: Thrust Bearings

    7.4 design modification information (No.C0957-00) in chapter 7. If you require information about the bearing head before this design modification, refer to the instruction manual (No.2202B0-JJ-DA-J-N_2012.01.). Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-54...
  • Page 129 Lock washer (AW16/AW20) 40-1 42-2 female rotor Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-55...

  • Page 130: Precautions For Removal

    However, to clarify the difference between the inner side and outer side of the machine, after assembling with the bearing number engravings on the outer side, make a V-shaped mark using blue whetstone on the machine’s inner side of the bearing.. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-56...
  • Page 131 The conical spring washer must be attached after adjustment of end clearance. Tighten the hexagon socket head cap screw (M8×30/M12×50/M16×65) evenly and lightly using a wrench. For further details, refer to "5.4.20 Adjustment of End Clearance". Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-57...

  • Page 132: Separation Of Suction Cover And Main Rotor Casing

    Hexagon socket head cap screw O-ring (P375/P450/P580) (M16×60/M16×75/M20×110) Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-58...

  • Page 133: Common Precautions For Removal/Installation

     If it is difficult to separate the suction cover from the main rotor casing, lift the main rotor casing slightly using a crowbar while removing the suction cover. 5.4.17.3 Precautions for Installation  O-ring (P375/P450/P580) After disassembly, replace the existing O-rings with new ones. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-59...

  • Page 134: Common Precautions For Removal/Installation

    5.4.18.1 Common Precautions for Removal/Installation  Retaining ring  The retaining ring may jump out, causing injuries. Always use retaining ring pliers of appropriate size and wear protective goggles. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-60...

  • Page 135: Precautions For Removal

    Insert the guide to the spring pin (4 dia.×10) and align the cutout of the bearing to the guide. Install the bearing using the radial bearing installing tool. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-61...

  • Page 136: Rotors

    Grooved pin Slide valve, Vi Unloader slide valve Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-62...

  • Page 137: Common Precautions For Removal/Installation

    Unloader slide valve Slide valve, Vi 12.2 12.7 13.3  If lifted inappropriately, it may cause injuries. If it is difficult to lift them by hand, use appropriate lifting equipment. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-63...

  • Page 138: Precautions For Installation

     The male rotor and female rotor can be engaged at any orientation.  Key for balance piston Check for wear and damages. If anything wrong is found, replace the key. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-64...

  • Page 139: Separation Of Bearing Head And Main Rotor Casing

    O-ring (P375/P450/P580) (M16×60/ M16×75/ M20×110) Main rotor casing Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-65...

  • Page 140: Precautions For Removal

    Using the two eyebolts (M12 2 places/M16 2 places/M24 1 place) on the top of the main rotor casing, lift and carry the main rotor casing with lifting equipment. 5.4.20.4 Precautions for Installation  O-ring (P375/P450/P580) After disassembly, replace the existing O-rings with new ones. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-66...

  • Page 141: Bearing Head

    5.4.21.1 Common Precautions for Removal/Installation  Retaining ring  The retaining ring may jump out, causing injuries. Always use retaining ring pliers of appropriate size and wear protective goggles. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-67...

  • Page 142: Precautions For Removal

    Insert the guide to the spring pin (4 dia.×10) and align the cutout of the bearing to the guide. Install the bearing using the radial bearing installing tool. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-68...

  • Page 143: Suction Adapter (Except For 280J)

    Spring, check valve Plain washer Check valve stem Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-69...

  • Page 144: Common Precautions For Removal/Installation

     The suction adapter weights 14 kg for 170J and 26 kg for 220J. If lifted inappropriately, it may cause injuries. If it is difficult to lift the suction adapter by hands, use lifting equipment. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-70...

  • Page 145: Precautions For Removal

    After connecting the suction cover and the main rotor casing securely, tighten the hexagon socket head screws (M20×50/M22×60) on the suction cover to the specified torque. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-71...

  • Page 146: Unloader Slide Valve Guide

    Remove the parts in the order of the numbers shown in the figure. Install the parts in the reverse order of removing.  For periodic inspection, do not remove the unloader slide valve guide. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-72...

