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M Series
MAYEKAWA M Series User Manual
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2202G1JE-DA-M-N_20
10.01.
Third Edition 2010/1/5
3–14–15 Botan Koto-ku
, T
okyo 135-8482, Japan
Reciprocating Compressor
M Series Operation Manual
4M/6M/8M/62M/62M-FM
CAUTION
Before operating, inspecting, or serv
icing the compressor
, read this manual thoroughly
to fully
underst
and the content
s.
Keep this operation manual in a safe,
designated place for future reference
whenever the
manual is needed.
2
Table of Contents
Default Chapter
13
Table of Contents
13
1 Safety
19
Observation/Prevention
19
Observance (Do's)
19
Do's on Operation
19
Do's on Maintenance
19
Do's on Lockout/Tagout after Shutting off the Power
19
Do's about Personal Protective Devices
20
Do's about Handling of Hazardous and Toxic Substances
20
Do's about Handling Emergency Situation
20
Do's about Waste Oil, Fluid, and Materials
20
Other Do's
20
Don'ts
20
Warnings
21
Types and Meanings of Warnings
21
Safety Labels
22
Remaining Hazard
24
Safety Devices
26
Emergency Stop Button
26
Breakers of Motor Main Power and Control Power (with Lockout/Tagout Devices)
26
Safety Belt/Coupling Guard
27
Safety Valve
28
Automatic Control and Protection Equipment M Compressor
29
Compressor Cooling Fluid Temperature Failure Alarm
32
Oil Heater and Thermometer Switch
32
Example of Material Safety Data Sheet (MSDS)
33
2 Configuration and Specification of Compressor
35
Configuration of Compressor
35
Overall View of Compressor
35
Cross-Sectional View of Assembly
37
Oil Supply Mechanism
39
Unloader Mechanism
40
Specification of Compressor
41
Specification
41
Service Limits and Range
42
External Dimensions
43
Selection of V-Belt
46
3 Installation
47
Safety Precautions for Installation
47
Installation Works
48
Unpacking
48
Storage
48
Transfer
48
Preparation for Installation
50
Installation
52
Position of the Oil Returning Point in the Oil Separator / Procedure of Oil Returning
52
Protection Switch
52
Centering of the Compressor/Driving Machine and Attachment of the V-Belt
53
Centering of the Compressor/Driving Machine and Attachment of the Direct Coupling
56
Piping
58
Charging of Refrigerant Oil
60
Check after Installation
60
Documents Related to Installation *1
61
4 Operation of the Compressor and the System Refrigerant Oil
63
Precautions for Selecting the Refrigerant Oil
63
Initial Charging Method
64
Replenishment of the Refrigerant Oil
64
Set Oil Pressure
64
Oil Quantity
65
Initial Operation
66
Initial Operation Method
66
Operation Order of the Unloader
67
Operation Notices
69
Start/Stop Limitation
69
Action for Stopping the Compressor for Long Period of Time
69
Operation after the Compressor Has Been Stopped for Long Period of Time
69
5 Maintenance
71
Safety Precautions for Maintenance
71
Periodic Inspection
72
Daily Inspection
72
Monthly Inspection
73
Biannual Inspection
73
Maintenance (Overhaul)
74
Maintenance Period and Operation Conditions
74
First Maintenance Period
75
Second Maintenance Period
75
Refrigerant Oil Control Standard
76
Disassembly/Assembly
77
Exterior Equipment
77
Attentions for Removing the Oil Cooler Piping/Water Cooled Type Oil Cooler
79
Attentions for Removing the Mechlock
79
Attentions for Removing the Flywheel
79
Attentions for Removing the Motor End Bearing Assembly
80
Attentions for Removing the Motor Rotor
80
Attentions for Removing the Motor Cage
80
Attentions for Attaching the Flywheel
81
Attentions for Attaching the Mechlock
81
Attentions for Attaching the Motor Rotor
81
Attentions for Attaching the Oil Cooler Piping/Water Cooled Type Oil Cooler
82
Suction/Discharge Area
83
