Instruction Manual For W-Series Reciprocating Compressors: 2WA/4WA/6WA/8WA/42WA/62WA

2200M4JE-HO-W-N_2014.04.
Instruction Manual for

W-Series Reciprocating Compressors
2WA/4WA/6WA/8WA/42WA/62WA
4WB/6WB/8WB/12WB/42WB/62WB/12･4WB
ATTENTION
Please carefully and thoroughly read and understand all aspects described in this instruction
manual before operating, inspecting, or performing any maintenance work on the compressor.
Be sure to keep this instruction manual carefully at a predetermined place, such that the
manual is readily accessible whenever it is needed.
Specifications of this product are subject to change without prior notice.
3–14–15 Botan Koto-ku, Tokyo 135-8482, Japan

2200M4JE-HO-W-N_2014.04.
Preface
Preface
Thank you for purchasing the W-series reciprocating compressor (hereafter referred to
as “this product”) of MAYEKAWA Mfg. Co., Ltd. (hereafter referred to as “MAYEKAWA” )
Since the initial production and sales launch in 1955 of the first multi-cylinder high speed compressor,
MAYEKAWA has subsequently produced a number of series reciprocating compressor products
including the Type A, B, J, C, SF, and K products.
The W-series compressors have been in production and on sale since 1988, being improved from the
Type A, B and J products.
This instruction manual (hereafter referred to as “this manual”) provides safety information, operating
procedures, and maintenance procedures for the WA and WB type products (both included in the
W-series) for the user to be able to sufficiently understand the correct methods of handling the product,
in order to safely and effectively use the product. This manual is applicable to the following type
products:
2WA, 4WA, 6WA, 8WA, 42WA, 62WA,

4WB, 6WB, 8WB, 12WB, 42WB, 62WB, 12-4WB
Notes
• Type WB products are currently not in production as they have been replaced by the
successor Type WBH in January 2006 and then by Type WBHE since September
2008.
• If instruction manuals for Type WBH and WBHE products are required, please
contact MAYEKAWA as manuals for these products are separately available.
Please be sure to read this manual carefully before installing or using this product.
Also, please keep this manual at a convenient place near the product installation to ensure that it can
be quickly referred to should any unclear issues arise.
Revision History
Title of Instruction Manual Document No. Date of Initial Issue
Instruction Manual for W-Series
2200M4JE-HO-W-N_2014.04. April 21, 2014
Reciprocating Compressors
Prepared by /
Rev. No. Issue Date Revision Details
Approved by
－ March 1, Issued to meet the requirements set forth in the
1996 Product Liability Law established in July, 1994.
00 April 21, Complete revision and reissue as an electronic Ikehara / Hirao
2014 manual.
W-Series Reciprocating Compressor

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Revision History
Warranty and Disclaimer
Warranty Clauses
MAYEKAWA shall repair or replace parts of this product for no charge if any failure resulting from
defects in design or manufacture occurs, under normal use with the purpose and method that are in
accordance with the specifications of this product and this manual, within the warranty period.
The warranty period is "12 months from factory shipment of this product". If there is a separate
agreement, that agreement shall prevail in principle.
Disclaimer Clauses (Exclusion of Warranty Clauses)

Please note that we disclaim any responsibility for damage or malfunction to this product, as described
in the following items.
 Any failure or damage caused by an act of God including, but not limited to, windstorm, heavy
rain, flood, high tide, earthquake, subsidence of ground, lightning strike, fire, etc.
 Malfunctions, damage, or degradation due to misuse or unacceptable use of the product
(including improperly storing the product outdoors or under too hot/humid conditions,
excessively frequent liquid flow-back operation, extremely frequent start-stop cycles, etc.).
 Any failure or damage caused by other systems or devices not supplied by MAYEKAWA
including operation control methods of them.
 Any failure or damage caused by the use of any refrigerant (or gas) or lubricant not applicable
to this product.
 Any failure or damage caused by the performance of maintenance or inspection procedures
not recommended by MAYEKAWA.
 Any failure or damage caused by the use of any other than the genuine parts of MAYEKAWA.
 Any failure or damage caused by any conversion or modification of the product other than as
instructed by MAYEKAWA.
 Direct or indirect production warranty or all other related warranties that arose due to a failure
or damage of this product.

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Important Information
Intended Use of this Product

This product is a general purpose reciprocating compressor to be used for refrigeration, cold storage,
or air conditioning. Do not use this product for any purposes other than the intended use or outside the
scope of the specifications. Refer to Chapter 2, Section 2.2 “Compressor Specifications” of this manual
for specifications of this product.
In addition, it is requested that the maintenance actions described in this manual be taken using safe
and secure procedures.
Precautions for the Safe Use of this Product

Although MAYEKAWA is taking all possible and reasonable measures to ensure the safety of the
product, it is impossible for MAYEKAWA to foresee every possible risk that remains in the product, risk
due to human errors, or risk due to the operation environment.
In using this product, there are many things that are to be strictly followed or prohibited. However, it is
impractical to communicate all of such matters in this manual or using warning labels. As such, in
addition to the precautions provided in this manual, the user is required to consider other safety
measures that are generally required.
The following points are important work safety suggestions for everyone including the manager,
supervisor, and other personnel who may work on this product.
Before using this product, please read this manual carefully to sufficiently understand the details and
securely implement the safety procedures described in this manual.
 Operation, maintenance, and inspection of this product should be performed by qualified
personnel educated about the fundamentals of the product and trained about hazards
involved and measures to avoid danger.
 Anyone other than the ones who have been provided with the basic technical knowledge on
this product and trained on the potential risks and how to avoid the risks is not allowed to
approach the area where this product is installed.
 Observe all related federal/national and local codes and regulations.
 To prevent accidents, do not carry out any operation or maintenance other than those
described in this manual, or use the product for any unapproved purpose.
 Be sure to use only genuine parts for replacement.
 Not only workers but also managers should actively participate safety and health activities in
the workplace to prevent accidents.
 When closing or opening valves during work, apply lockout/tagout without failure, to prevent
the valves from closing or opening accidentally during the work.
“Lock-out” To lock with a key in order to keep people, except the workers involved, from
operating the product.
“Lockout” means disconnecting or keeping disconnected machines and devices by locking their
energy (power) sources. Lockout is not just simply turning off the power switches to stop the supply
of power, but includes immobilizing them with a key or similar device to keep any blocked switches
from being operated.
Lockout devices are devices such as keys, covers, and latches, to immobilize switches, valves,
opening and closing levers, etc., with a state of being locked.

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2200M4JE-HO-W-N_2014.04.
“Tag-out” To prevent any inappropriate work by hanging tag plates indicating “work in
progress”.
“Tagout” means to clearly indicate, by hanging tag plates, that a device is in lockout and that
operation of the device is prohibited. Tag plates forbidding operation, starting, opening, etc. are
warnings clearly stating to not operate energy (power) sources, and are not for stopping blocking
devices.
Observe the following precautions when performing maintenance work on electrical control.
 The work must be performed by a qualified person who has been trained on the electric
control of the particular target system as well as on the potential risks inherent to electric
control and how to avoid the said risks, on top of the generally required knowledge on
electrical work.
 Whenever servicing or inspecting electric machinery, be sure to cut off the motor main power
and control power, implement lock-out and tag-out procedures, and prevent any accidental
application of power during the work.
However, it should be noted that the system may be energized from other sources even if the motor
main power and control power are cut off, if power is supplied externally, i.e., not from the
refrigeration/cold storage unit that uses this product. In such a case, be sure to cut off the power supply
source, implement lock-out and tag-out procedures, and prevent any accidental application of power
during the work.
About this Manual

 This product is subject to continuous development and improvement without prior notice.
Accordingly, the details provided in this manual may partly differ from the actual condition. If
any problem is found during work, please contact one of our sales or service establishments.
 This manual is in English. If any other language is required, it is the customers’ responsibility
to prepare a manual for safety education and operation instructions.
 MAYEKAWA owns the copyright of this manual. Any part of relevant drawings and technical
documents, including this manual, may not be copied in any possible way, including the use of
electronic media, without prior permission from MAYEKAWA.
 The pictures and illustrations in this manual may not accurately represent the actual condition
of the product.
 In case this manual is lost or damaged, please promptly place an order for the copy to one of
our sales or service offices. The use of this product without this manual can be a cause of
possible accidents.
 When you sell this product, be sure to transfer this manual to the next owner.

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Structure of this Manual

Chapter/Section Title Description
Preface Describes the outline and usage of this manual.
Describes what MAYEKAWA warrants and what are covered by the
Warranty and Disclaimer warranties.
Warranty exemption is stated as disclaimer.
Describes important information related to this product and this
manual.
Describes safety information for the worker, safety rules for this
1. Safety product, and management details regarding the work safety that is
required for handling this product.
2. Compressor Mechanism Describes the main components of this product, functional
and Specifications information, specification, and operating limits.
3. Installation Describes the installation procedure of this product.
4. Operation of Compressor
Describes the precautions for operating this product.
and System
5. Maintenance and Describes sections and period for inspecting, and assembly and
Inspection disassembly of this product.
Describes troubleshooting methods for this product in case problems
6. Troubleshooting
occur during operation of this product.
7. Related Documents Describes documents such as development views and parts list.
Describes contact information for our local sales offices or service
Contact Information
centers, which are for ordering genuine parts.

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Table of Contents
Table of Contents
Introduction ........................................................................................................ i
Revision History ........................................................................................................ i
Warranty Notice ................................................................................................ ii
Warranty .................................................................................................................... ii
Disclaimer of Warranty ............................................................................................ ii
Important Notice .............................................................................................. iii
Intended Use of this Product ................................................................................. iii
Precautions for the Safe Use of this Product ....................................................... iii
About this Manual ................................................................................................... iv
Structure of this Manual .......................................................................................... v
Table of Contents ............................................................................................. vi
Chapter 1 Safety
1.1 Strict Requirements and Prohibitions........................................................ 1-1
1.1.1 Strict Requirements ............................................................................................. 1-1
1.1.1.1 Strict Requirements during Operation ......................................................... 1-1
1.1.1.2 Strict Requirements during Maintenance .................................................... 1-1
1.1.1.3 Strict Requirements on Lock-out/Tag-out Procedures after Power is Off .... 1-2
1.1.1.4 Strict Requirements on Personal Protective Equipment ............................. 1-2
1.1.1.5 Strict Requirements on the Handling of Dangerous Goods and
Hazardous Materials ................................................................................... 1-2
1.1.1.6 Strict Requirements on the Response to Emergency Situations................. 1-2
1.1.1.7 Strict Requirements on the Disposal of Waste Oil, Waste Liquid,
Scraps, etc. ................................................................................................. 1-2
1.1.1.8 Other Strict Requirements ........................................................................... 1-3
1.1.2 Prohibitions .......................................................................................................... 1-3
1.2 Warning Notices in this Manual .................................................................. 1-3
1.3 Residual Risk ............................................................................................... 1-4
1.4 Safety Devices .............................................................................................. 1-6
1.4.1 Emergency Stop Button ....................................................................................... 1-6
1.4.2 Circuit Breakers for the Motor Main Power and Control Power
(the use of lock-out/tag-out mechanism) .......................................................... 1-6
1.4.3 Safety Cover (drive system) ................................................................................ 1-7
1.4.4 Safety Valve ......................................................................................................... 1-7
1.4.5 Automatic Control and Protection Systems for the Compressor ......................... 1-8
1.4.6 No Water Alarm ................................................................................................. 1-12
1.4.7 Oil Heater and Thermal Switch .......................................................................... 1-12

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Table of Contents
Chapter 2 Compressor Mechanism and Specifications

2.1 Compressor Mechanism ............................................................................. 2-1
2.1.1 Overview of W-series Compressors .................................................................... 2-1
2.1.2 Sectional View of the Compressor ...................................................................... 2-1
2.1.3 Gas Compression Mechanism ............................................................................ 2-2
2.1.3.1 Suction Stroke ............................................................................................. 2-2
2.1.3.2 Compression Stroke .................................................................................... 2-2
2.1.4 Unloader Mechanism ........................................................................................... 2-4
2.1.5 Oil Supply Mechanism ......................................................................................... 2-6
2.1.5.1 Oil Supply Path ............................................................................................ 2-6
2.1.5.2 Oil Pump Types and Design Changes ........................................................ 2-8
2.1.5.3 Amount of Lubricant and Oil Pressure Adjustment ................................... 2-10
2.1.6 Oil Cooler ........................................................................................................... 2-11
2.1.7 Shaft Seal and Thrust Bearing .......................................................................... 2-12
2.1.7.1 Shaft Seal .................................................................................................. 2-13
2.1.7.2 Thrust Bearing ........................................................................................... 2-13
2.1.8 Safety Valve ....................................................................................................... 2-14
2.1.9 Oil Tank.............................................................................................................. 2-14
2.2 Compressor Specifications ...................................................................... 2-15
2.2.1 Standard Specifications ..................................................................................... 2-15
2.2.2 Service Limits and Service Range ..................................................................... 2-17
2.2.3 Outer Dimensions .............................................................................................. 2-18
2.3 Flywheel ...................................................................................................... 2-29
2.4 Direct Coupling .......................................................................................... 2-29
Chapter 3 Installation
3.1 Safety Precautions during Installation....................................................... 3-1
3.2 Installation Work .......................................................................................... 3-1
3.2.1 Unpacking ............................................................................................................ 3-1
3.2.2 Storage ................................................................................................................ 3-1
3.2.3 Transportation ...................................................................................................... 3-2
3.2.4 Preparation for Installation ................................................................................... 3-3
3.2.5 Installation ............................................................................................................ 3-3
3.2.5.1 Placement .................................................................................................... 3-3
3.2.5.2 Return Oil from Oil Separator ...................................................................... 3-3
3.2.5.3 Protection Device ........................................................................................ 3-3
3.2.5.4 Piping ........................................................................................................... 3-4
3.2.6 Center-to-center Alignment between the Compressor and
Drive Mechanism (V-belt) ................................................................................. 3-5
3.2.6.1 Alignment Method and Criteria .................................................................... 3-5
3.2.6.2 Belt Tensioning ............................................................................................ 3-6
3.2.7 Center-to-center Alignment between the Compressor and Drive Mechanism
(Direct drive) ..................................................................................................... 3-7
3.2.8 Initial Charge ........................................................................................................ 3-7

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Table of Contents
3.2.8.1 Lubricant ...................................................................................................... 3-7

3.2.8.2 Refrigerant ................................................................................................... 3-7
3.2.9 Checkout after Installation ................................................................................... 3-7
Chapter 4 Operation of Compressor and System

4.1 Lubricant (Refrigerant Oil) .......................................................................... 4-1
4.1.1 Precautions for Selecting the Lubricant ............................................................... 4-1
4.1.2 Changing the Brand of the Lubricant ................................................................... 4-1
4.1.3 Initial Charging Method ........................................................................................ 4-2
4.1.4 Replenishment of Lubricant ................................................................................. 4-2
4.1.5 Oil Pressure Setting ............................................................................................. 4-2
4.2 Operation Sequence of the Unloader ......................................................... 4-3
4.3 Initial Operation ............................................................................................ 4-4
4.3.1 Precautions for Initial Operation .......................................................................... 4-4
4.3.2 Initial Operation Method....................................................................................... 4-5
4.4 Operating Precautions ................................................................................ 4-6
4.4.1 Start/Stop Limit .................................................................................................... 4-6
4.4.2 Liquid Flow-Back Prevention ............................................................................... 4-6
4.5 Action to Take when the Compressor is Stopped for a Long Time ........ 4-7
Chapter 5 Maintenance and Inspection

5.1 Safety Precautions for Maintenance and Inspection ................................ 5-1
5.2 Maintenance and Inspection List................................................................ 5-2
5.2.1 Daily Management ............................................................................................... 5-2
5.2.2 Regular Inspection ............................................................................................... 5-3
5.2.3 Compressor Overhaul.......................................................................................... 5-4
5.2.3.1 Guideline for the Overhaul Timing ............................................................... 5-4
5.2.3.2 Level 1 Overhaul ......................................................................................... 5-4
5.2.3.3 Level 2 Overhaul ......................................................................................... 5-5
5.2.3.4 Level 3 Overhaul ......................................................................................... 5-5
5.3 Lubricant Management ................................................................................ 5-6
5.3.1 Management Criteria ........................................................................................... 5-6
5.3.2 Lubricant Replacement Timing ............................................................................ 5-7
5.4 Preparation for Overhaul ............................................................................. 5-8
5.4.1 Replacement Parts .............................................................................................. 5-8
5.4.2 Disassembly Tools and Workplace ..................................................................... 5-8
5.4.3 Refrigerant Gas Recovery ................................................................................... 5-8
5.4.4 Discharging the Lubricant and Cooling Water ..................................................... 5-9
5.4.5 Removal of V-belt or Coupling ............................................................................. 5-9
5.5 Disassembly ............................................................................................... 5-10
5.5.1 Removal of Cooling Water Pipe ........................................................................ 5-11
5.5.2 Removal of Head Cover .................................................................................... 5-12

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5.5.3 Removal of Head Spring.................................................................................... 5-12

5.5.4 Removal of Discharge Valve Assembly............................................................. 5-13
5.5.5 Unloader Mechanism ......................................................................................... 5-14
5.5.6 Oil Cooler and Hand Hole Cover ....................................................................... 5-15
5.5.7 Disassembling the Cylinder Block ..................................................................... 5-16
5.5.8 Cylinder Sleeve .................................................................................................. 5-17
5.5.9 Piston and Connecting Rod ............................................................................... 5-18
5.5.10 Piston Ring ........................................................................................................ 5-18
5.5.11 Shaft Seal Block ................................................................................................ 5-19
5.5.11.1 Cover Plate ................................................................................................ 5-20
5.5.11.2 Shaft Seal Collar ........................................................................................ 5-20
5.5.12 Thrust Bearing ................................................................................................... 5-21
5.5.13 Bearing Head ..................................................................................................... 5-21
5.5.14 Oil Pump ............................................................................................................ 5-22
5.5.15 Crank Shaft ........................................................................................................ 5-24
5.5.16 Main Bearing Head ............................................................................................ 5-25
5.5.17 Strainer and Others ........................................................................................... 5-26
5.5.17.1 CUNO Filter ............................................................................................... 5-26
5.5.17.2 Oil Strainer ................................................................................................. 5-26
5.5.17.3 Scale trap .................................................................................................. 5-26
5.5.17.4 Suction Strainer ......................................................................................... 5-27
5.6 Reassembly ................................................................................................ 5-28
5.6.1 Main Bearing and Main Bearing Head............................................................... 5-30
5.6.2 Crank Shaft ........................................................................................................ 5-31
5.6.3 Bearing Head and Thrust Bearing ..................................................................... 5-32
5.6.4 Shaft Seal and Cover Plate ............................................................................... 5-33
5.6.5 Oil Pump ............................................................................................................ 5-34
5.6.6 Cylinder Block .................................................................................................... 5-35
5.6.6.1 Piston and Piston Ring .............................................................................. 5-35
5.6.6.2 Connecting Rod ......................................................................................... 5-36
5.6.6.3 Cylinder Sleeve ......................................................................................... 5-37
5.6.7 Assembly of Cylinder to the Crank Case ........................................................... 5-38
5.6.8 Adjustment of the Unloader Mechanism............................................................ 5-41
5.6.9 Valve Plate ......................................................................................................... 5-42
5.6.10 Attachment of Strainers and Hand Hole Cover ................................................. 5-43
5.6.11 Idling Check ....................................................................................................... 5-44
5.6.12 Head Cover ........................................................................................................ 5-46
5.6.13 Cooling Water Pipe ............................................................................................ 5-48
5.6.14 Final Inspection .................................................................................................. 5-48
Chapter 6 Troubleshooting
Table 6-1 Troubleshooting ............................................................................................... 6-1
The motor does not start............................................................................................ 6-1
Abnormally high pressure .......................................................................................... 6-2
Discharge pressure is too low ................................................................................... 6-3
The suction pressure is too high ................................................................................ 6-3

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Suction pressure is too low ........................................................................................ 6-3

Abnormal noise during operation ............................................................................... 6-4
Overheating of the crankcase .................................................................................... 6-4
Excessive oil consumption......................................................................................... 6-5
No cooling .................................................................................................................. 6-6
Chapter 7 Related Documents

7.1 Development View of Parts ......................................................................... 7-1
7.2 Parts Configuration Table ........................................................................... 7-5
Table 7-1 Parts for WA-type Compressors ...................................................................... 7-5
Table 7-2 Parts for WB-type Compressors .................................................................... 7-16
7.3 Configuration of Plate Valves and Associated Parts.............................. 7-30
7.4 List of Tightening Torques for Bolts and Nuts........................................ 7-33
7.5 Criteria for Replacement of Parts ............................................................. 7-35
7.5.1 Filters and the Like ............................................................................................ 7-35
7.5.2 Crankshaft ......................................................................................................... 7-35
7.5.3 Connecting Rod ................................................................................................. 7-37
7.5.4 Piston, Piston Pin, and Piston Ring ................................................................... 7-38
7.5.5 Cylinder Sleeve .................................................................................................. 7-39
7.5.6 Discharge Valve Assembly/Suction Valve Assembly ........................................ 7-40
7.5.7 Main Bearing and Thrust Bearing ...................................................................... 7-41
7.5.8 Shaft Seal .......................................................................................................... 7-41
7.5.9 Oil Pump ............................................................................................................ 7-41
7.5.10 Bolts and Other Hardware ................................................................................. 7-41
7.5.11 Gaskets and O-rings .......................................................................................... 7-41
7.6 Standard Initial Assembly Clearance ....................................................... 7-45
7.7 Vibration Criteria ........................................................................................ 7-46
7.8 Disassembly Tools .................................................................................... 7-47
Chapter 8 Contact Information

8.1 How to Order Genuine Parts ................................................... 8-1
8.2 Sales Offices and Service Centers ............................................................. 8-1

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Chapter 1 Safety
Chapter 1 Safety
1.1 Observation/Prevention (DOs and DON'Ts)
1.1.1 DOs
1.1.1.1 DOs on Operation
 Make sure to attach safety and protective devices to the package unit.
 The safety devices and protection systems must be regularly checked for their normal
operation.
 If any safety device or protection system does not function normally or this product operates in
an abnormal manner, immediately stop the work and contact your supervisor. When the
system is to be restarted, you must observe the decision and instruction of the supervisor.
 If this product has stopped operation due to an unknown cause, immediately contact your
supervisor. Before restarting the system, you must seek the decision and instruction of the
supervisor.
 Depending on the type of refrigerant used, its leakage may generate a bad smell or poisonous
gas. Be sure to sufficiently ventilate the room while the machine is operated.
 Regarding the characteristics of the refrigerant and lubricant, e.g., corrosiveness, degradability,
and toxicity, be sure to obtain the Safety Data Sheet (SDS) of them and follow the instructions
given.
 When this product is not to be used for some period of time, close the suction (side) and
discharge (side) stop valves and shut off the motor power source, heater power, and control
power.
1.1.1.2 DOs on Maintenance

 Prepare work procedures based on a work plan. Be sure to perform danger forecasting before
starting the work.
 If two or more people are to work together, be sure to mutually check the work details and
procedures before the work. During the work, always keep track of the other workers’ actions.
 Before working on any troubleshooting during operation, before setting up this product, before
cleaning work, and before conducting maintenance or inspection work, be sure to shut off the
motor power source, control power, and power to other equipment, perform lock-out and
tag-out procedures, and take effective measures to prevent any accidental power-on during
the work.
 Before working on any troubleshooting during operation, before setting up this product, before
cleaning work, and before conducting maintenance or inspection work, be sure to check that
the internal pressure of this product and the refrigeration/cold storage unit is at the
atmospheric pressure.
 Depending on the type of refrigerant used, it may generate a bad smell or poisonous gas or
could cause an oxygen deficient atmosphere. Before starting the work, measure the oxygen
content in the work area, as appropriate, and provide sufficient ventilation. The ventilation
must be continued steadily until the work is completed.
 Regarding the characteristics of the refrigerant and lubricant, e.g., corrosiveness, degradability,
and toxicity, be sure to obtain the Safety Data Sheet (SDS) of them and follow the instructions
given.
 After work, the tools used must be returned to the predefined location. Be sure not to leave
them inside the package unit.
W-Series Reciprocating Compressor 1.1 Observation/Prevention (DOs and DON'Ts)

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2200M4JE-HO-W-N_2014.04.
Chapter 1 Safety
1.1.1.3 DOs on Lockout/Tagout after Shutting Off the Power

 A lock-out/tag-out mechanism must be installed for the main circuit breakers that supply power
to the motor and power to the control system. The lock-out/tag-out after power down is a very
effective means to ensure the safety when two or more workers are working on the system at
the same time, as it can prevent possible injury of workers that may be caused by accidental
power-on of the driving source by one of the workers.
 If there is a risk of danger, especially during cleaning, maintenance/inspection, or
troubleshooting work, be sure to let the workers perform the lock-out/tag-out procedures after
the motor main power and control power has been shut off.
 Because the workers may neglect to perform the lock-out/tag-out procedures or cut-off the
power in the following situations, be sure to instruct them to strictly follow the correct
procedure by clearly identifying the work that require lock-out/tag-out and the reasons why it is
needed.
 As it is a cumbersome task for the workers to cut off the motor main power and control
power and use lock-out/tag-out devices before starting the work, they might neglect to do
it.
 The workers might determine by themselves that it should be OK just to cut off the motor
main power and control power, and not use any lock-out/tag-out devices.
1.1.1.4 DOs about Personal Protective Gear

 The work must be performed by preparing or using the personal protective gear that conforms
to the applicable legal requirements and safety standards.
 Before use, each personal protective gear must be checked for proper functioning.
 Wear designated regular working wear or uniform and securely fasten the cuff buttons.
 Do not wear a tie or other accessories that may get caught by a moving or rotating part.
Wear a helmet as your hair may also get caught.
 Do not have anything in your pocket to prevent objects from falling into the machine.
1.1.1.5 DOs about Handling of Hazardous and Toxic Substances

 For each of the dangerous goods and hazardous materials, obtain the safety data sheet (SDS)
from the manufacturer.
Carefully check the details of the safety data sheet (SDS), handle the material according to the
recommended handling procedures provided by the manufacturer, and keep the SDS in
storage.
1.1.1.6 DOs about Handling Emergency Situations

 Develop an emergency action plan according to the applicable legal requirements and post it
at a safe place.
1.1.1.7 DOs about Waste Oil, Fluid, and Materials

 Disposal of the refrigerant, oil, and other materials used in this product is restricted in various
ways in terms of environmental protection. Be sure to dispose them at the designated site
using specified procedures by observing the rules set forth by the applicable laws, regulations,
and any voluntary regulations of the customer.
W-Series Reciprocating Compressor 1.1 Observation/Prevention (DOs and DON'Ts)

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Chapter 1 Safety
1.1.1.8 Other DOs

 The entire floor around the refrigeration/cold storage unit must always be kept clean, and
safety passages must be provided.
 During work, walk only on the above mentioned safety passages. Note that the safety
passages must always be kept free from hindrances such as tools, cleaning liquid, etc.
 When water or oil is spilled onto this product or on the floor, immediately wipe it off for not to
cause someone to slip and be injured.
1.1.2 DON'Ts
 Never remove or reposition any safety device based on your own judgment, including any
modification of electrical interfaces.
 Never disable the function of safety devices by short-circuit connections or bypassing the
circuits without prior permission.
 Never leave this product in an unsafe condition by removing a safety cover, etc.
 Do not to touch, clean, or lubricate any moving part of this product.
 While power is turned on, never touch any energized part such as a relay terminal or terminal
block by bare hand.
1.2 Warning Notices in this Manual

The warning notices given in this manual inform the user of any dangerous situation that may be
expected during the work using the four categories as listed in the following table.
Ignorance of these warnings can lead to a significant personal injury, and in some extreme cases, it
could lead to loss of life.
In addition, the main unit or any accessory equipment may be severely damaged. Be sure to observe
the instructions in the warning notice.
Table 1-1 Types and Meanings of Warnings
Type Meaning
Indicates that there is a high risk of death or severe injury if it is not avoided.
Indicates that there is a potential risk of death or severe injury if it is not avoided.
Indicates that there is a risk of light or medium injury if it is not avoided.
Indicates that there is a potential risk of property damage if it is not avoided.
W-Series Reciprocating Compressor 1.2 Warning Notices in this Manual

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Chapter 1 Safety
1.3 Residual Risks

The following information is provided assuming that this product will be operated, inspected, and
maintained while it is used in a general refrigeration, cold storage, or air conditioning system.
However, it is impossible for us to foresee all the sources of risk in the particular refrigeration, cold
storage, or air conditioning system that the customer will actually use.
As such, the customer is requested to take proper measures regarding the possible sources of
risk.
Table 1-2 Hazardous Sources
Measures to be taken when
Measures to be taken in
Risk Area Predicted hazard cleaning, inspection,
operation
and/or parts replacement
A Drive system  Contact with or getting  Installation of a guard,  Lock-out/tag-out for the motor
caught in a rotating part cover, or other protection main power and control power
 Falling off of moving part device
 Recovery after  Keep away
interruption of energy
supply
B Head cover  Getting a burn by  Installation of a guard or  Wearing a personal protection
touching it when it is hot other protection device
 Wearing a personal  Perform the work only when
protection device the temperature is 40°C or less
 Keep away
C Discharge  Getting a burn by  Installation of a guard or  Wearing a personal protection
pipe touching it when it is hot other protection device
 Wearing a personal  Perform the work only when
protection device the temperature is 40°C or less
 Keep away
D Unloader  Electric shock  Installation of a guard or  Lock-out/tag-out for the control
solenoid other protection power
valve  Wearing a personal
protection device
 Keep away
E Heater  Electric shock  Installation of a guard,  Lock-out/tag-out for the power
 Burn cover, or other protection to the heater
device  Wearing a personal protection
 Wearing a personal device
protection device  Perform the work only when
 Keep away the temperature is 40°C or less
F Suction  Contact with or  Wearing a personal  Wearing a personal protection
(side) stop inhalation of hazardous protection device device
valve material  Sufficient ventilation  Sufficient ventilation
 Low temperature burn  Installation of a guard or
other protection
G Discharge  Contact with or  Wearing a personal  Wearing a personal protection
(side) stop inhalation of hazardous protection device device
valve material  Sufficient ventilation  Sufficient ventilation
 Burn  Installation of a guard or  Perform the work only when
other protection the temperature is 40°C or less
H Gas purge  Contact with or  Wearing a personal  Wearing a personal protection
valve inhalation of hazardous protection device device
material  Sufficient ventilation  Sufficient ventilation
I Oil drain  Burn  Do not touch while in  Wearing a personal protection
 Contact with hazardous operation device
material  Perform the work only when
the temperature is 40°C or less
J Noise  Hearing impairment due  Wearing a personal —
to loud noise protection device
K Motor  Getting a burn by  Wearing a personal  Lock-out/tag-out for the motor
touching it when it is hot protection device main power and control power
 Electric shock  Wearing a personal protection
device
 Perform the work only when
the temperature is 40°C or less
W-Series Reciprocating Compressor 1.3 Residual Risks

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Chapter 1 Safety
Symbol Risk Area Symbol Risk Area

A Drive system F Suction stop valve
B Head cover G Discharge stop valve
C Discharge pipe H Gas purge valve
D Unloader solenoid valve I Oil drain
E Heater - -
Figure 1-1 Risk Areas (example: 6WA)
W-Series Reciprocating Compressor 1.3 Residual Risks

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Chapter 1 Safety
1.4 Safety Devices

For the safe use and protection of this product, necessary safety devices must be equipped as
required by the applicable laws and regulations and according to the following descriptions.
To keep the safety devices in a normal condition at all times, proper and regular maintenance and
inspection are essential. Accordingly, it must be treated as one of the essential tasks in the
maintenance and inspection activities for the equipment. Be sure to provide the user of this
product with sufficient information regarding the type of safety devices used, their locations,
functions, and how to inspect such safety-related devices.
 Check the safety devices after turning on the power and before operation of this
product. If they do not operate normally, immediately take countermeasures.
1.4.1 Emergency Stop Button

 Overview, functions, and objectives
The emergency stop buttons are used for emergency shutdown of this product when an
emergency situation arises.
 Installation location
At the local control panel and in the operation control room
 Stopping and recovery methods

The operating procedures for the emergency stop button, i.e., how to stop the operation and
restore the normal operating condition, must be clearly defined and the information provided to
the user of this product.
 Inspection method and inspection interval

The emergency stop button must be tested for normal operation before each commission and
at regular interval. The inspection procedures and the inspection interval for the emergency
stop button must be clearly defined and the information provided to the user of this product.
1.4.2 Circuit Breakers for the Motor Main Power and Control Power
(with lock-out/tag-out mechanism)
If there is a risk of danger due to accidental power-on of the drive system during the work being
conducted after the motor main power and control power have been shut off, e.g., during
cleaning, maintenance/inspection, or troubleshooting work, it is necessary to install a
lock-out/tag-out mechanism to the circuit breakers of the motor main power and control power
in order to prevent possible injury of the workers.
 How to implement and restore the lock-out/tag-out function

The methods of implementing and restoring the lock-out/tag-out function must be sufficiently
communicated to the user of this product by clearly describing the said methods by referring to
the relevant specifications provided by OSHA (Occupational Safety & Health Administration) or
others.

Refer to the instruction manual of the unit for the inspection method and inspection interval for
the lock-out/tag-out mechanism.
W-Series Reciprocating Compressor 1.4 Safety Devices

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Chapter 1 Safety
1.4.3 Safety Cover (drive system)

The safety cover is used to prevent the workers from contacting with or getting caught in the
drive system of this product.
1 2
No. Name No. Name

1 Safety cover, drive system (for direct drive) 2 Safety cover, drive system (for belt drive)
Figure 1-2 Example installation of the safety cover for the drive system (6WA)

The inspection procedures and the inspection interval for the safety cover must be clearly
defined and the information provided to the user of this product.
1.4.4 Safety Valve

The safety valves are used to prevent rupture of the compressor when the internal pressure of
the compressor becomes excessively high.
The safety valve on the discharge side must be installed between the compressor and the stop
(service) valve. It must be functional even when the service valve is fully closed while the
compressor is operated.
 The discharge side of the safety valve must be properly processed according to the
applicable laws and regulations for the refrigerant type.
If ammonia gas is released in the air, it is likely to cause health damage such as
intoxication or bad smell. If the gas is discharged into a closed space such as a
machine room, it can cause a significant accident such as oxygen deficit.
 Setting
The set pressure of the safety valve must be at or below the design pressure of the
compressor. The set pressure of the safety valve must be clearly specified and the information
provided to the user of this product.
The safety valve must be tested for normal operation before each commission and at regular
interval. The inspection procedures and the inspection interval for the safety valve must be
clearly specified and the information provided to the user of this product.

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Chapter 1 Safety
1.4.5 Automatic Control and Protection Devices for the Compressor

 Reduced oil pressure protection device (OP)
When the oil pressure of the compressor (i.e., the oil pressure gauge reading minus the
suction pressure) is reduced due to insufficient amount of the refrigerant oil, clogging of
the filter, and/or mixing of refrigerant into the refrigerant oil, this device will automatically
shut down the motor drive circuit to stop the operation of the compressor.
This function prevents the possibility of abnormal friction or seizure of the sliding surface
as well as the inoperability of the unloader.
 High pressure protection device (HP)

When the discharge pressure of the compressor becomes extremely high due to
misoperation of the compressor, no water in the condenser, etc., this device will
automatically cut off the motor circuit to stop the operation of the compressor.
In this way, possible explosion or other harmful effect to the system is prevented.
 Compressor capacity control: Low pressure control device (LP)

For a compressor, the number of cylinders determines the number of capacity control
stages.
In principle, the capacity is controlled for each bank consisting of two cylinders. Thus, if the
compressor has 8 cylinders, the capacity control can be made at 4 stages. Similarly, 6 (4)
cylinder compressors can have 3 (2) stages for capacity control.
There are two methods of capacity control, i.e., one is to automatically control the capacity
by detecting the suction pressure and the other is to manually control the capacity.
The automatic capacity control uses the signal detected by the low pressure control switch
to open or close the solenoid valve in the hydraulic path. This will operate the unloader
piston, which is the mechanism to control the capacity of the compressor. For the
operation sequence, refer to Chapter 4, Section 4.2 “ Operation Sequence of the
Unloader” of this manual.
 Connecting point
Figure 1-3 Pressure Detection Points (2WA, 4WA)

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Chapter 1 Safety
Figure 1-4 Pressure Detection Points (6WA, 8WA, 42WA, 62WA)

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Chapter 1 Safety
 Setting
The setting of reduced oil pressure protection (OP), high oil pressure protection (HP) and low
pressure control (LP) must be clearly specified by referring to the following table and the
information provided to the user of this product.
Table 1-3 Example Setting

Operate (ON) Release (OFF) Timer Recovery
Reduced oil pressure Low pressure + Low pressure + 30 sec. Manual
protection device (OP) 0.15 MPa 0.17 MPa recovery
High pressure protection 2.0 MPa or less* ― None Manual
device (HP) recovery
Low pressure control Depends on the refrigerant used and the system. Automatic
device (LP) recovery
[POINT]
 Set the operating point for the high pressure protection device (HP) at a pressure lower than the
safety valve starting pressure. It is recommended that it is set to a value any abnormality can be
quickly detected, considering the refrigerant used and the system characteristics. In addition, if
the pressure is electrically measured and a control circuit (e.g., sequencer) is used to generate
the alarm, it is recommended to generate a pre-alarm when the pressure gets near the abnormal
level.

Each compressor protection device must be checked for the settings and tested for normal
operation before each commissioning and at regular interval. The inspection procedures and
the inspection interval for each compressor protection device must be clearly specified and the
information provided to the user of this product.
 For the operational test, use a pressurization tester or other device to confirm that
the alarm and/or switch are normally operated. Never operate the compressor in a
dangerous condition, such as when the valves are fully closed.
 If the reduced oil pressure protection device (OP) or high pressure protection device
(HP) is operated, the cause of the operation must be removed before recovery to the
normal operation.

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Chapter 1 Safety
1.4.6 No Water Alarm

This alarm is used to prevent possible overheating of the head cover and/or refrigerant oil due
to the inoperability of the water-cooling head cover and/or water-cooling oil cooler.
Cooling water system
 Setting
The no water alarm setting must be clearly specified and the information provided to the user
of this product.

The no water alarm must be tested for normal operation before each commissioning and at
regular interval. The inspection procedures and the inspection interval for the no water alarm
must be clearly specified and the information provided to the user of this product.
1.4.7 Oil Heater and Thermal Switch
 If the heater and the thermal switch is not dipped in oil when it is powered, the heater
can be easily overheated and broken (heating with no oil).
Always carefully check the oil level before applying power to the heater.

The oil heater is a cartridge-type sheath heater. It is a pressure-resistant sealed type heater,
with the heating wire covered by insulators and the outside of the unit is sealed by a stainless
tube, and is designed to maximize the heat dissipation area.
The oil heater is used to prevent excessive mixing of the refrigerant into the oil as well as to
prevent possible condensation of the refrigerant in the crank case while the compressor is not
operated. As such, it is used only while the system is not operated (not used during operation).
The thermal switch used to control the temperature of the heater is mounted inside the heater.
The temperature setting dial can be checked by opening the heater cover.
 Setting
The thermal switch setting must be clearly specified and the information provided to the user of
this product.

