3225 C Instruction Manual: Compound 2-Stage Screw Compressor

2201MYJE-MY-C8-N_2015.04.
Compound 2-stage Screw Compressor

3225 C Instruction Manual
**
3225LLLC/3225LLMC/3225LLSC/3225LLC/3225LMC/3225LSC
3225MLC/3225MMC/3225MSC/3225SLC/3225SMC/3225SSC
CAUTION
Before operating, servicing, or inspecting this product, read this manual thoroughly to fully
understand the contents.
Keep this Instruction Manual in a safe, designated place for future reference whenever the
manual is needed.
Specifications of this product and contents of this manual are subject to change without
prior notice due to technical improvements, and the like.
2201MYJE-MY-C8-N_2015.04.
Preface
Preface
Thank you for purchasing the C-series compound 2-stage screw compressor 3225**C
(hereinafter referred to as "this product").
This Instruction Manual (hereinafter referred to as "this manual") provides safety information and
operation and maintenance procedures, so that users correctly understand how to handle this product
and, as a result, can use it safely and efficiently. This manual is applicable to the following models:
3225LLLC-*B*-51 3225LLLC-*B*-61 3225LLMC-*B*-51 3225LLMC-*B*-61 3225LLSC-*B*-51 3225LLSC-*B*-61

3225LLC-*B*-51 3225LLC-*B*-61 3225LMC-*B*-51 3225LMC-*B*-61 3225LSC-*B*-51 3225LSC-*B*-61
3225MLC-*B*-51 3225MLC-*B*-61 3225MMC-*B*-51 3225MMC-*B*-61 3225MSC-*B*-51 3225MSC-*B*-61
3225SLC-*B*-51 3225SLC-*B*-61 3225SMC-*B*-51 3225SMC-*B*-61 3225SSC-*B*-51 3225SSC-*B*-61
* -51 (-61) may not be written. For more information, see 2.2 "Model designation of the compressor"
in this manual Chapter 2.
Make sure you read this manual before installing or using this product.
Keep this manual in a safe place near this product for quick reference.
Revision History
Title Document No. First edition issue date
3225**C Instruction Manual 2201MYJE-MY-C8-N_2015.04. Nov. 14, 2014
Revision
Issue date Major Contents of revisions Created/approved by:
No.
00 Nov. 14, 2014 Overall review associated with reissue as Ikehara / Hirao
electronic document, document No. change
01 Apr. 30, 2015 Modified the constitution of Chapter 4 and Ikehara / Muta
Chapter 5. Correction of describing, etc.
Compound 2-stage Screw Compressor 3225**C

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2201MYJE-MY-C8-N_2015.04.
Warranty and Disclaimer
Warranty
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.
MAYEKAWA is not liable for production or man-made disaster compensation due to malfunction or
damage of this product.
Disclaimer of Warranty
Although MAYEKAWA warrants the clauses mentioned above, the following clauses are exempted.
 Malfunction or damage of this product caused by natural disaster, or other accidental forces
(such as fire, thunderbolt, windstorm, intense rainfall, flood, tidal wave, earthquake, land
subsidence, etc.).
 Malfunction or damage caused by misusage described below.
 Malfunctions, damage, or deterioration of this product due to abnormal or improper use
(including improperly storing this product outdoors or under too hot/humid conditions,
unexpected inspections, tests, operations, too frequent liquid flow-back operation*, and
too frequent start-stop cycles, etc.).
 Malfunction or damage caused by devices or equipments not provided by MAYEKAWA
including operation control methods of those devices.
 Malfunction or damage caused by refrigerants, gases, or refrigerant oils, and operating
conditions (design conditions) not approved for this product.
 Malfunction or damage caused by maintenance or inspection not recommended by
MAYEKAWA.
 Malfunction or damage caused by parts that are not genuine.
 Malfunction or damage caused by remodeling the product without approval of
MAYEKAWA.
 Malfunction or damage caused by unexpected misusage
"Liquid flow-back operation" is ･･･

Normally, while the compressor sucks in the refrigerant liquid only after vaporizing it in the
evaporator, it may directly sucks it in because of the faulty adjustment or failure of the
expansion valve. We call this state of compressor operation "liquid flow-back operation".
No compressor can compress a liquid. The compressor may be damaged should the liquid be
sucked in.