  • Page 147: Adjustment Of End Clearance

    After grinding the flat surface, measure the whole circumference of the spacer by using a micrometer, and check that the thickness is even. Rotate the male rotor counterclockwise several turns. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-73...
  • Page 148 Perform the same operation to the hexagon socket head cap screws (M8×30/M12×50/M16×65) of the thrust bearing gland for the female rotor. Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-74...

  • Page 149: Inspection For Runout Male Rotor Shaft

    Tighten it evenly several times while changing the combination of engagement between tightening tool claw and locknut groove. Check the runout of the male rotor shaft Check the runout of the seal cover mount face Screw Compressor J-series 5.4 Disassembly and Assembly of the Compressor 5-75...

  • Page 150: Troubleshooting

     Heat exchange strainers, and then take necessary failure at heat measures. exchanger Also, inspect devices and parameters (setting values) for expansion value aperture adjustment device, and then take necessary measures. Screw Compressor J-series...
  • Page 151 If there is any oil floating, check for oil leak in oil cooler heat transmission tube, and take measures. For damage in pipes, etc., caused by excessive vibration, take vibration reduction measures (including sympathetic vibration measures). Screw Compressor J-series...
  • Page 152 Uncondensed gas Leak on low Inspect for leak, and take necessary in the system pressure side measures. Cases of erosion Then, air purge the heat exchanger. of compressor’s suction thermometer protection pipe have also been confirmed. Screw Compressor J-series...
  • Page 153 Then, replace malfunctioning devices. Non-condensable Leak on low Inspect for leak, and take necessary gases in the system pressure side measures. Then, air purge the heat exchanger. Screw Compressor J-series...
  • Page 154 Overheat operation Refer to Factor “Insufficient refrigerant circulation volume” in item 02. High supply oil Refer to the Direct cause “High temperature supply oil temperature” in item 06. Screw Compressor J-series...
  • Page 155 Squeaking normally subsides after together, squeaking for them to fit few dozens of hours, but it could sound caused by together. continue in rare cases. →In this case, contact our service contact of sliding surfaces might be centers. heard. Screw Compressor J-series...
  • Page 156 Install a capacity control hydraulic increases line with an in-line check valve (internal reversal-stoppage valve) and an oil bypass line. Screw Compressor J-series...
  • Page 157 However, if no other causes for rotors abnormal vibration are found, and if on-site overhaul has been repeatedly performed, this might be the factor. Overhaul compressor at an institution such at MAYEKAWA Moriya Factory with dynamic balance measurement/ adjustment equipment. Screw Compressor J-series...
  • Page 158 If any defects are found, * To prevent this replace the faulty devices. phenomenon, As with temperature type expansion gas‐liquid valve, for incompatible orifice due to separator the change in operating conditions, (accumulator) replace orifice. can be installed. Screw Compressor J-series...
  • Page 159 Inspect suction strainer and oil filter. contaminating welding spatter, If any problems to element, replace compressor etc., from upstream side Overhaul compressor. Collect foreign substances and Neglect of objects. Identify the source and take collecting tools and measures. rags during overhaul Screw Compressor J-series 6-10...
  • Page 160 →If sympathetic vibration is machinery, including piping and suspected, contact our sales support. offices or service centers. Screw Compressor J-series 6-11...

