1. DL manuals
  2. M
  3. Repeater
  4. 160 GR
  5. Instruction Manual

M 160 GR Instruction Manual

Manual is about: Natural Gas Booster

Summary of 160 GR

  • Page 1

    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 m...

  • Page 2

    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 .........................................................................................................................................

  • Page 3

    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 co...

  • Page 4

    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 ...

  • Page 5

    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 compre...

  • Page 6

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.6 b) remove the guide pin from the case. When the current port is “k” or “l,” the guide pin is located in the bottom area of the suction cover. When the current ...

  • Page 7

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.7 number of rotations of handle 3-1/2 4‐7/8 8-1/2 direction of rotations clockwise counter-clockwise counter-clockwise position of fixing pin suction cover rotor...

  • Page 8

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.8 ・ vi changing procedures ① the position of k-port ② remove the variable vi guide pin. ③ turn the capacity control handle 3 1/2 times in counter-clockwise, and ...

  • Page 9

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.9 ・ vi changing procedures 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/...

  • Page 10

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.10 3.1.2 when the current port is not known when the position of the current port is not known, move the variable vi valve to the position of the stopper on the ...

  • 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 mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.12 each port and the position of the variable vi guide pin k-port l-port m-port h-port.

  • Page 13

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.13 4. Parts expanded view 4-1 160gr standard.

  • Page 14

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.14 4-2 160gr with integral pump.

  • Page 15

    4-3 mayek parts stru 16 kawa all rights cture diagr 0gr natural g reserved. Sub ram gas booster i bject to change nstruction ma e without notice anual e. Lat revised iin october 200 07 p.15 5.

  • Page 16

    Mayek 16 kawa all rights 0gr natural g reserved. Sub gas booster i bject to change nstruction ma e without notice anual e. Lat revised iin october 200 07 p.16 6.

  • Page 17

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.17 5. Parts list no name no name 1 main rotor casing 43-1 thrust bearing gland m1 2 hexagon socket head cap screw 43-2 thrust bearing gland m2 3 alignment pin 43...

  • Page 18

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.18 no name no name 41-2 bearing spacer f 196-2 oil control throttle comp fs 42-1 spacer, thrust bearing m alignment 196-3 oil control throttle comp md 42-2 space...

  • Page 19

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.19 6. Outer dimension.

  • Page 20

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.20 7. Disassembly preparation although screw compressors are reliable machines, they need to be disassembled to have their parts inspected after operating for a ...

  • Page 21

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.21 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 ...

  • Page 22

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.22 the order of disassembly follow the order shown below to disassemble and inspect the compressor. The order of the compressor disassembly: 1) mechanical shaft ...

  • Page 23

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.23 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 to...

  • Page 24

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.24 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 si...

  • Page 25

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.25 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 (...

  • Page 26

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.26 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 lo...

  • Page 27

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.27 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 sock...

  • Page 28

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.28 figure 18 hexagon socket head screw figure 19 removing spring retainer 7.4.5.2 inspection a) check the spring (83) for any defects. If there is, replace the p...

  • Page 29

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.29 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, the...

  • Page 30

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.30 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 casin...

  • Page 31

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.31 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. ...

  • Page 32

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.32 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...

  • Page 33

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.33 7.4.9.2 inspection a） check the gear tooth surface for any remarkable hit or wear. If there is, look for the cause and replace the part. B） when there is an u...

  • Page 34

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.34 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...

  • Page 35

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.35 figure 35 thrust cramp bolt figure 36 removing thrust gland b) remove the thrust bearing glands 2 (43-2, 43-4). Lift the tabs of the lock washers (39-1, 39-2)...

  • Page 36

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.36 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 ...

  • Page 37

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.37 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...

  • Page 38

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.38 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 pr...

  • Page 39

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.39 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...

  • Page 40

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.40 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 i...

  • Page 41

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.41 8.3 rotor casing, rotor a） when replacing the main bearings and the side bearings, put shrink fit on the inner-ring with the rotor. B） apply oil on the bearin...

  • Page 42

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.42 c） first, install the washer and the thrust adjusting washer, and proceed to the thrust bearings. Install the thrust bearings in the way that the tip of the “...

  • Page 43

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.43 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 n...

  • Page 44

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.44 spindle thrust bearing lock nut : torque lock nut (an13)tightening torque general (n・m) max.(n・m) 160glr 512 640 thrust bearing cramp : torque speed up gear t...

  • Page 45

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.45 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...

  • Page 46

    160gr natural gas booster instruction manual mayekawa all rights reserved. Subject to change without notice. Lat revised in october 2007 p.46 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 n...