The thermal switch must be tested for normal operation before each commissioning and at
regular interval.
The inspection procedures and the inspection interval for the thermal switch must be clearly
specified and the information provided to the user of this product.

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Chapter 2 Compressor Mechanisms and Specifications

2.1 Compressor Mechanisms
2.1.1 Overview of W-series Compressors
The W-series reciprocating compressors are piston compressors designed to be used
with various types of refrigerant. While the W-series includes type WA, WB, and WJ compressors, this
manual is intended only for the type WA and WB compressors.
The main difference between the WA and WB-types is in the bore/stroke ratio, where the WA-type has
the bore/stroke of 95/76 mm and the WB-type has 130/100 mm.
The WA-type includes 5 different models, i.e., 4WA, 6WA, 8WA, 42WA, and 62WA, and it boasts a long
production run since September 1988.
While the production of the WB-type compressors have been already terminated being succeeded by
the type WBH compressors from January 2006 and further succeeded by the WBHE type compressors
from September 2008, the seven standard models, i.e., 4WB, 6WB, 8WB,12WB, 42WB, 62WB,
12-4WB, in the WB series are mostly still in operation worldwide.
These models have different number of cylinders to meet the needs of the customers for various
capacity ranges. Also, for intermediate capacity range requirements, the rotation speed is changed. In
this way, it is designed to meet a variety of customer needs.
2.1.2 Sectional View of the Compressor
Head cover Head spring
Plate valve
(discharge/suction)
Gasket
Piston and cylinder

sleeve
Crank shaft
Crank case
Figure 2-1 Sectional View of the Compressor
W-Series Reciprocating Compressor 2.1 Compressor Mechanisms

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2.1.3 Gas Compression Mechanism

The inside structure of the compressor is such that the gas discharge compartment is separated from
the gas suction compartment in an integrated construction casted crank case.
The crank shaft, i.e., the drive shaft, which is supported by bearings at both ends, forms a crank to
convert the rotating motion to the reciprocating motion. By linking the connecting rod to the crank
(crank-pin), the piston is moved up and down to suck and compress the refrigerant gas. The crank has
oppositely placed two crank pins (separated by 180 degrees in phase), and each pin is assembled with
the connecting rods, the number of which is half the number of cylinders.
One rotation of the crank shaft makes one up/down cycle of the piston to complete the suction and
discharge strokes.
Top dead center Suction stroke Bottom dead center Discharge stroke
Figure 2-2 Movement of the Crank Shaft and Piston
The W-series has five types of cylinder layout, i.e., 2 cylinders × 2 lines (2 × 2) V-shape layout of 4
cylinders (crank angle interval of 90 degrees), 3 × 2 layout of 6 cylinders (crank angle interval of 60
degrees), 4 × 2 layout of 8 cylinders (crank angle interval of 22.5 degrees), 3 × 4 layout of 12 cylinders
(crank angle interval of 60 degrees), and 4 × 4 layout of 12-4 cylinders (crank angle interval of 45
degrees).
Mechanical seals are used for sealing the crank shaft.
2.1.3.1 Suction Stroke

a) When the piston goes down, the discharge plate valve is pressed onto the seat surface of the
cylinder lip by the gas pressure after the discharge and the discharge spring force.
b) While the piston continues to go down, a pressure difference is generated between the suction gas
chamber and the cylinder, of which gas pressure pushes up the suction plate valve from the path
through the cylinder lip. As a result, the refrigerant gas vaporized in the evaporator is introduced into
the cylinder.
c) When the piston reaches the bottom dead center, the gas chamber pressure becomes
approximately equal to the cylinder internal pressure, and the suction plate valve is pushed onto the
seat surface by the suction spring force. This completes the suction stroke and it move to the
compression stroke.
2.1.3.2 Compression Stroke

a) As the crank shaft rotation continues, the piston starts to go up. When the gas pressure inside the
cylinder starts to increase, the cylinder internal pressure is applied to the back of the suction plate
valve and the valve is further pressed closely onto the seat surface.
b) As the piston further goes up, the pressure inside the cylinder is further increased. When the
pressure exceeds the pressure of the condenser, it pushes up the discharge plate valve to
discharge the gas from the cylinder to compete the compression stroke at the top dead center. By
repeating the above cycle, continuous compression will be made.

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Figure 2-3 Flow of Refrigerant Gas in the Compressor
Figure 2-4 Sectional View of the Cylinder

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 Suction and discharge valves and head spring

The W-series compressors have a valve plate for each cylinder. Each valve plate is fastened to the
crank case together with the discharge valve cage guide.
Although the discharge valve assembly can
move in the up/down direction being guided by
the discharge valve cage guide, it will be fixed
in position during regular operation because it
is pushed down by the head spring.
However, when the pressure is suddenly
increased due to liquid compression for
example, the discharge valve assembly will
push up the head spring to avoid over
compression, thereby protecting the
compressor components such as the piston.
Normal Compressed
(Head spring operates)
Figure 2-5 Head Spring Function
2.1.4 Unloader Mechanism

The unloader (capacity control) mechanism is implemented in order to reduce the start-up load of the
compressor and to deal with the variation in the refrigeration load during operation. The unloader
mechanism is operated by hydraulic pressure. By keeping some suction valves open at all times, it
disables the compression process of the selected cylinders. As such, by changing the number of
disabled cylinders, it can change the capacity of the entire compressor.
Figure 2-6 illustrates the mechanism of operation. While the inlet gas is sucked into the cylinder
through a path provided in the flange of the sleeve, this path is opened or closed by the suction plate
valve (orange ring in the figure). The loaded state is shown to the left side of the figure. When the
unloader piston (shown as a green cylinder) is pushed by the oil pressure, the spring (coil-shaped blue
part) is pushed and compressed to move the unloader push rod (rod in light blue) to the right. The
unloader push rod has two square bosses (to work on two cylinders), and they push the respective cam
rings (dark blue rings) to move them for approximately 15 degrees.
Each cam ring has a slope cut. When one end of the lift pin (red pin) is in this slope cut, the other end of
the lift pin will not make contact with the suction plate valve, making the plate valve freely movable in
the up/down direction. This is the state when the cylinder is loaded for operation.
The unloaded state is shown to the right side of the figure. When the back of the unloader piston is no
more pressed by the oil pressure, the piston moves to the left. As a result, the lift pin will be placed on
the flat part of the cam ring, out of the cut in the cam ring. This positions the lift pin higher than when it is
in the loaded state, and the plate valve is constantly pushed up (to keep the valve open).
As the plate valve is always open, the gas introduced into the cylinder chamber will not be compressed
when the piston goes up and will escape into the suction chamber without changing the gas pressure.
Figure 2-6 Unloader Mechanism

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The internal oil pump will start operation only after the compressor has been started up. Because of this,
the cylinders with an unloader mechanism will not compress the gas until the oil pressure becomes
high enough, even if the hydraulic system has been enabled.
This effect reduces the initial start up torque to some extent. If it is strongly desired to further reduce the
load at the startup, it is recommended to start from the minimum load and to gradually increase the
number of loaded cylinders.
Unloader solenoid valve Manual unloader valve
When it is desired to unload the cylinder, open the unloader solenoid valve (or manual unloader valve)
to release the oil pressure by discharging the oil from the unloader, as the oil from the oil pump is
designed to always flow into (i.e., push) the unloader piston. Close the solenoid valve (or manual
unloader valve) when it is desired to load the cylinder.
By using solenoid valves and low pressure switch or sensor (LP) signals, you can set up the system to
automatically control the capacity.
For the smooth operation of the unloader mechanism, a small item in the oil supply piping is
implemented with a diaphragm of 1 mm diameter, considering the balance between supply and
discharge of the oil.
On the oil discharge side, the W-series compressors are implemented with solenoid (manual) valves
with a 3 mm diameter orifice.
When R404A is to be used as the refrigerant, valves with a 5 mm diameter orifice will be used to avoid
possible slow operation.
When the solenoid valve is closed, the oil out of the oil
pump passes through a 1 mm diameter diaphragm and
pushes the unloader piston in the unloader cylinder.
When the solenoid valve is opened, the oil in the
unloader is discharged to the crank case through a 5
mm diameter orifice and 6 mm (inside diameter) pipe.
Although the oil through the 1 mm diameter orifice is
still supplied, less flow resistance in the discharge side
and the force of the unloader push rod and device
spring prevent the unloader piston from moving. As
such, the unloader piston will not move and the system
will become unloaded.
Either a manual valve or solenoid valve may be used
for the unloader by changing the bonnet.
Figure 2-7 Manual Valve and Solenoid

Valve

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2.1.5 Oil Supply Mechanism
2.1.5.1 Oil Supply Path

A sufficient amount of lubricant will be retained in the oil receiver in the bottom of the crank case, and
the oil will pass through the strainer at the bottom to be sucked by the oil pump attached to the end of
the crank shaft. The resulting pressurized oil will be supplied to the various parts.
The oil pressurized by the oil pump is first

fed to the outside from the main bearing
head through a pipe, cooled by the oil
cooler, and then returned to the crank case
again from the oil cooler outlet. In this, the
flow is slightly different between the WA and
WB-types.
In the case of WA-type, the oil coming out

of the oil cooler is supplied to the bearing
head and then internally branched to the
shaft seal and the thrust bearing.
The oil to the shaft seal is supplied through
a small hole and returns to the crank case
from the top of the bearing head.
The oil to the thrust bearing enters the
crank shaft through a lubrication groove in
the thrust bearing and supplied to the crank
pin and connecting rod, while the remaining
oil is supplied through an oil hole to the
main bearing and main bearing head and
supplied to the unloader. Figure 2-8 Oil flow of WA-type compressors
The remaining oil returns to the crank case
through the pressure control valve.
In the case of WB-type, as the amount of oil

supply from the oil hole in the crank shaft to
the main bearing is insufficient, the oil out of
the oil cooler is also supplied in parallel
using a pipe in the crank case.
Among the WB-type models, as the models
12WB and 12-4WB are with a longer crank
shaft, the oil is supplied from three
locations, i.e., from the intermediate crank
shaft bearing, thrust bearing, and main
bearing, to make it safer.
Figure 2-9 Oil Flow of WB-type Compressors

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Figure 2-10 Oil Flow of Model 12-4WB Compressors
Oil pump for models 12WB and 12-4WB

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2.1.5.2 Oil Pump Types and Design Changes

Different types of oil pumps are used in the W-series compressors, including the ones for WA-type, for
WA-type low speed version (650 min-1 or less), for WA-type to use HFC23 refrigerant, for single stage
WB-type, for two-stage WB-type, and for single stage WB-type to use HFC23 refrigerant. These pumps
have different types of name plates. The following table summarizes the types of oil pumps including
the associated design changes:
Table 2-1 Oil Pump Types and Design Changes for W-series Compressors
Design changes
Comp. Type
Name
Issue date
plate
Pump of design
type Change details Remarks
designation changes
notification
Old and new pump
assemblies are
WA-type Flange thickness: 19 mm → 20 mm compatible with each
Feb. 26,
MA Bolts of main unit: M8 × 4 → M6 × 6 other.
Type A 2007
Fastening bolts: M10 × 30 → M10 × 35 Production was
standard discontinued for old
(excluding units.
R23)
Added a through hole on the shaft, Fastening bolts:
MAS Apr. 25, 2012
changed the model name. M10 × 35
Old and new pump
assemblies are
WB-type single Flange thickness: 19 mm → 20 mm compatible with each
stage Feb. 26,
MB Bolts of main unit: M8 × 4 → M6 × 6 other.
2007
Type B-2 discontinued for old
(excluding units.
R23)
MBS Apr. 25, 2012
Old and new pump
assemblies are
Flange thickness: 19 mm → 20 mm compatible with each
WB-type Feb. 26,
MB2 Bolts of main unit: M8 × 4 → M6 × 6 other.
two-stage unit 2007
discontinued for old
Type B 2.5 units.
MB2S Apr. 25, 2012

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 According to the design change in February 2007, the flange surface is flat (see the
pictures below).
Table 2-2 Oil Pumps for W-series Special Applications

Name plate
Comp. Type Pump designation Remarks
type
12WB and 12-4WB Type 12B MD －
WA, up to 650 min-1 Type A, low speed MA-T
WA, R23 refrigerant Type A, R23 MA-041 Through hole on the shaft,
nitro-carburizing processing
WB single stage, R23
Type B 2, R23 MB-042
refrigerant
Before design change After design change
External appearance of oil pumps before and after the February 2007 design change

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2.1.5.3 Amount of Lubricant and Oil Pressure Adjustment

For both types WA and WB, the oil pressure is measured at the end of the oil supply line. The amount of
lubricant is checked at the oil sight glass. The standard is when the oil level is at the center of the sight
glass. You must supply oil when the oil level is too low to be observed.
Figure 2-11 Management Criteria for the Amount of Lubricant
Table 2-3 Initial Amount of Lubricant to be Supplied (liters)

42W 62W 42W 62W 12W 124W
Model 2WA 4WA 6WA 8WA 4WB 6WB 8WB
A A B B B B
Upper
limit 6.5 16.0 16.6 16.6 19.8 20.6 24.9 29.8 30.7 31.2 32.1 59.5 62.5
Normal 5.0 13.5 11.9 11.9 16.3 16.9 19.9 24.0 25.4 25.6 26.2 48.0 50.5
Lower
limit 3.5 11.5 7.5 7.5 13.0 13.4 15.4 19.4 19.7 20.3 20.9 38.8 40.5
With oil
tank － 30.0 30.0 30.0 35.0 35.0 40.0 45.0 46.0 50.0 50.0 70.0 70.0
The oil pressure is adjusted by the pressure control valve. Adjust the pressure control valve such that
the oil supply pressure is 0.2 to 0.25 MPa (0.4 MPa maximum) higher than the suction pressure.
At the time of starting up the compressor, if the oil temperature is low and the resulting viscosity is high
to cause high oil pressure, the spring will properly function to prevent an excessive high pressure, to
some extent.
Pressure control valve for the main bearing head Figure 2-12 Pressure Control Valve
Mechanism to Prevent
Excessively High Pressure

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2.1.6 Oil Cooler

There are two types of oil coolers used, i.e., refrigerant cooling type (liquid cooling/direct expansion)
and water cooling type.
These are shell and tube type and shell and coil type. In the case of the shell and tube type heat
exchanger, the oil is in the shell side. In the case of the shell and coil type, the oil is in the coil side.
In the past, shell and tube type coolers were generally used for fluorocarbon refrigerant while shell and
coil type coolers were generally used for ammonia refrigerant. However, since 2000, it is the standard
practice to use the shell and tube type coolers for both refrigerant types.
Direct expansion type oil cooler to use

refrigerant
Water cooling type oil cooler

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2.1.7 Shaft Seal and Thrust Bearing
Thrust bearing Part (Standard type) Thrust bearing Part (BB type)
Figure 2-13 Shaft Seal and Thrust Bearing
Table 2-4 List of Component Parts

No. Name Remarks
2 Crank shaft BB type is available
23 Bearing head BB type is available
27 Gasket, cover plate
28 Cover plate fastening bolt
29 Thrust bearing
NH3: Ball bearing (BB)
29-1 Ball/roller bearing (BB type)
Others: Roller bearing
30 Washer for thrust bearing fastening bolt
31 Thrust bearing fastening bolt
34 Double seal collar fixing ring
35 Double seal collar floating seat
36 Double seal collar lock pin
37 O-ring for double seal collar
38 Double seal collar spring
39 O-ring for shaft seal collar
40 Lock nut
41 Shaft seal ring
42 O-ring for shaft seal ring
43 Helical spring

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2.1.7.1 Shaft Seal

Mechanical seals are used for the shaft seals for simple structure and high reliability. There are three
sealing locations (boundaries) to separate the inside compartment of the compressor from the outside
air.
- Fixed part: O-ring for the shaft seal ring of the cover plate
- Fixed part: O-ring for the double seal collar of the crank shaft
- Sliding part: The contact surface between the shaft seal ring and the double seal collar fixing ring
Degradation, scratch, nick, or other defect on the applicable part can cause leakage.
2.1.7.2 Thrust Bearing

There are two types of thrust bearing, i.e., one is the “standard” type, and the other is the “ball bearing”
type (BB-type) thrust bearing.
The thrust bearing receives the thrust load caused by the pressure difference between the internal
pressure and the atmospheric pressure.
If the internal gauge pressure (suction pressure) is to exceed 0.35 MPa, the standard thrust bearing will
not be able to bear the load, and thus the ball bearing (BB) type thrust bearing must be used.
Refer to the note for Section 2.2.2, Table 2-7 for the details of the BB-type bearing.
Figure 2-14 WA-type Shaft Seal Part and Thrust Bearing Part

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2.1.8 Safety Valve

For the standard compressors to be used in Japan, the high pressure side is provided with an external
safety valve.
Figure 2-15 External Safety Valve
2.1.9 Oil Tank

In marine applications, oil tanks are often used. There are two types of oil tanks, i.e., one is the bottom
type to be placed in the base structure, and the other is the side-holding type to be used for directly
connected or common base structure. The former one is directly connected by flanges below the crank
case. Inside the tank is an oil strainer.
Bottom-type oil tank Side-holding type oil tank

(connected by flanges to the crank case)

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2.2 Compressor Specifications

2.2.1 Standard Specifications
Table 2-5 Standard Specifications for the WA-type Compressors
Item Unit 2WA 4WA 6WA 8WA 42WA 62WA
Number of Low-stage: 4 Low-stage: 6
- 2 4 6 8
cylinders High-stage: 2 High-stage: 2
Bore × Stroke mm 95×76
Designed pressure MPa 2.0
Number of -1 800 to
min 800 to 1450
revolutions 1100
Either direction (changing the direction of rotation
Direction of rotation – requires changing the oil pump mounting orientation)
Drive method – Direct drive / V-belt drive
800 min-1 m3/h 51.69 103.38 155.07 206.76 59.96 64.10
Displacement
-1 3
1000 min m /h 63.32 129.22 193.84 258.45 74.95 80.12
m3/h
-1 3 71.07
1200 min m /h -1 155.07 232.60 310.14 89.94 96.14
(1100 min )
-1 3
1450 min m /h － 187.37 281.06 374.75 108.68 116.17
25, 50, 75, 0, 50,100 0, 33, 66, 100
Capacity
Range % 100 50, 100 33, 66, 100

100 (low-stage only) (low-stage only)
control
Hydraulic control Solenoid valve (unloaded when energized)

Method –
/ Manual valve (unloaded when opened)
Selection – Refer to Chapter 4, Section 4.1 “Lubricant (Refrigerant Oil)” of this manual
Lubricant
Oil pressure MPa Suction pressure + 0.20 to 0.25 (0.4 Max.)
Product mass kg 370 580 700 820 720 840

Low-stage: Low-stage:
50A 65A
Since 2001 40A 50A 65A 80A
Suction pipe
High-stage: High-stage:
40A 40A
NH3 50A NH3 65A NH3 80A 50A 65A
Until 2000 40A
Freon 65A Freon 80A Freon 90A High-stage: High-stage:
Connecting pipe
40A 40A
50A 50A
Discharge pipe
Since 2001 40A 50A 65A 65A

High-stage: High-stage:
40A 40A
NH3 65A 50A 50A
Until 2000 40A 50A 65A
Freon 80A High-stage: High-stage:
40A 40A
Pressure gauge 6 mm (Standard) / 8 mm (Marine use)
Cooling water pipe 20A
■ Unless otherwise specified, the pressure unit “MPa” represents the gauge pressure in this manual.
■ The product mass includes the water cooling head cover, oil cooler, and V-pulley.
W-Series Reciprocating Compressor 2.2 Compressor Specifications

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Table 2-6 Standard Specifications for the WB-type Compressors
Item Unit 4WB 6WB 8WB 12WB 42WB 62WB 12·4WB

Low-stage: Low-stage: Low-stage:
Number of 4 6 12
– 4 6 8 12 High-stage: High-stage: High-stage:
cylinders
2 2 4
Bore × Stroke mm 130×100
Designed pressure MPa 2.0
Number of -1
revolutions min 800 to 1200
Either direction (changing the direction of rotation
Direction of rotation – requires changing the oil pump mounting orientation)
Direct Direct drive Direct
Drive method – Direct drive / V-belt drive
drive / V-belt drive drive
Displacement
800 min-1 m3/h 254.72 382.08 509.43 764.14 147.74 157.93 315.85
m3/h
1000 min-1 m3/h 318.40 477.59 636.79 955.19 184.67 197.41 394.82
-1
1200 min m3/h 382.08 573.11 764.15 1146.23 221.61 236.89 473.78
0, 50,100 0, 33, 66, 0, 33, 66,
33, 66, 25, 50,
Range % 50, 100 33, 66, 100 (lower 100 (lower 100 (lower
100 75, 100
Capacity
stage only) stage only) stage only)

control
Method – Hydraulic control Solenoid valve (unloaded when energized) /

Manual valve (unloaded when opened)
Lubricant
Selection – Refer to Chapter 4, Section 4.1 “Lubricant (Refrigerant Oil)” of this manual
Oil
pressure MPa Suction pressure + 0.20 to 0.25 (0.4 Max.)
Product mass kg 1100 1410 1550 3300 1440 1560 3900

Since Production 80A 100A Production
80A 100A 100A
Suction pipe
2001 terminated High-stage: High-stage: terminated

65A 65A
NH3 90A NH3 100A
80A 90A 125A
Until 2000 90A Freon Freon 90A
High-stage: High-stage: High-stage:
100A 125A
Connecting pipe
65A 65A 80A

Since Production 65A 65A Production
Discharge pipe
80A 80A 100A

2001 terminated High-stage: High-stage: terminated
50A 50A
NH3 80A NH3 90A
65A 65A 80A x 2
Until 2000 80A Freon Freon 80A
High-stage: High-stage: High-stage:
90A 100A
50A 50A 50A x 2
Pressure gauge 6mm (Standard) / 8mm (Marine use)
Cooling water pipe 20A
■ Unless otherwise specified, the pressure unit “MPa” represents the gauge pressure in this manual.
■ The product mass includes that of the water cooling head cover, oil cooler, and V-pulley.
However, the mass of the flywheel is not included for the direct motor drive type 12WB and 12-4WB
compressors.

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2.2.2 Operation Limits and Operation Range

 Operation limits
Table 2-7 Service Limits for the Compressor
Item Unit WA-type / WB-type Remarks

Maximum discharge
MPa 1.96
pressure
If it exceeds 0.35 MPa and less
Maximum suction than 0.59 MPa, select the BB
MPa 0.35
pressure type (refer to the comment
below)
Minimum suction
MPa -0.073 (-550 mmHg)
pressure
Single stage machine:
Maximum differential
1.47
pressure at high/low MPa
Two stage machine:
pressure
1.52
Maximum oil supply
MPa Ps + 0.4 Ps = Suction pressure
pressure
Minimum oil supply
MPa Ps + 0.10 Ps = Suction pressure
pressure
Maximum discharge 120 (Freon)

°C
gas temperature 140 (NH3)
Maximum supply oil Temperature at oil cooler outlet

°C 50
temperature port
Minimum supply oil
°C 30
temperature
Cooling water outlet
°C 50 or less Temperature at jacket outlet
temperature
Cooling water pressure MPa 0.5 or less
Degree of superheat:
°C 20 or less Liquid flow-back is not allowed.
SH
Maximum belt drive WA-type: 75
kW
power WB-type: 115
■ Unless otherwise specified, the pressure unit “MPa” represents the gauge pressure in
this manual.
■ Refer to Chapter 4, Section 4.4.1 “Start/Stop Limit” of this manual for the limitations (start
and stop limits) to be applied when the running compressor is stopped and restarted.
■ BB (Ball bearing) specification
The standard specification for the W-series compressors assumes the operation limit
suction pressure of 0.35 MPa. If the suction pressure is more than 0.35 MPa and less than
0.59 MPa, you can use the compressor by choosing the BB (ball bearing) type specification.
The BB specification model will have a special crank shaft, bearing heads, and thrust
bearings that are exclusively used for the BB-type models.
For BB-type models, two types of thrust bearing portions are used. The combination of thrust
bearing and ball bearing is used for ammonia refrigerant, and the combination of thrust
bearing and roller bearing is used for other refrigerants.

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2.2.3 Outer Dimensions
Figure 2-16 Outer Dimensions Diagram 2WA

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Figure 2-22 Outer Dimensions Diagram 4WB (for reference)

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2.3 V-pulley
Table 2-8 V-pulley Chamfer Specification
Model
V-pulley 4WA 6WA 4WB 6WB
2WA 8WA 8WB
42WA 62WA 42WB 62WB
Outer diameter 350 406 406 406 460 460 460
Chamfer
C4 C4 C6 C8 C8 C10 C12
specification
2.4 Direct Coupling
Figure 2-27 Sectional View of Direct Coupling
Table 2-9 Direct Coupling

Model Coupling name Coupling type D (mm)
in Figure 2-27
A, WA BB-290 A4-40-PN-139.7 Standard (139.7)
B, WB, WBH BX-600-142.7 AB-50-PN-190.5 Custom (190.5)
B, WB, WBH, 12WB
(90 kW or more) GB03-190.5 GB-03-PN-190.5 Custom (190.5)
W-Series Reciprocating Compressor 2.3 V-pulley

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3.1 Safety Precautions during Installation
[POINT]
 The description in Chapter 3 “Installation” assumes that the compressor is installed to a package
unit intended for standard type refrigeration/cold storage.
If the package unit you are actually using is not the one for standard type refrigeration/cold
storage, prepare a proper installation manual by referring to the description in this chapter and
paying due consideration to safety, before installing the compressor.
If there are any questions, please contact one of our local sales offices or service centers.
 In some cases, it may be required that installation is performed by qualified personnel. Make
sure that the work is performed by qualified personnel in compliance with local laws,
ordinances and other regulations/requirements.
 Read this chapter and related documents, and fully understand their contents before
performing installation.
 Electrical works should be performed only by electrical engineers.
3.2 Installation Work

3.2.1 Unpacking
Check that the compressor is free from any damage or abnormality.
[POINT]
 If there is any abnormality or missing part with the compressor, please contact one of our sales
or service establishments.
 All packing materials that are no more needed after unpacking must be disposed of in a carefully
controlled manner in accordance with the applicable laws, regulations, and any voluntary
regulations of the customer.
3.2.2 Storage
If the compressor is to be stored before the installation:
 Keep it indoors, and
 Fill the compressor with Nitrogen gas and seal it (at the gauge pressure of approx. 0.15 MPa).
[POINT]
 Upon packing, the compressor is filled with Nitrogen gas to prevent rust.
3.2.3 Transportation
 Should the compressor being lifted up drop, there is a high risk of death or severe
injury. Provide sufficient protection such that no one can enter an area below a
compressor being lifted up.
For the weight of the compressor, refer to Table 2-5 “Standard Specifications for the WA-type
Compressors” or Table 2-6 “Standard Specifications for the WB-type Compressors” in Chapter 2,
Section 2.2.1 of this manual. For the outer dimensions, refer to Chapter 2, Section 2.2.3 “Outer
Dimensions” of this manual.
W-Series Reciprocating Compressor 3.1 Safety Precautions during Installation

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1. When lifting the compressor, be sure to prepare and use a lifting device and other proper tools
capable of lifting the compressor weight within the specified safety load limit.
2. A sufficient space must be provided to ensure that the lifting work can be safely conducted.
3. Make sure to check the wire ropes before use. Carefully check the wire ropes for any kink, knot, or
broken strand. Never perform the lifting work before it has been confirmed that the wire ropes
have no problems. If any doubt remains, ask a qualified specialist to check the condition.
4. If only the compressor body is to be lifted, use the eye bolts of the compressor to hook the wire
ropes.
5. If the base structure and motor are attached to the compressor, use the eye bolts of the
compressor and the base structure to hook the wire ropes. Never use the eye bolts of the motor.
6. Check that the transportation path is free from any obstacles that can hinder smooth transport,
according to the size of the compressor.
7. Before lifting, check that the hook is positioned above the center of gravity of the compressor.
8. Before starting to lift up the compressor, instruct all the workers to be sufficiently away from the
lifting area.
9. Just before starting to lift up, provide the coworkers with a sign (such as a call, hand signal, etc.)
of starting the lifting action. Do not start to lift up unless the sign (such as a call, hand signal, etc.)
has been fully acknowledged.
10. Slowly wind the wire ropes up to the point the compressor is about to leave the ground.
11. Then, wind up the wire ropes a little further until the compressor is slightly up away from the
ground. Check that the compressor is not tilted. If the compressor is tilted, return the compressor
to the ground and correct the tilt by adjusting the wire ropes. After that, restart the lifting operation.
12. Slowly lift up the compressor. A sudden lifting may cause damage to the wire ropes and/or other
hoisting tools or some part of the compressor.
13. After the hoisting has started, check the condition to see that the wire ropes and other hoisting
tools are in normal condition. Check that the compressor is not tilted.
14. When moving the compressor in the lifted condition, be sure to use guiding ropes.
15. Evacuate people from the forward path and check the safety in the direction of the movement.
16. Do not lift the compressor above the safety passage unless absolutely necessary.
17. Do not place the compressor on a safety passage. The safety passages shall always be kept
unblocked.
18. Before lifting down the compressor, clear the area from any obstacles. Make sure the compressor
will not be tilted or become unstable.
19. When lifting down the compressor, also notify the coworkers around the area of the fact.
20. If the compressor is to be placed on two or more blocks, properly adjust the height of each block
for the compressor to be stably leveled on the blocks.
21. Be sure to carefully and gradually lift down the compressor so that it is not damaged by shock.
W-Series Reciprocating Compressor 3.2 Installation Work

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3.2.4 Preparation for Installation

 Installation space
Prepare an installation space where the operation, cleaning, maintenance, and inspection work can
be easily performed by referring to the relevant figures in Chapter 2, Section 2.2.3 “Outer
Dimensions” of this manual.
Because the crank shaft must be taken out from the main body during an overhaul work, a
sufficient space must be provided on the bearing head side, for a length corresponding to the full
width of the crank shaft, as measured from the crank case end. Also on the opposite main bearing
side, a space of more than 60% of the full crank shaft length shall be provided.
In addition, along the direction of taking out the cylinders, a clearance of at least 500 (650) mm
shall be provided for the WA-type (WB-type), to avoid interference with other components such as
pipes.
 Lighting
Provide sufficient lighting to allow easy operation, cleaning, maintenance, and inspection work.
 Ventilation
If natural ventilation is not sufficient, install proper ventilation fans according to the laws and
regulations.
 Cooling water
Ensure that a sufficient amount of cooling water is provided as required by the customer’s system.
 Piping
Refer to the relevant figures in Chapter 2, Section 2.2.3 “Outer Dimensions” of this manual.
3.2.5 Installation
3.2.5.1 Placement
Make sure that the compressor mounting surface of the target refrigeration, cold storage, or air
conditioning system is sufficiently flat and level. If it is not sufficiently leveled, tightly fastening the
compressor mounting bolts can cause deformation of the compressor and could hinder normal
operation.
3.2.5.2 Return Oil from Oil Separator

Use a float valve, and do not return oil from the receiver.
3.2.5.3 Protection Device

To protect the compressor and prevent accidents, install the following protection devices.
For details, refer to Chapter 1, Section 1.4.5 “Automatic control and protection for the compressor” of
this manual.

 Low pressure control device (LP)

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3.2.5.4 Piping
The vibration of the compressor will be transmitted to the building via the base structure and the pipe
lines. Be careful about the installation of piping supports to prevent possible resonance of the building.
 Refrigerant piping
Be careful about the following points in connecting the refrigerant pipe line:
 The compressor is one of a few components that have movable parts in the target system.
Such movable parts are vulnerable to dust, dirt, and other foreign matters. Be careful during
the plumbing work not to put scales and other foreign matters inside the compressor.
 Some compressors (mainly the ones to be shipped overseas) are filled with Nitrogen gas to
prevent rust. Therefore, do not open the suction/discharge stop valves until it is needed to do
so.
 There must be no moisture in the piping system. Any moisture inside can cause troubles after
the operation has started. Be sure to connect pipes in dry condition.
 Improper work on the suction gas piping can cause problems such as no oil return to the
compressor and liquid hammering.
 When connecting a pipe to the compressor, be sure to use the same pipe size as that of the
compressor. If the size of the connecting pipe is smaller than that of the compressor, the flow
of the oil or refrigerant is impeded and can cause problems.
 Every connecting pipe must have a support for not to apply excess stress to the compressor.
Also, if vibration isolators are used for the base, the piping system must use suitable flexible
tubes.
 If generation of dew is expected for the pipe, it must be isolated.
 Cooling water pipe

Refer to the cooling water pipe system illustrated in Section 5.5.1 of this manual.
General precautions are as follows:
 No branching is allowed in the cooling water system from the oil cooler to the head
jacket. Otherwise, the resulting pressure loss (resistance) difference can stop the
flow of the cooling water at some places, and it is very dangerous.
 Overheating of the compressor will easily degrade the oil on the discharge side. Be
sure to operate the compressor with a sufficient flow of water.
If water-cooled oil cooler and water-cooled head cover are used, pay sufficient attention to the following
points when connecting the cooling water pipes:
 In the case of automatic operation, use a solenoid valve to prevent water flow when the motor
is stopped. If water flow is maintained while the motor is not operating, the refrigerant in the
refrigerator can condense, and as a result, it can cause increased oil consumption, valve
damage, and/or seizure of cylinders.

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Drive Mechanism (V-belts Drive)
 If any V-belt is to be replaced by a new one, replace all the V-belts together as a set,
by procuring a set of V-belts.
Even if the nominal dimension is the same, the length may vary to some extent. In
such a case, the force may be applied only on the shortest one, and it can damage the
belt or cause abnormal vibration.
Also, if new and old belts are mixed together, it can cause abnormal vibration due to
the different levels of wear.
 The V-belts must be kept free from oil or grease. Wipe out any oil or grease if
attached.
[POINT]
 Although the V-belts are tensioned to the specified initial tension at factory shipment of the
V-belts drive unit, initial elongation before they are actually used for operation may result in the
tension less than the minimum tension load. Be sure to check the tension load after the
installation, and adjust it to the correct tension load for new belts before starting the operation.
3.2.6.1 Alignment Method and Criteria

Check that the centerline of the refrigerator shaft and the centerline of the motor shaft are exactly
parallel with each other by using a stretched string from the side of the compressor V-pulley to the side
of the motor pulley. If they are misaligned, the high speed rotation accelerates the wear of belts, applies
excessive stress on the bearings, and shortens the service life of the refrigerator and motor.
Alignment criteria: L = 1 mm max.
Figure 3-1 Alignment Criteria

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3.2.6.2 Belt Tensioning

Loosen the slide base of the motor to get the pulleys of the compressor and motor closer, and place the
V-belts into their slots in the loosened state. After checking that the V-belts are correctly placed into the
V-grooves, apply tension to the belts by pulling the motor by fastening the bolt.
Deflection = 0.008 × span length (mm) (Span length is nearly equal to the wheelbase)
1: Tension meter
2: Wheelbase
3: Deflection
4: Span length
Figure 3-2 Deflection
Table 3-1 Quick Reference for the Deflection (mm)

Wheelbase
Compressor V-belt type
1000 1100 1200 1300 1400 1500
WA-type
C-type standard & red 16 18 19 21 22 24
WB-type
Table 3-2 Quick Reference for Tension Load (N per belt)

New belt Re-tensioning Minimum tension
Compressor V-belt type
load
WA-type
C-type standard & red 40 to 45 30 to 35 25 min.
WB-type
Note 1: The first re-tensioning shall be made 2 to 3 hours after the operation has started.
Note 2: To check the tensioning of the V-belts, rotate the pulley to check the tension load.
Note 3: When the minimum tension load is used, as it varies with the load condition, make sure that
the belts do not act violently during operation.
Note 4: The re-tensioning after one year’s operation shall be 25 N per belt.
[POINT]
 When new belts are used for 2 to 3 hours for the first time, the initial elongation, initial friction,
and removal of V-pulley paint will significantly reduce the tension load of them, to result in a load
less than the minimum tension load. If the use of the V-belts is continued in this condition, not
only the slippage of V-belts can reduce the service life of the belts but also can the belts act
violently, turn over due to one-sided wear, disengage, or cause other problems. Be sure to
re-tension the belts after the commissioning.
 Insufficient tension will reduce the service life of the belts. If the belts are replaced by new ones,
check the tension again after they have been used for 24 to 48 hours.

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Drive Mechanism (Direct drive)
Table 3-3 Allowable Misalignment
In the case of a direct drive, adjust the center-to- Allowable limit
center alignment between the compressor and the Eccentricity 6/100 mm
drive mechanism to within the allowable limit given in
3/100 mm
the table to the right. Deflection
(referenced to 100 mm
angle
diameter)
The concept of the measurement setup to use a special hub, dial gauge, and magnet stand is shown in
Figure 3-3 and Figure 3-4 for the eccentricity and deflection angle measurements, respectively. If more
details are required regarding the alignment work, please contact one of our sales offices or service
centers.
Figure 3-3 Shaft Eccentricity Figure 3-4 Shaft Deflection Angle

Measurement Measurement
3.2.8 Initial Charge
3.2.8.1 Lubricant
Perform initial charge of the lubricant by referring to Chapter 4, Section 4.1.3 “Initial Charging Method”.
3.2.8.2 Refrigerant
Fill the refrigerant according to the instruction manual for the package unit.
3.2.9 Checkout after Installation

The customer is requested to develop its own checklist and checkout procedures appropriate to the
customer’s own refrigeration, cold storage, or air conditioning system, by using the following summary
descriptions on the inspection items to be checked after installation of the compressor as a reference
material.
 Wiring for the automatic control

 Wiring between the control panel and switches
 Motor startup method (automatic/semi-automatic) and direction of rotation
 Insulation resistance of the motor

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 Operational test for protection devices

For details, refer to Chapter 1, Section 1.4.5 “Automatic Control and Protection for the Compressor”
of this manual.

 Low pressure control device (LP) and unloader solenoid valve
 Airtightness test and refrigerant leak test

The customer is requested to conduct the airtightness test and refrigerant leak test for the system.
 Never use oxygen or flammable gas for the airtightness test. Otherwise, there is a
risk of explosion.
 If carbon dioxide is used for the airtightness test of a compressor that uses
ammonia as a refrigerant, it may result in the deposition of ammonium carbonate,
and it can cause a failure.