  • Page 161: Related Documents

    7 Related Documents 7 Related Documents Development View and Configuration Table of the Parts  Development View and Configuration Table (170J) Figure 7-1 Development View of 170J (1/2) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 162 2205B0JE-DA-J-N_2014.05. 7 Related Documents Figure 7-2 Development View of 170J (2/2) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 163 JIS B 2401 G115 PAH81-115 PC12-115 Housing, balance piston CS03600-J170 Retaining ring C type internal JIS B 2804 (H120) NG11-120 Thrust bearing assembly, male 38-1 7312BEAXT7DF CS03800-J170M rotor Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 164 Ball bearing #6000 CS07800-200 Retaining ring C type external JISB2804 (S10) NG12-010 Bearing gland CS08000-200 Hexagon socket head cap screw M6×15 NB35406-015 82-1 O-ring JIS B2401 P10A PAH80-010A PC11-010A Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 165 458-2 Plug R1/4 NF06-008 Plug R3/8 NF06-010 Check valve slider CS48100-J170 O.D 23, wire Spring, check valve diameter 1.8 CS48500-J170 Free length 95 Locknut FU nut FU04SS NG42-04 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 166 Vi position sensor assembly I plug CS72700-J170 E plug CS72800-J170 Spring pin 3 dia.×10 NE3203-010 731-A Plug R1/8 NF06-004 731-B Plug R1/8 NF06-004 732-A Plug R1/8 NF06-004 732-B Plug R1/8 NF06-004 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 167 Hexagon socket head cap screw manual as No. 794 Vi position Vi position sensor box sensor assembly. I plug 664-069 2013.10.31 Design modification notification Spring pin 664-054 2012.03.29 (follow-up) No.C0957-00 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 168 2205B0JE-DA-J-N_2014.05. 7 Related Documents  Development View and Configuration Table (220J) Figure7-3 Development View of 220J (1/2) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 169 2205B0JE-DA-J-N_2014.05. 7 Related Documents Figure7-4Development View of 220J (2/2) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts...
  • Page 170 Retaining ring C type external JIS B 2804 (S65) NG12-065 Sleeve, balance piston 200*UD CS03300-J220 3 → 2 Spring pin 6 dia.×12 NE3206-012 35-1 O-ring JIS B 2401 P120 PAH80-120 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-10...
  • Page 171 Unloader indicator cam M CS07700-J220M — — Unloader indicator cam L CS07700-J220L — — Ball bearing #6000 CS07800-200 Retaining ring C type external JISB2804 (S10) NG12-010 Bearing gland CS08000-200 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-11...
  • Page 172 458-1 Plug R3/4 NF06-020 458-2 Plug R3/8 NF06-010 Plug R3/8 NF06-010 Check valve slider CS48100-J220 O.D 32, wire diameter 2.6 Spring, check valve CS48500-J220 Free length 250 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-12...
  • Page 173 728-1 E plug CS72810-J220 728-2 E plug gland CS72820-J220 728-3 E plug flange CS72830-J220 728-4 O-ring JIS B2401 G45 PAH81-045 PC12-045 728-5 Hexagon head screw M16×45 NB111016-045 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-13...
  • Page 174 For O-rings material other than HNBR or FKM, the part code No. are differ depending on the material. For customers using O-rings other than the standard material, contact before purchasing the O-ring. Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-14...
  • Page 175 Potentiometer shift to the exclusive Hexagon socket head cap screw instruction manual as No. 794 Vi position sensor box Vi position sensor assembly. I plug 674-049 2013.10.31 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-15...
  • Page 176 2205B0JE-DA-J-N_2014.05. 7 Related Documents  Development View and Configuration Table (280J) Figure7-5 Development View of 280J (1/2) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-16...
  • Page 177 2205B0JE-DA-J-N_2014.05. 7 Related Documents Figure7-6Development View of 280J (2/2) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-17...
  • Page 178 Sleeve, balance piston 250*UD CS03300-J280 3 → 2 Spring pin 6 dia.×12 NE3206-012 35-1 O-ring JIS B 2401 G150 PAH81-150 35-2 O-ring JIS B 2401 G190 PAH81-190 PC12-190 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-18...
  • Page 179 PC11-010A 82-2 O-ring JIS B2401 P16 PAH80-016 PC11-016 Retainer, O-ring CS08300-J170 Spacer, unloader cylinder cover CS08400-J170 Shaft key CS09100-J280 Mechanical seal assembly CS10002-320EBS (including 100-1 to 100-5) Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-19...
  • Page 180 Bush, P14 type O-ring CS53700-J170 16 dia.×70 with Parallel pin NE2316-070A female thread Plug R1/2 NF06-015 607-A Plug R1/8 NF06-004 607-B Plug R1/4 NF06-008 607-C Plug R1/4 NF06-008 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-20...
  • Page 181 For O-rings material other than HNBR or FKM, the part code No. are differ depending on the material. For customers using O-rings other than the standard material, contact before purchasing the O-ring. Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-21...
  • Page 182 These shift to the exclusive Potentiometer instruction manual as No. 794 Hexagon socket head cap screw Vi position sensor assembly. Vi position sensor box I plug 684-053 2013.10.31 Screw Compressor J-series 7.1 Development View and Configuration Table of the Parts 7-22...

