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MAYEKAWA 160 GR Instruction Manual

Natural gas booster
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160GR Natural Gas Booster Instruction Manual
160 GR
Natural Gas Booster
Disassembly and Re-Assembly Instruction Manual
This manual is to provide instructions how to disassemble and re-assemble the 160GR machine.
Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007
p.1

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  • Page 1 160GR Natural Gas Booster Instruction Manual 160 GR Natural Gas Booster Disassembly and Re-Assembly Instruction Manual This manual is to provide instructions how to disassemble and re-assemble the 160GR machine. Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007...

  • Page 2: Table Of Contents

    160GR Natural Gas Booster Instruction Manual Contents 1. Introduction ............................4 2. Capacity Control Procedures ....................... 4 3. Variable Vi Structure ..........................4 3.1.1 When the position of the current port is known ..............5 3.1.2 When the Current Port is not known ..................10 4.
  • Page 3 160GR Natural Gas Booster Instruction Manual Installation of speed up Spindle ..................43 Speed up Gear Casing Cover ..................... 44 8.10 Balance Piston Cover ......................44 8.11 Unloader Cover ........................44 8.12 Mechanical Shaft Seal ......................45 8.13 9. Procedures to Adjust End Clearance ....................45 Mayekawa all rights reserved.

  • Page 4: Introduction

    160GR Natural Gas Booster Instruction Manual 1. Introduction The 160GR is a compressor engineered for the natural gas booster. Provided that it will be operated by an engine, the compressor itself has an internal speed up gear that allows different ratios according to the required air volume. Also, the Vi on the outlet port can be changed in 4 steps with the manual capacity control as the standard.

  • Page 5: When The Position Of The Current Port Is Known

    The compressor is set at the M port when shipped. Choose the most appropriate Vi setting for the expected operating conditions. When the appropriate port is to be other than the M port, the Vi setting needs to be changed before operations. When the pressure conditions dramatically change during an operation, the Vi needs to be changed to an appropriate setting.
  • Page 6 When changing the ports from the “K / L “ ports to the “M / H” ports, or vice versa, the plug needs to be removed from the case and replaced with the Variable Vi valve fixing bolts.
  • Page 7 Clockwise Counter-clockwise Counter-clockwise Position of fixing pin Suction Cover Rotor Casing Rotor Casing From the M Port M Port ⇒ K Port M Port ⇒ L Port M Port ⇒ H Port Moving Distance 50.5 29.5 21.5 (mm) Number of Rotations...
  • Page 8 160GR Natural Gas Booster Instruction Manual ・Vi Changing Procedures < From K-Port to L-Port > ① the Position of K-Port ② Remove the Variable Vi guide pin. ③ Turn the capacity control handle 3 1/2 times counter-clockwise, move Variable Vi slide valve to the L-port position. ④...
  • Page 9 160GR Natural Gas Booster Instruction Manual ・Vi Changing Procedures < From L-Port to M-Port > ① The position L-Port ② Remove the Variable Vi guide pin from the bottom of the suction cover. ③ Turn the capacity control handle 4 7/8 times in counter-clockwise and remove the set bolt from the bottom of the rotor casing.

  • Page 10: When The Current Port Is Not Known

    On the “M” and “H” ports, contrarily, the Variable Vi support guide pin should be attached to the bottom of the rotor casing, and the plug should be attached to the bottom of the suction cover.
  • Page 11 160GR Natural Gas Booster Instruction Manual Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.11...
  • Page 12 160GR Natural Gas Booster Instruction Manual Each Port and the Position of the Variable Vi guide pin K-Port L-Port M-Port H-Port Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.12...

  • Page 13: Parts Expanded View

    160GR Natural Gas Booster Instruction Manual 4. Parts Expanded View 4-1 160GR Standard Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.13...

  • Page 14: 160Gr With Integral Pump

    160GR Natural Gas Booster Instruction Manual 4-2 160GR with Integral Pump Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.14...

  • Page 15: Parts Structure Diagram

    0GR Natural G Gas Booster I nstruction Ma anual Parts Stru cture Diagr Mayek kawa all rights reserved. Sub bject to change e without notice e. Lat revised i i n October 200 0 7 p.15 5...
  • Page 16 0GR Natural G Gas Booster I nstruction Ma anual Mayek kawa all rights reserved. Sub bject to change e without notice e. Lat revised i i n October 200 0 7 p.16 6...

  • Page 17: Parts List

    HEXAGON SOCKET HEAD CAP SCREW SHAFT KEY MALE ROTOR MECHANICAL SEAL ASSY. FEMALE ROTOR SPEED UP GEAR CASTING 27-1 MAIN BEARING M GASKET, SPEED UP GEAR CASTING 27-2 MAIN BEARING F SPEED UP GEAR CASTING COVER 28-1 SIDE BEARING M...
  • Page 18 41-2 BEARING SPACER F 196-2 OIL CONTROL THROTTLE COMP FS 42-1 196-3 OIL CONTROL THROTTLE COMP MD SPACER, THRUST BEARING M ALIGNMENT 42-2 196-4 OIL CONTROL THROTTLE COMP FD SPACER, THRUST BEARING F ALIGNMENT 196-5 237-C TORSIONAL SLIP WASHER C...