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4.1 Lubricant (Refrigerant Oil)

The lubricant (refrigerant oil) is used for the purpose of lubricating the moving/sliding members of the
compressor, preventing abnormal wear, and cooling each section. For this, the following properties are
required for the oil:
 An appropriate viscosity is maintained within the operating temperature and pressure ranges.
 The liquidity is maintained even under extreme low temperature conditions (within the operating
temperature range of the refrigerating system).
 It is chemically stable and will not corrode or change the quality of the components used (such
as metals or rubbers).
 The wax component will not be separated even under low temperature conditions.
 Sludge and carbon are not easily generated even under high temperature conditions.
 Water is not contained.
4.1.1 Precautions for Selecting the Lubricant

 The type (brand) of the lubricant depends on the refrigerant to be used. For details, contact one
of our sales offices or service centers.
 For NH3 refrigerant, do not use polyolester (POE) or Poly alpha olefin (PAO).
 Mineral oils as specified in ISO-VG 46 – 68 are recommended.
As the minimum requirement, the required viscosity shall be ensured for the oils supplied to
sliding members. If any lubricant that can absorb a significant amount of refrigerant
(inter-soluble oil) is used, the viscosity under the operating conditions may significantly be
reduced from that specified in the product specification. Select a lubricant that can maintain the
viscosity of 20 to 70 mm2/s under normal operating conditions.
 Take into account the circulation of the lubricant in the entire system. After lubricating and
cooling the various sections of the compressor, the lubricant will mostly return to the oil receiver
of the crank case. However, some part of the lubricant will be discharged together with the
refrigerant. While the oil discharged from the compressor will mostly be captured by the oil
separator and returned to the compressor, some part will be sent to the condenser and
evaporator. As such, the lubricant is required to maintain a sufficient liquidity and stability in the
various types of components with varying temperature range.
4.1.2 Change of Lubricant Brand

 When the brand of the lubricant used is changed, mixing of the old and new oils can cause
unexpected problems. Pay sufficient attention when you are to change the lubricant.
 If the manufacturers are different, contact both of them to check if there is no problem. Even if
the manufacturer is the same, similar confirmation is required when the brand name of the
lubricant is to be changed.
 There is no problem in changing the viscosity grade within the same brand. However, the
viscosity grade after the change must be suitable to the operation.
W-Series Reciprocating Compressor 4.1 Lubricant (Refrigerant Oil)

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4.1.3 Initial Charging Method

The initial charge and oil supply after an overhaul
is made from the initial charge port, in order to fill
the oil cooler, oil filter, and all the oil paths with
the lubricant.
Figure 4-1 Initial Charge Port for the Lubricant
4.1.4 Replenishment of Lubricant

The oil level will gradually become lower as the operation is continued. Supply additional oil according
to the following procedures while the oil level can still be checked at the oil sight glass. For the decision
regarding the amount of oil, refer to Chapter 2, Section 2.1.5.3, Figure 2-11 “Management Criteria for
the Amount of Lubricant” in this manual.
 When filling lubricant, prevent air and moisture from entering the oil.
 The refrigerant oil to be replenished must be clean, with no contamination.
 To prevent bubbling inside the crank case, be sure to slowly and gradually supply the
oil.
 The refrigerant oil must be stored under sealed conditions until it is used, for not to
absorb moisture in the air.
[How to supply oil while in operation (example)]
a) Attach the charge hose to the oil supply and discharge valve shown in Figure 4-2, and put the end
of the hose into the can of new oil.
Then, slightly open the valve to purge the air
inside the hose using the gas pressure in the
compressor.
b) Gradually close the suction stop valve of the
compressor to the point the suction pressure is
only slightly vacuumed (approx. -0.026 MPa).
c) Gradually open the oil supply and discharge
valve to constantly suck the oil.
d) After the required amount of oil has been
supplied, securely close the oil supply and
discharge valve.
e) Gradually open the suction stop valve to
resume the steady operation. Fig. 4-2 Oil Supply and Discharge Valve
4.1.5 Oil Pressure Setting

Adjust the oil pressure control valve to make the oil pressure 0.20 to 0.25 MPa (0.4 MPa maximum)
higher than the suction pressure.
W-Series Reciprocating Compressor 4.1 Lubricant (Refrigerant Oil)

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4.2 Operation Sequence of the Unloader

The figure below shows the operation sequence of the unloader. The number in parentheses indicates
the order of the unloading sequence. In the figures of 12WB and 12-4WB, the lines connecting between
banks indicate that the connected banks are mechanically linked to operate together.
Figure 4-3 Unloader Operation Sequence
W-Series Reciprocating Compressor 4.2 Operation Sequence of the Unloader

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4.3 Initial Operation

4.3.1 Precautions for Initial Operation
 Check the open/close status of each valve before operation. In particular, operating
the compressor with the high pressure side valves closed carries a risk that it may
cause a rupture. Also, if the valves that connect to various protection devices are
closed, the protection devices will not operate properly.
 Be sure to fully open the source valve of safety valves at all times, except when the
safety valves are to be inspected.
 Before operation, the belt (coupling) guard must be attached. Operating the
compressor without installing the belt (coupling) guard carries a risk that the
operator could be caught in rotating parts to result in severe personal injury or death.
 Ensure that sufficient safety measures are in place when operating valves or
conducting inspection with the compressor running. While the compressor is
running, there are all sorts of risks including death, severe injury, minor injury,
electric shock, burn, and so on.
The refrigerant system installed must be operated for a long time maintaining the initial functions. For
this, the initial operation has an important significance.
Within 24 hours after starting the initial operation, dust, scale, rust, sand, and other foreign matters in
the pipe system tend to be collected in the compressor being carried by the flow of refrigerant gas. Tiny
foreign matters not captured by the suction strainer or scale trap will be mixed in the oil and can cause
a failure or abnormal wear.
While sucking of foreign matters into the compressor lasts for a long time during operation, the amount
of such matters is the largest during this initial period of operation.
Check the existence of foreign matters by inspecting the suction strainer and scale trap, and also by
checking the contamination of the lubricant.
As the condition of the oil in the crank case should indicate the state of contamination in the refrigerant
system, you can determine that the inside of the system is clean if the oil in the crank case is kept clean
and clear for a long period of time. If the oil is dark or impure dark brown, some foreign matters in the
system are contaminating the oil. In such a case, be sure to change the oil as soon as possible to
prevent foreign matters from entering the sliding/moving parts of the compressor.
In particular, check for any abnormal overheating or abnormal noise in the compressor.
[POINT]
 When cleaning the oil strainer and suction strainer/scale trap, it is necessary to properly process
the refrigerant and to open the compressor. For the processing of the refrigerant and compressor
disassembly/assembly procedures, refer to Chapter 5, “Maintenance and Inspection” of this
manual.
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4.3.2 Initial Operation Method
 If the compressor to be used has been in storage for a long time, i.e., more than
one year after the delivery, be sure to open each head cover, hand hole cover, and
seal cover to check the inside. At that time, supply sufficient oil to the opened parts
and change the O-ring of each mechanical seal.
a) Before running the compressor, perform manual turn or inching (short run of 1 to 2 seconds) for a
few times to check that the oil pressure gauge is operational. Also check at the sight glass that the
oil level is slightly lowered at the same time.
b) Operate the compressor.
c) Perform the initial operation according to Table 4-1 “Guidelines for Oil Replacement and Filter
Inspection”.
Table 4-1 Guidelines for Oil Replacement and Filter Inspection

Replacement of oil and Cleaning of suction
Elapsed time
cleaning of oil strainer strainer
After completion of refrigerant
must recommended
charging operation
After completion of
commission must must
100 hours after starting
operation must must
500 hours after starting Oil analysis
operation Cleaning of oil strainer must
Note:
If contamination of the lubricant or clogging of the filter is found, perform oil replacement or
inspection/cleaning regardless of the above guideline.
W-Series Reciprocating Compressor 4.3 Initial Operation

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4.4 Operating Precautions

For the daily control items and their details, refer to Chapter 5, Section 5.1 of this manual. Other
important operating precautions are given in the following paragraphs.
4.4.1 Start/Stop Limit

For normal operation of the compressor, the start/stop limits, stop duration, and other requirements are
specified as follows.
The start/stop times and stop duration are specified in order to prevent possible burning of electric
circuits and components or overheating and seizure of the compressor cylinders.
Table 4-2 Specifications for Start/Stop Times, Stop Duration, etc.
Limit
Item
Water cooled type Air cooled type
Number of start/stop cycles 4 cycles per hour 2 cycles per hour
Minimum stop duration 15 minutes or more 30 minutes or more
Minimum operation time 15 minutes or more
Number of unloader operations 5 times per hour or less
4.4.2 Liquid Flow-Back Prevention

The “liquid flow-back” is a phenomenon when the refrigerant liquid reaches the compressor without
being completely evaporated with the gas. The liquid flow-back phenomenon may cause insufficient
lubrication of the compressor, generation of abnormal vibration and noise, and/or abnormal foaming of
the lubricant (oil loss). To prevent liquid flow-back operation, properly adjust the expansion valve of
each cooler.
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4.5 Action to Take when the Compressor is Stopped for a

Long Time
If the compressor is to be stopped for a long time, be sure to recover the refrigerant from the
compressor, close the suction and discharge stop valves and the stop valve in the downstream of the
oil filter of the oil supply line, and shut off the main power to the motor, heater power, and power to the
control panel.
If the inoperative period lasts for a month or longer, perform the following services once a month:
 Measure the pressure of the system;
 Check for any leak of refrigerant from each section of the system; and
 Turn the compressor shaft (for at least 10 turns).
When the system is to be operated after being inoperative for one year or longer, check for any
refrigerant leak and replace the oil.
In addition, open each head cover, hand hole cover, and seal cover to check the inside. At that time,
supply sufficient oil to the opened parts and change the O-ring of each mechanical seal.
Measure the insulation resistance of the motor to confirm that it can run without problems.
Apply power to the oil heater at least one hour prior to starting the operation. Also, before starting to
operate the system, check the temperature and pressure inside the package to make sure that the
refrigerant is not condensed in the package.
W-Series Reciprocating Compressor 4.5 Action to Take when the Compressor is Stopped for a Long Time
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5.1 Precautions for Maintenance and Inspection

 After completing the refrigerant recovery work and before working on the maintenance and
inspection, be sure to shut off the main motor power, control power, and other power to each
piece of equipment and valve. After they are shut off, be sure to make the switches inoperable
by others. Also, be sure to attach notification tags to prohibit operation (lock-out/tag-out).
 When any manual stop valve has been closed, be sure to make the valve inoperable by others
and put a notification tag to prohibit operation (tag-out).
 Disassembly, inspection, and handling of the compressor shall be performed only after the
disassembly and assembly procedures have been sufficiently understood. This manual is not
intended to provide complete disassembly and assembly procedures for the compressor.
Instead, it describes only the important points regarding the maintenance service for the
compressor.
 If complete disassembly and assembly procedures for the compressor are required, please
contact your nearest branch or sales office of our company.
 Be sure to use only genuine parts for replacement. Using anything other than
genuine parts may result in an unexpected problem.
 Do not convert or modify the compressor or its components without prior permission from
MAYEKAWA. Otherwise, it can lead to a damage of the compressor or failure to maintain the
function of the compressor.
 When disassembling/assembling the compressor, use the correct tools specified.
 When the compressor is to be overhauled, check that the internal pressure of the refrigerator is
at the atmospheric pressure before starting the work.
 Make sure that the temperature of the high temperature sections such as head covers and
discharge lines is at normal ambient temperature, before working on them.
 Whenever handling a heavy object, take sufficient care and use effective support tools such as
stud bolts (safety bolts).
 When handling a heavy object, use a crane or other lifting device. Otherwise, the work must be
done by at least two people.
 When two or more people are to work together, be sure to mutually check the respective roles
in the work and always keep track of the other workers’ actions.
 Each power must be turned on and off carefully by a qualified personnel, for not to cause
electric shock accidents.
 If qualification is required in working on other electrical equipment or structure, be sure to have
the work carried out by a qualified person.
W-Series Reciprocating Compressor 5.1 Precautions for Maintenance and Inspection

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5.2 Maintenance and Inspection List

5.2.1 Daily Management
For the purpose of daily maintenance, check the items listed in Table 5-1 “Daily Inspection Items” and
record the results.
By regularly recording the daily operational data in an operation log, it should be able to detect any
significant change in the system. This practice is particularly effective in preventing possible failures of
the compressor.
It is particularly important to keep track of the records that indicate the relationship between the
temperature and pressure, as it is closely related to the evaporation and condensation of the
refrigerant, in quickly finding any abnormal condition of the compressor or the system.
Keeping an operation log can facilitate the efforts to properly track down the cause of failure or accident
that may occur in the compressor or the system, making it easier to quickly and accurately deal with
the situation.
Besides the ones in Table 5-1, there are other check points to be regularly observed, recorded, and
managed in other components of the refrigeration system as well as in the load conditions. For these
points, please refer to the instruction manual of each component unit of the refrigeration system.
Table 5-1 Daily Inspection Items
Inspection item Inspection details Remarks

Hours of operation h Total hours of operation  Used to determine the interval
Compressor
of regular maintenance and

inspection
Suction pressure MPa Difference from the specified  Cleanliness of the cooling pipe
pressure for the specified surface
evaporation temperature  Temperature and flow of the
items cooled
Discharge MPa Difference from the condensation  Cleanliness of the condenser
pressure pressure for the specified cooling cooling pipe
water temperature  Mixing of non-condensing gas
 Amount and temperature of the
cooling water
Oil supply MPa Difference from the discharge  Whether the differential
pressure pressure pressure is decreasing or not
 Liquid flow-back operation
 Wear of compressor parts
Suction °C Whether the upper/lower limit  Temperature and flow of the
temperature temperatures are not exceeded items cooled
Discharge °C Whether it is within the upper limit  Mixing of non-condensing gas
temperature temperature  Supply oil temperature,
insufficient amount of oil
 Failure of the compressor
Supply oil °C Whether upper/lower limit  Cleanliness of the cooling pipe
temperature temperatures are not exceeded of the oil cooler
Oil level in the – Whether upper/lower limits are  Note that the apparent oil level
crank case not exceeded rises if the refrigerant is highly
absorbed in the oil.
Leakage from mL/h Amount of leak per hour: Guideline for inspection:
shaft seal - Normal leak with WA-type: ≤3  WA-type overhaul: ≥9
- Normal leak with WB-type: ≤6  WB-type overhaul: ≥18
Noise and – Abnormal noise or vibration  Failure of the
vibration compressor/motor
 Problems with belts/coupling
Cooling water – Water leak, disengagement
hose
W-Series Reciprocating Compressor 5.2 Maintenance and Inspection List

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Inspection item Inspection details Remarks

Motor current A Whether it is increased from the  Failure of the compressor
Others
time of the commission

Temperature °C Whether it is within the  Overheating and failure of the
inside machine acceptable temperature range for motor
room the motor
Liquid level of the － Liquid level height  Add refrigerant
liquid receiver
Refrigerant leak － Any refrigerant leak  In the machine room and in the
check facility on the load side
■ Unless otherwise noted, the pressure unit “MPa” represents the gauge pressure in this manual.
5.2.2 Periodic Inspection

Conduct inspection for the following items according to the specified schedule.
In addition, regarding other related items such as any safety devices, gas leak detectors, or other utility
(gas/electricity) protection devices that constitute the cooling system together with the compressor,
even if they are not directly connected to the compressor, any regulatory requirements that require
inspection and recording of the results must be observed according to the instructions provided.
Table 5-2 Periodic Inspection Items

Item Inspection interval Remarks
Tension and degradation of belts Monthly inspection
If there is the looseness, tighten it
Looseness of V-pulley set bolt Monthly inspection
up
Inspection and cleaning at 100
Suction strainer and 500 hours after starting
Scale trap the initial operation
Oil strainer After that, inspection and
(External oil filter) cleaning shall be performed at
3000 hours interval.
Pressure gauge/pressure sensor Yearly inspection
Thermometer/temperature sensor Yearly inspection
Protection devices and safety
Yearly inspection
valves
Replacement after 100 hours
of operation since the initial
operation
Replacement after 500 hours When the analysis results do not
Lubricant of operation since the initial meet the management criteria
operation provided in "5.3 Management of
Lubricant" of this manual, replace
Oil analysis every six months
oil.
Follow the instruction manual
Motor greasing
for the motor
Cooling water system Yearly inspection To be cleaned if not clean enough
Inspection every year or every To be replaced if any abnormality
Shaft seal
6000 hours of operation* is found
Inspection every year or every To be replaced if any abnormality
Direct coupling
6000 hours of operation* is found
■ The inspection shall be performed according to the calendar time or operating hours, whichever
comes first.

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5.2.3 Compressor Overhaul

5.2.3.1 Guideline for the Overhaul Interval
 The required interval of maintenance and inspection services will vary depending
on the compressor model, refrigerant, rotating speed, usage condition, state of
system, and type of oil. The cost of parts replacement will be charged to the
customer even if the part failure occurs before reaching the overhaul time listed
in this section.
 Replacement of consumables used in the W-series compressor shall normally be
made at the time of overhaul.
The recommended overhaul interval is shown in the table below as a guideline.

Here, it is assumed that:
(1) The operating condition is within the specified operation range, and
(2) The number of start/stop cycles is within the specified limit.
Table 5-3 Guideline for the Overhaul Interval
Type of inspection Recommended interval

First overhaul 6000 hours of operation or one calendar year, whichever comes first
Second overhaul 12000 hours of operation or two calendar years, whichever comes first
5.2.3.2 First Overhaul Period

Remove each cover plate, head cover, and hand hole cover and take out the pistons and connecting
rods. If no abnormality is found, it is unnecessary to remove the crank shaft or the bearing housing.
Table 5-4 First Overhaul Items

No. Inspection point Action
2 Crank shaft pins Inspection and replacement if any abnormality is found
Thrust roller bearing
29 Inspection and replacement if any abnormality is found
(BB type uses thrust ball bearing)
32 Shaft seal Inspection and replacement if any abnormality is found
61 Cylinder sleeve Inspection and replacement if any abnormality is found
71,72 Suction valve and spring Replacement
82 Connecting rod bush Inspection and replacement if any abnormality is found
Needle bearing for high-stage
83 Replacement
connecting rods
84 Connecting rod bearing halves Replacement
85 Piston Inspection and replacement if any abnormality is found
86 Piston pin Inspection and replacement if any abnormality is found
88 Piston ring Replacement
110,116 Discharge valve and spring Replacement
119 Oil strainer Cleaning
154 Suction strainer and scale trap Cleaning
Water cooling jacket cover and
– Cleaning
water side of the oil cooler
– Gasket Replacement
– O-ring Replacement

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– Lubricant Replacement
Motor grease Refer to the instruction manual of the motor.
5.2.3.3 Second Overhaul Period

The second overhaul items are listed in the table below. Remove the crank shaft and main bearing
head.
Table 5-5 Second Overhaul Items

2 Crank shaft Inspection and replacement if any abnormality is found
2 Crank shaft pins Inspection and replacement if any abnormality is found
12 Main bearing Inspection and replacement if any abnormality is found
29 Thrust bearing Inspection and replacement if any abnormality is found
Thrust ball bearing Replacement
29
(BB type uses thrust roller bearing)
32 Shaft seal Replacement
61 Cylinder sleeve Inspection and replacement if any abnormality is found
71,72 Suction valve and spring Replacement
82 Connecting rod bush Replacement
Needle bearing for high-stage Replacement
83
connecting rods
84 Connecting rod bearing halves Replacement
85 Piston Inspection and replacement if any abnormality is found
86 Piston pin Replacement
88 Piston ring Replacement
110,116 Discharge valve and spring Replacement
119 Oil strainer Cleaning
154 Suction strainer and scale trap Cleaning
Water cooling jacket cover and Cleaning
–
water side of the oil cooler
– Gasket Replacement
– O-ring Replacement
– Lubricant Replacement
5.2.3.4 Third Overhaul Period

In addition to the first and second overhaul items, replace the valve plate [No.73] and discharge valve
sheet [No.111] at the interval of 24,000 hours of operation or 4 years, whichever comes first, as a
guideline.

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5.3 Lubricant Management

5.3.1 Management Criteria
Lubricants are classified into the following categories and different management criteria are applied to
each category.
(1) Mineral oil: Naphthenic oil, Synthetic oil: Alkyl benzene (AB), Polyalphaolefine (PAO)
(2) Inter-soluble synthetic oils for NH3 refrigerant: Polyalkylene Glycols (PAG)
 Oil sampling and analysis is recommended every six months.

 If the following management criteria are not satisfied, replace the oil.
* Note that the water content of PAG shall be excluded from the above oil replacement
criteria. Refer to the note *2 in the table below.
The analysis items and the criteria are shown in the following tables.
Note that these criteria may be changed without notice according to actual results.
Table 5-6 Mineral Oil and Synthetic Oils (AB), (PAO)
Item Criteria
Color phase Max. L6.0 according to ASTM D1500
Total acid value 0.3 mg KOH/g or less
Kinetic viscosity Within ±15% from that of fresh oil
Water content 100 massppm or less
Degree of Degree of contamination measured by mass method (millipore value) shall
contamination be 25 mg/100 ml or less.
Table 5-6 Inter-Soluble Synthetic Oils (PAG)*1
Item Criteria
Color phase Max. L4.0 according to ASTM D1500
Total acid value 0.1 mg KOH/g or less
Kinetic viscosity Within ±15% from that of fresh oil
Water content 2000 massppm or less *2
Degree of Degree of contamination measured by mass method (millipore value) shall
contamination be 25 mg/100 ml or less.
*1 When NH3 refrigerant is used with PAG, the inside of the equipment can be easily rusted due to
water absorption. Furthermore, as PAG has a higher cleaning effect than conventional mineral
oils, the rust developed in the equipment can be easily carried to the compressor, to make the
degree of contamination higher during the initial phase of operation. As such, it is recommended
to replace the oil with new oil, after 2,000 to 3,000 hours of operation. To prevent possible
absorption of water during oil charge, rainy days should be avoided. Complete charging within
15 minutes after the pail can is opened.
*2 This value is only for reference purposes, due to possible water absorption during the sampling,
as the oil has high water absorption characteristic. Also, in the case of NH3 refrigerant, NH3 may
be detected as water. If this limit is repeatedly exceeded in two or more samplings, it should be
judged that it does not satisfy the management criteria.
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5.3.2 Lubricant Replacement Interval
5.3.2.1 After Starting the Initial Operation

As the oil can easily be contaminated and degraded relatively quickly during the initial operation due to
scales and deposits remaining in piping and vessels, replace the oil after 100 hours of operation.
Furthermore, sample and analyze the lubricant after 500 hours of operation. If it is found as a result of
the analysis that the management criteria given in Table 5-6 or Table 5-7 are not satisfied, the oil must
be replaced.
5.3.2.2 During Normal Operation

Lubricant degrades gradually as the system is operated over time. The rate of degradation depends on
the operating condition, type of oil, and amount of foreign matters and moisture contained in the oil.
The lubricant must be sampled and analyzed every six months. If it is found as a result of the analysis
that the management criteria given in Table 5-6 or Table 5-7 are not satisfied, the oil must be replaced.
If the oil filters are frequently clogged or the oil color quickly becomes darker and unclear, replace the
oil after removing the cause of the problem.
In addition, replace the oil every time the compressor is overhauled.
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5.4 Preparation for Overhaul

5.4.1 Replacement Parts
Prepare the required genuine parts according to Chapter 7, Table 7-1 “Parts
Configuration Table” in this manual.
All the O-rings and gaskets of the parts disassembled during the overhaul work must be replaced by
new ones as they can be easily damaged in the disassembly process.
When ordering parts, be sure to inform the (a) model name, (b) serial number, (c) part name, (d) part
number (code), and (e) quantity required to one of our sales offices or service centers.
Especially when the (b) serial number of the compressor is not identified, it will be difficult to decide the
required parts because we can not specify the design and manufacturing specifications.
5.4.2 Disassembly Tools and Workplace

Before proceeding with the disassembly work, prepare necessary disassembly tools for the WA or WB
type compressor by referring to Chapter 7, Section 7.8 “Disassembly Tools” in this manual.
It is also recommended to prepare general hand tools, green silicon carbide grinding stone, emery
paper(#80-#100), emery paper(over #800), parts cleaning oil, lubrication oil, a lubricator, an oil can for
oil sump, waste cloth and so on.
In the disassembly/inspection workplace, temporary storage places to put the tools, disassembled
parts, and replacement parts, workplace for the disassembly work, safety passages, and necessary
off-limit signs shall be provided.
5.4.3 Refrigerant Gas Recovery

Before the disassembly work, the refrigerant contained in the product must be recovered for not to
discharge it into the air.
There are a few methods of recovering the refrigerant. For example, one method is to operate the
refrigerator, close the supply source valve, turn the gas into liquid, and recover the liquid at the receiver.
Another method is to use a refrigerant recovery machine to recover the liquid. As such, choose the
means that best meets your purpose.
Prepare a working flow sheet of the system beforehand. Prior to the recovery work, check the valves to
be controlled during the recovery work by comparing them with the ones in the flow sheet, and clearly
note the valves to be operated, other connected devices, and tubes on the flow sheet.
Two flow sheets must be prepared, i.e., one at the foreman and the other for posting in the workplace.
In addition, prepare a work procedure document for the refrigerant recovery work to reflect the actual
conditions of the workplace, and sufficiently share the work details among all the coworkers through
checking and confirmation before actually starting the work.
 Before the work, be sure to check and communicate the work details and procedures
among all coworkers, and carry out hazard prediction activities based on the information
shared. Neglecting to do this will increase the risk of on-the-job accidents and injuries to
a considerable level.
 All the valves that have been opened or closed during the work must be prevented from
accidental operation through proper lock-out and tag-out procedures.
W-Series Reciprocating Compressor 5.4 Preparation for Overhaul

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If the lubricant (oil) used is mutually soluble to the refrigerant, a large amount of refrigerant should be
contained in the oil. Accordingly, after the refrigerant has been recovered once, the refrigerant
contained in the oil will be evaporated to increase the pressure inside the crank case. As such, be sure
to recover the refrigerant repeatedly for a few times, until the pressure becomes low and no more
increased.
After completing the recovery work, shut down the related drive power and control power, and securely
carry out the lock-out and tag-out procedures.
5.4.4 Discharging the Lubricant and Cooling Water

After completing the refrigerant recovery work, fill the crank case with air to bring down the internal
pressure to the atmospheric pressure, and then open the oil supply and discharge valve to discharge
the oil. Also, discharge the cooling water from the water drain plug or water drain valve.
5.4.5 Removal of V-belt or Coupling

a) Disengage the V-belt or coupling to separate this product from the motor.
b) Remove the pulley or the coupling hub on the compressor by using a pulley extractor. As the shaft
is tapered, it is easy to remove the unit by slightly loosening it.
c) If a flange type motor or water-cooled semi-closed motor is used, refer to the instruction manual of
the package unit or motor. If the overhaul is only for the compressor, keep the motor as it is.
 The V-pulley (or the coupling hub) is a heavy piece of equipment. The removal work must
be performed by a number of people appropriate to carry the weight.
W-Series Reciprocating Compressor 5.4 Preparation for Overhaul

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5.5 Disassembly
Removal of cooling water pipe
Removal of head cover
Removal of head spring
Removal of discharge valve ASSY * ASSY: assembly = assembled

unit
Unloader mechanism
Oil cooler and hand hole cover
Disassembling the cylinder part
Cylinder sleeve
Piston and connecting rod
Piston ring
Shaft seal (mechanical seal)
Thrust bearing
Thrust bearing head
Oil pump
Crank shaft
Main bearing head
Strainer and others
Figure 5-1 Work Flow of Compressor Disassembly
W-Series Reciprocating Compressor 5.5 Disassembly

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5.5.1 Removal of Cooling Water Pipe

a) Figure 5-2 shows the pipe lines for the
cooling water.
b) Each jacket of the compressor is connected
with a braided high pressure hose. As the
braided high pressure hose is tightened by a
hose band onto the hose nipple, loosen the
hose band to remove the hose.
If the hose nipple is connected by a flange,
as shown in the picture to the right, it should
be easier to remove the flange than to loosen
the hose band.
Note that if the braided high pressure hose is
a black one, it can not be reused once
removed.
Figure 5-2 Pipe Lines for the Cooling Water (WA/WB Type Compressor)

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5.5.2 Removal of Head Cover

(Weight of water-cooled head cover - WA: 15 kg, WB: 24 kg)
Either water-cooled or air-cooled head cover is used for the compressor. In the case of water-cooled
head cover, if it is desired to clean the water side of the jacket, the jacket part can be removed from the
head cover. When removing the jacket, be sure to start from the upper covers.
 Dropping the head cover can cause injury or damage to the compressor. Be sure to
use stud bolts (safety retention bolts) during the work.
a) Loosen and remove all fastening bolts except for two

bolts placed in the opposite positions. Loosen the Stud bolt (safety bolt)
remaining two bolts slightly. If the gasket for the head
cover is not closely adhered, the head cover will be
easily lifted by the spring force. Alternately loosen
the two bolts until the spring force is fully released.
b) Remove the two bolts by alternately loosening them.
c) Lift up the head cover along the stud bolt to remove

it.
 If the head cover does not come off, the gasket is closely adhered. In such a case,
use a disassembly tool with the forcing bolt of it screwed into the service screw hole
on the left and right side of the head cover flange to detach the gasket. The head
cover may spring out suddenly at any time, to cause injury to the worker.
5.5.3 Removal of Head Spring

As shown in the picture to the right, the head springs
are placed between the back side of the head cover
and the discharge cage assembly.
The top of each cage has a round step onto which
the inner diameter of the coil spring fits for correct
positioning.
You can easily remove the spring by lifting it up.
 In case of the operation with the high discharge temperature of the refrigerant such
as ammonia, the springs may be closely adhered to the discharge valve cage due to
accumulation of carbides formed. In such a case, you should be careful as the
discharge valve assembly may come off with the head spring first and then drop.

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5.5.4 Removal of Discharge Valve Assembly

(Weight of discharge valve assembly - WA: 1.2 kg, WB: 3.0 kg)
The cage is simply being inserted (fitted) to the cage
guide, i.e., the internal diameter of the cage guide is
slightly larger than the outer diameter of the cage. By
pulling the nut of the cage, you can remove the cage
out of the cage guide.
However, if the cage is not pulled straight up, it may
get stuck along the way.
In such a case, return it to the original position once
and then pull it straight up again.
 Be careful not to drop any foreign matter into the cylinder after the cage has been
removed. Any foreign matter dropped into the cylinder can scratch the inner surface
of the cylinder when the piston is moved up and down during the cylinder
disassembly process to be described later.
 Disassembly of the Discharge Valve Assembly

Disassembly should be avoided unless it is necessary for parts replacement or repair work. When
replacing the assembly, check the marking on the cage to identify the correct type to be ordered, as
different valve lifts are used depending on the operational condition.
The special tool shown in the picture below must be used when disassembling the assembly.
Remove the nut and pull out the bolt to remove all the parts.
114: Second nut

113: First nut
109: Discharge valve cage
116: Discharge valve spring
110: Discharge valve
111: Discharge valve seat
112: Discharge valve fastening bolt
Figure 5-3 Discharge Valve Assembly

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5.5.5 Unloader Mechanism

It is unnecessary to disassemble the unloader unless there is a problem with the unloader mechanism.
When disassembling the unloader part, remove the oil pipe first.
a) Remove the unloader piston cover fastening bolts to remove the unloader piston cover.
b) Pull out the unloader piston, unloader push rod, and unloader device spring.
c) The unloader push rods have different lengths depending on the cylinder position. Therefore, it is
necessary to record the combination of the unloader push rod number and the corresponding
cylinder number when the rod is removed. By this, possible assembly error can be prevented.
Cylinder number markings
Marking (number) on the crank case Unloader (device spring and push rod)
[POINT]
 The components of the unloader mechanism are divided into the ones to be attached to the crank
case and the ones to be attached to the cylinder sleeve.
Unloader components (to be attached to the crank case)
Table 5-8 Unloader Components (to be attached to the crank case)
No. Part Name

135 Unloader push rod
142 Unloader device spring
143 Unloader push rod washer
144 Unloader push rod fastening bolt
145 Unloader piston

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Unloader components (to be attached to the cylinder sleeve)
Table 5-9 Unloader Components (to be attached to the cylinder sleeve)

No. Part Name
62 Unloader cam ring (left-down slope) * No. 63 for right-down slope
65 Retaining ring
68 Lift pin
69 Lift pin spring
70 Lift pin stop ring (split pin)
5.5.6 Oil Cooler and Hand Hole Cover

(Weight of oil cooler for WA-type - Coolant cooling: 26 kg, Water cooling: 16 kg)
(Weight of oil cooler for WB-type - Coolant cooling: 37 kg, Water cooling: 32 kg)
(Weight of hand hole cover - WA: 8.5kg, WB: 21 kg)
It is necessary to first open the hand hole cover before disassembling the cylinder part and other
parts. If the oil cooler is attached to the hand hole cover, it must be removed before removing the
hand hole cover.
If the oil cooler is mounted on the pedestal (unit frame) and it will not interfere with the compressor
disassembly work, it is unnecessary to remove it.
First, loosen the nuts of the joints and other hardware to remove the oil pipes connected to the oil
cooler.
a) There are two types of mounting hardware for mounting the oil cooler to the compressor. If bolts are
used, after sufficiently loosening the two or four bolts on both sides of the oil cooler, lift up the oil
cooler and pull it towards you to avoid the heads of the bolts, and you can remove it.
Mounting nut
Mounting bolt

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b) If any pipe lines are connected to the hand hole cover, such as the automatic oil return pipe from
the oil separator and a pressure equalizer pipe from the oil tank, remove them.
In addition, when an oil heater is attached,, remove the electrical wiring. While it is unnecessary to
remove the oil heater from the hand hole cover, it must be handled with care for not to spill water or
oil on it or hit it with other parts.
c) Remove the bolt at the top center of the hand hole cover and replace it with a stud (safety retention)
bolt.
d) Loosen and remove all the remaining bolts. If the gasket is adhered to the cover, use a disassembly
tool with the forcing bolt of it screwed into the serive screw hole on the flange of the hand hole cover
to detach the gasket.
e) Pull the hand hole cover towards you along the stud bolt to remove it. If an oil heater is installed, be
careful not to hit the inside part of it with the crank case or other part.
5.5.7 Disassembling the Cylinder Part

(Weight of the cylinder assembly - WA: 6.5 kg/set, WB: 14.5 kg/set)
Because the width of the large end of the connecting rod is wider than the bore of the cylinder, the
connecting rod can not pass through the cylinder. Accordingly, when the cylinder part is to be
disassembled, the assembly of the cylinder sleeve, piston, and connecting rod must be removed
together from the crank case, as an assembled set.
a) First, after the cylinder (piston) assembly to be removed is determined, rotate the crank shaft to set
the piston at the bottom dead center (the lowest position).
b) Loosen the bolt [75] fastening the discharge cage guide [74] and pull out to remove it.
c) Put your fingers into the center hole of the valve plate, and
remove the valve plate and discharge valve cage guide
together. The suction valve [71] will remain on the seat of
the cylinder sleeve.
d) Remove the suction valve.
When the valve plate [73] is removed, the cylinder will be
freed from the crank case.
Removal of valve plate
f) By accessing from the hand hole, remove the nuts of the

connecting rod fastening bolts [78] of the piston assembly
to be removed.
Remove the second nut [81] first, and then the first nut [80].
Pulling down the connecting rod cap will disengage the
lower half of the bearing halves (L) [84].
g) To prevent the connecting rod fastening bolts from hitting the crank shaft while the cylinder piston
assembly is pulled out, remove the connecting rod fastening bolts beforehand.

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h) Screw the eye bolt of the disassembly tool into the

threaded hole on top of the piston and pull out the
cylinder assembly from the crank case. If the cylinder
sleeve is tightly engaged with the crank case, use
some wire on the rib part of the cylinder sleeve collar
to pull out together with the piston.
In particular, as the high-stage side of a single two
stage compressor is installed with an O-ring, a
considerable force is required in pulling out the
cylinder sleeve.
[POINT]
 When pulling out the cylinder piston assembly, pulling only the piston will cause the piston ring to
come out from the top of the cylinder. As it will make it difficult to pull out the piston and
connecting rod assembly from the cylinder sleeve later, be careful not to pull only the piston.
 When pulling out the cylinder assembly of a slant cylinder, the large end of the
connecting rod may be caught by the partition wall in the crank case. To prevent the
connecting rod large end from being caught, use your hand to support it from the
hand hole while pulling out the cylinder assembly.
i) During the disassembly process, put the cylinder, piston, and connecting rod assemblies in the
order of the cylinder number. The connecting rod caps already disassembled should also be placed
together with the corresponding connecting rods.
5.5.8 Cylinder Sleeve

This work shall be performed with the unit placed on a clean wood
board, rubber sheet, or plastic sheet.
a) Place the cylinder sleeve upside down (with the suction valve side
facing down) on a clean surface carefully not to damage the unit. At
this point, it is advised to rotate the cam ring to let the lift pins out,
to prevent the seat surface from being damaged by touching the
workbench surface.
b) As shown in the picture to the right, pull the connecting rod out of
the cylinder sleeve while pushing down the cylinder sleeve.
[POINT]
 Normally, it is unnecessary to remove the cam ring from the
cylinder sleeve. There are two types of cam rings differentiated
by the slope of the triangular cut-out portion, i.e., right-down or
left down. As this difference is due to the mounting position
onto the crank case, which determines the direction of
operation, be careful not to make mistakes when reassembling
cylinder sleeve to the crank case.

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5.5.9 Piston and Connecting Rod

a) Place the piston upside down on the work surface.
b) Remove the piston pin lock spring using a proper tool such as a pair of pliers.
c) Remove the piston pin by pushing it from one side. If the piston pin is tightly engaged with the
piston, lightly tap the pin with a piece of wood to remove it.
d) By removing the piston pin, the piston is separated from the connecting rod. Do not remove the
bearing halves at the large end from the connecting rod unless they are to be replaced.
[POINT]
 Each connecting rod is marked with a three-digit number to indicate the combination between the
main body and the rod cap. Also, the cylinder number is marked on the opposite side.
Once removed, be sure to put them together as a set.
Combination number Cylinder number
5.5.10 Piston Ring

Preferably, the piston ring should not be removed unless it is to be replaced. When removing the piston
ring, be sure not to excessively widen the ring end gap.
To remove the piston ring, use a special tool as shown
in the picture to the right. If no such tool is available,
use a vinyl wire or lock tie to make a loop to pull both
ends apart to widen the ring as shown.
 Because if the piston ring is excessively

widened during the removal process, it may
become strained and distorted to cause oil
loss, be sure to follow the above work Piston ring removal tool
procedures (see the figure to the right).

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5.5.11 Shaft Seal Part
Figure 5-4 WA-type Shaft Seal and Thrust Bearing
Figure 5-5 WB-type Shaft Seal and Thrust Bearing

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5.5.11.1 Cover Plate

(Cover plate - WA: 11.0 kg, WB: 30.5 kg)
a) Remove two bolts at the top center of the cover plate and replace them with stud bolts for safety
retention.
b) Remove all cover plate fastening bolts [28] except for the two bolts that are on opposite sides.
c) Alternately loosen the two remaining bolts. As the gasket
may be tightly adhered to the cover plate, it is advised to
lightly tap the flange of the cover plate [26] using a
shock-less hammer after loosening the bolts to some extent,
for easy removal. Since oil accumulated inside of this part,
be sure to place a container below to receive oil before
starting to work.
d) Pull out the cover plate straight, maintaining a right angle to
the crank shaft. The cover will be removed with the internal
seal ring [41].
e) Remove the seal ring (see the picture to the right).
5.5.11.2 Shaft Seal Collar

a) After the cover plate has been removed, use a special tool to unscrew and remove the lock nut [40]
as shown in the picture below. In doing this, be careful not to damage the sliding surface of the
double seal collar [33].
b) After removing the lock nut, pull out the double seal collar using the groove in the periphery. Even if
it is difficult to remove, never put the tip of a screwdriver or others between the seal collar and the
thrust bearing to pry it. Be sure to use the groove on the seal collar.
Special tool for loosening the seal collar lock nut Removal of seal collar
Double seal collar

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5.5.12 Thrust Bearing

In the case of a standard single stage compressor, remove the fastening bolts [31] first, and then pull it
out using forcing bolts.
As the bearing head is engaged with clearance, it can be pulled out by lightly lifting the shaft.
There are two types of thrust bearings.