  • Page 183: List Of Tightening Torques For Bolts And Nuts

    Vi position sensor rod housing gland 10(100) M6×25 Hexagon socket head cap screw Vi position sensor support 10(100) M6×25 Hexagon socket head cap screw Vi position sensor box 6(60) M5×15 Screw Compressor J-series 7.2 List of Tightening Torques for Bolts and Nuts 7-23...
  • Page 184 Hexagon socket head cap screw Vi position sensor support 10(100) M6×25 Hexagon socket head cap screw Vi position sensor box 6(60) M5×15 728-5 E plug flange 110(1100) Hexagon head screw M16×45 Screw Compressor J-series 7.2 List of Tightening Torques for Bolts and Nuts 7-24...
  • Page 185 ANSI#300 5” 140(1400) Hexagon head screw M20×65 R1 1/4 220(2200) ANSI#300 8” 240(2400) Hexagon head screw M22×80 R1 1/2 240(2400) ANSI#300 12” 300(3000) Hexagon head screw M30×100 Screw Compressor J-series 7.2 List of Tightening Torques for Bolts and Nuts 7-25...
  • Page 186 Therefore, angle ranges are specified also for the second time tightening. Figure 7-9 Position where mark is put Screw Compressor J-series 7.2 List of Tightening Torques for Bolts and Nuts 7-26...

  • Page 187: List Of Tools For Disassembly

    Socket for locknut (FU07) FUT#07 (for FU07) Socket for locknut (FU09) FUT#09 (for FU09) Socket wrench 13 mm Socket wrench 18 mm Note: There standard tools mean tools generally sold on the market. Screw Compressor J-series 7.3 List of Tools for Disassembly 7-27...

  • Page 188: Design Modification Notification (Follow-Up)

     No.C0956-02 The change of Balance piston for J series （Aug. 5, 2013） ）  No.C0957-00 The change of the tightening fittings of thrust bearings for J series （Jun. 30, 2013） Screw Compressor J-series 7.4 Design Modification Notification (follow-up) 7-28...
  • Page 189 2012 Mar.2 Mayekawa Mfg. Co., Ltd. Compressor Manufacturing Dept. Design modification notification No.C0953-00 Notification : The change of the standard materials of O-rings for J series The standard materials of O-rings have been changed from NBR to HNBR from the serial number below.
  • Page 190 2013 Aug. 5 Mayekawa Mfg. Co., Ltd. Compressor manufacturing Dept. Design modification notification No.0956-02 Notification : The change of Balance piston for J series The balance pistons for J series have been changed as below; 1. Change the sizes of balance piston(P/N 30) and balance piston sleeve(P/N 33). (associated with the change of specification of the J series unit to the forced oil supply system) 170J：φ82...
  • Page 191 Applicable model： J series (170J, 220J, 280J) Design modification No.： 664-056、664-057、674-033、674-034、684-037、684-038 Applicable serial No.：After the number indicated below modified parts are mounted. 170JS： 1751017 170JM： 1731037 170JL： 1711105 220JS： 2250021 220JM： 2230034 220JL： 2210040 280JS： 2850030 280JM： 2830022 280JL： 2810010 However, the serial numbers indicated below have mounted modified balance pistons in advance.
  • Page 192 2013 Jan. 30 Mayekawa Mfg. Co., Ltd. Compressor Manufacturing Dept. Design modification notification No.C0957-00 Notification : The change of the tightening fittings of thrust bearings for J series The thrust bearing tightening fittings for J series have been changed as below; ...

  • Page 193: Appendix 1

    Tips for Design, Manufacturing, and Installation of the Compressor Package The J-series screw compressor is delivered as a package in standard. The appendix describes points to be considered when designing or manufacturing the package or installing the compressor package. Appendix 1.1...
  • Page 194  The oil separator must have sufficient rigid structure so that no misalignment trouble occurs to the compressor and motor during operation due to the oil separator heat stress or deformation due to pressure. Screw Compressor J-series Appendix 1.1 Precautions for Design of the Compressor Package Appendix1-2...
  • Page 195 1) Lubrication oil line For the lubrication system, an inlet port of ANSI #300 1” (common in J-series) is provided on the bearing head and another inlet port of Rc1/2 (170J), Rc3/4 (220J), or ANSI #300 3/4”...
  • Page 196 170J, 1 1/2B for 220J, and 2 1/2B for 280J. 5) While installing the pipes, take sufficient care not to allow any contamination such as spatters to remain in the piping and enter the compressor. Screw Compressor J-series Appendix 1.1 Precautions for Design of the Compressor Package Appendix1-4...
  • Page 197 Equal to or more than 100 meshes (equal to or more than 200 meshes when using a dry process evaporator ) are recommended for the suction gas strainer. Screw Compressor J-series Appendix 1.1 Precautions for Design of the Compressor Package...

