MAYEKAWA 4M User manual

2200B2JE-DA-M-N_2009.02.
First edition: 2009/02/02
3±14±15 Botan Koto-ku, Tokyo 135-8482, Japan
Reciprocating Compressor
M Series Operation Manual
4M/6M/8M
CAUTION
Before operating, inspecting, or servicing the compressor, read this manual thoroughly to
fully understand the contents.
Keep this operation manual in a safe, designated place for future reference whenever the
manual is needed.

Reciprocating Compressor M Series
i
Preface
Thank you for having purchased our M series reciprocating compressor (hereinafter indicated as "this
machine").
This operation manual (hereinafter indicated as "this manual") describes safety information, and operational
and maintenance procedures in detail for safe and effective use of this machine.
Before installing or using this machine, make sure to read this manual.
Keep this manual in a safe place near the machine for quick reference.
Caution: Descriptions in this manual and specification of this machine is subject to change without notice.

Reciprocating Compressor M Series
ii
Warranty and Disclaimer
Warranty Clauses
If malfunctions occur related to design or manufacture of the product under a normal limitation of use
condition following documents such as operation manual of this product, and if it is within the warranty
period, we will repair or replace the product.
The warranty period is "12 months from factory shipment of this product". If there is an article of agreement,
the description written on the agreement takes precedence in principle.
Disclaimer Clauses (Exclusion of Warranty Clauses)
Please note that we assume no product liability for the following disclaimer clauses for this product.
zMalfunction or damage which has been caused by accidental forces such as natural disasters
(windstorm, intense rainfall, flood, tidal wave, earthquake, land sinkage, thunderbolt, fire disaster, etc.)
zMalfunction, damage, or defect of this product which has been subjected to abnormal use, improper use
(such as keeping this product outside the building or in locations subject to high temperatures and high
humidity, excessive liquid back operation, and repeating start-up/stoppage of the product excessively.)
zMalfunction or damage which has been caused by devices or equipment that is not delivered by us or by
operation control method of those devices.
zMalfunction or damage which has been caused by using refrigerant (or gases) that are not approved for
this product.
zMalfunction or damage which has been caused by performing maintenance and inspection that is not
recommended by us.
zMalfunction or damage which has been caused by using parts other than MAYEKAWA genuine parts.
zMalfunction or damage which has been caused by redesigning this product that has not instructed by
Mayekawa/Mycom.
zProduction warranty or any other related warranty of this product.
zFor complete warranty, terms and condition details contact local Mayekawa/Mycom sales office

Reciprocating Compressor M Series
iii
Important Information
Intended Use of Machine
The M series compressor is a reciprocating compressor for refrigerating, cold storage, and air conditioning
systems on which NH3is used as the primary refrigerant. For the specification of this machine, refer to "2.2
Specification of Compressor".
When performing maintenance described we ask that you use qualified refrigeration personal.
Important Information for Safe Use of Machine
MAYEKAWA cannot anticipate all possible hazards including any potential hazards caused by human errors,
and hazards due to the environmental conditions where the machine is used.
There are plenty of guidelines that must be observed for operating the machine the warnings in this manual
and safety labels on the machine are, not all inclusive. When operating this machine, use extreme caution on
required personal safety as well as on the items described in this manual.
Listed below are the important rules for safety work with the machine that apply to all workers including
managers and supervisors.
Before using this machine, carefully read and fully understand the contents written in this manual and reliably
follow the safety procedures.
zOperation, maintenance, and inspection of this machine should only be performed by qualified personal
educated about the fundamentals of the machine and trained about the hazards involved and the
measures to avoid danger.
zObserve all related federal/national and local codes and regulations.
zThis machine may be modified without any prior notice. Therefore, the appearance of actual machine
may slightly differ from the descriptions in this manual. If you have any questions contact your sales
offices or service centers.
zTo prevent an accident, do not attempt to carry out any operation or maintenance other than those
described in this manual, or use the machine for any unapproved purpose.
zReplace the parts with the genuine parts.
zEvery worker including managers and supervisors should actively participate in activities to insure
health and safety in the workplace.
Observe the following precautions when performing maintenance work on electrical control.
zElectrical maintenance of the machine must be performed by certified/qualified personal and only those
educated about the electrical control of the machine.
zBefore servicing or inspecting the electrical equipment or devices, turn "OFF" the motor main power
and control power, and perform lockout/tagout to prevent them from being turned on during the work.
Even when the motor main power and control power are turned "OFF", the machine may be alive if the power
is supplied from outside of the refrigeration system, cold storage, and air conditioning systems. In such cases,
be sure to shut off the power supply on the power source side, and perform lockout/tagout to prevent the
machine from being turned on during the work.