ii
2201MYJE-MY-C8-N_2015.04.
Important Information
Intended Use of This Product

This product is a general-purpose screw compressor for refrigeration, cold storage and various gases
compression. Do not use this product for any other purposes that are not intended for or which depart
from the specifications. For specifications of this product, refer to "2.3 Compressor Specifications".
Please perform the maintenance items described in this manual by using safe and assured procedures.
For Safe Use of This Product

Although MAYEKAWA has paid a lot of attention to safety measures for this product, all hazards
including potential hazards caused by human errors, or due to environmental conditions can not be
anticipated.
As there are too many items to be strictly observed or prohibited when using this product, it is
impossible to inform all of them through this manual. Therefore, when operating this product, pay
extreme caution on personnel safety as well as on items described in this manual.
Important rules for safety work with this product that apply to all workers including managers and
supervisors are listed below.
Please read this manual before using this product. Fully understand the instructions provided there,
and be sure to perform 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 this product and trained about hazards
involved and measures to avoid danger.
 Do not allow any person other than those educated on the fundamental expertise of this
product and trained about hazards involved and measures to avoid dangers to approach this
product while it is operating or during maintenance.
 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. Do not use this product for any purpose other than intended.
 Replace the parts with genuine parts.
 Not only workers but also managers should actively participate safety and health activities in
the workplace to prevent accidents.
 When closing or opening a valve during work, make sure to apply lockout/tagout to prevent
the valve from being accidentally closed or opened during the work.
[Lockout] 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.
[Tagout] 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.

iii
2201MYJE-MY-C8-N_2015.04.
Observe the following precautions when performing maintenance work on electrical control.
 Electrical maintenance of the product must be performed by certified/qualified personnel and
only those educated about the electrical control of the product.
 Before servicing or inspecting the electrical equipment or devices, turn "OFF" the motor main
power and control power, and perform lockout/tagout to prevent the power from being turned
on during work.
Even when the motor main power and control power are turned "OFF", this product may be turned on if
the power is supplied from outside the package unit. Make sure the power supply on the power source
side is shut off, and perform lockout/tagout to prevent the product from being turned on during work.
About This Manual

 This product may be modified without prior notice. Therefore, the appearance of actual
machine may differ from the descriptions in this manual. If you have any questions, contact
our sales offices or service centers. For each sight of MAYEKAWA, refer to "Contact
Information" in this manual or following URL. http://www.mayekawa.com/about/network/
 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.
 This manual is copyrighted. Drawings and technical references including this manual shall not,
in whole or part, be copied, photocopied, or reproduced into any electronic medium or
machine-readable form without prior permission from MAYEKAWA.
 Photographs or drawings included in this manual may differ from the appearance of actual
product.
 If this manual is lost or damaged, immediately request our local sales offices or service
centers for a new manual. Using this product without the manual may result in safety issues.
 If you resell this product, never fail to attach this manual to this product.
Construction of This Manual

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

iv
2201MYJE-MY-C8-N_2015.04.
Warranty
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.
MAYEKAWA is not liable for production or man-made disaster compensation due to malfunction or
damage of this product.
Disclaimer of Warranty
Although MAYEKAWA warrants the clauses mentioned above, the following clauses are exempted.
 Malfunction or damage of this product caused by natural disaster, or other accidental forces
(such as fire, thunderbolt, windstorm, intense rainfall, flood, tidal wave, earthquake, land
subsidence, etc.).
 Malfunction or damage caused by misusage described below.
 Malfunctions, damage, or deterioration of this product due to abnormal or improper use
(including improperly storing this product outdoors or under too hot/humid conditions,
unexpected inspections, tests, operations, too frequent liquid flow-back operation*, and
too frequent start-stop cycles, etc.).
 Malfunction or damage caused by devices or equipments not provided by MAYEKAWA
including operation control methods of those devices.
 Malfunction or damage caused by refrigerants, gases, or refrigerant oils, and operating
conditions (design conditions) not approved for this product.
 Malfunction or damage caused by maintenance or inspection not recommended by
MAYEKAWA.
 Malfunction or damage caused by parts that are not genuine.
 Malfunction or damage caused by remodeling the product without approval of
MAYEKAWA.
 Malfunction or damage caused by unexpected misusage
"Liquid flow-back operation" is ･･･

Normally, while the compressor sucks in the refrigerant liquid only after vaporizing it in the
evaporator, it may directly sucks it in because of the faulty adjustment or failure of the
expansion valve. We call this state of compressor operation "liquid flow-back operation".
No compressor can compress a liquid. The compressor may be damaged should the liquid be
sucked in.