Refer to the note below Table 2-7 in Chapter 2, Section 2.2.2 of this manual.
For compressors with high suction pressure, BB (ball bearing) type thrust bearings are used. The
BB-type bearings have a step to accommodate the thrust rolling bearing.
Also, if the suction pressure is low, such as in the case of single two stage compressors or booster
compressors, two O-rings are used in the mating part in the periphery of the thrust bearing. As a
considerable force is required to pull out, use the service screw holes on the thrust bearing to pull out.
Service screw holes to pull out the thrust bearing Standard thrust bearing
5.5.13 Bearing Head

(Bearing head - WA: 12.8 kg, WB: 29.0 kg)
Remove related piping components such as pressure gauges and oil pressure protection switches.
If any oil gauge or other component is directly mounted on the main bearing head, remove them to
prevent possible damage during the disassembly and assembly processes.
Remove the bearing head fastening bolts [25], and then pull out the bearing head using the service
screw holes provided.
Be sure to properly support the bearing head [23] during the work by suspending it or placing it on a
support - if it is not properly supported when disengaged, it may hit the shaft and damage it.

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5.5.14 Oil Pump

As different types of oil pumps are used in the W-series compressors while design changes have also
been made, refer to Chapter 2, Section 2.1.5.2 “Oil Pump Types and Design Changes” for details.
Do not further disassemble the oil pump [56] after it has been removed as an assembly.
a) Before removal, be sure to record the arrow

direction that shows the direction of rotation.
b) Screw the forcing bolt down to pull out the oil pump
from the main bearing head [88] (remove the rust
prevention cap indicated by the arrow in the picture
to the left).
As only one forcing bolt is used, gradually screw
down the bolt while frequently hitting the opposite
side using a shock-less hammer to lift it evenly.
c) As the O-ring will remain on the side of the main

bearing head, be sure to remove it.
d) When the oil pump has been removed, the drag

crank [3] can be seen as it is attached to the end of
the crank shaft. As the pin of the drag crank is
mated with the hole in the crank shaft, it can be
horizontally pulled out.
Figure 5-6 WA-type Main Bearing Head and Associated Parts

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Figure 5-7 WB-type Main Bearing Head and Associated Parts
Figure 5-8 Type 12WB/12-4WB Main Bearing Head and Associated Parts

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5.5.15 Crank Shaft

When the bearing head is removed, the crank shaft is supported by one end, i.e., by the main bearing
[23].
a) To protect the crank pin area from damage, sufficiently
wrap the area with protective cloth, masking tape, etc.
b) Insert an appropriate square timber or other bar from
the hand hole to use it as a lever to hold the weight of
the shaft, and slowly pull the shaft out of the crank
case. Carefully keep the crank shaft level until the
shaft end has been fully disengaged and taken out of
the main bearing, as tilting it just prior to the
disengagement can damage the sliding surface of the
main bearing.
 Procedures for 12WB and 12-4WB

Pull out the crank shaft with the intermediate shaft bearing attached.
The taper pin [131] that is fixing the intermediate shaft bearing to the crank case becomes movable
by loosening the fastening nuts and patting on them with a shock-less hammer to release the
tension of the outer shell. Use a box wrench from the cylinder hole to loosen the bolts little by little.
If the model has a step in intermediate shaft bearing area, a crank shaft holding fixture to use a
section of a large diameter pipe as shown in Figure 5-10 may be used to facilitate the removal work.
In this case, the both ends of the sliding fixture are fixed in place by bolts. The crank shaft can be
easily slid on the fixture to make the removal work easier.
The intermediate shaft bearing can be separated into upper and lower pieces by removing the
fastening bolts and then the taper pin. As the intermediate shaft bearing has a sufficient design
margin, a relatively longer service life can be expected if it is kept free of any foreign matters.
Figure 5-10 One Method of Extracting

the Crank Shaft
Figure 5-9 Intermediate Shaft Bearing

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5.5.16 Main Bearing Head

(Main bearing head - WA: 22.95 kg, WB: 45 kg, 12WB: 42.4 kg)
a) Remove the oil pipe connected to the main bearing head. If any oil pressure gauge or other
component is directly mounted on the main bearing head [8], remove them to prevent possible
damage during the disassembly and assembly processes.
b) Loosen the main bearing head fastening bolts [10], [11].
In the case of WA-type compressors, one of the main bearing head fastening bolts cannot be
loosened unless the CUNO filter is removed beforehand.
c) Remove the gasket by screwing two forcing bolts into the two service screw holes placed oppositely.
Pull the bearing head evenly to remove it from the crank case. You must be very careful, as the
main bearing head is very heavy.
d) As the main bearing [12] is mounted inside the main bearing head, remove the main bearing screw
[13] to pull out the main bearing.
Main bearing
screw
Main bearing

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5.5.17 Strainer and Others
5.5.17.1 CUNO Filter

The CUNO filter is mounted by bolts on the oil pump discharge side of the main bearing head. Remove
the bolts and pull the filter towards you to remove it as an assembly.
 The CUNO filter consists of a main filter body with stacked thin metal plates and a
scraper part with extremely thin metal plates to remove foreign matters attached in
the periphery. Be very careful during the disassembly and assembly work not to hit
the filter part.
Do not try to disassemble the CUNO filter assembly.
5.5.17.2 Oil Strainer

The oil strainer [119] is screwed into the oil strainer cover [121].
In the case of a standard type, the oil strainer can be pulled
out with the cover by removing the strainer cover fastening
bolts [123].
If the hand hole cover is open, you can also loosen the
strainer screw itself by turning the hex part of the unit by a
spanner.
If the strainer is not clean, remove any dirt on the surface
and then use compressed air or nitrogen gas to blow out the dusts from the inside.
5.5.17.3 Scale Trap

The 2WA, 4WA, 4WB, 12WB, and 12-4WB model
compressors have no scale trap.
a) Remove the fastening bolts [181] that are fastening
the bottom scale trap cover [179] of the scale trap
[175].
b) Once the scale trap cover has been removed, the
internal wire mesh [178] can be easily removed as
it is only pushed down in place by the scale trap
cover.
 Even after the gas inside the crank case has been properly processed, this part may
still contain lubricant and/or refrigerant in the low temperature state. When opening
the cover, be very careful not to get such liquid thrown on you. For this, loosen the
fastening bolts slowly and be sure to check the residual internal pressure or
existence of any trapped liquid.

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5.5.17.4 Suction Strainer

The 62WA, 42WB, and 62WB model compressors have no suction strainer.
The suction strainer [154], which is located inside the crank case, is supported by the suction end
cover [161] in the 12WB and 12-4WB models and by the suction end cover and spring [158] in other
models.
In either case, the internal strainer can be easily pulled out by removing the suction end cover.
Figure 5-11 Suction Strainer
 At the time of shipment of the compressor, a canvas bag [156] (used to capture
any foreign matters) will be inserted inside the wire mesh in the scale
trap/suction strainer to protect the wire mesh from possible damage by foreign
matters sent from the system during the initial commission. If the use of these
bags is continued even after completing the commissioning, the bags would be
broken to cause a failure of the compressor. As such, be sure to remove them after
the commissioning has been completed.

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5.6 Reassembly
 Be sure to use only genuine parts for replacement. Use of

non-genuine parts is very risky, as it can lead to possible damage or explosion of the
compressor and/or other equipment during operation. Also, there is a high risk of
electric shock due to electric leakage.
 Be very careful when you carry a heavy piece of equipment. The work must be
performed by a number of people appropriate to carry the weight. Also, be sure to
use stud bolts (safety retention bolts) and other support tools for the work.
Neglecting the above warning can lead to low back pain of the worker or injury due to
dropping of the parts.
 During the assembly work on the compressor, use the correct tools specified. Using
worn-out or damaged tools or tools inappropriate for the work increases the risk of
personal injury.
 For the composition of the suction valve and discharge valve, refer to Chapter 7,
Section 7.3 “Configuration of Plate Valves and Associated Parts” in this manual.
 When replacing parts, check the type and compatibility before the assembly work.
 If any minor defect is observed on the parts to be assembled, such as a minor
scratch caused during disassembly or surface rust due to a long storage period, use
a sand paper (#800 to #1200) to remove them.
 Assembly parts shall be washed using wash oil (e.g., light oil) and kept clean.
 Washed parts shall be dried by compressed air or wiped up using clean cloth. Do not
use synthetic textiles or woolen textiles to prevent fibers from attaching the parts.
 Prepare new lubricant in an oil feeder and apply the oil to various sliding surfaces
immediately before the assembly work.
 Apply a sufficient amount of lubricant on both sides of the gasket before assembly.
 Some gaskets have holes for oil supply purposes other than bolt holes. During
assembly, carefully check the oil hole locations for not to part any oil supply line by a
gasket.
 All tools used must be kept clean before use. Do not use worn-out, deformed, or
damaged tools as they may cause damage to the assemblies and parts.
 When tightening the fastening bolts, first fasten four diagonally opposite bolts
applying 50 percent of the tightening torque specified in the table below. Then,
fasten all bolts in the clockwise order applying the specified torque. When fastening
a part with a gasket, the bolts fastened earlier tend to become loose as the remaining
bolts are fastened. So, be sure to tighten the first two bolts again.
Table 5-10 Tightening Torque of Hex Bolts

Size M10 M12 M16 M20 M22
N·m 40 80 120 220 300
Torque
kg·cm 400 800 1200 2200 3000
W-Series Reciprocating Compressor 5.6 Reassembly

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* The tightening torques for the flywheel (pulley) set bolts, the first and second crank pin fastening nuts,
and the first and second discharge valve fastening nuts are separately specified. Refer to the
relevant figures in Chapter 7, Section 7.4 “List of Tightening Torques for Bolts and Nuts” of this
manual.
Start the reassembly work after completing the cleaning of the assembly parts and tools. Most of the
reassembly work will be performed in the reverse order of the disassembly work. Perform the
reassembly work by observing the precautions and referring to the details in Section 5.5 “Disassembly”
in this manual.
Main bearing and main bearing head
Crank shaft
Bearing head and thrust bearing
Oil pump
Shaft seal and cover plate
Cylinder part
Assembly of cylinder to the crank case
Adjustment of the unloader mechanism
Valve plate
Attachment of strainers and hand hole cover
Idling check
Head cover
Cooling water pipe
Final inspection
Figure 5-12 Flow of Reassembly Work

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5.6.1 Main Bearing and Main Bearing Head

During the assembly work, be careful about the position of bolt holes and oil holes of gaskets. If any
hole is not placed in a correct position, it can lead to oil supply failure.
a) Insert the main bearing [12] into the main bearing head [8].
Check that the screw hole of the countersunk screw (main bearing screw [13]) is correctly aligned
with the oil hole.
 In the case of WB-type single two stage compressors, two O-rings [12-1] are used on
the outside of the main bearing to maintain the oil pressure. Be sure to install them
as these O-rings can be easily forgotten.
b) Tighten the main bearing screws. Check that each head of main bearing screws is not protruded
from the thrust receiving surface of the main bearing.
c) Stick the main bearing head gasket [9] to the main bearing head. Make sure that the oil holes of the
gasket are correctly positioned on the oil holes of the main bearing.
d) Attach the main bearing head to the crank case and tighten the fastening bolts with the specified
torque.
In the case of WA-type compressors, be sure to mount the CUNO filter as soon as the main bearing
head has been attached to prevent any dust or foreign matters from getting into the oil line.
 When the main bearing head has been inserted to the crank case by about 70 percent
of the total amount, check again that the two oil holes of the head are correctly aligned
with the holes on the crank case. After the correct positioning has been confirmed,
make the main bearing head closely contact with the flange of the crank case.
[POINT]
 In the case of 12WB and 12-4WB models, mount the intermediate shaft bearing onto the crank shaft
first, and then temporarily fix the intermediate shaft bearing to the crank case. Make sure the joint
surface at the center is level and that the outer periphery is positioned at the center of the fitting hole.
The final tightening of the intermediate shaft bearing bolts shall be made after all other shaft bearings
have been fully assembled.
[POINT]
 (for reference only) The main bearing for the WB-type

compressors has nearly the same outline and dimensions
as that for the SF/SFW-series (special marine type)
compressors. If an oil groove is present on the collar side
of the metal, it should be for SF/SFW-series compressors.
If the main bearing for the SF/SFW-series compressors
are used at or below the atmospheric pressure, the crank
shaft will be pushed toward inside by the differential
pressure between the inside and outside of the crank case.
As the crank shaft will make contact with the collar of the
main bearing being pushed by the force, the oil groove is
provided for the purpose of lubrication.
However, in the case of the W-series compressors, because the move of the crank shaft due to the
differential pressure is limited by a lock nut, the collar of the main bearing will not be significantly
loaded by such a contact, in principle.

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5.6.2 Crank Shaft

There are two types of the crank shaft according to the standard and BB (ball bearing) specifications.
Be careful about the difference when the crank shaft is to be replaced.
a) Similarly to the case of disassembly, properly protest the crank pin area,
b) Insert the crank shaft using proper tools (squared timber) and with as many people as required for
carrying the weight.
When inserting the crank shaft into the main bearing, put the shaft at once in one motion without
stopping on the way. Stopping on the way can damage the main bearing due to the weight of the
crank shaft.
If any squared timber is used, check that no piece of wood is left in the crank case.
[POINT]
 The BB (ball bearing) specification crank shaft has a step to mount the inner ring of the thrust ball
bearing as shown in the picture below. Insert the crank shaft into the thrust bearing with the inner
ring of the thrust ball bearing assembled on the step portion of the crank shaft.
Step on the shaft to install the inner ring of the

thrust ball bearing
Standard crank shaft BB-specification crank shaft
Thrust bearing with ball bearing

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5.6.3 Bearing Head and Thrust Bearing

a) Similarly to the case of the main bearing head, check the alignment of the oil holes of the bearing
head [23] against the oil holes of the gasket [24]. Assemble the bearing head with the oil supply
hole up. Tighten the four hexagon socket head cap screws [25] with the specified torque.
b) Mount the thrust bearing [29] with the oil hole up and the oil grooves in the 45° (2 o'clock and 10
o'clock) positions. As in the case of the main bearing [12], WB-type compressors use a thrust
bearing of which size is the same as the ones for the SF/SFW-series compressors.
If both sides of the thrust bearing have an oil groove, it is for the WB-type compressors. The thrust
bearing for the SF/SFW-series has an oil groove only on the inside of the crank case, not on the
thrust surface of the seal collar.
Also, some parts for older models have the oil supply hole in the opposite (i.e., 180 degrees
different) position. In this case, the oil grooves are at 4 o'clock and 8 o'clock positions when the oil
hole is at the 12 o'clock position. These are the parts for the compressors produced before 1969. If
these parts are used for newer models produced after 1969 by mistake, the oil grooves will be
positioned at 4 o'clock and 8 o'clock, and it makes it easier to accumulate dirt in the grooves.
Make sure before assembly that the positional relationship between the oil hole and oil grooved is
correct.
 In the case of WB type single two stage compressors, two O-rings [29-3] are used on
the outside of the thrust bearing to maintain the oil pressure. Be sure to install them
as these O-rings can be easily forgotten.
c) For the fastening bolts, be sure to use the washers [30]. As the back metal of the bearing is
aluminum (i.e., softer than the bolt), tightening the bolts without a washer not only damages the
bearing fastening surface, but also makes the tightening torque insufficient in some cases.

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5.6.4 Shaft Seal and Cover Plate

a) Attach the double seal collar [33] and check the movement condition of the spring [38].
Place something on a clean flat surface, and push it by hand to confirm that it moves smoothly and
uniformly without being caught.
b) Turn the crank shaft so that its locking ball is at the top.
c) Assemble it by aligning the locking ball position with the detent cut in the double seal collar. In this,
be careful not to damage the O-ring [42] inside the seal by making it contact with the thread of the
lock nut.
d) Push the double seal collar all the way up to the end, and screw the lock nut [40] on the thread of
the shaft. As a fine pitch thread is used here, carefully turn the nut by checking that it is correctly
engaged with the thread without being inclined.
e) Use a special lock-nut tightening tool to tighten the lock nuts one by one. In this, as a hammer is
used to hit the handle of the tightening tool while tightening the nut, be very careful not to damage
the sliding surface of the seal collar by the hammer.
f) After tightening the nut, measure the
amount of movement of the crank
shaft in the thrust direction (i.e., thrust
gap) using a thickness gauge as
shown in the picture to the right.
The correct gap is in the range of 0.08
to 0.18 mm. Measure the gap at four
places, i.e., top, bottom, left, and
right.
g) Check that the spring pin [44] attached to the cover plate [26] is not bent. Apply lubricant to the
O-ring [42] and place it in the seal ring [41]. Then, place the seal ring [41] in the cover plate [26]. In
doing this, align the position of the 4 mm diameter hole on the seal ring with the position of the
spring pin [44] attached to the cover plate. After the assembly, press the seal ring to confirm that it
moves smoothly and evenly.
h) As the cover plate is quite heavy, screw two stud bolts into the top two screw holes of the crank
case for ensuring the safety.
i) Apply oil on the sliding surface of both seals (i.e., double seal collar and seal ring). Also apply oil
on the gasket [27] and place it on the cover plate side. When installing the cover plate, hold it with
the oil drain hole side down and keep the flange surface of the cover plate at right angle to the
crank shaft to mount it. In this, be careful not to make the seal contact with the crank shaft.
j) At first, tighten diagonally opposite fastening bolts gradually and evenly. After checking that the
cover plate is securely fastened to the crank case, screw all the remaining bolts and tighten them
with the specified tightening torque.

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5.6.5 Oil Pump

a) Turn the crank shaft so that the hole for the drag crank pin is at the top position.
b) Insert the pin of the drag crank [3]. In this, adjust the position to set the cut-out slot in the center.
For this, use the center hole of the crank shaft as a reference (See the below right picture).
Drag crank
pin
c) Set the O-ring [58] for the oil pump on the main bearing head [8], and set the oil pump gasket [59]
on the oil pump [56].
d) After manually turning the oil pump shaft to adjust the position of the flat surfaces of the shaft to be
engaged with the cut-out slot of the drag crank, insert the oil pump into the main bearing head.
If the slot of the drag crank is not successfully engaged with the oil pump shaft, the oil pump will
stop moving at about 10 mm before the correct position. Do not try to forcibly fasten the bolts in
this state.
In such a case, as the cut-off portions on the oil pump shaft are out of position with the cut-out slot
of the drag crank, pull out the oil pump, adjust the shaft angle, and reinstall the pump.
e) Turn the oil pump such that the indicator plate that shows the direction of oil pump rotation is
positioned at the top. After making sure that the arrow direction
is the same as the direction of rotation of the crank shaft, tighten
the oil pump fastening bolts [60].
If it is found that the arrow on the indicator plate is in the reverse
direction, turn the oil pump further by 180 degrees to find
another indicator plate of which arrow should show the correct
direction of the compressor rotation.
 To quickly change the direction of rotation of the oil pump, you may pull out the oil
pump body by 1 to 2 mm and then turn it by 180 degrees. However, if the gasket may
be degraded or it is necessary to check, be sure to follow the above procedures to
check it from first. (If the oil pump body is pulled out by 10 mm or more, the oil pump
shaft will be disengaged from the drag crank.)
When changing the rotation direction by pulling out the oil pump by 1 to 2 mm, make
sure beforehand that the pressure inside the compressor is at the atmospheric
pressure.

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5.6.6 Cylinder Part
5.6.6.1 Piston and Piston Ring

a) Set the piston ring to the piston carefully not to
excessively widen the ring end gap, using the same
method used in the disassembly process. As the
piston rings have a marking at one end of the ring as
shown in the picture to the right, set the rings with
the marking facing up.
Set the upper three rings from the bottom side, i.e.,
in the order of the third ring, second ring, and then first ring.
b) When setting the fourth piston ring, place the piston upside down, carefully check the direction of
the marking on the ring, and set the ring in position.
c) After setting all piston rings, check that each piston ring can freely move in the groove. The typical
gap between the piston ring and the groove wall is 0.05 to 0.09 mm.
d) The end gap positions of piston rings shall be separated by 120 degrees with each other.
Table 5-12 Piston Ring Configuration of W-Series Compressors

(common to single stage and single two stage machines)
Standard
Propane, R23, (round haul netter NH3)
R404A, R507A, etc. NH3
1st FC–PC–BF–G1
2nd FC–P GA–P
3rd FC–PC–BC3P
4th FC–PC–BC3
FC: Special cast iron, GA: Special alloy, P: Plain

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5.6.6.2 Connecting Rod

Two types of connecting rods are used, i.e., one is the standard type (below left picture) and the other
is used in the high-stage of single two stage compressors (below right picture).
The ones for the high-stage use a needle bearing for the small end bush.
[POINT]
 The WB type connecting rods have the same size of the large end and small end as the ones
used for SF/SFX type compressors although the distances between the axes are different.
As such, there is a risk of making a mistake.
In the case of using the stock, please measure the distance between centers, just to make sure.
The distance is 300 mm for the connecting rods used in WB-type compressors.
300mm
a) Use the piston pin [86] to attach the piston [85] to the small end of connecting rod [77] ([76] for the
high-stage).
Each connecting rod is marked with the combination number and the cylinder number. The piston
must be attached to the connecting rod such that the orientation of the cylinder number marked on
top of the piston becomes the same as the orientation of the of combination number marked on the
connecting rod.

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 Do not hit the piston pin directly by an iron hammer even if it is tight, as the end face
may be enlarged. Use a shock-less hammer or a pad, such as a Teflon part, for not to
directly hit the pin, and handle it with care.
b) After inserting the piston pin, set the piston pin lock spring [87] in the ring groove of the piston pin
hole on both sides of the piston. Make sure that the piston pin lock spring is securely engaged in
the ring groove on both sides.
c) Attach the bearing halves onto the large end of the connecting rod. The bearing halves are
designed to fit with the large end of the connecting rod by its own tension. Align the protrusion at
the end of the bearing halves with the notch in the large end of the connecting rod and press the
bearing halves into place. The bearing halves consists of the upper metal bearing with an oil
groove and oil hole and the lower metal bearing without any oil groove or oil hole. Fit the upper
metal bearing to the connecting rod body and fit the lower metal bearing to the rod cap of the
connecting rod.
5.6.6.3 Cylinder Sleeve

a) Check the orientation of the cut-out portion of the cam ring (left down [62] or right down [63]) as
well as the assembly position (cylinder number) of the cam ring. Set the piston of the same
position as shown.
b) As the bottom end of the cylinder sleeve is tapered, i.e., “cylinder ring drop”, you can set the
cylinder in the upright position and easily insert the piston and connecting rod assembly from the
above.

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5.6.7 Assembly of Cylinder to the Crank Case

If the unloader mechanism in the crank case has been disassembled, reassemble the unloader by
referring to Section 5.5.5 “Unloader Mechanism” in the reverse order of the disassembly procedures.
a) As shown in the below left picture, set the protrusion of the unloader push rod exactly at the
bottom (or top, depending on the type and cylinder) of the center line of the hole of the crank case
from which the cylinder is assembled. If the protrusion of the unloader push rod is not on the
center line of the cylinder hole, remove the hexagon socket head cap screw on the unloader cover
and screw the eye bolt of the disassembly tool into the screw hole. Then, turn the eye bolt to push
the unloader piston for position adjustment, as shown in the below right picture.
Position of the protrusion of the unloader Position adjustment of the unloader

push rod (when it is at the bottom) push rod
b) Turn the crank shaft to the position the piston

of the cylinder will be at the bottom dead
center. As seen from the cylinder hole of the Oil hole
crank case, the oil holes of the crank pin of the
crank shaft will be seen in front of you, as
shown in the picture to the right.
Crank shaft
c) Apply a sufficient amount of lubricant to the cylinder sleeve gasket, such that the gasket will not fall
off when it faces down upon assembling the cylinder assembly, and attach it to the back side of the
lip of the cylinder sleeve [61].
d) Prepare the connecting rod cap that is paired with the connecting rod of the cylinder assembly to
be assembled. Check that the three-digit combination numbers of the pair agree.
e) Lay the cylinder assembly on its side and screw the eye bolt of the disassembly tool into the screw
hole at the center of the recessed area on the head of the piston.
f) Check again the cylinder number and the slope of the cam ring (left down [62] / right down [63]).
Adjust the position of the cut-out portion of the cam ring such that it is positioned at the protrusion
of the unloader push rod of the cylinder being assembled onto the crank case. At this time, also set
the cut-out portion of the retaining ring [65] to align with the cut-out portion of the cam ring.

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g) When mounting the cylinder assembly into the crank case, carry it out in the reverse order of the
disassembly procedures. In this, set the piston in the cylinder to the top dead center position. The
cylinder number marking on the piston must be in the
upper position.
[POINT]
 In this state, in the case of a cylinder assembly that
can be mounted in the tilted state (i.e., according to
the structure of the crank case or cylinder
arrangement), the three-digit combination number
marking on the large end of the connecting rod should
be on the bottom side when it is mounted to the crank
pin of the crank shaft.
h) Once the large end of the connecting rod of the cylinder assembly has passed the inner hole of the
crank case, support the cylinder assembly by your hand from another cylinder hole on the crank
case while doing the assembly work.
i) Once the lip of the cylinder sleeve is inside the crank case, hold the large end of the connecting rod
in the direction of the crank shaft pin while gradually pushing down the piston to engage the large
end to the crank pin.
 If the piston is pushed without holding the large end of the connecting rod in the
direction of the crank shaft pin, the bottom end of the connecting rod can easily hit
the crank pin to give damage to it.
j) Attach the connecting rod fastening bolts. Set the cut-out

portion of the bolt head (which prevents turning of the bolt) to
the cut-out portion of the rod body.
k) Mount the rod cap by making sure that the orientation of the
three-digit combination number on connecting rod cap is the
same as that of the connecting rod body. Use your hand to
attach a washer to each of the connecting rod fastening bolts
and then attach the nuts.
m) Alternately fasten the first connecting rod fastening nuts and
then tighten them with the specified torque. Then, attach the
second connecting rod fastening nuts and tighten them with
the specified torque.
 Hold the nut portion of the assembled connecting rod and try to move it to the right
and left. If it does not move, it may be the case that the connecting rod cap is
reversely mounted to the connecting rod or the rod cap used is that of a different
cylinder.

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n) After completing the assembly of one cylinder, proceed to the assembly of the next cylinder.
Turn the crank shaft to the position the piston of the cylinder to be assembled next will be at the
bottom dead center.
[POINT]
● At this time, the cylinder sleeve is not fixed in place. As the cylinder sleeve can be easily lifted
when the piston goes up, hold the lip of the cylinder sleeve while turning the crank shaft to a
position convenient for the assembly.
o) Repeat the above procedures until completing the assembly of the last cylinder. When completed,
check that there is no mistake in each part.
After checking from the hand hole of the crank case that the three-digit combination numbers of
each connecting rod agree with each other, the work to mount the cylinder assemblies in the crank
case is complete.
Figure 5-13 Sectional View of the Cylinder and Other Components

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5.6.8 Adjustment of the Unloader Mechanism

If the cylinder sleeve has not been replaced, the lip
portion of the cylinder sleeve should have a
triangular marking that has been made after the
unloader has been adjusted in the factory.
In addition, the crank case has a line marking to be
used for the alignment.
The adjustment is completed by simply aligning the
triangular marking on the cylinder sleeve with the
line marking on the crank case, for each of the left
and right cylinders.
If the cylinder sleeve has been replaced by a new

one, there should be no triangular alignment
marking on the cylinder sleeve. In this case, the
adjustment shall be made using the line marking
on the crank case as a reference.
a) First, set the lift pin of the left side cylinder sleeve (the pin in the blue circle of the above picture)
just adjacent to the line marking on the crank case.
b) Screw in and out the adjustment eye-bolt to adjust the height of the lift pin to make the head of the
lift pin leveled with the seat surface of the cylinder sleeve. As shown in the below right picture, use
a scale or something to check the height for an accurate adjustment.
Adjustment of push rod position Adjustment of lift pin height
c) After completing the height adjustment for the left-side cylinder, adjust the lift pin height of the right
side cylinder. The height of the lift pin of the right side cylinder can be adjusted by turning the
cylinder sleeve in either the CW or CCW direction. Once the height of the head of the lift pin is
level with the seat surface of the cylinder sleeve, the adjustment of the unloader mechanism is
completed for both the left and right cylinders.
d) To make the adjustment of the unloader mechanism easier for the next time, use a center punch or
other marking tool to lightly mark a point on both the left and right cylinder sleeves just adjacent to
the corresponding line mark on the crank case.
[POINT]
● Before adjusting the height of the lift pin, find the highest height lift pin among the six lift pins to
use it for the height adjustment.

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5.6.9 Valve Plate

a) Set the suction valve springs [72] in the spring
holes of the valve plate [73]. As the springs are
slightly tapered, put the larger diameter end
first in the spring hole, and then twist it in the
winding direction to press in the spring into the
spring hole.
b) If the cylinder to mount the valve plate has the
unloader mechanism, push in the unloader
piston first to set it in the loaded condition
(push down the lift pin).
 If the above procedure is not followed and the valve plate is assembled with the lift
pin up, the suction valve can be easily broken or deformed and cause a failure such
as no compression (gas leak).
c) Assemble the suction valve together with the valve plate [73]. Then, check that the suction valve is
securely set.
d) The positioning of the valve plate is different for the WA-type and WB-type compressors.
■ WA-type:
The periphery of the valve plate is positioned by the mating portion on the crank case.
The sleeve seat surface is 0.1 mm out of the crank case.
■ WB-type:
The lip of the sleeve has a step which mates with the step on the bottom surface of the valve
plate to determine the position. The sleeve seating surface is 0.9 mm lower than the crank
case surface.
e) Stack the discharge cage guide [74], screw two fastening bolts on the top and bottom of the valve
plate, and fasten them to the extent the assembled parts will not move easily.
f) Then, similarly assemble the part for the adjacent cylinder. After both valve plates have been
assembled, evenly tighten all the fastening bolts to finally tighten them with the specified torque.
g) After the valve plates have been mounted, remove the hanger eye bolt of the unloader cover.
Promptly fasten a cap bolt with a washer, for not to forget fastening it.

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5.6.10 Attachment of Strainers and Hand Hole Cover

a) Screw the oil strainer [119] into the oil strainer cover [121] and mount it to the crank case.
b) Insert the scale trap mesh [178] and suction strainer [154], and attach the respective covers.
c) Before mounting the hand hole cover, check that nothing is forgotten, such as the fastening of the
connecting rod fastening nuts, or any foreign matter in the crank case.
d) For the purpose of safety, screw the stud bolt of the disassembly tool into the top center position.
There are two types of hand hole cover, i.e., with a window [45] and without a window [46]. Mount
the hand hole cover with a window (oil sight glass) [45] on the side which is easier to check the oil
level.
Attach the gasket [47] and hand hole cover, and then screw-in the hand hole cover fastening bolts
[48]. Remove the stud bolts, screw the fastening bolts, and lastly tighten the bolts with the
specified torque.
e) Mount the oil cooler and connect the external oil pipes.
Be sure to mount all the pipes that have been removed during disassembly, including the unloader
pipe and pressure pipes of pressure gauges. Before assembling the pipes, use compressed air to
blow out any foreign matters inside pipes and clean them. Securely fasten the pipe joints.
f) Mount the flywheel (pulley) or coupling hub on the crank shaft and install the V-belt or coupling
assembly to make the compressor ready for idling run.
 For the purpose of safety, be sure to mount the belt cover or coupling guard.
g) Remove the plug (3/4”) on the upper center part of the hand hole cover and supply lubricant. After
finishing the oil supply, do not forget to fasten the plug with seal tape on the thread.

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5.6.11 Idling Check

This process must be performed before mounting the discharge valve assembly, head spring, and
head cover.
By idle running the compressor in this condition, you can confirm that every part of the compressor is
operating normally and that there are no assembly errors.
 Oil pressure check

Until the oil pressure gauge becomes operational, repeat the cycle of starting the compressor and
stopping it in a few seconds. After checking that the oil pressure rises, start to run the compressor
continuously.
Turn the oil pressure control valve to make sure that the oil pressure changes.
Then, set the pressure to the gauge pressure of 0.25 MPa.
 Just after starting to run the compressor, the lubricant temperature is still low
and thus the viscosity is also high. If the compressor is started up with the oil
pressure control valve in the fully closed state, the gauge pressure may exceed 1
MPa to cause possible adverse effects to the oil pump. Before starting up the
compressor, once fully close the oil pressure control valve (i.e., turn it in the CW
direction). Then, after turning it in the CCW direction for three turns to open the
valve, start up the compressor.
If the oil pressure gauge does not show pressure when the start and stop cycle is repeated for
several times, the oil line of the compressor may have problems. Resume the idling run after
checking the oil line and removing any errors.
 Checking the idling noise of the compressor

Carefully listen to the idling noise of the compressor for several minutes after it has been started up.
If the compressor has been normally assembled, the idling noise should be relatively low periodical
sounds from various moving parts.
If it is felt that the sound is abnormal, there may have been some error in the assembly process. In
such a case, immediately stop the compressor, find out the cause of the abnormal noise, and
resume the idling run after the cause has been removed.
 Checking the lubrication inside the cylinder

Visually check the condition of lubrication inside each cylinder, by shining a flashlight inside as
shown in the picture below. The ideal condition is when the internal surface of the cylinder is
covered by an oil film of uniform thickness.

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[POINT]
 In the case the cylinder sleeve or piston ring has been replaced, some oil droplet may come out
from the cylinder as the sliding surface has not been well run in.
If the amount of droplets is abnormally large, there is a possibility that the piston ring has been
deformed due to an excess stress applied during the piston ring fitting work.
In such a case, replacement of the piston ring is recommended as it may increase oil
consumption.
 Checking the operation of the suction/discharge valves and unloader
 As the work is to be performed while the piston is moving, be very careful in

conducting the operational check.
Insert the discharge valve assembly into the discharge valve cage guide, and press it on. If you
can hear a large compression sound, the suction valve of the cylinder should be operating
normally.
If the cylinder is equipped with an unloader mechanism, turn on the solenoid valve or open the
manual valve to set it in the unloaded state while hearing the compression sound to make sure that
the compression sound is gradually reduced.
When the compression sound has almost gone, turn off the solenoid valve or close the manual valve
to check that the compression sound becomes gradually louder. If the level of the compression
sound is decreased /increased when the valve is opened /closed, the unloader mechanism is
operating normally.
After successfully completing all the above checking procedures, stop running the compressor and
assemble the remaining parts.
 Before resuming the assembly work, be sure to shut off all power to the
compressor, including the drive motor power, control power, and all other related
power supplies to prevent accidental restart of the compressor.

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5.6.12 Head Cover

After completing the idling run check, assemble the discharge cage assembly head spring, and head
cover.
a) Before inserting the discharge valve assembly into the discharge valve cage guide [74], check the
normal operation of the discharge valve [110]. Push down the discharge valve using your thumbs
as shown in the below left picture. If the valve moves up and down, it is operating normally.
If the discharge valve assembly has been disassembled, e.g., for parts replacement, reassemble
the valve in the reverse order of the disassembly.
When installing the discharge valve spring [116], as in the case of the valve plate, put the larger
diameter end first in the spring hole, and then twist it in the winding direction to press in the spring
into the spring hole.
When tightening the first nuts [113] and second nuts [114], use the disassembly tool shown in the
above right picture to tighten them with the specified torques.
b) After checking that the discharge valve operates normally, insert the discharge valve assembly
into the discharge valve cage guide of the correct piston cylinder number.
c) Attach the head springs to each discharge valve assembly as shown in the below right picture.
 In the case of 8-cylinder compressors, you should be careful in this process as the
spring attached to the lowest position cylinder can easily drop, due to the tilt of the
cylinder. Mounting the spring with its winding end placed at the upper part of the
discharge valve cage mount prevents the spring from dropping.

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d) When installing the head cover ([49] for air cooled type /
[50] for water cooled type), screw-in a stud bolt at the top
center position, for safety purposes.
Stick the head cover gasket [51] by hanging it on the
stud bolt. While being careful about the correct
orientation, mount the head cover by passing the stud
bolt through the top center bolt hole.
 When installing the head covers, be sure to start the work from the lower
cylinders because working on the upper cylinder first may cause foreign
matters to get into the lower cylinder.
e) Then, tighten the head cover fastening bolts [52].

Press down the head cover to some extent while the cover is pushed back by the head springs,
insert two bolts at diagonally opposite positions, and manually screw them for about 2 turns.
After screwing the remaining bolts similarly to the first two bolts, remove the stud bolt and screw-in
the last bolt. From this state, use a tool to fasten all the bolts one-by-one by alternately selecting
opposite positions.
Lastly, tighten all bolts with the specified torque.
f) If the head jacket cover [53] has been removed from the water-cooled head cover [50], reinstall it
onto the water-cooled head cover.
In this, be careful about the position of the marking and correct orientation of the
cooling water pipe.
Assemble the unit with the end of the center rib of the head cover (below left picture) facing the
end of the center rib of the head jacket cover (below right picture).
In the case of the standard specification, the cooling water inlet/outlet side of the head jacket
cover will face the oil pump side of the compressor.

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2200M4JE-HO-W-N_2014.04.
5.6.13 Cooling Water Pipe

The braided high pressure hoses shall be attached along the cooling line, by selecting proper length of
the hose. In the case of black braided high pressure hoses, brand-new hoses must be used for each
overhaul.
a) Attach the braided high pressure hose to the hose nipple after passing it through the hose band.
When connecting the braided high pressure hose to the hose nipple, be sure to push-in the hose
end approximately 15 mm further than the last lock notch of the hose nipple as shown in the below
left picture.
b) Tighten the braided high pressure hose by the hose band.