Reciprocating Compressor M Series
iv
About This Manual
zThis manual is English. If any other language is required it is the FXVWRPHU¶V responsibility to prepare a
manual for safety education and operation instructions.
zThis manual is copy written. The drawings and technical references including this manual shall not, in
whole or part, be copied, photocopied, or reproduced to any electronic medium or machine±readable
form without any prior permission from MAYEKAWA.
zThe photos or drawings included in this manual may slightly differ from the appearance of actual
machine.
zIf this manual is lost or damaged, immediately place a purchase order to your local sales offices or
service centers for a new manual. Using the machine without the manual may result in safety issues.
zIf you resell the machine, never fail to attach this manual to the machine.
Construction of This Manual
Title of section and chapter Description details
Preface Describes the outline of this manual and how to read this manual.
Warranty and Disclaimer Describes clauses and coverage of warranty.
Exclusion of warranty clauses is described as disclaimer.
Important Information Describes important information related to the machine and this manual.
1. Safety
Describes safety information for the worker, safety rules for this machine,
and management details regarding the work safety that is required for
handling the machine.
2. Configuration and
Specification of Compressor
Describes the main components of the machine, functional information,
specification, and service limits.
3. Installation Describes the installation procedure of the machine.
4. Operation of the Compressor Describes the precautions for operating the machine.
5. Maintenance Describes sections and period for inspecting, and assembly and disassembly
of this product.
6. Troubleshooting Describes the methods of the machine in case of problem occurring during
operation of the machine.
7. Related Document Describes supplemental documents such as illustrated parts breakdown and
parts list.
How to Order Genuine Parts
Confirm the applicable parts in "7.1 Development View and Configuration Table of the Parts" of "Chapter 7,
Related Document". And inform the product name, part number, part name, and required quantity to your
local sales offices or service centers.

Reciprocating Compressor M Series
v
Inquiry
If you need further information or have any questions, please contact your local sales offices or service
centers.
Description Location
Telephone and facsimile
No.
MAYEKAWA MFG. CO., LTD
(HEAD OFFICE)
3±14±15 BOTAN KOTO-KU, TOKYO
135-8482, JAPAN
TEL: [phone]
FAX: (81) 3±3643-7094
MAYEKAWA MFG. CO., LTD
(MORIYA PLANT)
2000, TAYSUZAWA MORIYA±SHI,
IBARAKI±PREF., 302±0118, JAPAN
TEL: (81) 297±48±1361
FAX: (81) 297±48±5269
CANADA
MYCOM CANADA LTD.
(VANCOUVER OFFICE)
UNIT 110, 6620 McMillan WAY,
RICHMOND, B.C., V6W 1J7, CANADA
TEL: [phone]
FAX: [phone]
MYCOM CANADA LTD.
(TORONTO OFFICE)
1745 BONHILL ROAD, UNIT 6
MISSISSAUGA, ON L5T 1C1
TEL: [phone]
FAX: [phone]

Reciprocating Compressor M Series
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Revision Description
Operation
manual name
M series
operation
manual
Document
No. 2200B2JE-DA-M-N_2009.02. First edition issue date 2009/2/2
Revision
No.
Issuance
Date
Contents of revisions
(modified clause, page, and details) Created/approved by:

Reciprocating Compressor M Series
vii
Table of Contents
1 Safety
1.1 Observation/Prevention .............................................................................1-1
1.1.1 Observance (Do's) ................................................................................................. 1-1
1.1.1.1 Do's on Operation........................................................................................ 1-1
1.1.1.2 Do's on Maintenance................................................................................... 1-1
1.1.1.3 Do's on Lockout/Tagout after Shutting off the Power .................................. 1-1
1.1.1.4 Do's about Personal Protective Devices ..................................................... 1-1
1.1.1.5 Do's about Handling of Hazardous and Toxic Substances.......................... 1-2
1.1.1.6 Do's about Handling Emergency Situation.................................................. 1-2
1.1.1.7 Do's about Waste Oil, Fluid, and Materials ................................................. 1-2
1.1.1.8 Other Do's.................................................................................................... 1-2
1.1.2 Don'ts..................................................................................................................... 1-2
1.2 Warnings.....................................................................................................1-3
1.2.1 Types and Meanings of Warnings ......................................................................... 1-3
1.2.2 Safety Labels ......................................................................................................... 1-4
1.3 Remaining Hazard ......................................................................................1-6
1.4 Safety Devices ............................................................................................1-8
1.4.1 Emergency Stop Button......................................................................................... 1-8
1.4.2 Breakers of Motor Main Power and Control Power
(with Lockout/Tagout Mechanisms)....................................................................... 1-8
1.4.3 Safety Belt/coupling Guard .................................................................................... 1-9
1.4.4 Safety Valve......................................................................................................... 1-10
1.4.5 Automatic Control and Protection Equipment M compressor.............................. 1-11
1.4.6 Compressor Cooling Fluid Temperature Failure Alarm ....................................... 1-14
1.4.7 Oil Heater and Thermometer Switch ................................................................... 1-14
1.5 Example of Material Safety Data Sheet (MSDS) .....................................1-15
2 Configuration and Specification of Compressor
2.1 Configuration of Compressor....................................................................2-1
2.1.1 Overall View of Compressor .................................................................................. 2-1
2.1.2 Cross-Sectional View of Assembly........................................................................ 2-2
2.1.3 Oil Supply Mechanism ........................................................................................... 2-4
2.1.4 Unloader Mechanism............................................................................................. 2-5
2.2 Specification of Compressor.....................................................................2-6
2.2.1 Specification .......................................................................................................... 2-6
2.2.2 Service Limits and Range...................................................................................... 2-6
2.2.3 External Dimensions.............................................................................................. 2-8
2.3 Selection of V / C-belt.................................................................................2-9

Reciprocating Compressor M Series
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3 Installation
3.1 Safety Precautions for Installation ............................................................3-1
3.2 Installation Works.......................................................................................3-2
3.2.1 Unpacking .............................................................................................................. 3-2
3.2.2 Storage .................................................................................................................. 3-2
3.2.3 Transfer.................................................................................................................. 3-2
3.2.4 Preparation for Installation..................................................................................... 3-4
3.2.5 Installation.............................................................................................................. 3-5
3.2.5.1 Installation.................................................................................................... 3-5
3.2.5.2 Position of the Oil Returning Point in the Oil Separator / Procedure of
Oil Returning................................................................................................ 3-5
3.2.5.3 Protection Switch......................................................................................... 3-5
3.2.5.4 Centering of the Compressor/Driving Machine and Attachment of
the V/C-belt.................................................................................................. 3-6
3.2.5.5 Piping........................................................................................................... 3-9
3.2.5.6 Charging of Refrigeration Oil......................................................................3-11
3.2.6 Check after Installation ........................................................................................ 3-11
3.3 Documents Related to Installation *1......................................................3-12
4 Operation of the Compressor
4.1 Refrigerant Oil ............................................................................................4-1
4.1.1 Precautions for Selecting the Refrigeration Oil...................................................... 4-1
4.1.2 Initial Charging Method.......................................................................................... 4-2
4.1.3 Replenishment of the Refrigeration Oil.................................................................. 4-2
4.1.4 Set Oil Pressure..................................................................................................... 4-2
4.1.5 Oil Quantity ............................................................................................................ 4-3
4.2 Initial Operation ..........................................................................................4-4
4.2.1 Initial Operation Method......................................................................................... 4-5
4.3 Operation Order of the Unloader...............................................................4-6
4.4 Operation Notices.......................................................................................4-7
4.4.1 Start/Stop Limitation .............................................................................................. 4-7
4.4.2 Action for Stopping the Compressor for Long Period of Time............................... 4-7
4.4.3 Operation after the Compressor has been stopped for Long Period of Time ....... 4-7
5 Maintenance
5.1 Safety Precautions for Maintenance .........................................................5-1
5.2 Periodic Inspection ....................................................................................5-2
5.2.1 Daily Inspection ..................................................................................................... 5-2
5.2.2 Monthly Inspection................................................................................................. 5-3
5.2.3 Biannual Inspection ............................................................................................... 5-3
5.3 Maintenance (Overhaul).............................................................................5-4
5.3.1 Maintenance Period and Operation Conditions..................................................... 5-4
5.3.2 First Inspection ...................................................................................................... 5-5
5.3.3 First Maintenance .................................................................................................. 5-5