ii
2201MYJE-MY-C8-N_2015.04.
Intended Use of This Product

This product is a general-purpose screw compressor for refrigeration, cold storage and various gases
compression. Do not use this product for any other purposes that are not intended for or which depart
from the specifications. For specifications of this product, refer to "2.3 Compressor Specifications".
Please perform the maintenance items described in this manual by using safe and assured procedures.
For Safe Use of This Product

Although MAYEKAWA has paid a lot of attention to safety measures for this product, all hazards
including potential hazards caused by human errors, or due to environmental conditions can not be
anticipated.
As there are too many items to be strictly observed or prohibited when using this product, it is
impossible to inform all of them through this manual. Therefore, when operating this product, pay
extreme caution on personnel safety as well as on items described in this manual.
Important rules for safety work with this product that apply to all workers including managers and
supervisors are listed below.
Please read this manual before using this product. Fully understand the instructions provided there,
and be sure to perform 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 this product and trained about hazards
involved and measures to avoid danger.
 Do not allow any person other than those educated on the fundamental expertise of this
product and trained about hazards involved and measures to avoid dangers to approach this
product while it is operating or during maintenance.
 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. Do not use this product for any purpose other than intended.
 Replace the parts with genuine parts.
 Not only workers but also managers should actively participate safety and health activities in
the workplace to prevent accidents.
 When closing or opening a valve during work, make sure to apply lockout/tagout to prevent
the valve from being accidentally closed or opened during the work.
[Lockout] 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.
[Tagout] 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.

iii
2201MYJE-MY-C8-N_2015.04.
Observe the following precautions when performing maintenance work on electrical control.
 Electrical maintenance of the product must be performed by certified/qualified personnel and
only those educated about the electrical control of the product.
 Before servicing or inspecting the electrical equipment or devices, turn "OFF" the motor main
power and control power, and perform lockout/tagout to prevent the power from being turned
on during work.
Even when the motor main power and control power are turned "OFF", this product may be turned on if
the power is supplied from outside the package unit. Make sure the power supply on the power source
side is shut off, and perform lockout/tagout to prevent the product from being turned on during work.
About This Manual

 This product may be modified without prior notice. Therefore, the appearance of actual
machine may differ from the descriptions in this manual. If you have any questions, contact
our sales offices or service centers. For each sight of MAYEKAWA, refer to "Contact
Information" in this manual or following URL. http://www.mayekawa.com/about/network/
 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.
 This manual is copyrighted. Drawings and technical references including this manual shall not,
in whole or part, be copied, photocopied, or reproduced into any electronic medium or
machine-readable form without prior permission from MAYEKAWA.
 Photographs or drawings included in this manual may differ from the appearance of actual
product.
 If this manual is lost or damaged, immediately request our local sales offices or service
centers for a new manual. Using this product without the manual may result in safety issues.
 If you resell this product, never fail to attach this manual to this product.
Construction of This Manual

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

iv
2201MYJE-MY-C8-N_2015.04.
Table of Contents
Table of Contents
Preface .................................................................................................................... ⅰ
Revision History ..................................................................................................... ⅰ
Warranty and Disclaimer ....................................................................................... ⅱ
Important Information ............................................................................................ ⅲ
Intended Use of This Product ........................................................................................... ⅲ
Important Information for Safe Use of This Product .......................................................... ⅲ
About This Manual ............................................................................................................. ⅳ
Construction of This Manual .............................................................................................. ⅳ
Table of Contents ................................................................................................... ⅴ
Chapter 1 Safety
1.1 Strict Requirements and Prohibitions........................................................ 1-1
1.1.1 Strict Requirements (Do’s)................................................................................... 1-1
1.1.1.1 Do’s on Operation ........................................................................................ 1-1
1.1.1.2 Do’s on Maintenance ................................................................................... 1-1
1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power ................................. 1-1
1.1.1.4 Do’s about Personal Protective Gear .......................................................... 1-2
1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances.......................... 1-2
1.1.1.6 Do’s about Handling Emergency Situations ................................................ 1-2
1.1.1.7 Do’s about Waste Oil, Fluid, and Materials ................................................. 1-2
1.1.1.8 Other Do’s.................................................................................................... 1-3
1.1.2 Prohibitions (Don’ts) ......................................................................................... 1-3
1.2 Warnings ....................................................................................................... 1-3
1.3 Residual Risks ............................................................................................. 1-4
1.4 Safety Devices .............................................................................................. 1-6
1.4.1 Emergency Stop Button ....................................................................................... 1-6
1.4.2 Breakers of motor main power and control power
(with Lockout/Tagout Mechanism) ...................................................................... 1-6
1.4.3 Compressor Protective Devices .......................................................................... 1-7
Chapter 2 Compressor Specifications and Structure