As shown in the above left picture, the hose nipple has three notches to prevent disengagement.
Securely tighten the hose band after setting the position of the hose band such that the two wires
of the hose band will bite into the two notches on the nipple.
If the hose has been removed together with the flange, such as the one at the head jacket cover,
replace the gasket on the flange with a new gasket. Also, after fastening the flange, check that the
hose band is securely tightened as shown in the above right picture.
 If the hose band is not sufficiently tightened, it can not only cause cooling water
leakage, but also lead to spraying out of the cooling water on the motor or
control panel when the hose is disengaged, to lead to a failure of such electric
systems. So, be careful to securely tighten the band. Also, regularly check the
tightness of the hose bands.
5.6.14 Final Inspection

Lastly, check the tightness of the fastening bolts of the head cover, hand hole cover, and other parts as
well as the tightness of the pipe joints and plugs again, to complete the entire assembly work.
After the assembly work has been completed, use nitrogen gas to perform airtightness test of the
compressor.
During the test, check that there are no leak from the gaskets, pipe joints, and plugs that have been
worked on.
After the airtightness test has been completed, discharge the nitrogen gas in the compressor from the
purge valve.
Then, after sufficiently evacuating the inside of the compressor by using a vacuum pump, open the
stop valves of the compressor for connection to the cooling system. Note that the lubricant must be
supplied during the evacuation process.

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2200M4JE-HO-W-N_2014.04.
Table 6-1 Troubleshooting
 The motor does not start

Symptom Possible cause Result Action to take
The motor won’t Motor failure Circuit breaker is Inspection, repair, or
start with opened. replacement
hum-sound Motor burnt out
The belts tension is too high. Circuit breaker is Adjustment
opened.
Motor burnt out
Voltage drop Circuit breaker is
opened.
Motor burnt out
Failure or near-seizure of Motor burnt out. Inspection, repair, or
cylinder sleeve, piston, Seizure of sleeve, replacement
piston ring, or bearing metal piston, and/or shaft
(shaft seal), if the pulley seal
cannot be turned by hand
after removing the belts.
Poor or wrong wiring in the Burn-out of parts in Inspection and repair
automatic control or (single the automated
phase) electrical system system or others
No response The circuit breaker is Inoperable Inspection and replacement
when the opened.
magnet switch
Contact failure of the magnet Inoperable Inspection, repair, or
button is
switch, or protection switch is replacement
pressed
left activated.
Broken wire Inoperable Inspection, repair, or
replacement
After activation of OP Inoperable Reset the device
(reduced oil pressure
protection device) or HP
(high pressure protection
device), it is left as it is or not
reset.
The power turns Wiring error (in the automatic Inoperable Inspection and repair
on only when the control system)
magnet button is
Contact failure of any Inoperable Inspection, repair, or
kept pressed
auxiliary contact, etc. replacement
The motor stops OP (reduced oil pressure Inoperable

soon after the protection device) has Seizure of sliding
startup activated. surface of the
compressor
(a) Insufficient amount of (a) Supply oil
lubricant
(b) Oil pressure is too low (b) Adjust the oil pressure

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2200M4JE-HO-W-N_2014.04.

The motor stops HP (high pressure protection) Motor burn-out or
soon after the has activated due to inoperable
startup excessively high discharge
pressure.
(a) The condenser is full of (a) Purge non-condensing
non-condensing gas. gas
(b) The suction pressure is (b) Reduce the load
too high.
Due to liquid flow-back, the Inoperable Inspection, repair, or
oil pressure cannot be operation adjustment.
increased, and OP has Replace the lubricant in the
activated. crank case, or supply warm
oil after sucking the
refrigerant in the crank case
using another compressor.
Wiring error between Burn-out of control Inspection and repair

automatic control system and system components
magnet switch
Overload relay has activated, Unable to startup Wait until the bimetal is
or the bimetal temperature of cooled down (about 5
OP is high minutes). In the case of OP,
switch to manual operation
to startup the motor, and
switch back to automatic
mode after 10 minutes.
Note that the cause of the
failure must be identified
and corrected.
 Abnormally high pressure

The condenser The flow of the cooling water Activation of HP or Increase the amount of
is warmer than is insufficient, or the water safety valve, and cooling water,
normal temperature is too high. increased power or lower the water
consumption temperature.
Head cover is The flow of the cooling water Activation of HP or Adjust the amount of
overheated is insufficient, or the cooling safety valve, and cooling water, or clean the
pipe is contaminated. increased power cooling pipe.
consumption
Warm cooling Fan failure or clogging of Reduced cooling Inspection, repair, or

water of the spray nozzle or strainer capacity cleaning
evaporator-cond
enser

6-2
2200M4JE-HO-W-N_2014.04.

The top of the The refrigerant or lubricant Reduced cooling
condenser is has accumulated in the capacity
warm, but the condenser to reduce the
bottom is not. cooling area
In addition, the
crank case can (a) Clogging between the (a) Inspection, adjustment,
easily get condenser and receiver or removal of problem
frosted.
(b) Over charge of the (b) Discharge the excess
refrigerant (refrigerant is refrigerant.
contained in the
condenser since the
receiver is already full)
The discharge (a) Air in the condenser, or Reduced cooling (a) Purge the air from the
pressure gauge failure of the discharge capacity air purge valve.
shows some pressure gauge
pressure and the
condenser is (b) The oil separator is full of (b) Discharge the excess
somewhat warm. lubricant, closing the lubricant.
path of the gas.
 Discharge pressure is too low

The liquid pipe is The liquid pipe or suction pipe Reduced capacity Valve adjustment,
frosted and is obstructed. inspection, and cleaning
suction pressure
becomes
vacuum.
The crank case is Wet compression due to Liquid hammering Narrow the opening of the
frosted, and the excessive opening of the may occur, and the expansion valve while
head cover is expansion valve (suction discharge portion of running the compressor.
also cold. temperature is low due to the compressor may
liquid flow-back) be damaged.
Suction pressure Insufficient amount of No cooling Fill the refrigerant.
is low, and some refrigerant
hissing sound is
heard from the
expansion valve.
Suction pressure Gas leakage due to wear of Degraded capacity Inspection, repair, and/or
is high. the suction valve, discharge and baking of the replacement of the valve
valve, or piston ring sleeve portion and piston rings

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2200M4JE-HO-W-N_2014.04.
 The suction pressure is too high

Crankcase is The opening of the expansion Liquid Operational adjustment (Narrow
frosted. valve is too wide. hammering the opening of the expansion
occurs valve.)
Increased current Increased load Motor burnt Operational adjustment

out
Discharge Degraded performance of the No cooling Overhaul and parts replacement

pressure is low. compressor (possible crack in
No frost on the the suction/discharge valve
suction side line, etc.) or gas leakage from
the safety valve
 Suction pressure is too low

Cold room Insufficient amount of No cooling Charge the refrigerant or adjust
temperature or refrigerant or too narrow the operational parameters
brine temperature opening of the expansion
is too high, valve
compared with
the level of
suction pressure
Liquid flow-back (a) Lubricant is contained in No cooling (a) Discharge lubricant from the
occurs when the the cooling pipe. drain valve.
expansion valve
is opened (b) Excessive formation of (b) Remove the frost or ice.
frost or ice on the cooling
pipe
Since the initial The size of the cooling pipe No cooling Investigate and improve any
operation, the and suction pipe is too small errors in the design or piping work
suction pressure for the length or the
has been too low resistance is too high.
for the cold room
temperature or
brine
temperature.
Suction pressure Clogging of the suction gas Cleaning
is lower than it strainer
was during the
initial operation.

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2200M4JE-HO-W-N_2014.04.
 Abnormal noise during operation

Generation of (a) Existence of foreign Possible (a) Disassembly, repair, and/or
continuous matter in the compression damage to the replacement
metallic noise block discharge and
suction blocks
(b) Damaged discharge (b) Disassembly and
valve, suction valve, replacement
and/or piston ring
High temperature Wear, seizure, or damage of Possible Disassembly and replacement
in the shaft seal the metal damage in the (note that the oil supply pipe may
area compression be clogged)
block or
bearing wear
Damaged oil pump Possible wear Stop operation, investigate the
cause, and replace the part.
Crankcase is Liquid flow-back Damage in the Stop operation, investigate the

frosted. discharge cause, and replace parts.
block and Narrow the opening of the
piston or expansion valve while the
bearing wear compressor is running. If it is very
severe, first close the suction stop
valve and gradually open it.
High discharge Oil hammering Damage in the Prevent oil loss (if it occurs
noise from the discharge together with liquid flow-back,
head cover block and/or also apply the above measures).
piston
 Overheating of the crankcase

Overheating of Increased compression ratio Oil loss by Increase the amount of
the head cover (Increased condenser burning and condenser cooling water or lower
(when both the temperature, increased carbon the water temperature
discharge refrigerant load) attachment
pressure and
Carbonization of lubricant due Wear or Disassembly, inspection, and
suction pressure
to increased discharge damage of the cleaning or replacement
are high)
temperature, accumulation of metal or
carbide, and the resulting sleeve seizure
blocking of the path of the gas
Damaged discharge valve Reduced Disassembly, inspection, and
plate or gas leakage cooling replacement
capacity
Gas leak from safety valve Reduced Decrease the discharge pressure
cooling or adjust the safety valve
capacity

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2200M4JE-HO-W-N_2014.04.

Increased oil Failure of oil cooler, insufficient Increased Clean oil cooler and increase
temperature lubricant, contamination of oil, wear due to cooling water. Replace lubricant.
or heating of pump due to decreased Clean the oil filter.
clogging of oil filter viscosity of oil
Impeded flow of Insufficient amount of cooling Wear or Replace degraded lubricant,

the compressor water or clogging in the water seizure of the clean, and increase the cooling
jacket cooling path metal and/or water.
water carbon
attachment to
the discharge
block
The shaft seal Imminent seizure of the sliding Repair or replacement
Seizure or
part is especially part
damage of the
hot
sliding part
 Excessive oil consumption

Crankcase is Lubricant foaming due to liquid Inoperable Operational adjustment
easily frosted. flow-back
Particularly frequent during
negative pressure operation
No apparent Closure of the pressure Reduced oil Inspection/cleaning or cleaning of
abnormality is equalizing hole of the pressure the strainer
found crankcase (or too wide
opening in the case of
negative pressure operation)
or clogging of the suction
strainer
Piston ring wear Replacement
Cylinder sleeve wear Replacement

Improper fitting of the piston Reassemble it correctly.
rings
Missing to attach the pressure Attach it properly.
equalizing pipe
Wear of the unloader piston Replace the worn part or install a
case special unloader piston with
rubber.
Head cover is When the discharge Carbon Adjust the operation parameters
overheated temperature is increased, the deposit to lower the discharge
amount of oil vapor increases. temperature.
The bottom of the Clogging of the separator Reduced oil Inspection and adjustment
separator can be Failure of the float valve pressure
touched by hand

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2200M4JE-HO-W-N_2014.04.

Oil level goes Too frequent start/stop cycles Low oil level Reduce the number of start/stop
down after cycles.
increased
start/stop cycles.
Oil level goes Phased unloading has not Foaming Perform phased
down when been performed (i.e., sudden loading/unloading.
unloaded. unloading).
 No cooling
Symptom Possible cause Action to take

Suction pressure does Insufficient capacity
not go down. (a) Compressor (a) Inspect the system. If it is found
normal, add more capacity.
(b) Condenser (b) Inspect the system. If it is found
normal, add more capacity.
Increased load If it is only a temporary increase,
continue the operation.
If it continues, add more capacity
Insufficient thermal insulation or Review, reconstruct, and/or repair
degradation
Abnormally high pressure Reduce the discharge pressure

(increase flow of cooling water, add
condenser, clean condenser, air vent,
etc.)
Gas leakage Inspection and repair
Suction pressure is Overheated run (excessive closure of Adjust (open) the expansion valve.
low (with no frost on the expansion valve)
the suction pipe, and it Insufficient length of the cooling pipe Add capacity.
easily causes liquid
flow-back). Excessive frost on the cooling tube Remove frost.
Lubricant is contained in the cooling Discharge the oil.
pipe.
Aperture of the suction line Rework on the pipe system
Discharge pressure is Insufficient cooling water or increased Increase the water flow.
high water temperature
Insufficient capacity of the condenser Add capacity.
Contamination on the cooling surface Cleaning
of condenser
Discharge pressure is Overcharging of the refrigerant Remove excess refrigerant.
high (the bottom of the Clogging in the discharge line pipe Rework on the pipe system
condenser is cold, the
receiver is full).
Excessive oil loss Piston ring wear Replacement
(increased discharge Galling Inspection and repair
temperature)
Gas leakage Inspection and repair

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2200M4JE-HO-W-N-2014.04.

7.1 Development View of Parts
Figure 7-1 Development View of Parts Around the WA-type Cylinder
W-Series Reciprocating Compressor 7.1 Development View of Parts

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2200M4JE-HO-W-N-2014.04.
Figure 7-2 Development View of the Entire WA-type (8WA) Compressor

7-2
2200M4JE-HO-W-N-2014.04.
Figure 7-3 Development View of Parts Around the WB-type Cylinder

7-3
2200M4JE-HO-W-N-2014.04.
Figure 7-4 Development View of the Entire WB-type (62WB) Compressor

7-4
2200M4JE-HO-W-N-2014.04.
7.2 Parts Configuration Table

Table 7-1 Parts for WA-type Compressors
Qty
No. Name Item Code Remarks
2 4 6 8 42 62
2A/2WA
1 Crankcase CR00100-A02 1 - - - - -
(for metric system)
4A/4WA
1 Crankcase CR00100-A04 - 1 - - - -
(for metric system)
6A/6WA
1 Crankcase CR00100-A06 - - 1 - - -
(for metric system)
8A/8WA
1 Crankcase CR00100-A08 - - - 1 - -
(for metric system)
42A/42WA
1 Crankcase CR00100-A042 - - - - 1 -
(for metric system)
62A/62WA
1 Crankcase CR00100-A062 - - - - - 1
(for metric system)
2 Crankshaft CR00209-ALA02 AL 2A/2WA 1 - - - - -
2 Type BB Crankshaft CR00209-BBA02 BB 2A/2WA 1 - - - - -
2 Type BB Crankshaft CR00209-ALA04 AL 4A/4WA/4J - 1 - - - -
2 Type BB Crankshaft CR00209-BBA04 BB 4A/4WA/4J - 1 - - - -
AL
2 Crankshaft CR00209-ALA06 - - 1 - 1 -
6A/6WA/42A/42WA/6J
2 Type BB Crankshaft CR00209-BBA06 BB 6A/6WA/42WA/6J - - 1 - 1 -
AL
2 Crankshaft CR00209-ALA08 - - - 1 - 1
8A/8WA/62A/62WA/8J
BB
2 Type BB Crankshaft CR00209-BBA08 - - - 1 - 1
8A/8WA/62A/62WA/8J
3 Drag Crank CR00300-AB A, WA, B, WB 1 1 1 1 1 1
12.7×12.4×85
4 Pulley Key CR00400-A 1 1 1 1 1 1
(rounded at one end)
5 Pulley Flat Washer CR00500-ASF 75 1 1 1 1 1 1
6 Pulley Lock Washer CR00600-AB A, WA, B, WB M27 1 1 1 1 1 1
7 Pulley Set Bolt CR00700-AB M27×50 (P=1.5) 1 1 1 1 1 1
8 Main Bearing Head CR00800-MA AM 1 1 1 1 1 1
Gasket, Main Bearing
9 CR00900-AN 1 1 1 1 1 1
Head
Main Bearing Head
10 NB14012-040 M12×40 6 6 6 6 6 6
Fastening Bolt
Main Bearing Head
11 NB14012-120 M12×120 2 2 2 2 2 2
Fastening Bolt
12 Main Bearing CR01200-A A, WA 1 1 1 1 1 1
M5×20
13 Main Bearing Screw NA22505-020 1 1 1 1 1 1
(Countersunk screw)
14 CUNO Filter Assembly CR0149-AJ A, WA, J 1 1 1 1 1 1
Gasket, CUNO Filter
15 CR01500-AN A, WA 1 1 1 1 1 1
Cover
CUNO Filter Cover M10×30 P=1.5
16 NBS14010-30 4 4 4 4 4 8
Fastening Bolt (small head)
Oil Supply and
20 NF063-0303 JO valve 3/8×3/8 1 1 1 1 1 1
Discharge Valve
Oil Pressure Control
22 NL152-SFX Round handle type 1 1 1 1 1 1
Valve Assembly
23 Bearing Head CR02300-MA AM (for metric system) 1 1 1 1 1 1
AM, BB
23 Type BB Bearing Head CR02300-MAB 1 1 1 1 1 1
(for metric system)
W-Series Reciprocating Compressor 7.2 Parts Configuration Table

7-5
2200M4JE-HO-W-N-2014.04.
Qty
2 4 6 8 42 62
24 Gasket, Bearing Head CR02700-AN 1 1 1 1 1 1
M12×30 Hexagon
Bearing Head Fastening
25 NB35412-030 Socket Head Cap 4 4 4 4 4 4
Bolt
Screw
26 Cover Plate CR02600-A A, WA 1 1 1 1 1 1
27 Gasket, Cover Plate CR02700-AN 1 1 1 1 1 1
Cover Plate Fastening
28 NB14012-080 M12×80 8 8 8 8 8 8
Bolt
29 Thrust Bearing CR02900-A 1 1 1 1 1 1
29 Type BB Thrust Bearing CR02900-ABBME 1 1 1 1 1 1
29 Thrust Ball Bearing CR70800-A 51118 A (NH3) 1 1 1 1 1 1
29 Thrust Roller Bearing CR70900-A 1 1 1 1 1 1
Washer for Thrust For M10 (small round
30 CR03000-AB 6 6 6 6 6 6
Bearing Fastening Bolt washer)
Thrust Bearing
31 NB14010-030 M10×30 6 6 6 6 6 6
Fastening Bolt
Mechanical Seal
32 CR03209-NA A (NH3) (HNBR) 1 1 1 1 1 1
Assembly
Mechanical Seal
32 CR03209-WA WA (HNBR) 1 1 1 1 1 1
Assembly
A, WA (Freon) with
33 Double Seal Collar CR0339-FA 1 1 1 1 1 1
O-ring
33 Seal Collar CR0339-NA A (NH3) with O-ring 1 1 1 1 1 1
33 Double Seal Collar CR0339-WA WA with O-ring 1 1 1 1 1 1
Double Seal Collar
34 - 1 1 1 1 1 1
Fixing Ring
Double Seal Collar
35 - 1 1 1 1 1 1
Floating Seat
Double Seal Collar Drive
36 - φ4×12 (alignment pin) 1 1 1 1 1 1
Pin
O-ring for Double Seal
37 PC61-045 AS568A 342 FKM 1 1 1 1 1 1
Collar
O-ring for Double Seal
37 PA61-045 AS568A 342 NBR 1 1 1 1 1 1
Collar
Double Seal Collar
38 CR03800-AB 6 6 6 6 6 6
Spring
Double Seal Collar
38 CR0389-A A, WA 1 1 1 1 1 1
Spring Set
O-ring for Shaft Seal
39 PC61-039 AS568A 336 FKM 1 1 1 1 1 1
Collar
39 PA61-039 AS568A 336 NBR 1 1 1 1 1 1
Collar
40 Lock Nut CR04000-A M70 (P=1) 2 2 2 2 2 2
41 Shaft Seal Ring CR04100-A A, WA 1 1 1 1 1 1
42 PC61-046 AS568A 343 FKM 1 1 1 1 1 1
Ring
42 PA61-046 AS568A 343 NBR 1 1 1 1 1 1
Ring
43 Helical Spring CR04300-A A, WA 12 12 12 12 12 12
43 Helical Spring Set CR0439-FA A, WA (Freon) 1 1 1 1 1 1
43 Helical Spring Set CR0439-NA A, WA (NH3) 1 1 1 1 1 1
44 Spring Pin (roll pin) NE3203-010 φ3×10 (alignment pin) 1 1 1 1 1 1
- Locking Ball - φ3/16 - 1 1 1 1 1

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2200M4JE-HO-W-N-2014.04.
Qty
2 4 6 8 42 62
Hand Hole Cover
45 CR0459-A01 A, WA with Gasket - 1 1 1 1 1
(with window)
Hand Hole Cover
46 (without window/with CR0459-A02 A, WA with Gasket - 1 1 1 1 1
hole)
Hand Hole Cover
46 (without window/without CR0459-A03 A, WA with Gasket - 1 1 1 1 1
hole)
Hand Hole Cover
46 CR0459-A2 2A with Gasket 1 - - - - -
(without window) 2A
Gasket, Hand Hole
47 CR04700-AN 1 2 2 2 2 2
Cover
Hand Hole Cover
48 NB14012-040 M12×40 14 32 32 32 32 32
Fastening Bolt
Head Cover (air cooled)
49 CR0499-AA A with Gasket 1 2 3 4 3 4
A
Head Cover (air cooled)
49 CR0499-WAA WA with Gasket 1 2 3 4 3 4
WA
Head Cover
50 CR0499-AW A with Gasket 1 2 3 4 3 4
(water cooled)
Head Cover
50 CR0499-WAW WA with Gasket 1 2 3 4 3 4
(water cooled)
Head Cover
50 CR0509-WA1 WA MYCOM1 1 2 3 4 3 4
(water cooled) Assembly
Head Cover
50 CR0509-WA2 WA MYCOM2 1 2 3 4 3 4
(water cooled) Assembly
Head Cover (sea water)
50 CR0509-WAK1 WA MYCOM1 1 2 3 4 3 4
Assembly
50 CR0509-WAK2 WA MYCOM2 1 2 3 4 3 4
Assembly
Head Cover (refrigerant)
50 CR0509-WAR1 WA MYCOM1 1 2 3 4 3 4
Assembly
50 CR0509-WAR2 WA MYCOM2 1 2 3 4 3 4
Assembly
51 Gasket, Head Cover CR05100-AN 1 2 3 4 3 4
Head Cover Fastening
52 NB15512-040 WA M12×40 16 32 48 64 48 64
Bolt, WA
Head Cover Fastening
53 NB15512-055S A M12×55 16 32 48 64 48 64
Bolt, A
Head Jacket Cover WA MYCOM1 with
53 CR0539-WA1 1 2 3 4 3 4
(water cooled) Gasket
53 CR0539-WA2 1 2 3 4 3 4
(water cooled) Gasket
53 CR0539-WAK1 1 2 3 4 3 4
(sea water) Gasket
53 CR0539-WAK2 1 2 3 4 3 4
(sea water) Gasket
Head Jacket Cover
54 NB17010-025 M10×25 10 20 30 40 30 40
Fastening Bolt
Gasket, Head Jacket
55 CR05500-WAW 1 2 3 4 3 4
Cover (water cooled)
Water Cooled Head
- CR85400-WA WA 1 2 3 4 3 4
Cover, Zinc ZAP
Gasket, Water Cooled
- CR85500-WA WA 1 2 3 4 3 4
Head Cover, Zinc ZAP
Gasket, Head Jacket
55 CR05500-WAR - 2 3 4 3 4
Cover (refrigerant)
Standard for A /WA
56 Oil Pump A CR0569-AVS 1 1 1 1 1 1
(800 to 1450 min-1)
58 O-ring for Oil Pump PC61-041 AS568A 338 FKM 1 1 1 1 1 1
58 O-ring for Oil Pump PA61-041 AS568A 338 NBR 1 1 1 1 1 1
59 Gasket, Oil Pump CR05900-AN 1 1 1 1 1 1

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2200M4JE-HO-W-N-2014.04.
Qty
2 4 6 8 42 62
60 Oil Pump Fastening Bolt NBS14010-30 M10×30 (small head) 6 6 6 6 6 8
61 Cylinder Sleeve A CR0619-A2 A, WA with Gasket 2 4 6 8 6 6
Cylinder Sleeve
61 CR0619-ZAL A, WA with Gasket, - - 2 2 2 2
Assembly Left
Cylinder Sleeve
61 CR0619-ZAR A, WA with Gasket, 2 2 2 4 2 -
Assembly Right
62 Cam Ring (left down) CR06200-AL - - 2 2 2 6
63 Cam Ring (right down) CR06200-AR 1 2 2 4 2 -
65 Retaining Ring CR06500-A A, WA 1 2 4 6 4 6
66 Gasket, Cylinder Sleeve CR06600-A A, WA 2 4 6 8 6 8
O-ring for Cylinder
67 PC61-050 AS568A 347 FKM - - - - 2 2
Sleeve
O-ring for Cylinder
67 PA61-050 AS568A 347 NBR - - - - 2 2
Sleeve
68 Lift Pin CR06800-A A, WA 6 12 24 36 24 36
69 Lift Pin Spring CR06900-A A, WA 6 12 24 36 24 36
Split Cotter Pin for Lift
70 CR07000-AB A, WA, B, WB E4 6 12 24 36 24 36
Pin
71 Suction Valve CR07100-A A, WA 2 4 6 8 6 8
- Suction Valve Assembly CR0719-NA A,WA (NH3) 2 4 6 8 6 8
71 Suction Valve Assembly CR0719-FA A, WA (Freon) 2 4 6 8 6 8
72 Suction Valve Spring CR07200-AB A, B 12 24 36 48 48 48
72 Suction Valve Spring CR07200-AB For low-stage: Type II - - - - 36 36
For high-stage: Type
72 Suction Valve Spring CR11600-AB4 12 24 36 48 12 12
IV (chrome plated)
- Suction Valve Spring Set CR0729-A2 For low-stage: Type II - - - - 1 1
For high-stage: Type
- Suction Valve Spring Set CR0729-WA4 1 1 1 1 1 1
IV (chrome plated)
A (NH3) single
73 Valve Plate A/NH3 CR07300-NA stage/two stage 2 4 6 8 6 8
machines
A (Freon) single stage
73 Valve Plate A/R CR07300-FA machine/high-stage of 2 4 6 8 2 2
two stage machine
A (Freon) single stage
73 Valve Plate CR07300-NA machine/low-stage of - - - - 4 6
two stage machine
WA (NH3) single
stage
73 Valve Plate WA/NH3 CR07300-NWA 2 4 6 8 2 2
machine/high-stage of
two stage machine
WA (Freon) single
stage
73 Valve Plate WA/R CR07300-FWA 2 4 6 8 2 2
machine/high-stage of
two stage machine
WA (NH3, Freon)
73 Valve Plate CR07300-NA low-stage of two stage - - - - 4 6
machine
74 Discharge Cage Guide CR07400-A A 2 4 6 8 6 8
74 Discharge Cage Guide CR07400-WA WA 2 4 6 8 6 8
Discharge Cage Guide
75 NB14010-050 A M10×50 (P=1.0) 10 20 30 40 30 40
Fastening Bolt A
75 NB15510-045P1 WA M10×45 (P=1.0) 10 20 30 40 30 40
Fastening Bolt WA

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Connecting Rod (for
76 CR07600-AN A, WA needle - - - - 2 2
high-stage)
Connecting Rod (for
77 CR07600-AM A, WA bushing 2 4 6 8 4 6
low-stage)
78 Crank Pin Fastening Bolt CR07800-A A, WA 4 8 12 16 12 16
Crank Pin Fastening Bolt
78 CR0789-A A, WA 4 8 12 16 12 16
Set
Washer for Crank Pin
79 CR07900-A A, WA 4 8 12 16 12 16
Fastening Bolt
First Nut, Crank Pin
80 CR08000-A1 A, WA 4 8 12 16 12 16
Fastening
Second Nut, Crank Pin
81 CR08000-A2 A, WA 4 8 12 16 12 16
Fastening
Connecting Rod A, WA AP8-2F
82 CR08200-AF 2 4 6 8 6 6
Bushing low-stage
Connecting Rod
A, WA TA25
83 Bushing (needle CR08300-A - - - - 2 2
high-stage
bearing)
Bearing Halves
84 CR0849-A A, WA 2 4 6 8 6 8
(top/bottom set)
Bearing Halves
84 CR0849-A05 A, WA 0.5 mm 2 4 6 8 6 8
(top/bottom set)
Bearing Halves
84 CR0849-A10 A, WA 1.0 mm 2 4 6 8 6 8
(top/bottom set)
85 Piston CR08500-ALAMH A, WA AL 2 4 6 8 6 8
86 Piston Pin CR08600-A A, WA 2 4 6 8 6 8
87 Piston Pin Lock Spring CR08700-A A, WA 4 8 12 16 12 16
Piston Pin Lock Spring
- CR0879-A A, WA 2 4 6 8 6 8
Set
88 Piston Ring Set CR0899-FA A (Freon), J 2 4 6 8 6 8
88 Piston Ring Set CR0899-NA1 A (NH3) 2 4 6 8 - -
A (NH3) two stage
88 Piston Ring Set CR0899-NA2 - - - - 6 8
machine
88 Piston Ring Set CR0899-WA1 WA 2 4 6 8 6 8
88 Piston Ring Set CR0899-WA2 WA (Propane) 2 4 6 8 6 8
Piston Ring (A,
89 CR08900-AFCBFG1 1st 2 4 6 8 6 8
FC-PC-BFG1)
90 Piston Ring (A, FC-P) CR08900-AFCP 2nd 2 4 6 8 6 8
Piston Ring (A,
100 CR08900-AFCBC3P 3rd 2 4 6 8 6 8
FC-PC-BC3P)
Piston Ring (A,
101 CR08900-AFCBC3 4th 2 4 6 8 6 8
FC-PC-BC3)
A single stage, (Freon)
- Piston Ring (A, FC-UC) CR08900-AFCUC 2 4 6 8 6 8
two stage machine
- Piston Ring (A, GA-P) CR08900-AGAP A (NH3) 2 4 6 8 6 8
- Piston Ring (A, GA-UC) CR08900-AGAUC - - - - - -
Discharge Valve
108 CR10800-ACN A (NH3) low-stage - - - - 4 6
Assembly
Discharge Valve
108 CR10800-ASR A (Freon) low-stage - - - - 4 6
Assembly
Discharge Valve WA (NH3) single
108 CR10800-WACN 2 4 6 8 2 2
Assembly stage/high-stage
Discharge Valve WA (Freon) single
108 CR10800-WACR 2 4 6 8 2 2
Assembly stage/high-stage
109 Discharge Valve Cage CR10900-ACN A (NH3) low-stage - - - - 4 6
109 Discharge Valve Cage CR10900-ASR A (Freon) low-stage - - - - 4 6

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WA (NH3) single
109 Discharge Valve Cage CR10900-WACN 2 4 6 8 2 2
stage/high-stage
WA (Freon) single
109 Discharge Valve Cage CR10900-WACR 2 4 6 8 2 2
stage/high-stage
110 Discharge Valve CR11000-A A, WA 2 4 6 8 6 8
111 Discharge Valve Seat CR11100-A A, WA 2 4 6 8 6 8
Discharge Valve
112 CR11200-A A, WA 2 4 6 8 6 8
Fastening Bolt
Discharge valve
- CR1129-A A, WA 2 4 6 8 6 8
fastening Bolt Set
First Nut, Discharge
113 CR08000-B1 2 4 6 8 6 8
Valve Fastening
Second Nut, Discharge
114 CR08000-B2 2 4 6 8 6 8
Valve Fastening
Type A: Type 1 (up to
116 Discharge Valve Spring CR11600-A1 12 24 36 48 36 48
May 1972)
Type A: Type 3 (after
116 Discharge Valve Spring CR11600-AB3 14 28 42 56 42 56
Dec. 1974)
Type WA: Type 3
116 Discharge Valve Spring CR11600-AB3 - - - - 32 48
low-stage
Type WA: Type 4
116 Discharge Valve Spring CR11600-AB4 single 16 32 48 64 16 16
stage/high-stage
Discharge Valve Spring
- CR1169-A3 Type A: Type 3 2 4 6 8 6 8
Set
Discharge Valve Spring Type WA: Type 3
- CR1169-A3 - - - - 4 6
Set low-stage
Type WA: Type 4
- CR1169-WA4 single 2 4 6 8 2 2
Set
stage/high-stage
- CR1169-A1 Type A: Type 1 2 4 6 8 6 8
Set
117 Head Spring CR11700-A A 2 4 6 8 6 8
117 Head Spring CR11700-WA WA 2 4 6 8 6 8
118 Oil Strainer Holder CR11800-A 1 1 1 1 1 1
119 Oil Strainer Element CR11900-A 1 1 1 1 1 1
121 Oil Strainer Cover CR12100-A A, WA with hole 1 1 1 1 1 1
121 Oil Strainer Cover CR12100-A01 A, WA without hole 1 1 1 1 1 1
Gasket, Oil Strainer
122 CR12200-AN A, WA 1 1 1 1 1 1
Cover
Oil Strainer Cover
123 NBS14010-30 M10×30 (small head) 4 4 4 4 4 4
Fastening Bolt
Oil Strainer Assembly
- CR1239-A A, WA with gasket 1 1 1 1 1 1
with Gasket
135 Push Rod, Unloader
CR13500-A041 4A/4WA -1 - 1 - - - -
/141 Slide Valve (4A1)
CR13500-A061 6A/6WA -1 - - 1 - - -
CR13500-A062 6A/6WA -2 - - 1 - 1 -
CR13500-A063 6A/6WA -3 - - - - 1 -
CR13500-A081 8A/8WA -1 - - - 1 - -
CR13500-A082 8A/8WA -2 1 - - 1 - -
CR13500-A083 8A/8WA -3 - - - 1 - 2

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CR13500-A084 8A/8WA -4 - - - - - 1
142 Unloader Device Spring CR14200-A A, WA 1 1 2 3 2 3
143 Push Rod Washer CR14300-A A, WA/ 32*10*3 1 1 2 3 2 3
144 Push Rod Fastening Bolt NB12010-020 M10×20 (small head) 1 1 2 3 2 3
145 Unloader Piston CR14500-FCA 1 1 2 3 2 3
146 Unloader Piston Cover CR14600-A A, WA 1 1 2 2 2 3
Gasket, Unloader Piston
147 CR14700-AN A, WA 1 1 2 2 2 3
Cover
Unloader Piston Cover
149 NB14010-035 M10×35 6 6 12 18 12 18
Fastening Bolt
Hexagon Socket Head
150 Cap Screw, Unloader NB3541/4-015 W1/4×15 1 1 2 3 2 3
Piston Cover
Washer, Hexagon
150-1 ND113-065 1 1 2 3 2 3
Socket Head Cap Screw
Unloader Piston and
151 CR15100-A08 8A/8WA - - - 1 - -
Suction Cover
152 CR15200-A08N 8A/8WA - - - 1 - -
and Suction Cover
Unloader Piston and
153 Suction Cover Fastening NB14010-035 M10×35 - - - 1 - -
Bolt
154 Suction Strainer CR15400-A02 2A/2WA 1 - - - - -
154 Suction Strainer CR15401-A04 4A/4WA/6A/6WA - 1 2 - 1 -
154 Suction Strainer, 8A long CR15401-A08L 8A/8WA (long) - - - 1 - -
Suction Strainer, 8A
154 CR15401-A08S 8A/8WA (short) - - - 1 - -
short
156 Suction Strainer Canvas CR15600-A A, WA - 1 2 2 1 -
156 Suction Strainer Canvas CR1500-A2 2A/2WA 1 - - - - -
Suction Strainer Holding
158 CR15800-A A, WA - 1 2 1 1 -
Spring
158 CR15800-A02 2A/2WA 1 - - - - -
Spring
158 CR15800-A08S 8A/8WA short - - - 1 - -
Spring
Suction Strainer Lock
159 CR15900-A A, WA - 1 2 2 1 -
Spring
Suction Strainer Lock
159 CR15900-A02 2A/2WA 1 - - - - -
Spring 2A
160 CR16000-A42 42A/42WA - - - - 1 -
Hardware 42A
161 Suction End Cover A CR16100-A A, WA - 1 2 1 - -
161 Suction End Cover 2A CR16100-A02 2A/2WA 1 - - - - -
Gasket, Suction End
162 CR16200-AN A, WA - 1 2 1 - -
Cover A
Gasket, Suction End
162 CR16200-A02N 2A/2WA 1 - - - - -
Cover 2A
Suction End Cover
163 NB14010-035 M10×35 4 6 6 6 - -
Fastening Bolt
164 Oil Sight Glass CR16400-AB 70D A, WA, B, WB 1 1 1 1 1 1
O-ring for Oil Sight
165 PA61-035 AS568A 332 NBR 2 2 2 2 2 2
Glass
O-ring for Oil Sight
165 PC61-035 AS568A 332 FKM 2 2 2 2 2 2
Glass

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166 Oil Sight Gland CR16600-AB 70D 3/8 1 1 1 1 1 1
Oil Sight Gland
167 NBS14010-30 M10×30 (small head) 4 4 4 4 4 4
Fastening Bolt
4AE1 low-stage
168 Discharge Elbow CR16800-A04 - - - - 1 1
discharge
168 Discharge Elbow CR16800-A06 6AE1 (NH3, Freon) - - 1 - - -
168 Discharge Elbow CR16800-A08 8AE1 (NH3) - - - 1 - -
168 Discharge Elbow CR16800-A082 8AE2 (Freon) - - - 1 - -
62AE1 high-stage
168 Discharge Elbow CR16800-A062 - - - - 1 1
discharge
Suction Elbow
- CR16800-A062H 62AE1, hole - - - - 1 1
(high-stage suction)
Suction Elbow Fastening
- NB14012-050 M12×50 high-stage - - - - 2 2
Bolt
Suction Elbow Fastening
- NB14012-080 M12×80 high-stage - - - - 2 2
Bolt
Tooth Washer, Suction M12 high stage
- ND422-12 - - - - 4 4
Elbow Fastening suction
Discharge Elbow Domestic land use,
168 CR16800-AN04 - - - - 1 1
(low-stage discharge) 4AE1N (NH3)
Domestic land use,
168 Discharge Elbow CR16800-AN06 - - 1 - - -
6AE1N (NH3)
Domestic land use,
168 Discharge Elbow CR16800-AN08 - - - 1 - -
8AE1N (NH3)
Domestic land use,
168 Discharge Elbow CR16800-AN082 - - - 1 - -
8AE2N (NH3)
Discharge Elbow Domestic land use,
168 CR16800-AN062 - - - - 1 1
(high-stage discharge) 62AE1N (NH3)
Suction Elbow Domestic land use,
168 CR16800-AN062 - - - - 1 1
(high-stage suction) 62AE1N (NH3)
Gasket, Discharge
169 CR72000-040N Body side, 40A - - - - 1 1
Elbow
Gasket, Discharge
169 CR72000-065N Body side, 65A - - 1 1 1 1
Elbow
Gasket, Discharge
169 CR72000-080N Body side, 80A - - - 1 - -
Elbow
Discharge Elbow
170 NB14012-050 M12×50 high-stage - - - - 2 2
Fastening Bolt
Discharge Elbow
170 NB14016-080 M16×80 high-stage - - - - 2 2
Fastening Bolt
Discharge Elbow
170 NB14016-055 M16×55 low-stage - - 4 - 4 4
Fastening Bolt
Discharge Elbow
170 NB14020-060 M20×60 - - - 4 - -
Fastening Bolt
Tooth Washer,
High-stage discharge,
- Discharge Elbow ND422-12 - - - - 2 2
for M12
Fastening
Tooth Washer,
Low-stage discharge,
- Discharge Elbow ND422-16 - - 4 - 6 6
for M16
Fastening
Tooth Washer,
- Discharge Elbow ND422-20 For M20 - - - 4 - -
Fastening
171 Service Valve NF063-0303 JO valve 3/8×3/8 1 1 1 1 1 1
172 Gasket, Discharge CR72000-040N MYCOM flange G 40A 1 - - - 1 1
172 Gasket, Discharge CR72000-050N MYCOM flange G 50A - 1 - - 1 1
172 Gasket, Discharge CR72000-065N MYCOM flange G 65A - - 1 1 - -