Reciprocating Compressor M Series
ix
5.4 Refrigerant Oil Control Standard...............................................................5-6
5.5 Disassembly/Assembly..............................................................................5-7
5.5.1 Exterior Equipment ................................................................................................ 5-7
5.5.1.1 Removing the Oil Cooler Piping/
Water Cooled Type Oil Cooler ..................................................................... 5-8
5.5.1.2 Removing the Mechanical lock.................................................................... 5-8
5.5.1.3 Removing the Flywheel ............................................................................... 5-8
5.5.1.4 Assembly of the Flywheel............................................................................ 5-8
5.5.1.5 Assembly of the Mechanical lock ................................................................ 5-9
5.5.1.6 Assembly of the Oil Cooler Piping/
Water Cooled Type Oil Cooler ..................................................................... 5-9
5.5.2 Suction/Discharge Area ....................................................................................... 5-10
5.5.2.1 Removing the Suction/Discharge Shut-off Valve........................................5-11
5.5.2.2 Assembly of the Suction/Discharge Shut-off Valve ....................................5-11
5.5.2.3 Removing the Discharge Manifolds............................................................5-11
5.5.2.4 Assembly of the Discharge Manifolds ....................................................... 5-12
5.5.3 Head Cover/Hand Hole Cover ............................................................................. 5-13
5.5.3.1 Removing the Head Jacket Cover............................................................. 5-14
5.5.3.2 Removing the Head Cover ........................................................................ 5-14
5.5.3.3 Removing the Hand Hole Cover................................................................ 5-15
5.5.3.4 Assembly of the Hand Hole Cover ............................................................ 5-16
5.5.3.5 Assembly of the Head Cover..................................................................... 5-16
5.5.3.6 Assembly of the Head Jacket Cover ......................................................... 5-17
5.5.4 Valve Plate/Piston Assembly/Cylinder Sleeve Assembly.................................... 5-18
5.5.4.1 Attachment of the Spacer .......................................................................... 5-19
5.5.4.2 Removing the Valve Plate ......................................................................... 5-19
5.5.4.3 Removing the Piston Assembly................................................................. 5-19
5.5.4.4 Assembly of the Cylinder Sleeve Assembly .............................................. 5-20
5.5.4.5 Assembly of the Piston Assembly ............................................................. 5-20
5.5.4.6 Assembly of the Suction Plate Valve/Suction Valve Spring....................... 5-22
5.5.4.7 Assembly of the Valve Plate ...................................................................... 5-22
5.5.4.8 Removal of the Spacer .............................................................................. 5-23
5.5.5 Unloader .............................................................................................................. 5-24
5.5.5.1 Assembly of the Unloader Push Rod Washer ........................................... 5-25
5.5.5.2 Assembly of the Unloader Push Rod Assembly........................................ 5-25
5.5.5.3 Assembly of the Solenoid Valve Unloader Cover Integrated .................... 5-25
5.5.6 Seal Cover/Mechanical Seal/Oil Seal .................................................................. 5-26
5.5.6.1 Removing the Seal Cover Assembly ......................................................... 5-27
5.5.6.2 Removing the Oil Seal Retainers .............................................................. 5-27
5.5.6.3 Removing the Oil Seal............................................................................... 5-27
5.5.6.4 Assembly of the Oil Seal ........................................................................... 5-27
5.5.6.5 Assembly of the Mechanical Seal Collar ................................................... 5-28
5.5.6.6 Assembly of the Seal Cover Assembly...................................................... 5-28
5.5.7 Main Bearing Head Assembly/Oil Pump Assembly/Oil Filter Assembly ............. 5-29
5.5.7.1 Removing the Main Bearing Head Assembly............................................ 5-30
5.5.7.2 Assembly of the Main Bearing Head Gasket............................................. 5-30
5.5.7.3 Assembly of the Main Bearing Head Assembly ........................................ 5-30