2.1 Overview of the 3225**C ............................................................. 2-1
2.2 Model Designation of the Compressor ................................................... 2-1
2.3 Compressor Specifications ........................................................................ 2-2
2.3.1 Standard Specifications ....................................................................................... 2-2
2.3.2 Operation Limits ................................................................................................... 2-4
2.3.3 Outer Dimensions ................................................................................................ 2-5
2.4 Structure of Compressor .......................................................................... 2-17
2.4.1 Sectional View ................................................................................................... 2-17

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2201MYJE-MY-C8-N_2015.04.
Table of Contents
2.5 Mechanisms ............................................................................................... 2-18

2.5.1 Basics of the Screw Compressor ...................................................................... 2-18
2.5.2 Suction Process ................................................................................................. 2-18
2.5.3 Compression Process........................................................................................ 2-19
2.5.4 Discharge Process............................................................................................. 2-19
2.5.5 About Volume Ratio (Vi) .................................................................................... 2-19
2.5.6 Capacity Control Mechanism ............................................................................. 2-21
2.5.7 Bearings and Balance Piston ............................................................................ 2-21
2.5.8 Shaft Seal Block ................................................................................................ 2-21
2.6 Gas and Oil Flow ........................................................................................ 2-22
Chapter 3 Installation
3.1 General Precautions for Installation .......................................................... 3-1
3.2 Installation Works ........................................................................................ 3-1
3.2.1 Unpacking ............................................................................................................ 3-1
3.2.2 Storage ................................................................................................................ 3-1
3.2.3 Transportation ...................................................................................................... 3-1
3.2.4 Preparation for Installation ................................................................................... 3-4
3.2.5 Installation ............................................................................................................ 3-5
3.2.5.1 Installation.................................................................................................... 3-5
3.2.5.2 Shaft Alignment between the Compressor and Driving Machine ................ 3-5
3.2.5.3 Piping Connection ....................................................................................... 3-6
3.2.5.4 Equipment and Devices for Protection of the Compressor ......................... 3-6
3.2.6 Airtightness Test .................................................................................................. 3-7
3.2.7 Lubricating Oil Charge ......................................................................................... 3-7
3.2.7.1 Initial Charge of Lubricating Oil ................................................................... 3-7
3.2.7.2 Additional Charge of Lubricating Oil ............................................................ 3-7
3.2.8 Charge of Refrigerant .......................................................................................... 3-7
3.2.9 Check after Installation ........................................................................................ 3-7
Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil) ................................................................. 4-1
4.1.1 Precautions for Selecting the Lubricating Oil....................................................... 4-1
4.1.2 Recommended Lubricating Oils .......................................................................... 4-1
4.1.2.1 Recommended Lubricating Oils for Ammonia Refrigerant .......................... 4-1
4.1.2.2 Oils for systems using Hydrofluorocarbon refrigerants ............................... 4-2
4.1.3 Change of Lubricating Oil Brand ......................................................................... 4-3
4.1.4 Precautions for Handling lubricating Oil .............................................................. 4-4
4.1.5 Lubricating Oil Management Criteria ................................................................... 4-5
4.1.6 Lubricating Oil Replacement Timing .................................................................... 4-6
4.1.6.1 After Starting the Initial Operation ............................................................... 4-6
4.1.6.2 During Normal Operation............................................................................. 4-6

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2201MYJE-MY-C8-N_2015.04.
Table of Contents
4.2 Precautions for Operation ........................................................................... 4-7

4.2.1 Prevention of Liquid Flow-back Operation........................................................... 4-7
4.2.2 Purging of Non-Condensable Gases ................................................................... 4-7
4.3 When Stopping the Compressor for a Long Time .................................... 4-8
Chapter 5 Maintenance and Inspection