  • Page 19: Outer Dimension

    160GR Natural Gas Booster Instruction Manual 6. Outer Dimension Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.19...

  • Page 20: Disassembly

    160GR Natural Gas Booster Instruction Manual 7. Disassembly Preparation Although screw compressors are reliable machines, they need to be disassembled to have their parts inspected after operating for a certain amount of time. In this chapter, the procedures and instructions for disassembly and parts inspection will be provided. Disassembling a compressor at the installed site is limited to: the shaft seal parts, the unloader parts, and the balance piston parts.
  • Page 21 160GR Natural Gas Booster Instruction Manual the suction cover and the bearing head. These bolts cannot be removed after the compressor is placed on the paten. Figure 1 Bolt under Suction Cover Figure 2 Bolt under Rotor Casing There is a large amount of residual oil inside the compressor. Extract the oil in advance. The oil inside can be extracted by removing the plug on the bottom of the suction cover and the rotor casing, or plug (454-2) on the suction cover.

  • Page 22: Mechanical Shaft Seal

    160GR Natural Gas Booster Instruction Manual The Order of Disassembly Follow the order shown below to disassemble and inspect the compressor. The order of the compressor disassembly: 1) Mechanical shaft sea 2) Unloader cover and unloader thrust bearing 3) Balance piston cover 4) Balance piston 5) Speed up gear casing cover 6) Speed up gear casing...
  • Page 23 160GR Natural Gas Booster Instruction Manual b） Remove the seal cover. The mating ring is attached to the seal cover. Keep the seal cover parallel to the shaft, in order to make sure the ring does not touch the shaft. Then, remove the “O”...

  • Page 24: Unloader Cover

    160GR Natural Gas Booster Instruction Manual 7.4.1.2 Inspection a） Inspect the sliding surfaces of the mating ring and the seal ring. If the surfaces are evenly worn, and the amount of the wear is not significant, they can be reused. However, if the wear is not even, or if there is a peel on the surfaces, they can cause the seal leak.

  • Page 25: Unloader Thrust Bearing

    160GR Natural Gas Booster Instruction Manual Figure 10 Removing Unloader cover bolt Figure 11 Removing Variable Vi Support pin (with Suction Cover on) d） The “O” ring (82) to seal the unloader push rod (67) is installed on the unloader cover. When pulling the unloader cover out, keep the hole of the cover parallel to the unloader slide rod.
  • Page 26 160GR Natural Gas Booster Instruction Manual 7.4.3.1 Disassembly a） Pull out the hexagon socket head screw (81) on the unloader thrust bearing cramp (80). b） Lift the tabs of the thrust washer for the lock nut that are bent to hold the inner race Loosen and remove the lock nut (69) by using the lock nut wrench.

  • Page 27: Balance Piston Cover

    160GR Natural Gas Booster Instruction Manual 7.4.4 Balance Piston Cover 7.4.4.1 Disassembly a） Remove the top 2 hexagon socket head screws (24), and insert safety bolts. Remove all the other hexagon socket head screws (24). Figure 16 Removing Bolts on Balance Piston Cover Figure 17 Removing Balance Piston Cover b）...

  • Page 28: Balance Piston, Balance Piston Sleeve

    In order to reduce the load on the M rotor, a piston is located on the suction end of the M rotor which puts the oil pressure to the discharge side in order to balance out the thrust load, which results in a longer life span of the bearing.

  • Page 29: Speed Up Gear Casing Cover

    160GR Natural Gas Booster Instruction Manual Figure 20 Stop Ring on Balance Piston Figure 21 Removing Balance Piston Sleeve 7.4.6.2 Inspection Although there might be some wear on the balance piston, there is no problem unless the wear is significant. Replace the “O”...

  • Page 30: Speed Up Gear Casing

    160GR Natural Gas Booster Instruction Manual d） Also, as inserting the eye bolts so that the speed up gear casing cover (171) and the speed up gear casing (169) are in a parallel, the speed up gear casing cover will be detached from the set alignment pins (19).

  • Page 31: Disassembly Of Speed Up Gear Parts On The Driving Side

    160GR Natural Gas Booster Instruction Manual Figure 25 Removing Support Metal Figure 26 Attaching Safety Bolts c） Insert the removed bolts into the screwed hole of the speed up gear casing (169) evenly. The speed up gear casing will be detached from the set alignment pins. d）...
  • Page 32 160GR Natural Gas Booster Instruction Manual so that the speed up gear comes atop the casing. Lift the tabs of the lock washer (270) and loosen the lock nut (269) with the proper lock nut wrench. b） Flip the speed up gear casing and fix it on the platen again. Place blocks (etc.) underneath the platen to avoid collisions between the part and the ground.