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5.5.8 Crankshaft............................................................................................................ 5-31
5.5.8.1 Removing the Crankshaft .......................................................................... 5-32
5.5.8.2 Assembly of the Thrust Roller Bearing (Shaft Side).................................. 5-33
5.5.8.3 Assembly of the Crankshaft....................................................................... 5-34
5.5.9 Bearing Head ....................................................................................................... 5-35
5.5.9.1 Removing the Bearing Head ..................................................................... 5-36
5.5.9.2 Replacing the Main Bushing (Bearing Head Side) .................................... 5-36
5.5.9.3 Assembly of the Thrust Roller Bearing (Bearing Head Side) .................... 5-36
5.5.9.4 Assembly of the Bearing Head.................................................................. 5-37
5.5.10Discharge Valve Cage Assembly ........................................................................ 5-38
5.5.10.1 Assembly of the Discharge Valve Spring................................................... 5-38
5.5.11 Piston Assembly ........................................................................................ 5-39
5.5.11.1 Assembly of the Connecting Rod Bushing ................................................ 5-39
5.5.11.2 Assembly of the Piston Rings.................................................................... 5-40
5.5.12Cylinder Sleeve Assembly................................................................................... 5-41
5.5.12.1 Assembly of the Cam Ring ........................................................................ 5-41
5.5.13Seal Cover Assembly .......................................................................................... 5-42
5.5.13.1 Removing the Shower Flushing Sleeve .................................................... 5-42
5.5.13.2 Assembly of the Mechanical Seal Mating Ring ......................................... 5-43
5.5.13.3 Assembly of the Bellows Oil Sleeve .......................................................... 5-43
5.5.14Main Bearing Head Assembly ............................................................................. 5-44
5.5.14.1 Replacing the Main Bushing (Pump Side)................................................. 5-44
5.5.14.2 Assembly of the Thrust Washer (Pump Side) ........................................... 5-44
5.5.15Oil Filter Assembly............................................................................................... 5-45
6 Troubleshooting
6.1 Troubleshooting Table...............................................................................6-1
7 Related Document
7.1 Development View and Configuration Table of the Parts........................7-1
7.2 List of Tightening Torques for Bolts and Nuts.......................................7-11
7.3 List of Tools for Disassembly..................................................................7-12
7.4 Vibration and Sound Data........................................................................7-14
7.4.1 Vibration............................................................................................................... 7-14
7.4.2 Sound Data .......................................................................................................... 7-15
7.5 Oil Cooler Heat Rejection
(OHR)/Head Jacket Heat Rejection (JHR) (N4M, N6M, N8M)..................7-16
7.6 Starting Torque.........................................................................................7-25
7.7 Parts Inspection and Replacement Standards .......................................7-28

Reciprocating Compressor M Series
1-1
1 Safety
1.1 Observation/Prevention
1.1.1 Observance (Do's)
1.1.1.1 Do's on Operation
zAttach safety and protection devices into compressors operation sequence.
zRegularly inspect the safety and protective devices functioning properly.
zIf safety and protective devices do not work properly or the machine continues to run even during the
test of these devices, stop the operation! Inform your supervisor of it immediately.
zIf the compressor stops for unknown reasons, immediately inform your supervisor of it and obtain
his/her approval before restarting the compressor.
zSome refrigerants in use can generate toxic gases. Make sure to ventilate the air during work.
zThe properties of refrigerant and refrigerant oil can be corrosive, decomposability, and/or toxic, insure
to obtain the Material Safety Data Sheet (MSDS) and follow its instructions.
zWhen stopping the operation of this compressor, turn "OFF" the motor (main power), heater power,
and control power. Close the suction and discharge side shut-off valves. Follow proper compressor
evacuation procedures.
1.1.1.2 Do's on Maintenance
zMycom recommends that for safety during maintenance work, at least two personal will be required to
perform some tasks
zAlways turn OFF and lock out and tag the motor (main power), control power, and other devices
before troubleshooting the operation. Also do this before setup, cleaning, or maintenance and
inspection of the compressor.
1.1.1.3 Do's on Lockout/Tagout after Shutting off the Power
zInstall lockout/tagout mechanisms on the main breakers of motor main power and control power.
Performing lockout/tagout after shutting off the power is very effective for preventing the compressor
being turned on accidentally and causing injury while two or more workers are working on
compressor.
zIf there are any possibilities of danger during works (especially during cleaning, maintenance and
inspection, and troubleshooting), turn "OFF" the motor main power and control power, and perform
lockout/tagout. (this does not need to be repeated as you state it clear enough up top)
1.1.1.4 Do's about Personal Protective Devices
zPrepare and use protective devices complying with the safety standards of the regulations.
zCheck the function of each protective device before using.
zWear designated clothes such as work outfits.
zDo not wear any neckties or jewelry as there is a possibility of being entangled by a movable part or
rotating part.
zPut on a helmet as your hair may get entangled.
zDo not have anything in your pocket to prevent objects from falling into the machine.
1.1.1.5 Do's about Handling of Hazardous and Toxic Substances
zObtain Material Safety Data Sheet (MSDS) from manufacturers of hazardous and toxic substances.
zCheck the MSDS and follow the handling instructions recommended by the manufacturers to handle
and store those substances.