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172 Gasket, Discharge CR72000-080N MYCOM flange G 80A - - - 1 - -
173 Discharge Stop Valve CR72300-W040 MYK GVF ASSY W 40A 1 - - - 1 1
173 Discharge Stop Valve CR72300-W050 MYK GVF ASSY W 50A - 1 - - 1 1
173 Discharge Stop Valve CR72300-W065 MYK GVF ASSY W 65A - - 1 1 - -
173 Discharge Stop Valve CR72300-W080 MYK GVF ASSY W 80A - - - 1 - -
4AT1 low-stage
175 Scale Trap CR17500-A04 - - - - 1 -
suction
175 Scale Trap CR17500-A061 6AT1 (NH3) - - 1 - - 1
175 Scale Trap CR17500-A062 6AT2 (Freon) - - 1 - - -
175 Scale Trap CR17500-A081 8AT1 (NH3) - - - 1 - -
175 Scale Trap CR17500-A082 8AT2 (Freon) - - - 1 - -
Gasket, Scale Trap
176 CR18200-K040 Body side, 40A - - - - - 1
Centering Location
Gasket, Scale Trap
176 CR18200-K050 Body side, 50A - - - - 1 -
Centering Location
Gasket, Scale Trap
176 CR18200-K065 Body side, 65A - - - - 1 -
Centering Location
Gasket, Scale Trap
176 CR18200-K080 Body side, 80A - - 1 - - 1
Centering Location
Gasket, Scale Trap
176 CR18200-K100 Body side, 100A - - - 1 - -
Centering Location
Scale Trap Fastening
177 NB14012-050 M12×50 - - - - 2 -
Bolt
177 NB14012-080 M12×80 - - - - 2 -
Bolt
Scale Trap Fastening M16 × 55 low-stage
177 NB14016-055 - - - - 4 -
Bolt suction
177 NB14020-060 M20×60 - - 4 4 - 4
Bolt
Tooth Washer, Scale M12 high-stage
177 ND422-12 - - - - 4 4
Trap Fastening suction
Tooth Washer, Scale
177 ND422-16 M16 low-stage suction - - - - 4 4
Trap Fastening
Tooth Washer, Scale
177 ND422-20 M20 - - 4 4 - 4
Trap Fastening
178 Scale Trap Wire Mesh CR17800-A N:AT7/F:8AT8 - - 1 1 1 1
for 4AT1 low-stage
179 Scale Trap Cover CR17900-A04 - - - - 1 -
suction
for 6AT1, 6AT2, 8AT1
179 Scale Trap Cover CR17900-A068 6AT1N, 6AT2N, - - 1 1 1 1
8AT1N
179 Scale Trap Cover CR17900-A08T2 for 8AT2 (Freon) - - - 1 - -
Gasket, Scale Trap
180 CR17900-A04N for 4AT1 - - - - 1 -
Cover
for 6AT1, 6AT2, 8AT1
Gasket, Scale Trap
180 CR17900-A068N 6AT1N, 6AT2N, - - 1 1 - 1
Cover
8AT1N
Gasket, Scale Trap
180 CR17900-A08R2 for 8AT2 (Freon) - - - 1 - -
Cover
Scale Trap Cover
181 NB14012-040 M12×40 - - 4 4 4 4
Fastening Bolt
MYK GVF ASSY W
182 Suction Stop Valve 40A CR72300-W040 1 - - - 1 1
40A
MYK GVF ASSY W
182 Suction Stop Valve 50A CR72300-W050 - 1 - - 1 -
50A
MYK GVF ASSY W
182 Suction Stop Valve 65A CR72300-W065 - 1 1 - - 1
65A

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182 Suction Stop Valve 80A CR72300-W080 MYK GVF ASSY W 80A - - 1 1 - -
182 Suction Stop Valve 90A CR72300-W090 MYK GVF ASSY W 90A - - - 1 - -
Companion Flange,
182-1 CR74000-040 MYCOM 40A (male) 1 - - - 1 1
Suction Stop Valve
Companion Flange,
182-1 CR74000-050 MYCOM 50A (male) - 1 - - 1 1
Suction Stop Valve
Companion Flange,
182-1 CR74000-065 MYCOM 65A (male) - 1 1 - - -
Suction Stop Valve
Companion Flange,
182-1 CR74000-080 MYCOM 80A (male) - - 1 1 - -
Suction Stop Valve
Companion Flange,
182-1 CR74000-090 MYCOM 90A (male) - - - 1 - -
Suction Stop Valve
Companion Flange
182B Fastening Bolt, Suction NB12012-065 SS400 M12×50 4 - - - 4 4
Stop Valve
Companion Flange
182B Fastening Bolt, Suction NB12016-075 SS400 M16×75 - 4 - - 4 -
Stop Valve
Companion Flange
182B Fastening Bolt, Suction NB12016-090 SS400 M16×90 - 4 4 - - 4
Stop Valve
Companion Flange
182B Fastening Bolt, Suction NB12020-090 SS400 M20×90 - - 4 4 - -
Stop Valve
Suction Stop Valve Stud-BT S45C
183 NBW44016-070 - 4 - - - -
Mounting Bolt M16×70
Suction Stop Valve Stud-BT S45C
183 NB42012-085 4 - - - - -
Mounting Bolt M12×85
Suction Stop Valve
183 NB14016-090 M16×90 - - 4 - - 4
Mounting Bolt
Suction Stop Valve
183 NB14020-100 M20×100 - - - 4 - -
Mounting Bolt
Suction Stop Valve
183 NB14016-080 M16×80 - - - - 4 -
Mounting Bolt
Suction Stop Valve
183 NB14012-080 M12×80 - - - - 4 4
Mounting Bolt
Gasket, Centering
184 Location, Suction Stop CR72000-040N MYCOM flange G 40A 1 - - - 1 1
Valve Mount
Gasket, Centering
184 Location, Suction Stop CR72000-050N MYCOM flange G 50A - - - - 1 -
Valve Mount
Gasket, Centering
184 Location, Suction Stop CR72000-065N MYCOM flange G 65A - 1 - - - 1
Valve Mount
Gasket, Centering
184 Location, Suction Stop CR72000-080N MYCOM flange G 80A - - 1 - - -
Valve Mount
Gasket, Centering
184 Location, Suction Stop CR72000-090N MYCOM flange G 90A - - - 1 - -
Valve Mount
Oil Cooler Assembly
185 CR18500-TAW A T-TCF0.15-0609P 1 1 1 - 1 -
(water cooled)
Oil Cooler Assembly
185 CR18500-TBW B T-TCF0.25-0617P - - - 1 - 1
(water cooled)
Oil Cooler Assembly 2A/2WA SUS
185 CR18500-A2S 1 - - - - -
(water cooled) (forward)
Oil Cooler Assembly 4A/4WA/6A/6WA SUS
185 CR18500-A4S - 1 1 - 1 -
185 CR18500-A8S - - - 1 - 1
185 CR18500-RA2S 1 - - - - -
(water cooled) (reverse)

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Oil Cooler Assembly 4A/4WA/6A/6WA SUS
185 CR18500-RA4S - 1 1 - 1 -
185 CR18500-RA8S - - - 1 - 1
Gasket, Oil Cooler
190 CR19000-A A, WA 1 1 1 1 1 1
Flange
Oil Cooler Assembly
192 CR18600-A2 2A/2WA (forward) 1 - - - - -
(refrigerant type)
Oil Cooler Assembly 4A/4WA/6A/6WA
192 CR18600-A4 - 1 1 - 1 -
(refrigerant type) (forward)
Oil Cooler Assembly
192 CR18600-A8 8A/8WA (forward) - - - 1 - 1
(refrigerant type)
Oil Cooler Assembly
192 CR18600-RA2 2A/2WA (reverse) 1 - - - - -
(refrigerant type)
Oil Cooler Assembly 4A/4WA/6A/6WA
192 CR18600-RA4 - 1 1 - 1 -
(refrigerant type) (reverse)
Oil Cooler Assembly
192 CR18600-RA8 8A/8WA (reverse) - - - 1 - 1
(refrigerant type)
Gasket, End Cover A
195 CR18500-GA T-TCF end cover A 1 1 1 1 1 1
(water cooled)
Gasket, End Cover A
195 CR19500-ADN A, WA end cover A 1 1 1 1 1 1
(direct expansion)
196 Gasket, End Cover B CR18500-GB T-TCF end cover B 1 1 1 1 1 1
Gasket, End Cover B T-TCF0.25-0617P
196 CR18500-GB024 - - - - - -
(water cooled) end cover B
Gasket, End Cover B
196 CR19600-ADN A, WA end cover B 1 1 1 1 1 1
(direct expansion)
Gasket, Oil Cooler
- CR18800-ABN A, WA, B, WB 1 1 1 1 1 1
Mouth Piece
Oil Cooler Zap, with
- CR1929-A A, WA 1 1 1 1 1 1
Gasket
197 Thermometer Set LC1103314 L/45 0 + 200 with case - 1 - - - -
197 Thermometer Set LC1102314 I/45 0 + 200 with case - - 1 1 - -
199 Thermometer Set LC1103311 L/45-50 + 50 with case - 1 - - 1 -
199 Thermometer Set LC1102311 I/45-50 + 50 with case - - 1 1 - -
L/45 -50 + 50 with
201 Thermometer Set LC1103311 - - - - 1 1
case
203 Thermometer Set LC1102312 I/45 0 + 100 with case - - - - 1 1
205 Solenoid Valve KF221-2 SX-7 200V 1 1 1 3 1 2
207 Manual Valve Assembly NL1440-F06 JO6010 6D 1 1 1 1 1 1
207 Manual Valve Assembly, NL1440-F08 JO6010 8D 1 1 1 1 1 1
207 Manual Valve Assembly NL1440-N06 JO5990 6D 1 1 1 1 1 1
207 Manual Valve Assembly, NL1440-N08 JO5990 8D 1 1 1 1 1 1
207 Manual Valve Assembly, NL1440-NS JO6000 8D 1 1 1 1 1 1
208 Eye Bolt NB600-16 M16 1 1 2 2 2 2
213 External Safety Valve CR21300-006P300 5602 3/4 300P 1 1 1 1 2 2
Oval Flange for Water
234 CR71800-1 HF-20 2 4 6 8 6 8
Cooled Head Cover
Gasket, Oval Flange for
235 Water Cooled Head CR71900-1 HF-20 2 4 6 8 6 8
Cover
Oval Flange for Water
236 Cooled Head Cover NB17010-025 SUS M10×25 4 8 12 16 12 16
Fastening Bolt
245 Oil Heater LF2102-220 MKCP-2002F 1 1 1 1 1 1

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- O-ring Set CR7109-FA2 F 2A/4A/6A/8A 1 1 1 1 - -
- O-ring Set CR7109-FA6 F 42A/62A - - - - 1 1
- O-ring Set CR7109-NA2 NH3 2A/4A/6A/8A 1 1 1 1 - -
- O-ring Set CR7109-NA6 NH3 42A/62A - - - - 1 1
For WA single stage
- O-ring Set CR7109-WA1 1 1 1 1 - -
compressor
For WA two stage
- O-ring Set CR7109-WA2 - - - - 1 1
compressor
- Gasket Set CR7117-FA4 F4WA - 1 - - - -
- Gasket Set CR7117-FA6 F6WA - - 1 - - -
- Gasket Set CR7117-FA8 F8WA - - - 1 - -
- Gasket Set CR7117-NA2 F2WA/N2WA 1 - - - - -
- Gasket Set CR7117-NA4 N4WA - 1 - - - -
- Gasket Set CR7117-NA6 N6WA - - 1 - - -
- Gasket Set CR7117-NA7 N42WA/F42WA - - - - 1
- Gasket Set CR7117-NA8 N8WA - - - 1 - -
- Gasket Set CR7117-NA9 N62WA/F62WA - - - - 1
- Gasket Set CR7118-FA4 F4A - 1 - - - -
- Gasket Set CR7118-FA6 F6A - - 1 - - -
- Gasket Set CR7118-FA8 F8A - - - 1 - -
- Gasket Set CR7118-NA2 N2A/F2A 1 - - - - -
- Gasket Set CR7118-NA4 N4A - 1 - - - -
- Gasket Set CR7118-NA6 N6A - - 1 - - -
- Gasket Set CR7118-NA7 N42A/F42A - - - - 1 -
- Gasket Set CR7118-NA8 N8A - - - 1 - -
- Gasket Set CR7118-NA9 N62A/F62A - - - - - 1
Set of Consumables for
- CR7129-FA A/R - - - - - -
Mechanical Seal
- CR7129-NA A/NH3 - - - - - -
Mechanical Seal
Rod Bushing
- Attachment/Removal CR70100-AB A, WA, B, WB 1 1 1 1 1 1
Tool
Discharge Valve
- CR70200-AB A, WA, B, WB 1 1 1 1 1 1
Disassembly Tool
Disassembly Tool Set
- CR70400-AM02 A, WA 1 1 1 1 1 1
AM02
- CR70400-AM02ME A, WA (for ME) 1 1 1 1 1 1
AM02/ME

7-16
2200M4JE-HO-W-N-2014.04.
Table 7-2 Parts for WB-type Compressors

Qty
4 6 8 12 42 62 12･4
1 Crankcase CR00100-B04 mm scale 4B/4WB 1 - - - - - -
1 Crankcase CR00100-B06 mm scale 6B/6WB - 1 - - - - -
1 Crankcase CR00100-B08 mm scale 8B/8WB - - 1 - - - -
mm scale
1 Crankcase CR00100-B12 - - - 1 - - -
12B/12WB
1 Crankcase CR00100-B124 mm scale 12･4B - - - - - - 1
mm scale
1 Crankcase CR00100-B042 - - - - 1 - -
42B/42WB
mm scale
1 Crankcase CR00100-B062 - - - - - 1 -
62B/62WB
2 Crankshaft CR00209-MB04H AL 4B/4WB 1 - - - - - -
2 Type BB Crankshaft CR00209-MB04HB BB 4B/4WB 1 - - - - - -
AL
2 Crankshaft CR00209-MB06H - 1 - - 1 - -
6B/6WB/42B/42WB
BB
2 Type BB Crankshaft CR00209-MB06HB - 1 - - 1 - -
6B/6WB/42B/42WB
AL
2 Crankshaft CR00209-MB08H - - 1 - - 1 -
8B/8WB/62B/62WB
BB
2 Type BB Crankshaft CR00209-MB08HB - - 1 - - 1 -
8B/8WB/62B/62WB
2 Crankshaft 12B CR00200-ALB12 AL 12B/12WB - - - 1 - - -
2 Crankshaft 12･4B CR00200-ALB16 AL 12･4B/12･4WB - - - - - - 1
3 Drag Crank A/B CR00300-AB A, WA, B, WB 1 1 1 - 1 1 -
3 Drag Crank 12B CR00300-B12 12B, 12WB - - - 1 - - 1
24×15.6×11
4 Pulley Key B CR00400-B (rounded at one 1 1 1 1 1 1 1
end)
5 Pulley Flat Washer CR00500-B B, WB 1 1 1 1 1 1 1
5 Pulley Flat Washer 90 CR00500-BL B, WB 1 1 1 1 1 1 1
A, WA, B, WB
6 Pulley Lock Washer CR00600-AB 1 1 1 1 1 1 1
M27
7 Pulley Set Bolt CR00700-AB M27×50 (P=1.5) 1 1 1 1 1 1 1
8 Main Bearing Head CR00800-MB BM 1 1 1 - 1 1 -
8 Main Bearing Head CR00800-B12 12B, 12WB - - 1 - - 1
9 Gasket, Main Bearing Head CR00900-BN B, WB 1 1 1 - 1 1 -
Gasket, Main Bearing Head
9 CR00910-B B, WB (old type) - - - - - - -
(old)
Gasket, Main Bearing Head
9 CR02400-B12N 12B, 12WB - - - 1 - - 1
12B
Main Bearing Head Fastening
10 NB1405/8-040 S45C 5/8×40 - - - - - - -
Bolt
10 NB35416-040 SCM3, M16×40 - - - 4 - - 4
Bolt
10 NB14016-055 S45C, M16×55 12 12 12 - 12 12 -
Bolt
12 Main Bearing B CR01200-B B, WB 1 1 1 - 1 1 -
12 Main Bearing 12B CR01200-B12 12B 12WB - - - 1 - - 1
JISB2401 P110
12-1 O-ring for Main Bearing PA11-110 - - - - 2 2 2
NBR
M6×20
13 Main Bearing Screw NA22506-020 (Countersunk 1 1 1 1 1 1 1
screw)

7-17
2200M4JE-HO-W-N-2014.04.
Qty
4 6 8 12 42 62 12･4
14 CUNO Filter Assembly B CR0149-B B, WB 1 1 1 - 1 1 -
14 CUNO Filter Assembly 12B CR0149-B12 12B 12WB - - - 1 - - 1
15 Gasket, CUNO Filter Cover CR01500-BN B, WB 1 1 1 1 1 1 1
CUNO Filter Cover Fastening M10×30 P=1.5
16 NB14010-030 4 4 4 4 4 4 4
Bolt (small head)
Oil Supply and Discharge Needle valve
20 KA2130-010 - 1 1 1 1 1 1
Valve AS 10A
Oil Supply and Discharge Needle valve
20 KA2132-010 1 1 1 - - - 1
Valve VS-03P03-OA
Oil Supply and Discharge
20 KA038-010RC MAO 10A RC3/8 - - 1 - - - 1
Valve
Oil Pressure Control Valve
22 NL151-N JO-5920 - 1 1 1 1 1 1
Assembly
22 NL152-F JO-5930 - - - - 1 - -
Assembly
22 NL152-SFX SFX - - 1 1 - - -
Assembly
23 Bearing Head CR02300-MB mm scale BM 1 1 1 - 1 1 -
23 Type BB Bearing Head CR02300-MBB mm scale BM, BB 1 1 1 - 1 1 -
mm scale 12B
23 Bearing Head 12B CR02300-MB12 - - - 1 - - 1
12WB
mm scale
23 Type BB Bearing Head 12B CR02300-MB12B - - - 1 - - 1
12B, 12WB BB
same as main
24 Gasket, Bearing Head CR00900-BN 1 1 1 - - - -
bearing head G.
24 Gasket, Bearing Head 12B CR02400-B12N 12B, 12WB - - - 1 - - -
25 Hexagon Socket Head Cap NB35416-035 SCM3 M16×35 - - - 4 - - 4
Screw
25 Hexagon Socket Head Cap NB35416-040 SCM3 M16×40 4 4 4 4 4 4 4
Screw
25 Bearing Head Fastening Bolt NB1405/8-040 S45C 5/8×40 - - - - - - -
26 Cover Plate CR02600-B B, WB 1 1 1 1 1 1 1
27 Gasket, Cover Plate CR02700-BN B, WB 1 1 1 1 1 1 1
28 Cover Plate Fastening Bolt NB14016-090 S45C M16×90 12 12 12 12 12 12 12
28 Cover Plate Fastening Bolt NB1405/8-040 S45C 5/8×90 - - - - - - -
29 Thrust Bearing B CR02900-B B, WB 1 1 1 - 1 1 -
B, WB BB
29 Type BB Thrust Bearing B CR02900-BBBME 1 1 1 - - 1 -
aluminum
29 Thrust Bearing 12B CR02900-B12 12B, 12WB - - - 1 - - 1
29 Thrust Bearing (old) CR02910-B B, WB (old type) - - - - - - -
29-1 Thrust Ball Bearing CR70800-B B, WB (NH3) 51126 1 1 1 1 1 1 1
29-1 Thrust Roller Bearing CR70900-B B, WB (Freon) 1 1 1 1 1 - 1
JISB2401 P145
29-3 O-ring for Thrust Bearing PA11-145 - - - - 2 2 2
NBR
Washer for Thrust Bearing For M12 (small
30 CR03000-SF62 6 6 6 - 6 6 6
Fastening Bolt round washer)
Washer for Thrust Bearing
30 ND320-012 - - - 6 - - 6
Fastening Bolt
31 Thrust Bearing Fastening Bolt NB14012-035 M12×35 6 6 6 6 6 6 6
31 Thrust Bearing Fastening Bolt NB1401/2-035 S45C 1/2×35 - - - - - - -
Mechanical Seal Assembly B
32 CR03209-NB B, WB (HNBR) 1 1 1 - 1 1 1
(HNBR)

7-18
2200M4JE-HO-W-N-2014.04.
Qty
4 6 8 12 42 62 12･4
Mechanical Seal Assembly 12B, 12･4B
32 CR03200-WBLH - - - 1 - - 1
12, 124B (HNBR) (HNBR)
Double Seal Collar with B, WB (Freon) with
33 CR0339-FB 1 1 1 1 - - -
O-ring O-ring
33 Seal Collar with O-ring CR0339-NB B (NH3) with O-ring 1 1 1 1 - - -
Double Seal Collar with
33 CR0339-WB WB with O-ring 1 1 1 1 - - -
O-ring
Double Seal Collar Fixing
34 - 1 1 1 1 1 1 -
Ring
Double Seal Collar Floating
35 - 1 1 1 1 1 1 -
Seat
36 Double Seal Collar Lock Pin - φ5×14spring pin 1 1 1 1 1 1 -
37 O-ring for Double Seal Collar PC61-053 AS568A 426 FKM 1 1 1 1 1 1 -
38 Double Seal Collar Spring CR03800-AB B, WB, A, WA 8 8 8 8 8 6 -
38 Double Seal Collar Spring Set CR0389-B B, WB - - - - - - -
39 O-ring for Shaft Seal Collar PC61-047 AS568A 344 FKM - - - - - - -
39 O-ring for Shaft Seal Collar PAH82-344 AS568A 344 HNBR 1 1 1 1 1 1 -
40 Lock Nut CR04000-B M95(P=1) 2 2 2 2 1 1 1
41 Shaft Seal Ring CR04100-B B, WB 1 1 1 1 1 1 -
42 O-ring for Shaft Seal Ring PA61-051 AS568A 348 NBR - - - - - - -
42 O-ring for Shaft Seal Ring PC61-051 AS568A 348 FKM - - - - - - -
42 O-ring for Shaft Seal Ring PAH82-348 AS568A 348 HNBR 1 1 1 1 1 1 -
43 Helical Spring CR04300-B B, WB 10 10 10 10 10 10 10
43 Helical Spring Set CR0439-B B, WB 1 1 1 1 1 1 1
44 Spring Pin NE3203-020 φ3×20 1 1 1 1 1 1 1
Hand Hole Cover (with
45 CR0459-B01 B, WB with Gasket 1 1 1 - 1 1 -
window)
Hand Hole Cover (without
window/with hole)
Hand Hole Cover (without
window/without hole)
45 Hand Hole Cover (former type
CR04909-B12A Tap,with Gasket - - - 4 - - 4
/46 B head cover)
47 Gasket, Hand Hole Cover CR04700-BN B, WB 2 2 2 - 2 2 -
Gasket, Hand Hole Cover
47 CR05100-BN - - - 4 - - 4
(WB head cover gasket)
Hand Hole Cover Fastening
48 NB14016-055 M16×55 32 32 32 - 32 32 -
Bolt
48 NB15516-060S SCM3/11T M16×60 - - - 88 - - -
Bolt
48 NB111016-060 10.9T M16×60 - - - 88 - - 88
Bolt
48 NB1405/8-055 SS400 W5/8×55 - - - - - - -
Bolt
49 Head Cover (air cooled) B CR0499-BA B with Gasket 2 3 4 6 3 4 -
49 Head Cover (air cooled) WB CR0499-WBA WB with Gasket 2 3 4 6 3 4 -
49 Head Cover (air cooled) 12B CR04909-B12A Tap, with Gasket - - - - - - 4
50 Head Cover (water cooled) B CR0499-BW B with Gasket 2 3 4 6 3 4 -
Head Cover (water cooled)
50 CR0499-WBW WA with Gasket 2 3 4 6 3 4 -
WB
50 CR04902-MBWH WBH - - - - - - 8
WBH

7-19
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Qty
4 6 8 12 42 62 12･4
50 CR0509-WB1 WB MYCOM1 2 3 2 - - - -
Assembly
50 CR0509-WB2 WB MYCOM2 2 3 2 - - - -
Assembly
50 CR0509-WBK1 WB MYCOM1 2 3 2 - - - -
Assembly
50 CR0509-WBK2 WB MYCOM2 2 3 2 - - - -
Assembly
50 CR0509-WBR1 WB MYCOM1 2 3 2 - - - -
Assembly
50 CR0509-WBR2 WB MYCOM2 2 3 2 - - - -
Assembly
51 Gasket, Head Cover CR05100-BN B, WB 2 3 4 10 3 4 12
13
52 Head Cover Fastening Bolt NB111016-045 10．9T M16×45 - - - - - 176
2
13
52 Head Cover Fastening Bolt NB14016-060 M16×60 44 66 88 66 88 88
2
- Head Cover Marking Plate CR05300-B1 B, WB MYCOM 2 3 4 6 3 4 8
Gasket, Head Cover Marking
- CR05500-B 2 3 4 6 3 4 8
Plate
Head Jacket Cover WB MYCOM1
53 CR0539-WB1 - - - - - 2 4
(water cooled) with Gasket
53 CR0539-WB2 - - - - - 2 4
(water cooled) with Gasket
53 CR0539-WBK1 - - - - - 2 4
(sea water) with Gasket
53 CR0539-WBK2 - - - - - 2 4
(sea water) with Gasket
Head Jacket Cover Fastening
54 NB17010-025 M10×25 24 36 48 72 36 48 96
Bolt
Gasket, Head Jacket Cover
55 CR05500-WBW 2 3 4 6 3 4 8
(water cooled)
Water Cooled Head Cover,
- CR85400-WB - - - - - - -
Zinc ZAP WB
Gasket, Water Cooled Head
- CR85500-WB - - - - - - -
Cover, Zinc ZAP WB
Gasket, Head Jacket Cover
55 CR05500-WBR 2 3 4 6 3 4 8
(refrigerant)
56 Oil Pump B with Gasket CR0569-B2 B, WB No. 2 1 1 1 - - - -
56 Oil Pump 12, 16B with Gasket CR0569-B3 12B, 12WB - - - 1 - - 1
56 Oil Pump B with Gasket CR0569-B25 B, WB No. 2.5 - - - - 1 1 -
58 O-ring for Oil Pump PA61-043 AS568A 340 NBR 1 1 1 - 1 1 -
58 O-ring for Oil Pump PC61-043 AS568A 340 FKM 1 1 1 - 1 1 -
59 Gasket, Oil Pump CR05900-BN 1 1 1 - 1 1 -
59 Gasket, Oil Pump 12B CR05900-B12N 12B, 12WB - - - 1 - - 1
60 Oil Pump Fastening Bolt NB14012-035 M12×35 6 6 6 - 6 6 -
60 Oil Pump Fastening Bolt NB14016-040 S45C M16×40 - - - 6 - - 6
60 Oil Pump Fastening Bolt NB111016-040 10.9T M16×40 - - - 6 - - 6
60 Oil Pump Fastening Bolt NB1405/8-040 S45C 5/8×40 - - - - - - -
61 Cylinder Sleeve B CR0619-B2 B, WB with Gasket 4 6 8 12 6 8 16
Cylinder Sleeve Assembly
61 CR0619-ZBL B, WB with Gasket 2 2 2 4 4 4 6
Left
Cylinder Sleeve Assembly
61 CR0619-ZBR B, WB 2 2 4 4 - 2 6
with Gasket, Right
62 Cam Ring (left down) CR06200-BL B, WB 2 2 2 4 4 4 6
63 Cam Ring (right down) CR06200-BR B, WB 2 2 4 4 - 2 6

7-20
2200M4JE-HO-W-N-2014.04.
Qty
4 6 8 12 42 62 12･4
65 Retaining Ring CR06500-B B, WB 4 4 6 8 4 6 12
66 Gasket, Cylinder Sleeve CR06600-B B, WB 4 6 8 12 6 8 16
67 O-ring for Cylinder Sleeve PC61-062 AS568A 435 FKM - - - - 2 2 4
67 O-ring for Cylinder Sleeve PA61-062 AS568A 435 NBR - - - - 2 2 4
68 Lift Pin CR06800-B B, WB 24 24 36 48 24 36 72
69 Lift Pin Spring CR06900-B B, WB 24 24 36 48 24 36 72
70 Split Cotter Pin for Lift Pin CR07000-AB A, WA, B, WB 24 24 36 48 24 36 72
71 Suction Valve CR07100-B B, WB 4 6 8 12 6 8 16
71 Suction Valve Assembly CR0719-NB B, WB (NH3) 4 6 8 12 6 8 16
71 Suction Valve Assembly CR0719-FB B, WB (Freon) 4 6 8 12 6 8 16
A/B type 4 single
72 Suction Valve Spring CR11600-AB4 32 48 64 96 16 16 32
stage/high-stage
A/B type 4 (R134a,
72 Suction Valve Spring CR11600-AB4 32 48 64 96 48 64 128
R404A, R507A)
A/B type 2
72 Suction Valve Spring CR07200-AB - - - - 18 18 36
low-stage
WB
- Suction Valve Spring Set CR0729-WB4 CR11600-AB4×8 4 6 8 12 48 64 128
springs
B-2
- Suction Valve Spring Set CR0729-B2 CR07200-AB×9 - - - - 4 6 12
springs
WB/NH3 single
73 Valve Plate CR07300-NWB 4 6 8 12 2 2 4
stage/high-stage
R134a, R404A,
73 Valve Plate CR07300-NWB - - - - 4 6 12
R507A low-stage
WB/R single
73 Valve Plate CR07300-FWB 4 6 8 12 2 2 4
stage/high-stage
74 Discharge Cage Guide WB CR07400-B WB 4 6 8 12 6 8 16
75 NB14012-060 M12×60 (P=1.25) 20 30 40 60 30 30 80
Fastening Bolt
75 NB111012-060 10.9T M12×60 - - - 60 - - -
Fastening Bolt
Discharge Cage Guide S45C 1/2×60 fine
75 NB1401/2-060 - - - - - - -
Fastening Bolt thread
Connecting Rod (for B, WB needle
76 CR07600-BN - - - - 2 2 4
high-stage) bearing
Connecting Rod (for
77 CR07600-BM B, WB bushing 4 6 8 12 4 6 12
low-stage)
78 Crank Pin Fastening Bolt CR07800-B B, WB 8 12 16 24 12 16 32
78 Rod Fastening Bolt Set CR0789-B B, WB 8 12 16 24 12 16 32
Washer for Crank Pin
79 CR07900-B B, WB 8 12 16 24 12 16 32
Fastening Bolt
First Nut, Crank Pin
80 CR08000-B1 B, WB 8 12 16 24 12 16 32
Fastening
Second Nut, Crank Pin
81 CR08000-B2 B, WB 8 12 16 24 12 16 32
Fastening
B, WB BP8-2F
82 Connecting Rod Bushing CR08200-BF 4 6 8 12 4 6 12
low-stage
Connecting Rod Bushing A, WA TAW40
83 CR8300-B - - - - 2 2 4
(needle bearing) high-stage
Bearing Halves (top/bottom
84 CR0849-B B, WB 4 6 8 12 6 8 16
set)
84 CR0849-B05 B, WB 0.5 mm - - - - - - -
set)
84 CR0849-B10 B, WB 1.0 mm - - - - - - -
set)

7-21
2200M4JE-HO-W-N-2014.04.
Qty
4 6 8 12 42 62 12･4
85 Piston CR08500-ALBMH B, WB AL 4 6 8 12 6 8 16
86 Piston Pin CR08600-B B, WB 4 6 8 12 6 8 16
Lock Spring, Piston Pin
87 CR08700-B B, WB 8 12 16 24 12 16 32
Locking
87 Piston Pin Lock Spring Set CR0879-B B, WB 4 6 8 12 6 8 16
88 Piston Ring Set CR0899-FB B, WB (Freon), SF 4 6 8 12 6 8 16
88 Piston Ring Set CR0899-NB B, WB (NH3) 4 6 8 12 - - -
B, WB (NH3) two
88 Piston Ring Set CR0899-NB2 - - - - 6 8 16
stage machine
88 Piston Ring Set CR0899-WB1 WB 4 6 8 12 6 8 16
88 Piston Ring Set CR0899-WB12 WB (Propane) - - - - - - -
89 Piston Ring (B, FC-PC-BFG1) CR08900-BFCBFG1 1st 4 6 8 12 6 8 16
90 Piston Ring (B, FC-P) CR08900-BFCP 2nd 4 6 8 12 6 8 16
90 Piston Ring (B, FC-UC) CR08900-BFCUC 2nd - - - - - - -
2nd for R23,
90 Piston Ring (B, GA-P) CR08900-BGAP - - - - - - 16
Propane
100 Piston Ring (B, FC-PC-BC3P) CR08900-BFCBC3P 3rd 4 6 8 12 6 8 16
101 Piston Ring (B, FC-PC-BC3) CR08900-BFCBC3 4th 4 6 8 12 6 8 16
Discharge Valve Assembly NH3 single
108 CR10800-WBCN 4 6 8 12 2 2 4
(WB, CN) stage/high-stage
Discharge Valve Assembly R22, R23 single
108 CR10800-WBCR 4 6 8 12 2 2 4
(WB, CR) stage/high-stage
Discharge Valve Assembly
108 CR10800-WBCR Propane 4 6 8 12 6 8 16
(WB, CR)
R134a, R404A,
108 CR10800-WBCRH R507A single 4 6 8 12 2 2 4
(WB, WCRH)
stage/high-stage
108 CR10800-BSN NH3 low-stage - - - - 4 6 4
(B, SN)
108 CR10800-BSR Freon low-stage - - - - 4 6 4
(B, SR)
Discharge Valve Cage NH3 single
109 CR10900-WBCN 4 6 8 12 2 2 4
(WB, CN) stage/high-stage
Discharge Valve Cage R22, R23 single
109 CR10900-WBCR 4 6 8 12 2 2 4
(WB, CR) stage/high-stage
Discharge Valve Cage
109 CR10900-WBCR Propane 4 6 8 12 6 8 16
(WB, CR)
R134a, R404A,
109 CR10900-WBCRH R507A single 4 6 8 12 2 2 4
(WB, WCRH)
stage/high-stage
109 CR10900-BSN NH3 low-stage - - - - 4 6 12
(B, SN)
109 CR10900-BSR Freon low-stage - - - - 4 6 12
(B, SR)
R134a, R404A,
110 Discharge Valve (SFW) CR11000-SFW R507A single 4 6 8 12 2 2 4
stage/high-stage
R134a, R404A,
110 Discharge Valve CR11000-B14 - - - - 4 6 12
R507A low-stage
NH3, R22, R23,
110 Discharge Valve CR11000-B14 4 6 8 12 6 8 16
Propane
111 Discharge Valve Seat CR11100-B B, WB 4 6 8 12 6 8 16
Discharge Valve Fastening
112 CR11200-B B, WB 4 6 8 12 6 8 16
Bolt
Discharge Valve Fastening
112 CR1129-B B, WB 4 6 8 12 6 8 16
Bolt Set

7-22
2200M4JE-HO-W-N-2014.04.
Qty
4 6 8 12 42 62 12･4
First Nut, Discharge Valve
113 CR11300-B1 4 6 8 12 6 8 16
Fastening
Second Nut, Discharge Valve
114 CR11300-B2 4 6 8 12 6 8 16
Fastening
AB Type 4 NH3,
14
116 Discharge Valve Spring CR11600-AB4 Freon single stage, 48 72 96 24 24 48
4
high-stage
14
116 Discharge Valve Spring CR11600-AB4 AB Type 4 Propane 48 72 96 72 96 192
4
AB Type 3 NH3,
116 Discharge Valve Spring CR11600-AB3 - - - - 36 54 108
Freon low-stage
2
WB Type 4 2 or 4 or
- Discharge Valve Spring Set CR1169-WB4 4 6 8 12 or
12springs/set 6 12
8
B Type 3
- Discharge Valve Spring Set CR1169-B3 - - - - 4 6 12
9springs/set
117 Head Spring CR11700-B B, WB 4 6 8 12 6 8 16
118 Oil Strainer Holder CR11800-B B, WB 1 1 1 - 1 1 -
118 Oil Strainer Holder 12B CR11800-B12 12B - - - 1 - - 1
119 Oil Strainer Wire Mesh CR11900-B B, WB 1 1 1 - 1 1 -
119 Oil Strainer Wire Mesh 12B CR11900-B12 12B - - - 1 - - 1
121 Oil Strainer Cover with Hole CR12100-B01 B, WB for marine 1 1 1 1 1 1 1
Oil Strainer Cover without
121 CR12100-B B, WB 1 1 1 1 1 1 1
Hole
122 Gasket, Oil Strainer Cover CR12200-BN B, WB 1 1 1 1 1 1 1
Oil Strainer Cover Fastening M10×30
123 NBH114010-030 4 4 4 4 4 4 4
Bolt (small head)
Oil Strainer Cover Fastening
123 NB1403/8-030 S45C 3/8×30 - - - - - - -
Bolt
Oil Strainer Assembly with
- CR1239-B B, WB 1 1 1 - 1 1 -
Gasket B
Oil Strainer Assembly with
- CR1239-B12 12B - - - 1 - - 1
Gasket 12B
Intermediate Shaft Bearing
125 CR12609-B12 - - - 1 - - 1
Assembly 12B
126 NB114016-050 8.8T M16×50 - - - 4 - - 4
Fastening Bolt
126 Washer, Tapered Pin ND110-16 SS400 M16 - - - 4 - - 4
128 CR12800-B12A - - - 2 - - 2
Half (A)
129 CR12800-B12B - - - 2 - - 2
Half (B)
131 Tapered Pin 12B CR13400-12B 8×100 - - - 4 - - 4
133 Tapered Pin Fastening Nut NB114016-050 S45C M16 - - - 4 - - 4
Tapered Pin for Intermediate
134 CR13100-B12 - - - 4 - - 4
Shaft Bearing, with Screw
135/ Push Rod, Unloader Slide
CR13509-B061 6B/6WB -1 - 1 - - 1 - -
141 Valve
CR13509-B062 6B/6WB -2 - 1 - - - - -
141 Valve
CR13509-B063 6B/6WB -3 - - - - 1 - -
141 Valve
CR13509-B081 8B/8WB -1 1 - 1 1 - 1 1
141 Valve
CR13509-B082 8B/8WB -2 - - 1 - - 1 1
141 Valve
CR13509-B083 8B/8WB -3 1 - 1 - - 1 1
141 Valve