  • Page 33: Spindle Roller Bearing

    7.4.11 Disassembly of the speed up gear on the driven side The speed up gear on the driven side is located at the M rotor side. The edge of the shaft is the journal of the sliding bearing. Proceed with the process after curing to avoid damaging the part.

  • Page 34: Thrust Bearing

    160GR Natural Gas Booster Instruction Manual Figure 33 Removing Lock nut Figure 34 Removing Speed Up Driven Gear 7.4.11.2 Inspection a） Check the gear tooth surface of the drive side speed up driven gear (179) for scars and wears. 7.4.12 Thrust Bearing The thrust bearing is used to determine the direction / position of the rotor shaft and to maintain a certain space between the rotor’s discharge end face and the bearing head.
  • Page 35 (41-1, 41-2). Remove these parts. Figure 39 Removing Thrust Bearing e) Make sure that the parts from the F rotor and the M rotor are not mixed with each other. As removing the parts, separate and organize the parts.

  • Page 36: Suction Cover

    160GR Natural Gas Booster Instruction Manual 7.4.11.2 Inspection a） Wash the thrust bearing thoroughly with washing oil. Check the ball surface for tarnish, scars, peeling, flaking, and distortion. Then check the retainer for wears and distortions. Finally check the inner-ring and the running trace of the outer-ring for scars, peeling, and flaking.

  • Page 37: Rotor, Rotor Casing, Variable Vi Slide Valve

    160GR Natural Gas Booster Instruction Manual Figure 42 Removing Suction Cover Figure 43 Removing Stop Ring d） Remove the stop rings (29-1, 29-2) with the stop ring pliers, and then remove the oil control throttles (196-1, 196-2). Next, remove the side bearings (28-1, 28-2). As the bearings are 中間...
  • Page 38 160GR Natural Gas Booster Instruction Manual b) Use V Blocks (etc.) to support the shaft of the removed rotor. Do not place the rotor directly on the floor and damage the outer rim. c) Follow the same procedures to remove the other rotor. When pulling the rotor out, balance it well so that the rotor shaft will not be damaged.
  • Page 39 160GR Natural Gas Booster Instruction Manual b) Check the rotor tooth for the hit and the outer rim for wears. If there is a remarkable wear, it could be that a foreign substance has entered. The suction strainer and the oil filter need to be examined.

  • Page 40: Re-Assembly

    160GR Natural Gas Booster Instruction Manual 8. Re-assembly When the inspections and repair of each part has been completed, proceed to the process of re-assembling the compressor. Reassembling process is essentially carried out in reverse order of disassembly. Use the same tools used for disassembly and pay attentions for safety. The tools to be used should be thoroughly cleaned.

  • Page 41: Rotor Casing, Rotor

    F rotor side. e） Place the tooth with the ① stamp of the M rotor between the ①, ② teeth of the F rotor, and insert the F rotor half-way. Then remove the nylon sling. Push the rotor all the way Suction Cover a）...

  • Page 42: Installation Of The Driven Side Speed Up Gear

    Likewise, thrust adjustment should be done on the F rotor. l） Place the dial indicator on the journal area of the M rotor, and let the shaft rotate to check the vibration of the shaft. The allowable vibration is within 0.33mm.

  • Page 43: Spindle Roller Bearings

    160GR Natural Gas Booster Instruction Manual b） Install the driven side speed up gear, the driven side gear spacer, the lock washer, and the packing in this order. Then use a wrench to tighten the lock nut. c） Then, make sure the vibration on the journal area of the shaft edge with a dial indicator by turning the rotor by hand.

  • Page 44: Speed Up Gear Casing Cover

    160GR Natural Gas Booster Instruction Manual Spindle Thrust Bearing Lock nut : Torque Lock nut (AN13)Tightening Torque General (N・m) Max.(N・m) 160GLR Thrust Bearing Cramp : Torque Speed up Gear Thrust Cramp Torque Set Value(N・m) 160GLR 49.0 8.10 Speed up Gear Casing Cover a）...

  • Page 45: Mechanical Shaft Seal

    160GR Natural Gas Booster Instruction Manual fix the cramp up to the specified torque, by gradually and evenly tighten them in diagonal. If the bolts are tightened to the specified torque one by one, the cramp will not be fixed evenly.
  • Page 46 160GR Natural Gas Booster Instruction Manual specified value. Use iron for shim. II. When the end clearance is smaller than the specified value When the rotor does not move with only the tightened lock nuts, the cause is either the lack in the thickness of the thrust adjusting washer or the excess thickness of the spacer.

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