Reciprocating Compressor M Series
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zAn example of Material Safety Data Sheet (MSDS) is provided as a reference at the end of
this chapter.
1.1.1.6 Do's about Handling Emergency Situation
zFormulate an emergency action plan complying with the regulations. Post it in a place where the
workers can always see it.
1.1.1.7 Do's about Waste Oil, Fluid, and Materials
zDisposing of refrigerant and oil used for the compressor are subject to a number of regulations for the
environmental protection purposes. Follow the local, state, federal acts and regulations and your
company's rules when disposing of such waste oil, fluid and materials.
1.1.1.8 Other Do's
zKeep the floor clean around the refrigerating, cold storage, and air conditioning systems, and keep
passages and walkways clear.
zWalk only on the areas set up as a work floor. Also, do not leave tools and cleaning solutions in that
area.
zIf water or oil is spilled on the compressor or the floor, immediately wipe it off to prevent workers
from injury.
1.1.2 Don'ts
zDo not remove or relocate any safety device, including electrical interfaces.
zDo not disable any safety device by short-circuiting or bypassing without any permission.
zDo not leave the compressor unsafe and unattended, by removing a safety cover or some other
measures.
zDo not touch, clean, or lubricate any moving part of the compressor during the operation.
zDo not touch relays or electric systems such as terminal block with bare hands when turning on the
power.

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1.2 Warnings
To alert workers to danger, the following two measures are always provided with the compressor.
zWarnings described in this manual
zSafety labels affixed on the compressor
1.2.1 Types and Meanings of Warnings
This manual includes the following four types of warnings to be used for expected hazards during operation
and maintenance of the compressor.
Neglecting such warnings may cause accidents, resulting in personal injury or even death.
Also, the compressor or its auxiliary equipment may be heavily damaged. Therefore, be sure to always
observe the instructions of the warnings.
Indicates an imminently hazardous situation which, if not avoided, will result in serious
injury or death.
Indicates a potential hazardous situation which, if not avoided, could result in serious injury
or death.
Indicates a potential hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property
damage.
Emphasizes important items and indicates valuable information.

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1.2.2 Safety Labels
The following shows the types of the safety labels and their positions affixed on the compressor. Always
follow the warnings instructed on the safety label affixed on the compressor.
zBe sure to follow the instructions of the safety labels. Otherwise, danger
resulting in personal injury, death, or property damage may arise.
zDo not smear, cover, or peel off the safety labels.
zIf the safety labels are damaged or missing, purchase and affix new labels to their
proper positions according to this manual.
zInform your service center of the product name, safety label No., and required quantity when
placing a purchase order for safety labels.
Types of Safety Labels
Table 1-1 Safety label
No. Safety labels Remarks
1
For specification with belt cover
2

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Affixing Positions of Safety Labels
The figure below shows the affixing positions of safety labels.
The numbers in the figure correspond to the ones in Table 1-1 Safety label.
Fig. 1-1 Affixing positions of safety labels (Ex: 6M)