7-23
2200M4JE-HO-W-N-2014.04.
Qty
4 6 8 12 42 62 12･4
CR13509-B084 8B/8WB -4 - - - - - 1 1
141 Valve
CR13509-B162 16B-2 - - - - - - 1
141 Valve
CR13509-B163 16B-3 - - - 1 - - 1
141 Valve
CR13509-B164 16B-4 - - - - - - -
141 Valve
142 Unloader Device Spring CR14200-B B, WB 2 2 3 4 2 3 6
143 Push Rod Washer CR14300-B B, WB/ 38*10*3 2 2 3 4 2 3 6
M10×20
144 Push Rod Fastening Bolt NB12010-020 2 2 3 4 2 3 6
(small head)
145 Unloader Piston CR14500-FCB B, WB 2 2 3 4 2 3 6
146 Unloader Piston Cover B CR14600-B B, WB 2 2 3 4 2 3 -
Unloader Piston Cover 12, 12B, 12WB, 12･4B,
146 CR14600-B12 - - - 4 - - 6
12-4B 12･4WB
147 CR14700-BN B, WB 2 2 3 - 2 3 -
Cover
Gasket, Unloader Piston 12B, 12WB, 12･4B,
147 CR14700-B12N - - - 4 - - 2
Cover 12･4WB
149 NB14010-035 M10×35 12 12 18 24 12 18 42
Fastening Bolt
149 NB12010-040 SS400 M10×40 - - - - - - 30
Fastening Bolt
Hexagon Socket Head Cap
150 Screw, Unloader Piston NB3541/4-015 SCM3 W1/4L15 2 2 3 4 2 3 6
Cover
150- Washer, Hexagon Socket
ND113-065 6.5×13×1 2 2 3 4 2 3 6
1 Head Cap Screw
154 Suction Strainer B CR15401-B B, WB 1 2 2 - - - -
154 Suction Strainer 12B CR15400-B12 12B, 12WB - - - 2 - - -
Suction Strainer 12･4B long 12･4B (long)
154 CR15400-B124L - - - - - - 1
(old) old type
12･4B/12･4WB
154 Suction Strainer 12･4B long CR15401-B124L - - - - - - 1
(long)
Suction Strainer 12･4B short 12･4B (short)
154 CR15400-B124S - - - - - - 1
(old) old type
12･4/B12･4WB
154 Suction Strainer 12･4B short CR15401-B124S - - - - - - 1
(short)
156 Suction Strainer Canvas B CR15600-B B, WB 1 2 2 - - - -
156 Suction Strainer Canvas 12B CR15600-B12 12B/12WB/12･4B - - - 2 - - 1
Suction Strainer Canvas 12･
156 CR15600-B124L 12･4WB - - - - - - 1
4B long
158 CR15800-B04 4B/4WB 1 - - - - - -
Spring 4B
158 CR15800-B068S 68B, short - 2 2 - - - -
Spring
Suction Strainer Lock Spring
159 CR15900-B B, WB 1 2 2 - - - -
B
Suction Strainer Lock Spring 12B/12WB/12･4B
159 CR15900-B12 - - - 4 - - 4
12B /12･4WB
161 Suction End Cover B CR16100-B B, WB - 2 2 - - - -
161 Suction End Cover 4B CR16100-B04 4B/4WB 1 - - - - - -
12B/12WB/12･4B
161 Suction End Cover 12B CR16100-B12 - - - 2 - - 2
/12･4WB
162 Gasket, Suction End Cover B CR16200-BN B, WB 1 2 2 - - - -

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Gasket, Suction End Cover 12B/12WB/12･4B
162 CR16200-B12N - - - 2 - - 2
12B /12･4WB
Suction End Cover Fastening
163 NB14012-040 S45C M12×40 6 16 16 16 - - 16
Bolt
Suction End Cover Fastening
163 NB111012-040 10．9T M12×40 - - - - - - 16
Bolt
70D A, WA, B,
164 Oil Sight Glass CR16400-AB 1 1 1 2 1 1 2
WB
165 O-ring for Oil Sight Glass PA61-035 AS568A 332 NBR 2 2 2 4 2 2 4
165 O-ring for Oil Sight Glass PC61-035 AS568A 332 FKM 2 2 2 4 2 2 4
166 Oil Sight Gland CR16600-AB 70D 3/8 1 1 1 2 1 1 2
Oil Sight Gland Fastening M10×30 (small
167 NB14010-030 4 4 4 8 4 4 8
Bolt head)
168 Discharge Elbow CR16800-A04 4AE1 - - - - - - 2
6BE1 (NH3, Freon)
168 Discharge Elbow CR16800-B06 - 1 - 2 - - 2
B
168 Discharge Elbow CR16800-B08 8BE1 (Freon) - 1 1 - - - -
168 Discharge Elbow CR16800-B082 8BE2 (Freon) - - 1 - - - -
Discharge Elbow (high-stage
168 CR16800-B062 62BE1 B, WB - - - - 1 1 -
discharge)
Discharge Elbow (low-stage Domestic land use,
168 CR16800-BN06 - 1 - - - - -
discharge) 6BE1N (NH3)
Domestic land use,
168 Discharge Elbow CR16800-BN08 - - 1 - - - -
8BE2N (NH3)
MYCOM flange
169 Gasket, Discharge Elbow CR72000-065N - - - - 1 1 2
gasket 65A
MYCOM flange
169 Gasket, Discharge Elbow CR72000-080N - - - - 1 1 2
gasket 80A
MYCOM flange
169 Gasket, Discharge Elbow CR72000-090N - 1 1 - - - -
gasket 90A
MYCOM flange
169 Gasket, Discharge Elbow CR72000-100N - - 1 - - - -
gasket 100A
Discharge Elbow Fastening
170 NB14016-055 S45C M16×55 - - - - 6 4 8
Bolt
170 NB114016-055 8.8T M16×55 - - - - - - 8
Bolt
170 NB14016-090 S45C M16×90 - - - - 2 2 -
Bolt
170 NB14020-060 S45C M20×60 - 4 4 8 - 4 8
Bolt
170 NB114020-060 8.8T M20×60 - - - 8 - - 8
Bolt
Tooth Washer, Discharge
- ND422-16 for M16 - - - - 8 8 8
Elbow Fastening
Tooth Washer, Discharge
- ND422-20 for M20 - 4 4 8 - 4 8
Elbow Fastening
171 Needle Valve KA2130-010 AS 10A - 1 - 2 2 2 4
171 Needle Valve KA2132-010 VS-03PO3-OA 1 1 1 - - - 4
MYCOM flange G
172 Gasket, Discharge CR72000-050N - - - - 2 2 4
50A
MYCOM flange G
172 Gasket, Discharge CR72000-065N - - - - 2 2 -
65A
MYCOM flange G
172 Gasket, Discharge CR72000-080N 3 2 - 4 - - 2
80A
MYCOM flange G
172 Gasket, Discharge CR72000-090N - 2 2 2 - - -
90A
MYK GVF ASSY W
173 Discharge Stop Valve CR72300-W050 - - - - 1 1 2
50A

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MYK GVF ASSY W
173 Discharge Stop Valve CR72300-W065 - - - - 1 1 -
65A
MYK GVF ASSY W
173 Discharge Stop Valve CR72300-W080 1 1 - 2 - - 2
80A
MYK GVF ASSY W
173 Discharge Stop Valve CR72300-W090 - 1 1 - - - -
90A
MYK GVF ASSY
173 Discharge Stop Valve CR72300-W100 - - 1 - - - -
W100A
173- Companion Flange, MYCOM 50A
CR74000-050 - - - - 2 1 2
1 Discharge Stop Valve (male)
CR74000-065 - - - - 2 1 -
CR74000-080 1 1 1 2 - - 2
CR74000-090 1 1 1 - - - -
CR74000-100 - 1 1 - - - -
173 Companion Flange Fastening
NB12016-075 SS400 M16×75 - - - - 4 4 8
B Bolt, Discharge Stop Valve
NB12016-090 SS400 M16×90 - - - - 4 4 -
NB12020-090 SS400 M20×90 4 4 - 8 - - 8
NB12022-110 SS400 M22×110 - - 4 - - - -
NC120-16 SS400 M16 - - - - 8 8 8
B Nut, Discharge Stop Valve
NC120-20 SS400 M20 4 4 - - - - 8
NC120-22 SS400 M22 - - 4 - - - -
Companion Flange Fastening
174 NB12016-080 SS400 M16×80 - - - - 4 4 8
Bolt, Discharge Stop Valve
174 NB12016-090 SS400 M16×90 - - - - 4 4 -
174 NB114016-080 8.8T M16×80 - - - - - - 8
174 NB114020-100 8.8T M20×100 - - - - - - 8
174 NB12020-090 SS400 M20×90 4 - - - - - -
174 NB12020-100 SS400 M20×100 - - - - - - 8
174 NB13020-100 S25C M20×100 - - - 8 - - -
174 NB14020-100 S45C M20×100 - 4 - - - - -
174 NB12022-100 SS400 M22×100 - - 4 8 - - -
174 NB12022-110 SS400 M22×110 - - 4 - - - -
Discharge Stop Valve
174 NC120-16 SS400 M16 - - - - 8 8 8
Fastening Nut
174 NC120-20 SS400 M20 4 4 - - - - 8
Fastening Nut
174 NC120-22 SS400 M22 - - 4 8 - - -
Fastening Nut
6AT1 high-stage
175 Scale Trap CR17500-A061 - - - - 1 1 -
suction
8AT1 low-stage
175 Scale Trap CR17500-A081 - - - - 1 - -
suction
6AT1N (NH3)
175 Scale Trap CR17500-AN061 - - - - 1 - -
domestic land use

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8AT1N (NH4)
175 Scale Trap CR17500-AN081 - - - - 1 - -
domestic land use
175 Scale Trap CR17500-B06 6BT1 (NH3) - 1 - - - 1 -
175 Scale Trap CR17500-B081 8BT1 (NH3, freon) - 1 - - - 1 -
8BT1N (NH3)
175 Scale Trap CR17500-BN081 - 1 1 - - - -
domestic land use
175 Scale Trap CR17500-BN082 8BT2N - - 1 - - - -
Gasket, Scale Trap Main MYCOM flange
176 CR72000-065N - - - - 1 1 -
Body gasket 65A
176 CR72000-080N - - - - 1 1 -
Body gasket 80A
176 CR72000-100N - 1 1 - - - -
Body gasket 100A
177 Scale Trap Fastening Bolt NB14020-060 S45C M20×60 - - - - 8 8 -
177 Scale Trap Fastening Bolt NB14022-065 S45C M22×65 - 4 4 - - - -
Tooth Washer, Scale Trap
177 ND422-20 M20 - - - - 8 8 -
Fastening
Tooth Washer, Scale Trap
177 ND422-22 M22 - 4 4 - - - -
Fastening
A, WA, 42B, 42WB,
178 Scale Trap Wire Mesh CR17800-A - - - - 2 1 -
62B, 62WB
178 Scale Trap Wire Mesh CR17800-B B, WB - 1 1 - - 1 -
178 Scale Trap Wire Mesh CR17800-B08R 8BR - - 1 - - - -
for 6AT1, 6AT2,
179 Scale Trap Cover CR17900-A068 - - - - 2 1 -
8AT1
179 Scale Trap Cover CR17900-B068 for 6BT1, 8BT1 - 1 1 - - 1 -
179 Scale Trap Cover CR17900-B08T2 for 8BT2 (Freon) - - 1 - - - -
Gasket, Scale Trap Cover for 6AT1, 6AT2,
180 CR18000-A068N - - - - 2 1 -
68A 8AT1
180 Gasket, Scale Trap Cover CR18000-BN for 6BT1, 8BT1 - 1 1 - - - -
Gasket, Scale Trap Cover
180 CR18000-B08RN 8BR - - 1 - - - -
8BR
Scale Trap Cover Fastening
181 NB14012-040 M12×40 - 8 8 - 8 8 -
Bolt
MYK GVF ASSY W
182 Suction Stop Valve 65A CR72300-W065 - - - - 1 1 -
65A
MYK GVF ASSY W
182 Suction Stop Valve 80A CR72300-W080 1 - - - 1 - 1
80A
MYK GVF ASSY W
182 Suction Stop Valve 90A CR72300-W090 1 1 - 1 - 1 -
90A
MYK GVF ASSY
182 Suction Stop Valve 100A CR72300-W100 - 1 1 - - 1 -
W100A
MYK GVF ASSY
182 Suction Stop Valve 125A CR72300-W125 - - 1 1 - - 1
W125A
182- Companion Flange, Suction MYCOM 65A
CR74000-065 - - - - 1 1 -
1 Stop Valve (male)
CR74000-080 - - - - 1 - 1
1 Stop Valve (male)
CR74000-090 1 1 - 1 - 1 -
1 Stop Valve (male)
CR74000-100 - 1 1 - - 1 -
1 Stop Valve (male)
CR74000-125 - - 1 1 - - 1
1 Stop Valve (male)
NB12016-060 SS400 M16×60 - - - - 4 4 -
B Bolt, Suction Stop Valve
NB12020-080 SS400 M20×80 - - - - 4 4 -

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NB12020-090 SS400 M20×90 4 - - 8 - - 12
NB12020-105 SS400 M20×105 - - 4 - - - -
NB12022-100 SS400 M22×100 - 4 - - - - -
NB10420-100 SNB7 M20×100 - - - 10 - - -
NC120-16 SS400 M16 - - - - 4 4 -
NC120-20 SS400 M20 4 - 4 10 4 4 12
NC120-22 SS400 M22 - 4 - - - - -
Suction Stop Valve Mounting
183 NB12016-090 SS400 M16×90 - - - - 4 4 -
Bolt
183 NB12020-090 SS400 M20×90 4 4 - - - - -
Bolt
183 NB10420-100 SNB7 M20×100 - - - - - - 10
Bolt
183 NB12020-100 SS400 M20×100 - 4 4 8 4 4 -
Bolt
183 NB12020-110 SS400 M20×110 - - 4 - - - -
Bolt
183 NB12022-105 SS400 M22×105 - 4 - - - - -
Bolt
Nut for Suction Stop Valve
183 NC120-16 SS400 M16 - - - - 4 4 -
Mounting Bolt
183 NC120-20 SS400 M20 4 4 4 8 4 4 12
Mounting Bolt
183 NC120-22 SS400 M22 - 4 - - - - -
Mounting Bolt
Gasket, Centering Location, MYCOM flange
184 CR72000-065N - - - - 4 2 -
Suction Stop Valve Mount gasket 65A
184 CR72000-080N - - - - 4 2 1
184 CR72000-090N 3 2 - - - - -
184 CR72000-100N - 1 2 - - - -
184 CR72000-125N - - 2 1 - - 1
184-
Spacer CR75500-090 90A 1 - - 1 - - -
1
184-
Spacer CR75500-125 125A - - - - - - 1
1
Oil Cooler Assembly (water B, WB SUS
185 CR18500-BS 1 1 1 - 1 1 -
cooled, forward) (forward)
Oil Cooler Assembly (water B, WB SUS
185 CR18500-RBS 1 1 1 - 1 1 -
cooled, reverse) (reverse)
Oil Cooler Assembly (water 12B, 16B, 12･4B
185 CR18500-B12 - - - 1 - - 1
cooled, forward) 12B (forward)
B
Oil Cooler Assembly (water
185 CR18500-TBK T-TCFB-0.25-0617 - - - - - - -
cooled)
P
Oil Cooler Assembly (water B
185 CR18500-TBW 1 1 1 - 1 1 -
cooled) T-TCF-0.25-0617P
Oil Cooler Shell (water
186 CR18507-B B, WB (forward) - - - - - - -
cooled, forward)
Oil Cooler Shell (water
186 CR18507-RB B, WB (reverse) - - - - - - -
cooled, reverse)
Oil Cooler Assembly
192 CR18600-B B, WB (forward) 1 1 1 - 1 1 -
(refrigerant type, forward)

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Oil Cooler Assembly 12B/12WB
192 CR18600-B12 - - - 1 - - 1
(refrigerant type, forward) 12B (forward)
Oil Cooler Assembly
192 CR18600-RB B, WB (reverse) 1 1 1 - 1 1 -
(refrigerant type, reverse)
195 Gasket, End Cover A CR18500-GA T-FCF end cover A - 1 1 - 1 1 -
196 Gasket, End Cover B CR18500-GB T-FCF end cover B - 1 1 - 1 1 -
Gasket, End Cover A 12B 12B, 12･4B
195 CR19500-BW12 - - - 1 - - 1
Water Cooled water cooled
Gasket, End Cover B 12B 12B, 12･4B
196 CR19600-BW12 - - - 1 - - 1
Water Cooled water cooled
Gasket, End Cover A Direct B refrigerant
195 CR19500-BDN 1 - 1 - - - -
Type N/A cooled
Gasket, End Cover B Direct B refrigerant
196 CR19600-BDN 1 - 1 - - - -
Type N/A cooled
Gasket, End Cover A Direct F12･4B
195 CR19500-BD12N - - - - - - 1
Type N/A 12B refrigerant cooled
Gasket, End Cover B Direct F12･4B
195 CR19600-BD12N - - - - - - 1
Type N/A 12B refrigerant cooled
Gasket, Oil Cooler Mouth
- CR18800-ABN A, WA, B, WB - 1 1 1 1 1 1
Piece
190 Gasket, Oil Cooler Flange CR19000-B B, WB - 1 1 1 1 1 1
- Oil Cooler Zap, with Gasket CR1929-B B, WB - - - - - - -
198 Thermometer and Case LC1102312 I/45 0 + 100 - - - - 1 1 2
198 Thermometer and Case LC1103314 L/45 0 + 200 1 - - - 1 1 2
198 Thermometer and Case LC1102314 I/45 0 + 200 - 1 1 1 - - -
199/
Thermometer and Case LC1103311 L/45 -50 + 50 1 - - 1 - - 1
201
199/
Thermometer and Case LC1102311 I/45 -50 + 50 - 1 1 - 1 2 -
201
205 Solenoid Valve KF221-1 SX-7 100V 1 1 1 1 1 1 1
SPOLAN
205 Solenoid Valve KF711-XOF1 - - - 1 - - 1
XOF-120V
207 Manual Unloader Valve NL142-NL JO-5990 1 1 1 - 1 1 -
207 Manual Unloader Valve NL142-NS JO-6000 (NH3) 1 1 1 - 1 1 -
207 Manual Unloader Valve CR71500 MV10-03G (Freon) 1 1 1 - - - -
208 Eye Bolt NB600-20 M20 - 2 2 - 2 2 -
208 Eye Bolt NB600-24 M24 1 - - - - - -
208 Eye Bolt NB600-30 M30 - - - 2 - - 2
213 External Safety Valve CR21300-006P300 5602 3/4 300P 1 1 1 2 2 2 4
213 Safety Valve KC02R013-040 KC02R013-040 - - - - - 1 -
RTK SVF50A
213 Safety Valve KC02R013-050 - - 1 - - 1 -
1.31 MPa
RTK SVF32A
213 Safety Valve KC02R013-032 - - - - 1 - -
1.31 MPa
RTK SVF25A
213 Safety Valve KC02R017-025 - - - - 1 1 -
1.72 MPa
RTK SVF50A
213 Safety Valve KC02R017-050 - - 1 - - - -
1.72 MPa
Oval Flange for Water Cooled
234 CR71800-1 HF-20 4 6 8 - 3 3 16
Head Cover

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Gasket, Oval Flange for
235 CR71900-1 HF-20 4 6 8 - 7 9 -
Water Cooled Head Cover
236 NB17010-020 SUS M10×20 8 12 16 - 6 6 32
Head Cover Fastening Bolt
236 NB17010-025 SUS M10×25 - - - - - 16 -
Head Cover Fastening Bolt
Cartridge heater
245 Oil Heater LF1202-110 - - 1 1 - - 1
MKCP-1102
Cartridge heater
245 Oil Heater LF1202-220 1 1 1 1 1 1 1
MKCP-2202
Cartridge heater
245 Thermo Heater LF2202-110 - - 1 1 - - 1
MKCP-T1102
Cartridge heater
245 Thermo Heater LF2202-220 - - 1 1 - - 1
MKCP-T2202
- O-ring Set, F4B/6B/8B CR7109-FB4 - - - - - - -
- O-ring Set, F42B/62B CR7109-FB6 - - - - - - -
- O-ring Set, F12B CR7109-FBA - - - - - - -
- O-ring Set, F12-4B CR7109-FBB - - - - - - -
- O-ring Set, N4B/6B/8B CR7109-NB4 - - - - - - -
- O-ring Set, N42B/62B CR7109-NB6 - - - - - - -
- O-ring Set, N12B CR7109-NBA - - - - - - -
- O-ring Set, N124B CR7109-NBB - - - - - - -
O-ring Set for WB Single
- CR7109-WB1 - - - - - - -
Stage Machine
O-ring Set for WB Two Stage
- CR7109-WB2 - - - - - - -
Machine
- Gasket Set F6WB CR7117-FB6 - - - - - - -
- Gasket Set F8WB CR7117-FB8 - - - - - - -
- Gasket Set N4WB/F4WB CR7117-NB4 - - - - - - -
- Gasket Set N6WB CR7117-NB6 - - - - - - -
- Gasket Set N8WB CR7117-NB8 - - - - - - -
- Gasket Set N12WB/F12WB CR7117-NBA - - - - - - -
Gasket Set N12･4WB/
- CR7117-NBB - - - - - - -
F12･4WB
- Gasket Set F6B CR7118-FB6 - - - - - - -
- Gasket Set F8B CR7118-FB8 - - - - - - -
- Gasket Set N4B/F4B CR7118-NB4 - - - - - - -
- Gasket Set N6B CR7118-NB6 - - - - - - -
- Gasket Set N8B CR7118-NB8 - - - - - - -
- Gasket Set N12B/F12B CR7118-NBA - - - - - - -
- Gasket Set N124B/F124B CR7118-NBB - - - - - - -
- CR7129-NA B/R - - - - - - -
Mechanical Seal
- CR7129-NB B/NH3 - - - - - - -
Mechanical Seal

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Rod Bushing
- CR70100-AB A, WA, B, WB - - - - - - -
Attachment/Removal Tool A/B
Discharge Valve Disassembly
- CR70200-AB A, WA, B, WB - - - - - - -
Tool A/B
- Disassembly Tool Set BM02 CR70400-BM02 B, WB - - - - - - -
- CR70400-BM02ME B, WB (for ME) - - - - - - -
BM02/ME

7-31
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7.3 Configuration of Plate Valves and Associated Parts

This section lists the configuration of various types of suction/discharge valves and associated parts
according to the different types of refrigerant. The item code for the spring in the table shows that of a
set of the necessary number of springs.
Table 7-3 Component Parts for WA-type Suction Plate Valves

High/Low
Refrigerant Item Name Specification Item Code
Stage
Valve Plate WN CR07300-NWA
Single
Spring Type IV × 6 CR0729-WA4
High
Plate Valve CR07100-A
NH3
Valve Plate N CR07300-NA
Low Spring Type II × 6 CR0729-A2
Valve Plate WR CR07300-FWA
Single
High
Freon and Plate Valve CR07100-A
Propane Valve Plate N CR07300-NA
Low Spring Type II × 6 CR0729-A2
Table 7-4 Component Parts for WA-type Discharge Plate Valves

High/Low
Stage
DV Cage WCN CR10900-WACN
Single
High
NH3
DV Cage CN CR10900-ACN
Low Spring Type III × 7 CR1169-A3
DV Cage WCR CR10900-WACR
Single
High
Freon
DV Cage SR CR10900-ASR
Low Spring Type III × 7 CR1169-A3
DV Cage WCR CR10900-WACR
Single
Propane Spring Type IV × 8 CR1169-WA4
High/Low
W-Series Reciprocating Compressor 7.3 Configuration of Plate Valves and Associated Parts
7-32
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Table 7-5 List of Component Parts for WB-type Suction Plate Valves
High/Low
Stage
Valve Plate WN CR07300-NWB
Single
Spring Type IV × 8 CR0729-WB4
High
Plate Valve CR07100-B
NH3
Valve Plate N CR07300-NB
Low Spring Type II × 9 CR0729-B2
Valve Plate WR CR07300-FWB
Single
High
R22 Plate Valve CR07100-B
R23 Valve Plate R CR07300-FB
Single
High
R134a, Plate Valve CR07100-B
R404A,
R507A Valve Plate WN CR07300-NWB
Low Spring Type IV × 8 CR0729-WB4
Single
High
Propane
Valve Plate N CR07300-NB
7-33
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Table 7-6 Component Parts for WB-type Discharge Plate Valves

High/Low
Stage
DV Cage WCN CR10900-WBCN
Single
High
Plate Valve CR11000-B14
NH3
DV Cage SN CR10900-BSN
Low Spring Type III × 9 CR1169-B3
DV Cage WCR CR10900-WBCR
Single
High
R22 Plate Valve CR11000-B14
R23 DV Cage SR CR10900-BSR
DV Cage WCRH CR10900-WBCRH
Single
High
R134a, Plate Valve CR11000-SFW
R404A,
R507A DV Cage SR CR10900-BSR
DV Cage WCR CR10900-WBCR
Single
Propane Spring Type IV × 12 CR1169-WB4
High/Low
7-34
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7.4 List of Tightening Torques for Bolts and Nuts

Table 7-7 Tightening Torques for Bolts and Nuts (WA-type)
Tightening
No. Item Name Size Torque
N･m kg･cm
7 Pulley Set Bolt M27×50 (P=1.5) 380 3800
10 Main Bearing Head Fastening Bolt M12×40 80 800
11 Main Bearing Head Fastening Bolt M12×120 80 800
16 CUNO Filter Cover Fastening Bolt M10×30 P=1.5 (small head) 40 400
M12×30 Hexagon Socket Head
25 Bearing Head Fastening Bolt 80 800
Cap Screw
28 Cover Plate Fastening Bolt M12×80 80 800
31 Thrust Bearing Fastening Bolt M10×30 (small head) 40 400
48 Hand Hole Cover Fastening Bolt M12×40 80 800
52 Head Cover Fastening Bolt M12×40 80 800
54 Head Jacket Cover Fastening Bolt M10×25 40 400
60 Oil Pump Fastening Bolt M10×30 (small head) 40 400
75 Discharge Cage Guide Fastening Bolt M10×45 (P=1.0) (small head) 40 400
80 First Nut, Crank Pin Fastening 3/8"-24 UNF (special nut) 60 600
81 Second Nut, Crank Pin Fastening 3/8"-24 UNF (special nut) 45 450
113 First Nut, Discharge Valve Fastening 1/2"-20 UNF (special nut) 110 1100
114 Second Nut, Discharge Valve Fastening 1/2"-20 UNF (special nut) 80 800
123 Oil Strainer Cover Fastening Bolt M10×30 (small head) 40 400
144 Push Rod Fastening Bolt M10×20 (small head) 40 400
149 Unloader Piston Cover Fastening Bolt M10×35 40 400
W1/4×15 Hexagon Socket Head
150 Unloader Piston Cover Fastening Bolt - -
Cap Screw
153 Unloader Piston and Suction Cover Fastening Bolt M10×35 for 8WA 40 400
163 Suction End Cover Fastening Bolt M10×35 single stage machine 40 400
167 Oil Sight Gland Fastening Bolt M10×30 (small head) 40 400
170 Discharge Elbow Fastening Bolt M12×50 high-stage 80 800
170 Discharge Elbow Fastening Bolt M16×55 low-stage 120 1200
170 Discharge Elbow Fastening Bolt M20×60 for 8WA 220 2200
177 Scale Trap Fastening Bolt M12×50 80 800
177 Scale Trap Fastening Bolt M16×55 low-stage suction 120 1200
181 Scale Trap Cover Fastening Bolt M12×40 80 800
Oval Flange for Water Cooled Head Cover
236 SUS M10×25 40 400
Fastening Bolt
W-Series Reciprocating Compressor 7.4 List of Tightening Torques for Bolts and Nuts
7-35
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Table 7-8 Tightening Torques for Bolts and Nuts (WB-type)

Tightening
No. Item Name Remarks Torque
N･m kg･cm
7 Pulley Set Bolt M27×50 (P=1.5) 380 3800
10 Main Bearing Head Fastening Bolt SCM3, M16×40 120 1200
10 Main Bearing Head Fastening Bolt S45C, M16×55 120 1200
16 CUNO Filter Cover Fastening Bolt M10×30 P=1.5 (small head) 40 400
- CUNO Filter Case Fastening Bolt S45C M16×90 120 1200
Bearing Head Fastening Hexagon Socket Head
25 SCM3 M16×35 120 1200
Cap Screw
Bearing Head Fastening Hexagon Socket Head
25 SCM3 M16×40 120 1200
Cap Screw
28 Cover Plate Fastening Bolt S45C M16×90 120 1200
31 Thrust Bearing Fastening Bolt M12×35 40? 80 800
48 Hand Hole Cover Fastening Bolt M16×55 120 1200
48 Hand Hole Cover Fastening Bolt 10.9T M16×60 120 1200
52 Head Cover Fastening Bolt 10.9T M16×45 120 1200
54 Head Jacket Cover Fastening Bolt M10×25 - -
60 Oil Pump Fastening Bolt M12×35 80 800
60 Oil Pump Fastening Bolt S45C M16×40 120 1200
75 Discharge Cage Guide Fastening Bolt M12×60(P=1.25) 80 800
80 First Nut, Crank Pin Fastening 1/2-20 UNF (special nut) 120 1200
81 Second Nut, Crank Pin Fastening 1/2-20 UNF (special nut) 80 800
113 First Nut, Discharge Valve Fastening 5/8-18 UNF (special nut) 120 1200
114 Second Nut, Discharge Valve Fastening 5/8-18 UNF (special nut) 80 800
123 Oil Strainer Cover Fastening Bolt M10×30 (small head) - -
126 Intermediate Shaft Bearing Fastening Bolt 8.8T M16×50 120 1200
133 Tapered Pin Fastening Nut S45C M16 120 1200
144 Push Rod Fastening Bolt M10×20 (small head) - -
149 Unloader Piston Cover Fastening Bolt M10×35 40 400
Hexagon Socket Head Cap Screw, Unloader
150 SCM3 W1/4×15 - -
Piston Cover
163 Suction End Cover Fastening Bolt S45C M12×40 80 800
167 Oil Sight Gland Fastening Bolt M10×30 (small head) 40 400
170 Discharge Elbow Fastening Bolt S45C M16×55 120 1200
177 Scale Trap Fastening Bolt S45C M20×60 220 2200
177 Scale Trap Fastening Bolt S45C M22×65 300 3000
181 Scale Trap Cover Fastening Bolt M12×40 80 800
236 SUS M10×20 40 400
Fastening Bolt
236 SUS M10×25 40 400
Fastening Bolt
W-Series Reciprocating Compressor 7.4 List of Tightening Torques for Bolts and Nuts
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7.5 Criteria for Replacement of Parts
7.5.1 Filters and the Like

When cleaning the wire mesh, check for any broken mesh or separation of soldered parts. If any defect
is found, be sure to repair it or replace it with a new one.
[POINT]
 Soldering of stainless steel parts requires the use of a special flux.
• If any foreign matter is caught in the fine mesh and cannot be removed, use compressed air to blow it
out from the downstream side of the liquid flow.
• The suction strainer/oil strainer is a corrugated cylindrical filter with a wide area of passage. If any
clogging is found, use compressed air to blow it out from the inside of the filter element.
• If any clogging is found in the external oil filter, replace the filter element.
• For the CUNO filter, check that it can smoothly spin and that the scraper plate is functioning perfectly.
If it cannot spin smoothly, remove any foreign matter between plates one by one, using a thin plate
(e.g., razor-blade).
7.5.2 Crankshaft
 Padding of the crankshaft cannot be made due to the nature of the material. Any
padding (e.g., by welding or plating) can cause the crankshaft to break.
a) Check that each bearing point of the crankshaft is not excessively worn. A significant wear will
develop a step between the sliding part and the non-sliding part of the bearing. Check for any step
visually or by touching the surface.
b) Use a micrometer to measure the shaft diameter at various worn points of the bearings. If the
measured diameter is less than the limit shown in the table below, replace the crankshaft.
(mm)
WA-type WB-type
Measurement Point Nominal Nominal
Use Limit Use Limit
Dimension Dimension
Crank pin D1 70 69.85 90 89.82
Thrust bearing D2 82.5 82.40 112 111.85
Main bearing D3 67 66.90 92 91.85
W-Series Reciprocating Compressor 7.5 Criteria for Replacement of Parts

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2200M4JE-HO-W-N-2014.04.
c) Check that there is no flaw on each sliding surface of the crankshaft. If any flaw is found, use a
piece of sand paper (#800 or finer) or grind stone to correct the flaw.
d) Remove all plugs attached to the crankshaft and clean the oil holes. After they have been cleaned,
check that oil can flow through the holes. Attach each plug as soon as the check is done. Missing to
attach any plug can result in a seizure accident due to insufficient oil pressure.
e) Check that the shaft seal attachment portion of the crankshaft is free from any flaw. If any flaw is
found, use a piece of sand paper (#800 or finer) or fine oilstone to correct the flaw.

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7.5.3 Connecting Rod

■ Roll bushing
Measure the inner diameter of the small end hole of the connecting
rod. If the measured inner diameter exceeds the use limit, replace
the roll bushing.
(mm)
WA-type WB-type
Measurement
Nominal Nominal
Point Use Limit Use Limit
Dimension Dimension
X in the right
25.15 25.25 40.0 40.10
figure
■ Needle bearing
Needle bearings must always be replaced at each overhaul. When replacing the needle bearing,
use a special tool to press fit, by fitting a metal block on the side of the bearing marking, for not to
deform the outer ring.
 Never use a hammer to drive in the bearing, as it can damage the needle bearing.
■ Bearing halves
a) Check the sliding surface of the large end bearing halves. If any foreign matter is found, replace
the bearing halves. In particular, if the crank shaft is worn, pay very careful attention to the
surface of the metal upon inspection.
b) Also be careful about the tension of the bearing halves. The internal radius of the bearing halves
is larger than the internal radius of the large end of the connecting rod, when they are
manufactured. As it is designed to make a perfect circle only after the top and bottom halves are
combined together and tightened, the measurement between the ends of disassembled bearing
halves should become longer due to the tension. If this tension is not present, replace the
bearing halves even if they are not worn.
c) Measure the thickness of the bearing halves at the central point. If the thickness is less than the
use limit, replace the bearing halves.
(mm)
Measurement WA-type WB-type
Nominal Nominal
Point Use Limit Use Limit
Dimension Dimension
X in the above
2.47 2.37 3.46 3.31
figure

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7.5.4 Piston, Piston Pin, and Piston Ring

a) Check the piston for any flaw mainly on the outer surface. If any
flaw is present, correct it using a grindstone. The direction of
grinding shall be perpendicular to the sliding direction. Measure the
outer diameter of the piston skirt. If the measured diameter is less
than the use limit, replace the piston.
(mm)
Use Limit
Measurement Point
WA-type WB-type
Outer diameter at D 94.75 129.63
b) Measure the outer diameter of the piston at three places.

If any of the measured outer diameters is less than the use limit, replace the piston.
(mm)
Use Limit
Measurement Point
WA-type WB-type
Outer diameter 25.08 39.90
c) For piston rings, besides checking the condition of the outer sliding surface including any flaw or
abnormal wear, check the normal wear at the same time.
To check the condition of wear, measure the gap between both ends of the piston ring. For this,
place the piston ring at a distance of 3 mm from the top of the cylinder sleeve and measure the gap.
If the measured gap exceeds the use limit, replace the piston ring.
(mm)
WA-type WB-type
Measurement
Point Nominal Nominal
Use Limit Use Limit
Dimension Dimension
Gap between
0.5 1.5 0.7 2.0
both ends
[POINT]
 The piston rings must be regularly replaced according to the recommended use period even if
the wear is within the use limit.
d) If any burr (circular ridge) is formed on the top and bottom of the sliding surface of the piston ring,
use a grind stone or other tool to chamfer the edges before using it.
Depending on the use condition, the piston ring grooves may also be worn. If the groove has
become considerably wide, i.e., if a 0.1 mm thickness gauge can be inserted to the groove with a
new ring, replace the piston as it can cause oil loss.

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7.5.5 Cylinder Sleeve

a) Inspect the upper surface of the suction valve seat. If any flaw is found, correct the flaw by polishing
or grinding. As the top clearance will change due to the correction, add the required number of
cylinder sleeve gaskets for the corrected amount. The thickness of each cylinder sleeve gasket is
0.1 mm.
b) Measure the height of the seat portion. If it exceeds the use limit, replace the sleeve.
(mm)
Use Limit
Measurement Point
WA-type WB-type
X in the above figure 0.15 0.15
c) If the inside surface of the cylinder sleeve has any flaw, use fine GC (green carbonite) grinding
stone or fine sandpaper to correct the defect.
d) The top 3 mm of the cylinder sleeve will not be worn. The most significant wear will occur at about 5
to 7 mm from the top. Measure the inside diameter of the cylinder, and replace it if it exceeds the
use limit.
(mm)
WA-type WB-type
Use Limit Use Limit
Dimension Dimension
Internal diameter of cylinder
95 95.10 130 130.15
sleeve
[POINT]
 When you see the inside surface of the cylinder by reflecting light, it will look like a rainbow when
the condition is good.

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2200M4JE-HO-W-N-2014.04.
7.5.6 Discharge Valve Assembly/Suction Valve Assembly

The discharge valve, suction valve, and valve springs must be regularly replaced.
While the service life depends on the conditions of use, refer to Chapter 5, Section 5.2.3.1 of this
manual for the typical replacement period.
a) Measure the thickness of the seat portion (M). If the wear on the seat portion exceeds 0.1 mm, the
valve needs to be replaced even if it has not reached the typical replacement period.
(mm)
WA-type WB-type
Use Limit Use Limit
Dimension Dimension
X in the above figure 1.3 1.2 1.4 1.3
b) Even if the seat portion is not excessively worn, replace the valve if the spring mating surface is
unevenly worn or distorted. If any flaw exists, it should be replaced as it may develop a crack due to
cyclic fatigue.
c) Regarding the inspection of springs, if any broken spring is found, also check the bottom of the
spring hole of the valve plate and cage. A broken spring can hit the bottom of the hole to make it
sink.
d) Measure the seat height of the valve plate and discharge valve seat. If the seat height is less than
0.1 mm, replace the valve plate and discharge valve seat.

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7.5.7 Main Bearing and Thrust Bearing

Measure the internal diameter of the main bearing and thrust bearing. If the use limit is exceeded,
replace it.
(mm)
Use Limit
Measurement Point
WA-type WB-type
Main bearing 67.15 92.18
Thrust bearing 82.65 112.18
[POINT]
 When belt drive is used, the thrust bearing on the motor side can be easily worn. As such, be
careful not to apply excessive tension of the V-belts.
7.5.8 Shaft Seal

Inspect the sliding surface of the stationary ring and rotating ring.
Although the shaft seal assembly is to be replaced after any abnormality is found by the inspection,
because only visually checking the sliding surface may be insufficient in determining any abnormality, it
is recommended to replace the seal assembly with a new one in such a case, as in the case of O-rings.
The O-rings must always be replaced with new ones.
7.5.9 Oil Pump

If the oil pressure is still low when the oil pressure control valve is closed during operation, and it is not
due to the clogging of the oil filter, the gear, metal, and/or shaft of the oil pump may be worn.
Remove the oil pump from the compressor. Then, hold the pump shaft and check if there is any play in
the axial and/or lateral direction. If any play is found, replace the oil pump assembly.
7.5.10 Bolts and Other Hardware

The crank pin fastening bolts and discharge valve fastening bolts must be carefully and thoroughly
inspected. In particular, these bolts must be very carefully checked after any oil hammering, liquid
hammering, or seizure accident. If any defect is found on the thread, be sure to replace it.
7.5.11 Gaskets and O-rings

All gaskets and O-rings must be replaced with new ones whenever disassembly and inspection is
performed.
While synthetic rubbers are used for O-rings, the O-rings of different material may be used according to
the type of the refrigerant, lubricant, and operating conditions. For details, please contact one of our
sales offices or service centers.