Attentions for Removing the Suction/Discharge Shut-Off Valve
84
Attentions for Attaching the Suction/Discharge Shut-Off Valve
84
Attentions for Removing the Discharge Manifolds
84
Attentions for Attaching the Discharge Manifolds
85
Head Cover/Hand Hole Cover
87
Attentions for Removing the Head Jacket Cover
88
Attentions for Removing the Head Cover
88
Attentions for Removing the Hand Hole Cover
89
Attentions for Attaching the Hand Hole Cover
90
Attentions for Attaching the Head Cover
90
Attentions for Attaching the Head Jacket Cover
91
Valve Plate/Piston Assembly/Cylinder Sleeve Assembly
92
Attachment of the Spacer （4M/6M/8M/62M
93
Attachment of Knob Bolt
93
Attentions for Removing the Valve Plate
94
Attentions for Removing the Piston Assembly
94
Attentions for Attaching the Cylinder Sleeve Assembly
94
Attentions for Attaching the Piston Assembly
95
Attentions for Attaching the Suction Plate Valve/Suction Valve Spring
97
Attentions for Attaching the Valve Plate
97
Removal of the Spacer (4M/6M/8M/62M)
97
Removal of Knob Bolt
98
Unloader
99
Attentions for Attaching the Unloader Push Rod Washer
100
Attentions for Attaching the Unloader Push Rod Assembly
100
Attentions for Attaching the Solenoid Valve Unloader Cover Integrated
101
Seal Cover/Mechanical Seal/Oil Seal
102
Attentions for Removing the Seal Cover Assembly
103
Attentions for Removing the Oil Seal Retainers
103
Attentions for Removing the Oil Seal
103
Attentions for Attaching the Oil Seal
103
Attentions for Attaching the Mechanical Seal Collar
104
Attentions for Attaching the Seal Cover Assembly
104
Main Bearing Head Assembly/Oil Pump Assembly/Oil Filter Assembly
105
Attentions for Removing the Main Bearing Head Assembly
106
Attentions for Attaching the Main Bearing Head Gasket
106
Attentions for Attaching the Main Bearing Head Assembly
106
Crankshaft
107
Attentions for Removing the Crankshaft
108
Attentions for Attaching the Thrust Roller Bearing (Shaft Side)
109
Attentions for Attaching the Crankshaft
110
Bearing Head
111
Attentions for Removing the Bearing Head (4M/6M/8M/62M)
112
Attentions for Replacing the Main Bushing (Bearing Head Side)
112
Attentions for Attaching the Thrust Roller Bearing (Bearing Head Side)
112
Attentions for Attaching the Bearing Head (4M/6M/8M/62M)
113
5.5.10 Discharge Valve Cage Assembly
114
5.5.10.1 Attentions for Attaching the Discharge Valve Spring
114
5.5.11 Piston Assembly
115
5.5.11.1 Attentions for Attaching the Connecting Rod Bushing/Needle Bearing
115
5.5.11.2 Attentions for Attaching the Piston Rings
116
5.5.12 Cylinder Sleeve Assembly
117
5.5.12.1 Attentions for Attaching the Cam Ring
117
5.5.13 Seal Cover Assembly
118
5.5.13.1 Attentions for Removing the Shower Flushing Sleeve
118
5.5.13.2 Attentions for Attaching the Mechanical Seal Mating Ring
119
5.5.13.3 Attentions for Attaching the Shower Flushing Sleeve
119
5.5.14 Main Bearing Head Assembly
120
Attentions for Replacing the Main Bushing (Pump Side)
120
Attentions for Attaching the Thrust Washer (Pump Side)
120
5.5.15 Oil Filter Assembly
121
6 Troubleshooting
123
6.1 Troubleshooting Table
130
7 Related Document
131
Development View and Configuration Table of the Parts
131
List of Tightening Torques for Bolts and Nuts
142
List of Tools for Disassembly
143
Vibration and Sound Data
145
Vibration
145
Oil Cooler Heat Rejection (Ohr)/Head Jacket Heat Rejection (JHR) (N4M, N6M, N8M)
147
Starting Torque
157
Parts Inspection and Replacement Standards
161
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MAYEKAWA M Series Specifications
General
Brand
MAYEKAWA
Model
M Series
Category
Air Compressor
Language
English
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