MAYEKAWA 160 GR User manual

160GR Natural Gas Booster Instruction Manual
Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.1
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.

160GR Natural Gas Booster Instruction Manual
Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.2
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. Parts Expanded View ........................................................................................................................13
4-1 160GR Standard .................................................................................................................13
4-2 160GR with Integral Pump ..................................................................................................14
4-3 Parts Structure Diagram......................................................................................................15
5. Parts List............................................................................................................................................17
6. Outer Dimension................................................................................................................................19
7. Disassembly ......................................................................................................................................20
Removing the Compressor..............................................................................................................20
7.1 Interior Gas Recovery ....................................................................................................20
7.2 Removing the connecting parts......................................................................................20
7.3 Suspending and Transferring the Compressor...............................................................20
7.4.1 Mechanical Shaft Seal....................................................................................................22
7.4.2 Unloader Cover ..............................................................................................................24
7.4.3 Unloader Thrust Bearing ................................................................................................25
7.4.4 Balance Piston Cover.....................................................................................................27
7.4.5 Unloader Spring Retainer...............................................................................................27
7.4.6 Balance Piston, Balance Piston Sleeve..........................................................................28
7.4.7 Speed up Gear Casing Cover ........................................................................................29
7.4.8 Speed up gear casing ....................................................................................................30
7.4.9 Disassembly of speed up gear parts on the driving side ................................................31
7.4.10 Spindle Roller Bearing....................................................................................................33
7.4.11 Disassembly of the speed up gear on the driven side ....................................................33
7.4.12 Thrust Bearing................................................................................................................34
7.4.12 Suction Cover.................................................................................................................36
7.4.13 Rotor, Rotor Casing, Variable Vi Slide Valve ..................................................................37
7.4.14 Bearing Head and Main Bearing ....................................................................................39
8. Re-assembly......................................................................................................................................40
8.1 Bearing Head and Main Bearing .........................................................................................40
8.2 Rotor Casing, Unloader Slide Valve, Variable Vi Slide Valve, Bearing Head.......................40
8.3 Rotor Casing, Rotor ............................................................................................................41
8.4 Suction Cover......................................................................................................................41
8.5 Thrust Bearings...................................................................................................................41
8.5 Installation of the driven side speed up gear .......................................................................42
8.6 Spindle Roller Bearings.......................................................................................................43
8.7 Building the Driving Side speed up Gear ............................................................................43
8.8 Installation of speed up Gear Casing ..................................................................................43

160GR Natural Gas Booster Instruction Manual
Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.3
8.9 Installation of speed up Spindle ..........................................................................................43
8.10 Speed up Gear Casing Cover .............................................................................................44
8.11 Balance Piston Cover..........................................................................................................44
8.12 Unloader Cover ...................................................................................................................44
8.13 Mechanical Shaft Seal ........................................................................................................45
9. Procedures to Adjust End Clearance.................................................................................................45

160GR Natural Gas Booster Instruction Manual
Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.4
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.
2. Capacity Control Procedures
On the standard 160GR specification, the capacity control is done manually by a handle.
Turning the handle in clockwise is for loading, and turning it in counter-clockwise is for
unloading.
The slide valve for the capacity control is fully loading when it is in contact with the surface of
the variable Vi slide valve. The position of Unload is determined by the stopper equipped on
the surface of the under slide rod.
Therefore, the position of full-load of the slide valve depends on the selected Vi; therefore,
the strokes of the slide valve vary as well. The strokes of the slide valve for each Vi setting
are described below.
[CAUTIONS]
・ Although there are stopper structures on the full-load position and the minimum load
position, do not turn the handle with unnecessary force when attempting capacity control.
・ When loading, turning the handle with a relatively little force can easily move the slide valve.
When the slide valve is in contact with t
・ the variable Vi slide valve for full-load, the handle becomes heavy. Then, forcing the handle
to turn may lead to the internal damage.
・
Garph2.1 Strokes for Slide Valve for Each Vi
Vi Setting The number of rotation
Unload ⇒Full-Load
2.3 29‐1/2
2.63 26
3.65 21
5.0 17-1/3
3. Variable Vi Structure
To change the Vi on the outlet port, the size of the radial outlet port needs to be changed by
moving the variable Vi supplementary slide valve on the full-load.
The variable Vi supplementary slide valve is fixed to the case by fix pins through pin holes on
the Variable Vi slide valve. The pin holes are located to accommodate the 4 different Vi
settings so that the Vi can be changed step-by-step.
On 160GR, the fix pins of the Variable Vi slide valve are attached from the outside of the case.
When the pins are removed, the interior gas will be discharged to the air. When changing Vi

160GR Natural Gas Booster Instruction Manual
Mayekawa all rights reserved. Subject to change without notice. Lat revised in October 2007 p.5
settings, make sure that the compressor is at a stop and that the gas inside the compressor is
discharged in the air.
Vi should not be changed while the compressor is running.
To Change Vi Settings
[CAUTIONS]
・ On this compressor, Vi should be changed after the compressor is opened to the
atmosphere.
・ Vi settings should be changed while the compressor is stopped. Also, make sure the drive is
not moving or will not move.
・ The interior air pressure of the compressor needs to be equal to the air pressure before
proceeding with changing Vi settings.
Figure1: Variable Vi Structure Cut-up View
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.
There are 4 ports: H (Vi=5.0), M (Vi=3.65), L (Vi=2.63), K (Vi=2.3).
3.1.1 When the position of the current port is known
When the position of the current port is known, change the Vi setting by referring to
[Graph1] and choosing the appropriate number of rotations and the direction of the rotation.
a) Make sure the slide valve is on full-load on the current Vi condition (Turn the capacity
control handle in clockwise until it stops).