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.

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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
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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
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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.

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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.

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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
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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

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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
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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