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2200M4JE-HO-W-N-2014.04.
■ Gaskets
Figure 7-5 Gaskets for WA-type Compressors

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2200M4JE-HO-W-N-2014.04.
Figure 7-6 Gaskets for WB-type Compressors (1/2)

7-45
2200M4JE-HO-W-N-2014.04.
Figure 7-7 Gaskets for WB-type Compressors (2/2)

7-46
2200M4JE-HO-W-N-2014.04.
7.6 Standard Assembly Clearance
Figure 7-8 Standard Initial Assembly Clearance for WA/WB Type Compressors
W-Series Reciprocating Compressor 7.6 Standard Assembly Clearance

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2200M4JE-HO-W-N-2014.04.
7.7 Vibration Criteria

 Vibration criteria and their application
The vibration assessment criteria are used to evaluate the vibration level of the reciprocating
compressor installed in the unit. Note that these criteria are applicable only when the pedestal, any pipe
line, or other parts are not mechanically resonated when the compressor is running at the rated speed.
 Measurement point
Compressor: Any point near the shaft bearing opposite to the loading side (at the oil pump) shall be
used, for measuring the vibration in the three mutually perpendicular directions, i.e., vertical, horizontal
and axial directions.
 Vibration velocity criteria

 The vibration severity is defined by the rms (root-mean-square) value of the vibration velocity
(mm/s min-1).
 The class is determined by the rated power of the motor that drives the compressor.
 It is applicable to both the belt drive and direct drive systems.
 If the vibration severity is to be represented by the displacement (D: μm P-P), use the following
conversion formula:
D＝30000 × √2 ÷ (πN)•Vrms
(N: rotation speed in min-1, V min-1: Vibration severity represented by the vibration speed - mm/s min-1)
 If the vibration performance is in the region of A or B, there should be no particular problems.
 If it is in the region of C, the action to take shall be determined through discussion between the
parties concerned.
 If it is in the region of D, immediately stop the operation and perform investigation.
Table 7-9 Vibration Velocity Criteria (mm/s min-1)

A: Excellent, B: Good, C: Caution, D: Unacceptable
Motor rated power

Vibration severity range
Fixed base Anti-vibration base
Class Vibration velocity rms Less than 50 to 100 kW 100 kW or Less than 50 to 100 kW 100 kW or
(mm/s min-1) 50 kW higher 50 kW higher
1.1 1.12 A/B A/B A/B A/B A/B A/B
1.8 1.78
2.8 2.82
4.5 4.46
7.1 7.07 C
11 11.2 C C
18 17.8 D C C
28 28.2 D D C
45 44.6 D D
71 70.7 D
W-Series Reciprocating Compressor 7.7 Vibration Criteria

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7.8 Disassembly Tools

The following table 7-10 lists the items included in the disassembly tool set listed in Table 7-1 "Parts for
WA-type Compressors" and Table 7-2 "Parts for WB-type Compressors" in this chapter. (Item codes
are CR70400-AM02 for WA-type and CR70400-BM02 for WB-type compressors.)
Table 7-10 Items Included in the Disassembly Tool Set
Qty
Name Outline Specification Remarks
WA WB
WAF 14 mm 1 1
17 mm 1 1
19 mm 1 1
Socket wrench 21 mm long - 1
24 mm - 1
24 mm long - 1
300 mm 1 1
Nut spinner handle 12.7 square drive
WAF 5 mm 1 1 For unloader

cover and
Hexagon wrench 10 mm 1 -
bearing head
14 mm - 1 cover
14 - 17 mm 1 1
Double ended
17 - 19 mm 1 1
wrench
Bolts
Pulley extractor 1 1
M20×10
M12×70
Lock nut wrench 270 mm 1 - For shaft seal

(MYCOM special) collar
320 mm - 1
1/4” 1 1 For piston and

Eye bolt unloader piston
5/16” - 1
Adjustable wrench 250 mm 1 1
152 mm 1 -
Extension bar
250 mm - 1
DV disassembly For Type A 1 - With two bolts

tool (MYCOM
special) For Type B - １ With two bolts
W-Series Reciprocating Compressor 7.8 Disassembly Tools

7-49
2200M4JE-HO-W-N-2014.04.
Qty
WA WB
1/4” 1 1 For JO valve and

Ratchet handle oil pressure
control valve
M12×70 1 - For head cover

Stud bolt
M16×60 - 1
20×160×160 mm 1 1 For cleaning

Sponge
φ15×20×750 mm 1 1 For supplying

Hose lubricant
Table 7-11 Other Recommended Tools (for reference only)
Qty
WA WB
Torque wrench 20 - 50 N･m 1 1
50 - 200 N･m 1 1
200 - 500 N･m 1 1
0 - 25 mm 1 1 For WB-type. It is
Outside micrometer
recommended to
25 - 50 mm 1 1
prepare a
75 - 100 mm 1 1 complete set as
100 - 125 mm - 1 shown in the
outline.
125 - 150 mm - 1
Cylinder gauge 50 - 150 mm 1 1
100 - 160 mm - 1
Vernier caliper 0 - 150 mm 1 -
0 - 200 mm - 1
Thickness gauge 0.04 - 0.30×100 1 1
W-Series Reciprocating Compressor 7.8 Disassembly Tools

7-50
Contact Information_2014.04.
Contact Information
How to Order Genuine Parts

Confirm the target parts by referring to 7.1 "Development View of Parts" and 7.2 "Parts Configuration
Table" in Chapter 7 "Related Documents" of this manual.
Please inform the Model Name and Serial Number, Part Name, Cord No., and required quantity to our
local sales offices or service centers.
When you need more information about the compressor or have questions, apart from the ordering of
parts, please contact our sales offices or service centers.
Sales Offices/Service Centers

 Sales Offices in Japan (as of April 10, 2014)
Description Location Phone/Fax
Head Office 3–14–15 BOTAN KOTO-KU, TOKYO 135-8482 TEL: 03-3642-8181

FAX: 03-3643-7094
Hokkaido 2-5-1, 3-JYO NIJYUUYONKEN NISHI-KU, TEL: 011-631-2052
Branch SAPPORO-CITY, HOKKAIDO 063-0803 FAX: 011-631-2053
Tohoku 8-72, ROKUTYONO-MEMINAMI-MACHI, TEL: 022-288-5001
Branch WAKABAYASHI-KU, SENDAI-CITY, MIYAGI 984-0013 FAX: 022-288-5155
Kanto 3–14–15 BOTAN, KOTO-KU, TOKYO 135-8482 TEL: 03-3642-8968
Branch FAX: 03-3641-8468
Chubu 2-9-6, MARUNOUCHI, NAKA-KU, NAGOYA CITY, AICHI 460-0002 TEL: 052-218-3307
Branch FAX: 052-218-3308
Kansai 1-4-27, EBIE, FUKUSHIMA-KU, OSAKA CITY, OSAKA 553-0001 TEL: 06-4795-6000
Branch FAX: 06-4795-6033
Chushikoku 2-3-40, TAKAYADAI, HIGASHIHIROSHIMA CITY, TEL: 082-491-1830
Branch HIROSHIMA 739-2117 FAX: 082-491-1838
Kyushu FUKUOKA-FUJILAND-BUILD. 10F, 2-3, NAKASHIMA-MACHI, TEL: 092-262-0016
Branch NAKASU, HAKATA-KU, FUKUOKA CITY, FUKUOKA 810-0802 FAX: 092-262-0115
 Manufacturing Bases in Japan (as of April 10, 2014)
Description Location Phone/Fax
Moriya Plant 2000, TATSUZAWA MORIYA-CITY, IBARAKI 302-0118 TEL: 0297-48-1361

FAX: 0297-48-5269
Higashi- 2-3-40, TAKAYADAI, HIGASHIHIROSHIMA CITY, TEL: 082-491-1828
Hiroshima HIROSHIMA 739-2117 FAX: 082-491-1838
Plant
Contact-1
 Global Network (as of April 10, 2014)
Telephone and
Description Location
facsimile No.
NORTH AMERICA
MAYEKAWA CANADA INC. 12180 RIVERSIDE WAY, TEL: (1) 604-270-1544
RICHMOND, B.C., V6W 1K5, CANADA
(VANCOUVER OFFICE) FAX: (1) 604-270-9870
MAYEKAWA CANADA INC. 1745 BONHILL ROAD, TEL: (1) 905-564-0664
(TORONTO OFFICE) UNIT #6&7 MISSISSAUGA, FAX: (1) 905-564-7614
ONTARIO, L5T 1C1, CANADA
MAYEKAWA CANADA INC. 4525 6A STREET N.E., CALGARY, TEL: (1) 403-250-1554
(CALGARY OFFICE) ALBERTA, T2E 4B2, CANADA FAX: (1) 403-250-1504
MAYEKAWA U.S.A. INC. 1850 JARVICE AVENUE, ELK GROVE TEL: (1) 773-516-5070
(CHICAGO OFFICE) VILLAGE, IL 60007, U.S.A. FAX: (1) 773-516-5071
MAYEKAWA U.S.A. INC. 250 WEST NYACK ROAD,SUITE TEL: (1) 914-301-9770
(NEW YORK OFFICE) 230,WEST NYACK, NY 10994, U.S.A. FAX: (1) 914-332-0400
MAYEKAWA U.S.A. INC. 130 SMART PARK DRIVE, LEBANON, TEL: (1) 615-773-2859
(HEAD QUARTERS) TN 37090, U.S.A. FAX: (1) 615-444-1995
(NASHVILLE PLANT)
MAYEKAWA U.S.A. INC. 19475 GRAMERCY PLACE, TEL: (1) 310-328-1362
(LA OFFICE) TORRANCE, CA 90501, U.S.A. FAX: (1) 310-782-6759
MAYEKAWA U.S.A. INC. 2615 W CASINO ROAD, UNIT-3D, TEL: (1) 425-645-9400
(SEATTLE OFFICE) EVERETT, WA 98204, U.S.A. FAX: (1) 425-353-3344
MAYEKAWA U.S.A. INC. 4700 SW MACADAM AVENUE, TEL: (1) 971-230-1795
(PORTLAND OFFICE) SUITE 201 PORTLAND, OREGON 97239, FAX: (1) 503-224-9259
U.S.A.
MAYEKAWA U.S.A. INC. 1272 CENTER COURT DR, SUITE 106, TEL: (1) 626-598-5030
(COVINA OFFICE) COVINA, CA 91724, U.S.A. FAX: (1) -
MAYEKAWA U.S.A.INC. 1219 SAFARI, SAN ANTONIO, TEL: (1) 210-599-4536
(SAN ANTONIO OFFICE) TX 78216, U.S.A. FAX: (1) 210-599-4538
MAYEKAWA U.S.A. INC. 3395 FARMTRAIL ROAD YORK, TEL: (1) 717-779-0138
(YORK OFFICE) PA 17406, U.S.A. FAX: (1) 717-779-0109
MAYEKAWA U.S.A. INC. 19475 GRAMERCY PLACE, TEL: (1) 310-328-6279
CHEMICAL PROCESS DIVISION TORRANCE, CA 90501, U.S.A. FAX: (1) 310-328-8487
(LA OFFICE &
MANUFACTURING)
MAYEKAWA U.S.A. INC. 3222 PASADENA FREEWAY PASADENA, TEL: (1) 281-447-2599
CHEMICAL PROCESS DIVISION TX 77503, U.S.A. FAX: (1) 281-447-6623
(HUSTON SERVICE OFFICE)
EUROPE / AFRICA
N.V.MAYEKAWA EUROPE S.A. LEUVENSESTEENWEG 605, TEL: (32) 2-757-9075
(HEAD OFFICE, FACTORY) 1930 ZAVENTEM, BELGIUM FAX: (32) 2-757-9023
MAYEKAWA DEUTSCHLAND UNTER-BOHNHOF-STRASSE 38A, TEL:(49) 89-5527-989-0

GMBH D-82110 GERMERING, DEUTSCHLAND FAX:(49)89-5527-989-19

Contact-2
Telephone and
facsimile No.
MAYEKAWA DEUTSCHLAND WEIDESTRASSE 122A, 22083 TEL:(49)40-2788-9149-0
GMBH (HUMBURG OFFICE) HAMBURG, DEUTSCHLAND FAX:(49)40-2788-9149-9
N.V.MAYEKAWA EUROPE 16 OAKHURST GARDENS, TEL: (44) 1322-433558
S.A.(UK)
BEXLEYHEATH, FAX: (44) 1322-433164
KENT DA7 5JP, UNITED KINGDOM
MAYEKAWA. S.L. CALLE MONTEVIDEO 5, NAVE 13 POL. TEL: (34) 91-830-0392
INDUSTRIAL CAMPORROSO 28806 FAX: (34) 91-830-0397
ALCALA DE HENARES, MADRID, SPAIN
MAYEKAWA FRANCAISE SARL 9, RUE MICHAEL FARADAY, 78180 TEL: (33) 1-30-58-26-00
MONTIGNY-LE-BRETONNEUX, FARNCE FAX: (33) 1-30-58-19-37
MAYEKAWA MFG. CO., LTD. KOROVY VAL ST., 7, OFFICE 228, TEL: (7) 499-230-01-76
MOSCOW LIAISON OFFICE 119049, MOSCOW,RUSSIA FAX: (7) 499-230-21-12
MAYEKAWA INTERTEC AG ROSENBERGSTRASSE 31, CH-6300 TEL: (41) 41-726-8626
ZUG, SWITZERLAND FAX: (41) 41-726-8620
MAYEKAWA INTERTEC AG P.O.BOX 341 TEL: (20) 22-503-2925
- EGYPT NEW CAIRO - 5th SETTLEMENT, NORTH FAX: (20) 22-503-2801
90th St. THE 47th BUILDING - 4th FLOOR,
OFFICE 419, EGYPT
MAYEKAWA MIDDLE EAST P.O.BOX 61349, PBU: RA08-UC05, TEL: (971) 4-888-6363
FZCO JEBEL ALI FREE ZONE, DUBAI, U.A.E. FAX: (971) 4-888-6373
MAYEKAWA TURKEY SOGUTMA ISTANBUL DUNYA TICARET MERKEZI TEL: (90) 212-4653631
SANAYI VE TICARET LIMITED A-2 BLOK KAT 10 No:325 YESILKOY FAX: (90) 212-4653635
SIRKETI 34149,
ISTANBUL, TURKEY
N.V. MAYEKAWA EUROPE S.A. 24,KAMEN ANDREEV STR. 1303, SOFIA, TEL: (359) 2-8910130
（BULGARIA） BULGARIA FAX: (359) 2-8910131
MAYEKAWA ITALIA S.R.L. VIA RICCARDO LOMBARDI 19/12, TEL: (39) 02-4892-9159
（MILANO OFFICE） 20153 MILANO, ITALY FAX: (39) 02-453-1728
MAYEKAWA ITALIA S.R.L. VIA PRADAZZO 7,40012 CALDERARA DI TEL: (39) 051-726-364
（BOLOGNA OFFICE） RENO, BOLOGNA, ITALY FAX: (39) 051-726-804
MAYEKAWA SOUTH AFRICA (PTY) LTD. WEST END, UNIT 3 PRIME PARK, PRINTERS TEL: (27) 21-551-1434
(CAPE TOWN OFFICE) WAY, MONTAGUE GARDENS 7441, FAX: (27) 86-546-3618
REPUBLIC OF SOUTH AFRICA
ASIA PACIFIC
MAYEKAWA AUSTRALIA UNIT 2, 44 MCCAULEY STREET TEL: (61) 2-9695-7000
PTY.LTD. MATRAVILLE NSW 2036, AUSTRALIA FAX: (61) 2-9695-7001
MAYEKAWA AUSTRALIA PTY. UNIT 2, 30 TUI STREET, OTAHUHU, TEL: (64) 9-276-2305
LTD.(NEW ZEALAND OFFICE) AUCKLAND 2024, NEW ZEALAND FAX: (64) 9-276-2306
MAYEKAWA INDIA PVT.LTD. 545, 1st FLOOR, SECTOR-20,VILLAGE TEL: (91) 12-4651-0181
(GURGAON OFFICE) DUNDAHERA FAX: (91) 12-4651-0188
GURAGAON-122016, HARYANA, INDIA
MAYEKAWA INDIA PVT.LTD. RS No.225/226/238,NAYAPAKKAM TEL: (91) 92-8258-2508
(CHENNAI FACTORY) VILLAGE, PUDDUVALLUR PANCHAYAT, FAX: -
VALARPURAM POST THIRUVALLUR
DISTRICT, TAMIL NADU 602105, INDIA

Contact-3
Telephone and
facsimile No.
MAYEKAWA INDIA PVT. LTD. OMER MANSION, ROOM No. 2c, 3RD TEL: (91) 33-40038043
(KOLKATA OFFICE) FLOOR, FAX: (91) 33-40038044
29 A WESTON STREET, KOLKATA,
WEST BENGAL 700012, INDIA
MAYEKAWA INDIA PVT. LTD. SHOP NO. 3, OPP. TV TOWER, NIKODAR TEL: (91) 9711303865
(JALANDHAR OFFICE) ROAD, JALANDHAR, PUNJAB 144201, FAX: —
INDIA
MAYEKAWA INDIA PVT. LTD. CS-9 SECOND FLOOR, RASHMI TEL: (91) 89-5450-2937
(AGRA OFFICE) PALACE, SULTAN GANJ KI PULIA, FAX: (91) 97-1130-3865
KAMLA NAGAR, AGRA, U.P. 282005,
INDIA
P.T.MAYEKAWA INDONESIA GRAHA PRATAMA BUILDING, 9TH TEL: (62) 21-8370-9484
FLOOR JL. M.T. HARYONO KAV.15 FAX: (62) 21-8370-9483
JAKARTA 12810, INDONESIA
P.T.MAYEKAWA INDONESIA JL. SUTRISNO No.274 MEDAN-20215, TEL: (62) 61-7323627
(MEDAN OFFICE) INDONESIA FAX: (62) 61-7358848
P.T.MAYEKAWA INDONESIA BUMI MANDIARI BUILDING, 7TH FLOOR TEL: (62) 31-531-6613
(SURABAYA OFFICE) SUITE 702B, JL. JEND. BASUKI FAX: (62) 31-532-4341
RACHMAT No. 129-137,
SURABAYA-INDONESIA
MAYEKAWA (M) SDN. BHD. No.3, JALAN PJU 3/50, SUNWAY TEL: (60) 3-78051406
DAMANSARA TECHNOLOGY PARK, FAX: (60) 3-78051409
47810 PETALING JAYA, SELANGOR,
MALAYSIA
MAYEKAWA PHILIPPINES 4/F UNIT A AND B SUNTREE TOWER, TEL: (63) 2-706-0473
CORP. 13 MERALCO AVENUE, SAN ANTONIO, FAX: (63) 2-706-0475
ORTIGAS CENTER, PASIG CITY 1605,
PHILIPPINES
MAYEKAWA PHILIPPINES ROOM 4, LEAH DAPROZA BUILDING TEL: (63) 83-552-3282
CORP. FISCAL DAPROZA AVENUE FAX: (63) 83-301-2698
(GENARAL SANTOS OFFICE) GENERAL SANTOS CITY 9500,
PHILIPPINES
MAYEKAWA SINGAPORE 6 TAGORE LANE SINGAPORE 787470 TEL: (65) 6451-1565
PTE.LTD. FAX: (65) 6451-4932
MAYEKAWA (TAIWAN) CO., LTD. No.2-1,XINZHAN RD.,QIANZHEN DIST., TEL: (886) 7-821-0886
KAOHSIUNG CITY,80672 FAX: (886) 7-821-4688
TAIWAN , REP.OF CHINA
MAYEKAWA (TAIWAN) CO., LTD. 1F., NO.2, SHIN JANN ROAD, TEL: (886) 7-812-7709
(CHEMICAL DEPARTMENT) CHIEN CHEN DIST., KAOHSIUNG, FAX: (886) 7-812-9019
TAIWAN 80672, REP.OF CHINA
MAYEKAWA (TAIWAN) CO., LTD. 8F, NO, 421, SUNG-SHAN ROAD, TAIPEI, TEL: (886) 2-2727-9711
(TAIPEI BRANCH) TAIWAN 11083, REP. OF CHINA FAX: (886) 2-2759-8484
MAYEKAWA (TAIWAN) CO., LTD. NO. 19, SEC.3, HUANJUNG RD., TEL: (886) 4-2251-4128
(TAICHUNG BRANCH) TAICHUNG, FAX: (886) 4-2251-4129
TAIWAN, REP. OF CHINA

Contact-4
Telephone and
facsimile No.
MAYEKAWA CHINA INDUSTRIES ROOM 3001, NANZHENG BUILDING, TEL: (86) 21-5234-1988
CO., LTD. NO.580 WEST NANJING RD., FAX: (86) 21-5234-1788
(SHANGHAI BRANCH) 200041 SHANGHAI, P.R. CHINA
MAYEKAWA CHINA MFG.CO., 201700 PLANT 1, NO.39, WEST XIQING TEL: (86) 21-6920-7718
LTD. ROAD, FAX: (86) 21-6920-7719
QINGPU, SHANHAI, P.R. CHINA
MAYEKAWA CHINA MFG.CO., 266701 RM.1205, BUILDING H, R&F TEL: (86) 20-8527-6161
LTD. TIANHE FAX: (86) 20-8527-6165
(GUANGZHOU BRANCH) PROSPEROUS PLACE, EAST LINHE
ROAD,
TIANHE DISTRICT, GUANGZHOU, P.R.,
CHINA
MAYEKAWA CHINA MFG. CO., ROOM 601, FULIN BUILDING TEL: (86) 532-8602-6169
LTD. (QINGDAO BRANCH) NO.87 SOUTH FUZHOU ROAD, FAX: (86) 532-8602-6269
SOUTH DISTRICT, QINGDAO CITY,
266071, CHINA
MAYEKAWA MFG. CO., LTD NO.643 HANWEI PLAZA, NO.7 TEL: (86) 10-6561-7811
(BEIJING LIAISON OFFICE) GUANGHUA ROAD, FAX: (86) 10-6561-1997
CHAOYANG DISTRICT,
BEIJING 100004, P.R. CHINA
MAYEKAWA CHINA MFG. CO., RM.A13-5, No.1 BUILDING, AREA A , TEL: (86) 411-8753-9620
LTD. (DALIAN BRANCH) WUCAI CITY, DALIAN ECO-TECH FAX: (86)411-8757-9620
DEVELOPMENT ZONE,
DALIAN 116100, CHINA
MAYEKAWA (THAILAND) CO., 2/3 MOO 14, 3RD FLOOR TEL: (66) 2-751-9610
LTD. BANGNA TOWER BLDG., TOWER A, FAX: (66) 2-751-9565
BANGNA-TRAD RD, K.M.6.5,
BANGKAEW BANGPLEE,
SAMUTPRAKARN 10540, THAILAND
MAYEKAWA (THAILAND) CO., 1/7 TRANG-PALIAN RD., MUANG, TEL: (66) 75-224-784
LTD. TRANG 92000, THALAND FAX: (66) 75-224-351
(TRANG BRANCH)
MAYEKAWA VIETNAM ONE ROOM 305, 3FL, TUOI TRE TOWER, TEL: (84) 8-3997-5284
MEMBER CO., LTD. 60A HOANG VAN THU, WARD 9, FAX: (84) 8-3997-5287
PHU NHUAN DIST., HO CHI MINH CITY,
VIETNAM
MYCOM KOREA CO., LTD. 2F, 345, CHEONGRA-RO , TEL: (82) 2-796-1766
(HEAD OFFICE) YONGSAN-KU, FAX: (82) 2-798-7715
SEOUL, 140-710, REP.OF KOREA
MYCOM KOREA CO., LTD. 19, BANGYE-RO, UICHANG-KU, TEL: (82) 55-294-8678
CHANGWON FACTORY CHANGWON-SI, GYEONGSANGNAM-DO FAX: (82) 55-299-7678
641-847, REP.OF KOREA
MYCOM KOREA CO., LTD. 5F, 26, JUNGANG-DAERO, JUNG-GU, TEL: (82) 51-242-3737
(BUSAN BRANCH) BUSAN 600-714, REP.OF KOREA FAX: (82) 51-243-8542

Contact-5
Telephone and
facsimile No.
MYCOM KOREA CO., LTD. 2F, YFC F/D, 57, SICHEONG-RO, TEL: (82) 61-685-5559
(YEOSU BRANCH) YEOSU-SI, FAX: (82) 61-685-7773
JEOLLANAM-DO, 555-807, REP. OF
KOREA
MAYEKAWA INTERTECH KOREA 2F, 345, CHEONGPA-RO, YONGSAN-GU, TEL: (82) 2-796-1766
CO., LTD SEOUL, 140-710, REP. OF KOREA FAX: (82) 2-798-7715
LATIN AMERICA
MAYEKAWA ARGENTINA S.A. AV. VELEZ SARSFIELD 670/74 C1282 TEL: (54) 11-4302-2791
(BUENOS AIRES OFFICE) AFT-CAPITAL FEDERAL BUENOS AIRES, FAX: (54) 11-4304-3015
REPUBLICA ARGENTINA
MAYEKAWA ARGENTINA S.A. OFICINA PTO. MADRYN LEOPOLDO TEL: (54) 2965-475414
(PUERTO MADRYN OFFICE) LUGONES 45 FAX: (54) 2965-475414
(U9129KDA)-PUERTO MADRYN PCIA DE
CHUBUT
REPUBLICA ARGENTINA
MYCOM PERU S.A.C. CALLE LUIS PASTEUR 1490, TEL: (51) 1-205-5400
LINCE, LIMA, PERU FAX: (51) 1-222-1543
MAYEKAWA CHILE S.A.C.el. CORDILLERA No.331, MODULO D14, TEL: (56) 2-739-0202
(SANTIAGO OFFICE) FLEX CENTER, PUERTO VESPUCIO, FAX: (56) 2-739-2700
QUILICURA, SANTIAGO, CHILE
MAYEKAWA CHILE S.A.C.el. ANIBAL PINTO No.215, OFICINA 403, TEL: (56) 41-223547
(CONCEPCION OFFICE) CONCEPCION, CHILE FAX: (56) 41-212443
MAYEKAWA CHILE S.A.C.el. BERNARDINO 1057 MODULO 6, TEL: (56) 65-257570
(PUERTO MONTT OFFICE) PARQUE INDUSTRIAL SAN ANDRES FAX: (56) 65-288073
PUERTO MONTT, CHILE
MAYEKAWA ECUADOR S.A. CALLE 15B Y AV. TEL: (593)4-262-9108
GUILLERMO PAREJA C.C.STEFANY FAX: -
LOCAL #4,
CALLA.LA GARZOTA 1 MZ.28 SOLOR 13,
GUAYAQUIL, ECUADOR
MAYEKAWA COLOMBIA S.A.S TRANSVERSAL 93 NO.53-48 INTERIOR TEL: (57) 1-430-9980
37, PAQUE INDUSTRIAL EL DORADO, FAX: (57) 1-437-0988
BOGOTA, COLOMBIA
MAYEKAWA COLOMBIA S.A.S. DIRECCION CR 43B No. 8 SUR 10 TEL: (57) 4-313-4343
(MEDELLIN OFFICE) OFICINA 404 EDF. OVIEDO MEDELLIN, FAX: (57) 4-313-4343
COLOMBIA
MAYEKAWA DO BRASIL RUA LICATEM 250, BLOCO B/C, JARDIM TEL: (55) 11-4654-8000
EQIPAMENTOS INDUSTRIAIS PEROVA-ARUJA-SP CEP:07428-280, FAX: (55) 11-4654-8002
LTDA. BRASIL
MAYEKAWA DO BRASIL LTDA. RUA DR. JOSE PEROBA, 275 - SALA 902 TEL: (55) 71-3341-0737
(BAHIA BRANCH) EDIFICIO METROPOLIS - BAIRRO FAX: —
STIEPE, SALVADOR –
BA,CEP:41770-235, BRASIL

Contact-6
Telephone and
facsimile No.
MAYEKAWA DO BRASIL AV. NEREU RAMOS, 75D, SALA 503A, TEL: (55) 49-3324-0681
EQIPAMENTOS INDUSTRIAIS EDIFICIO CENTRO PROFISSIONAL FAX: (55) 49-3322-4241
LTDA. (CHAPECO BRANCH) CEP:89801-023 C.P.:177 CHAPECO-SC,
BRASIL
MAYEKAWA DO BRASIL AVENIDA ISSAC POVOAS, 586 – SALA TEL: (55) 65-3023-7559
EQIPAMENTOS INDUSTRIAIS 405 EDIFICIO WALL STREET - CENTRO FAX: —
LTDA. (CUIABA BRANCH) CUIABA-MT, CEP 78055-560, BRASIL
MAYEKAWA DO BRASIL RUA XV DE NOVEMBRO, 2175 6 ANDAR TEL: (55) 41-3383-1518
EQIPAMENTOS INDUSTRIAIS SALA 30 SHOPPING CELLI FAX: (55) 41-3383-1987
LTDA. (CURITIBA BRANCH) CEP:83005-000
SAO JOSE DOS PINHAIS-PR, BRASIL
MAYEKAWA DO BRASIL RUA C, 255 – QUADRA 588 – LOTE 4/8 TEL: (55) 62-3093-5062
EQIPAMENTOS INDUSTRIAIS SALA 104 – CENTRO EMPRESARIAL FAX: —
LTDA. (GOIANIA BRANCH) SEBBA GOIANIA-GO, CEP 74280-010,
BRASIL
MAYEKAWA DO BRASIL AV. FRANCISCO DE CHAGAS OLIVEIRA, TEL: (55) 17-3227-0235
EQIPAMENTOS INDUSTRIAIS 344 JARDIM PINHEIRO SAO JOSE DO FAX: (55) 17-3227-3120
LTDA. (OESTE PAULISTA RIO PRETO-SP, CEP 15091-330, BRASIL
BRANCH)
MAYEKAWA DO BRASIL RUA AGENOR LOPES, 292 SALA 305 TEL: (55) 81-3342-7670
EQIPAMENTOS INDUSTRIAIS CEP:51021-110 BOA VIAGEM FAX: -
LTDA. (RECIFE BRANCH) RECIFE-PE, BRASIL
MAYEKAWA DO BRASIL RUA MUCK, 298 – SALA 601 EDIFICIO TEL: (55) 51-3429-1860
EQIPAMENTOS INDUSTRIAIS SANTA HELENA CEP:92010-250 FAX: —
LTDA. CANOAS-RS, BRASIL
(RIO GRANDE DO SUL BRANCH)
MAYEKAWA DO BRASIL AV. GOVERNADOR CARLOS
EQIPAMENTOS INDUSTRIAIS LINDENBERG, 873/107 CENTRO
LTDA. (LINHARES BRANCH) CEP:29900-020 LINHARES-ES, BRASIL
MAYEKAWA DO BRASIL RUA PROFESSOR MARIETA PEIXOTO, TEL: (55) 22-2772-6069
EQIPAMENTOS INDUSTRIAIS 62 CENTRO - MACAE – RJ, FAX: (55) 22-2759-3112
LTDA. (MACAE) CEP 27910-250, BRASIL
MAYEKAWA DO BRASIL AV.LUIZ CARLOS PRESTES, 350-SALA TEL: (55) 21-2431-3600

EQIPAMENTOS INDUSTRIAIS 313-EDIFICIO BARRA TRADE II, FAX: (55) 21-2430-8882
LTDA. BARRA DA TIJUCA, RIO DE JANEIRO-RJ
(RIO DE JANEIRO BRANCH) CEP:22775-055, BRASIL
MYCOM CENTROAMERICA S.A BODEGA #63, CONDOMINIO TEL: (506) 2441-4464
COMERCIAL TIERRA DOS, EL CACIQUE FAX: (506) 2441-4465
DE RIO SEGUNDO, ALAJUELA, COSTA
RICA
MYCOM VENEZUELA CALLE LOS MANGOS, TEL: (58) 212-216-6026
SALES & SERVICES,C.A. EDIFICIO SELEMAR, PISO 8, FAX: (58) 212-216-0608
(CARACAS OFFICE) SABANA GRANDE, CARACAS,
VENEZUELA

Contact-7
Telephone and
facsimile No.
MYCOM VENEZUELA AV.INTERCOMUNAL TURMERO, TEL: (58) 243-269-4913
SALES & SERVICE, C.A. EDF.TECHOMAT METROPOLITANO, FAX: (58) 243-269-3952
(MARACAY OFFICE) PISO 1, OFICINA 3, MARACAY,
EDO.ARAGUA, VENEZUELA
MYCOM VENEZUELA CALLE 148,CENTRO EMPRESARIAL TEL: (58) 261-418-1760
SALES & SERVICE, C.A. SAN FRANCISCO NIVEL 1 LOCAL 5 Y 6, FAX: -
(MARACAIBO OFFICE) ZONA INDUSTRIAL IIETAPA,SAN
FRANCISCO
EDO.ZUILIA, VENEZUELA
MYCOM VENEZUELA AV. MUNICIPAL DE PTO. LA CRUZ, EDIF. TEL: (58) 261-765-1059
SALES & SERVICE, C.A. LOCAL NRO.57, PLANTA ALTA,
(BARCELONA OFFICE) MUNICIPIO SOTILLO, PUERTO LA CRUZ,
VENEZUELA
MYCOM CHEMICAL PROCESS CALLE 148,CENTRO EMPRESARIAL TEL: (58) 261-418-1760
CORP. DE VENEZUELA S.A. SAN FRANCISCO NIVEL 1 LOCAL 5 Y 6, FAX: -
ZONA INDUSTRIAL IIETAPA,SAN
FRANCISCO
EDO.ZUILIA, VENEZUELA
MAYEKAWA DE MEXICO, AV.DE LOS 50MTS.NO.381, TEL: (52) 77-73-19-0925
S.A. DE C.V. CIVAC. JIUTEPEC MORELOS, C.P.62578, FAX: (52) 77-73-20-5762
(CUERNAVACA OFFICE) MEXICO
MAYEKAWA DE MEXICO, AV.COYOACAN #945 COL .DEL VALLE TEL: (52) 55-5062-0870
S.A. DE C.V. DEL. BENITO JUAREZ C.P.03100, FAX: (52) 55-5062-0898
(MEXICO CITY OFFICE) MEXICO,
D.F. MEXICO
MAYEKAWA DE MEXICO, SANTA MARIA No.3086, COL. VALLARTA TEL: (52) 3336-15-5765
S.A. DE C.V. SAN LUCAS GUADALAJARA, JALISCO, FAX: (52) 3336-15-1307
(GUADALAJARA OFFICE) C.P.44690, MEXICO
MAYEKAWA DE MEXICO, AV.CHAPULTEPEC NO.2233 OTE. TEL: (52) 81-8347-3085
S.A. DE C.V. FRACC, FAX: (52) 81-8347-5830
(MONTERREY OFFICE) BUENOS AIRES MONTERREY N.L.
C.P.64800, MEXICO
MAYEKAWA DE MEXICO, CALLE FRAY TORIBIO DE BENAVENTE TEL: (52) 662-216-2047
S.A. DE C.V. #38 COL. LOS ARCOS CD. FAX: (52) 662-216-2047
(HERMOSILLO OFFICE) HERMOSILLO, SONORA, C.P.83250,
MEXICO
MAYEKAWA DE MEXICO, CALLE AGUSTIN ZARAGOZA NO.219 TEL: (52) 462-624-9353
S.A. DE C.V. LOCAL-2 COL.DEPORTIVA, C.P.36612, FAX: (52) 462-624-9264
(IRAPUATO OFFICE) IRAPUATO, GTO. MEXICO
MAYEKAWA DE MEXICO, AV. NICOLAS BRAVO 1572, LOCAL 1 TEL: (52) 66-7715-4199
S.A. DE C.V. COL.MORELOS CULIACAN, SINALOA, FAX: (52) 66-7715-4150
(CULIACAN OFFICE) C.P.80170, MEXICO

Contact-8
2200M4JE-HO-W-N_2014.04.
MAYEKAWA MFG. CO., LTD.

3-14-15 Botan, Koto-ku, Tokyo 135-8482
TEL : 03-3642-8181
URL : http://www.mayekawa.com/

Instruction Manual For W-Series Reciprocating Compressors: 2WA/4WA/6WA/8WA/42WA/62WA

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2200M4JE-HO-W-N_2014.04.

Instruction Manual for

3–14–15 Botan Koto-ku, Tokyo 135-8482, Japan

2WA, 4WA, 6WA, 8WA, 42WA, 62WA,

W-Series Reciprocating Compressor

Warranty and Disclaimer

Disclaimer Clauses (Exclusion of Warranty Clauses)

W-Series Reciprocating Compressor

Intended Use of this Product

Precautions for the Safe Use of this Product

W-Series Reciprocating Compressor

About this Manual

W-Series Reciprocating Compressor

Structure of this Manual

W-Series Reciprocating Compressor

W-Series Reciprocating Compressor

Chapter 2 Compressor Mechanism and Specifications

W-Series Reciprocating Compressor

3.2.8.1 Lubricant ...................................................................................................... 3-7

Chapter 4 Operation of Compressor and System

Chapter 5 Maintenance and Inspection

W-Series Reciprocating Compressor

5.5.3 Removal of Head Spring.................................................................................... 5-12

W-Series Reciprocating Compressor

Suction pressure is too low ........................................................................................ 6-3

Chapter 7 Related Documents

Chapter 8 Contact Information

W-Series Reciprocating Compressor

1.1.1.2 DOs on Maintenance

W-Series Reciprocating Compressor 1.1 Observation/Prevention (DOs and DON'Ts)

1.1.1.3 DOs on Lockout/Tagout after Shutting Off the Power

1.1.1.4 DOs about Personal Protective Gear

1.1.1.5 DOs about Handling of Hazardous and Toxic Substances

1.1.1.6 DOs about Handling Emergency Situations

1.1.1.7 DOs about Waste Oil, Fluid, and Materials

W-Series Reciprocating Compressor 1.1 Observation/Prevention (DOs and DON'Ts)

1.1.1.8 Other DOs

1.2 Warning Notices in this Manual

Table 1-1 Types and Meanings of Warnings

W-Series Reciprocating Compressor 1.2 Warning Notices in this Manual

1.3 Residual Risks

W-Series Reciprocating Compressor 1.3 Residual Risks

Symbol Risk Area Symbol Risk Area

W-Series Reciprocating Compressor 1.3 Residual Risks

1.4 Safety Devices

1.4.1 Emergency Stop Button

 Stopping and recovery methods

 Inspection method and inspection interval

 How to implement and restore the lock-out/tag-out function

 Inspection method and inspection interval

W-Series Reciprocating Compressor 1.4 Safety Devices

1.4.3 Safety Cover (drive system)

No. Name No. Name

 Inspection method and inspection interval

1.4.4 Safety Valve

W-Series Reciprocating Compressor 1.4 Safety Devices

1.4.5 Automatic Control and Protection Devices for the Compressor