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1.3 Remaining Hazard
The following information is provided on the assumption that this compressor is operated, inspected, and
maintained while being used in general refrigerating, cold storage, and air conditioning systems. Note that all
hazardous sources cannot be predicted for the refrigerating, cold storage, and air conditioning systems you
may encounter.
Devise appropriate countermeasures for hazardous sources in your systems.
Table 1-2 Hazardous sources
Hazardous parts Predicted hazard Counter measures in
operation
Counter measures in
cleaning, inspection, and
parts exchange
A Driving section yContact and
entanglement in
rotational part
yDrop-off of moving
part
yRecovery after
interruption of
energy supply
yInstallation of guard
and cover
yLockout/tagout of motor
main power and control
power
B Head cover yBurn caused by
touching hot part
yInstallation of guard
yWearing protective
devices
yWearing protective devices
yOperation with a
temperature of 40°C(104°F)
C Discharge piping yBurn caused by
touching hot part
yInstallation of guard
yWearing protective
devices
yWearing protective devices
yOperation with a
temperature of 40°C(104°F)
or less
D Unloader solenoid
valve
yElectric Shock yInstallation of guard
yWearing protective
devices
yLockout/tagout of control
power
E Heater yElectric Shock
yBurns
yInstallation of guard
and cover
yWearing protective
devices
yLockout/tagout of the heater
power
yWearing protective devices
yOperation with a
temperature of 40°C(104°F)
or less
F Suction (side) shut-off
valve
yContact with and
inhale of toxic
substances
yLow temperature
burns
yWearing protective
devices
ySufficient ventilation
yInstallation of guard
yWearing protective devices
ySufficient ventilation
G Discharge (side)
shut-off valve
yContact with and
inhale of toxic
substances
yBurns
yWearing protective
devices
ySufficient ventilation
yInstallation of guard
yWearing protective devices
ySufficient ventilation
yOperation with a
temperature of 40°C(104°F)
H Gas purge valve yContact with and
inhale of toxic
substances
yWearing protective
devices
ySufficient ventilation
yWearing protective devices
ySufficient ventilation
I Oil drain yBurns
yContact with toxic
substances
yDo not contact with it
during operation
yWearing protective devices
yOperation with a
temperature of 40°C(104°F)
or less
J Noise and vibration yDamage caused by
noise
yWearing protective
devices
²

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Fig. 1-2 Hazardous sources

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1-8
1.4 Safety Devices
For safe use and protection of the compressor, make sure to attach safety devices to your compressor,
complying with the regulations and the following instructions for each device.
Periodically inspect devices for normal/proper operation. Maintenance must be performed as an important
part for the safety of machine and personal. Provide users of the compressor with necessary information on
the safety devices.
zCheck the safety devices after turning on the power and before operation of the
compressor. If they do not operate normally, immediately take repair or replace
safeties before starting compressor.
1.4.1 Emergency Stop Button
Overview/Function/Purpose
Used to stop the compressor immediately if an emergency occurs in the compressor.
Installation Procedures.
On the control board on the compressor and in the operation control room
Stop/Restart Methods
Develop stop and start procedures for the emergency stop button, and make sure LW¶V available to the users of
this compressor.
Inspection Method/Cycle
The emergency stop button requires test to ensure compressor is shut down when pressed. Ensure this is done
before testing the operation of compressor. Also perform this periodically after compressor is put into service.
1.4.2 Breakers of Motor Main Power and Control Power (with
Lockout/Tagout Mechanisms)
Overview/Function/Purpose
When a working on compressor ensure to lockout/tagout main and control power to prevent hazards to
workers (especially during cleaning, maintenance, inspection, and troubleshooting). While the motor main
power and control power are turned "OFF", install lockout/tagout to ensure that no one accidentally turns on
power causing injury to workers.
Methods of Performing and Releasing Lockout/Tagout
Make sure to formulate methods of performing and releasing lockout/tagout referring to the regulations
created by Occupational Safety & Health Administration (OSHA) or local governing body.

Reciprocating Compressor M Series
1-9
1.4.3 Safety Belt/coupling Guard
overview/Function/Purpose
Prevents contact and entanglement in the driving section of this compressor.
Installation Positions
Driving section
Fig. 1-3 Attachment of driving section safety cover (6M)
No. Description No. Description
1 Driving section safety cover (for belt) 2 Driving section safety cover (for coupling)
Inspection Method/Cycle
Make sure to formulate the inspection procedure of safety cover, and provide users of this compressor with
the necessary information.