5.1 Precautions for Maintenance and Inspection............................................ 5-1
5.2 Maintenance and Inspection List................................................................ 5-3
5.2.1 Daily Management ............................................................................................... 5-3
5.2.2 Periodic Inspection .............................................................................................. 5-5
5.2.3 Guidelines for the Timing of Compressor Overhaul ............................................ 5-6
5.3 Compressor Disassembly Preparation ...................................................... 5-7
5.3.1 Disassembly Tools and Workplace ..................................................................... 5-7
5.3.2 Replacement Parts .............................................................................................. 5-8
5.3.3 Refrigerant Gas Recovery ................................................................................. 5-11
5.3.4 Removal of Connections to the Unit .................................................................. 5-12
5.3.5 Removal and Lifting the Compressor ................................................................ 5-13
5.3.6 Draining Oil from the Compressor ..................................................................... 5-13
5.4 Disassembly and Inspection ..................................................................... 5-14
5.4.1 Unloader Indicator ............................................................................................. 5-15
5.4.1.1 Disassembly .............................................................................................. 5-15
5.4.1.2 Inspection .................................................................................................. 5-17
5.4.2 Unloader Cover .................................................................................................. 5-18
5.4.2.1 Disassembly .............................................................................................. 5-18
5.4.2.2 Inspection .................................................................................................. 5-19
5.4.3 Unloader Piston and Unloader Cylinder ............................................................ 5-20
5.4.3.1 Disassembly .............................................................................................. 5-20
5.4.3.2 Inspection .................................................................................................. 5-21
5.4.4 Shaft Seal Block ................................................................................................ 5-22
5.4.4.1 Disassembly .............................................................................................. 5-22
5.4.4.2 Inspection .................................................................................................. 5-23
5.4.5 Bearing Cover .................................................................................................... 5-24
5.4.5.1 Disassembly .............................................................................................. 5-24
5.4.6 Separating High-stage and Low-stage Blocks................................................... 5-25
5.4.6.1 Disassembly .............................................................................................. 5-25
5.4.7 Gear Coupling .................................................................................................... 5-25
5.4.7.1 Disassembly .............................................................................................. 5-25
5.4.7.2 Inspection .................................................................................................. 5-26
5.4.8 Removing Oil Injection Pipe............................................................................... 5-27
5.4.8.1 Disassembly ............................................................................................... 5-27
5.4.9 Balance Piston ................................................................................................... 5-28
5.4.9.1 Disassembly .............................................................................................. 5-28
5.4.9.2 Inspection .................................................................................................. 5-28
5.4.10 High-stage Suction Cover and Side Bearings ................................................... 5-29

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2201MYJE-MY-C8-N_2015.04.
Table of Contents
5.4.10.1 Disassembly .............................................................................................. 5-29

5.4.10.2 Inspection .................................................................................................. 5-30
5.4.11 Low-stage Suction Cover and Side Bearings .................................................... 5-31
5.4.11.1 Disassembly .............................................................................................. 5-31
5.4.11.2 Inspection .................................................................................................. 5-31
5.4.12 Thrust Bearing Block ......................................................................................... 5-32
5.4.12.1 Disassembly of the High-stage Thrust Bearing Block ............................... 5-32
5.4.12.2 Disassembly of the Low-stage Thrust Bearing Block ................................ 5-33
5.4.12.3 Inspection (High-stage and Low-stage) ..................................................... 5-33
5.4.13 High-stage Rotors and Main Rotor Casing ........................................................ 5-34
5.4.13.1 Disassembly .............................................................................................. 5-34
5.4.13.2 Inspection .................................................................................................. 5-35
5.4.14 Low-stage Rotors and Main Rotor Casing......................................................... 5-35
5.4.15 High-stage Bearing Head and Main Bearings ................................................... 5-36
5.4.15.1 Disassembly .............................................................................................. 5-36
5.4.15.2 Inspection .................................................................................................. 5-36
5.4.16 Low-stage Bearing Head and Main Bearings .................................................... 5-37
5.4.16.1 Disassembly .............................................................................................. 5-37
5.4.16.2 Inspection .................................................................................................. 5-37
5.5 Reassembly ................................................................................................ 5-38
5.5.1 Unloader Slide Valve and Guide Block.............................................................. 5-40
5.5.2 Bearing Head and Main Bearings ...................................................................... 5-41
5.5.3 Bearing Head and Main Rotor Casing ............................................................... 5-42
5.5.4 Installing the Rotors ........................................................................................... 5-43
5.5.5 Suction Cover and Side Bearings ...................................................................... 5-44
5.5.6 Balance Piston Sleeve ....................................................................................... 5-45
5.5.7 Installing the Suction Cover ............................................................................... 5-46
5.5.8 Thrust Bearing Block ......................................................................................... 5-48
5.5.8.1 End Clearance Measurement .................................................................... 5-50
5.5.8.2 End Clearance Adjustment Procedure ...................................................... 5-51
5.5.8.3 Tightening after Finishing the End Clearance Adjustment ........................ 5-52
5.5.8.4 Installing the Balance Piston ..................................................................... 5-53
5.5.9 Balance Piston Cover and High-stage Unloader Cylinder................................. 5-53
5.5.10 Bearing Cover .................................................................................................... 5-56
5.5.11 Shaft Seal Block ................................................................................................ 5-57
5.5.12 Low-stage Unloader Cylinder ............................................................................ 5-60
5.5.13 Unloader Cover .................................................................................................. 5-61
5.5.14 Coupling the High-stage and Low-stage Blocks ................................................ 5-62
5.5.15 Unloader Indicator ............................................................................................. 5-64
5.5.15.1 Potentiometer ............................................................................................ 5-64
5.5.15.2 Micro-switches and Micro-switch Cam ...................................................... 5-64
5.5.15.3 Reassembly ............................................................................................... 5-65