  • Page 198: Appendix 1.2 Tips For Compressor Package Manufacturing

    Remove the crane and finally tighten the two bolts on the counter-load side motor feet. If there is any gap between the motor feet and the motor base, adjust the height by inserting shims before tightening the bolts. Screw Compressor J-series Appendix 1.2 Tips for Compressor Package Manufacturing Appendix1-6...
  • Page 199  If the package is mounted on a floor or foundation without sufficient reinforcement, abnormal vibrations may occur from the compressor and/or the package. Screw Compressor J-series Appendix 1.3 Tips for Compressor Package Installation Appendix1-7...

  • Page 200: Contact Information

    Contact Information_2014.05. Contact Information How to Order Genuine Parts Confirm the target parts by referring to 5.2.4 "Replacement Parts of the Compressor in Overhauling" and/or 7.1 "Development View and Configuration Table of the Parts" in this manual. Please inform the Model Name and Serial Number, Part Name, Cord No., and required quantity to our local sales offices or service centers.
  • Page 201 Contact Information_2014.05.  Global Network (as of May 10, 2014) Telephone and Description Location facsimile No. NORTH AMERICA 12180 RIVERSIDE WAY, MAYEKAWA CANADA INC. TEL: (1) 604-270-1544 RICHMOND, B.C., V6W 1K5, CANADA (VANCOUVER OFFICE) FAX: (1) 604-270-9870 MAYEKAWA CANADA INC. 1745 BONHILL ROAD, TEL: (1) 905-564-0664 (TORONTO OFFICE)
  • Page 202 Contact Information_2014.05. Telephone and Description Location facsimile No. 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 MAYEKAWA. S.L. CALLE MONTEVIDEO 5, NAVE 13 POL.
  • Page 203 Contact Information_2014.05. Telephone and Description Location facsimile No. 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 MAYEKAWA INDIA PVT.LTD. RS No.225/226/238,NAYAPAKKAM TEL: (91) 92-8258-2508 (CHENNAI FACTORY) VILLAGE, FAX: - PUDDUVALLUR PANCHAYAT, VALARPURAM POST THIRUVALLUR DISTRICT,...
  • Page 204 Contact Information_2014.05. Telephone and Description Location facsimile No. 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, REP.OF CHINA MAYEKAWA (TAIWAN) CO., LTD. 8F, NO, 421, SUNG-SHAN ROAD, TEL: (886) 2-2727-9711 (TAIPEI BRANCH) TAIPEI,...
  • Page 205 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...
  • Page 206 Contact Information_2014.05. Telephone and Description Location facsimile No. MAYEKAWA COLOMBIA S.A.S TRANSVERSAL 93 NO.53-48 INTERIOR TEL: (57) 1-430-9980 37, PAQUE INDUSTRIAL EL DORADO, FAX: (57) 1-437-0988 BOGOTA, COLOMBIA MAYEKAWA COLOMBIA S.A.S. DIRECCION CR 43B No. 8 SUR 10 TEL: (57) 4-313-4343 (MEDELLIN OFFICE) OFICINA 404 EDF.
  • Page 207 313-EDIFICIO BARRA TRADE II, FAX: (55) 21-2430-8882 LTDA. BARRA DA TIJUCA, RIO DE (RIO DE JANEIRO BRANCH) 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...
  • Page 208 Contact Information_2014.05. Telephone and Description Location facsimile No. 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 BENAVENTE TEL: (52) 662-216-2047 S.A.
  • Page 209 2205B0JE-DA-J-N_2014.05 MAYEKAWA MFG. CO., LTD. 3-14-15 Botan, Koto-ku, Tokyo 135-8482, Japan 03-3642-8181 http://www.mayekawa.com...

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