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2201MYJE-MY-C8-N_2015.04.
Table of Contents
Chapter 6 Troubleshooting
01: Compressor does not start up ............................................................................ 6-1
02: Compressor stops immediately after startup ................................................... 6-1
03: Unusually low pressure (decrease of suction pressure) ................................. 6-2
04: Low oil pressure (low lubricating oil supply pressure) ................................... 6-2
05: Intermediate pressure is unusually high ........................................................... 6-3
06: Unusually high pressure (abnormal discharge pressure) ............................... 6-4
07: Discharge temperature is abnormally high ....................................................... 6-5
08: Leak from mechanical seal ................................................................................. 6-6
09: Squeaking of mechanical seal ............................................................................ 6-7
10: Capacity control position is indicated incorrectly ........................................... 6-7
11: Capacity control malfunction.............................................................................. 6-8
12: Compressor generates abnormal vibration and/or sound .............................. 6-9
Chapter 7 Related Documents

7.1 Development Views, Assembly Sectional Views ...................................... 7-1
7.2 Parts Configuration Table ......................................................................... 7-27
7.3 Tightening Torques for Bolts and Nuts ................................................... 7-34
7.4 About the O-rings Used............................................................................. 7-36
7.4.1 List of O-rings Used ........................................................................................... 7-36
7.4.2 O-ring Materials Used for Screw Compressor ................................................... 7-36
7.5 Tools for Disassembly............................................................................... 7-37
Contact Information
Sales 0ffices/Service Centers ..................................................................... Contact-1
Sales Offices in Japan ........................................................................................... Contact-1
Manufacturing Bases in Japan............................................................................... Contact-1
Global Network....................................................................................................... Contact-2
NORTH AMERICA ........................................................................................................ Contact-2
EUROPE and AFRICA .................................................................................................. Contact-2
ASIA PACIFIC ............................................................................................................... Contact-3
LATIN AMERICA ........................................................................................................... Contact-5

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2201MYJE-MY-C8-N_2015.04.
Chapter 1 Safety
Chapter 1 Safety
1.1 Strict Requirements and Prohibitions
1.1.1 Strict Requirements (Do’s)
1.1.1.1 Do’s on Operation
 Make sure to install safety and protective devices on the package unit.
 Regularly inspect the safety and protective devices if they function properly.
 If the safety or protective devices do not work properly or if this product operates abnormally,
immediately stop the operation and report to the supervisor. Obtain his/her approval and
direction before restarting the compressor.
 If this product stops for unknown reasons, immediately inform your supervisor of it. Obtain
his/her approval before restarting the compressor.
 Some types of refrigerants emit bad smell or toxic gases when they leak. Make sure to
ventilate the air during operation.
 For the properties of refrigerant and lubricating oil (corrosiveness, decomposability or toxicity),
be sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.
 When stopping the operation of this product, close the suction and discharge side shut-off
valves and turn "OFF" the motor (main power), heater power, and control power.
1.1.1.2 Do’s on Maintenance

 Prepare work procedures based on a work schedule. Be sure to perform danger forecasting
before starting the work.
 Before performing the work together with at least one other person, thoroughly confirm each
other's work details and procedures to acknowledge the other worker's movement.
 When troubleshooting during operation or before performing setup, cleaning, maintenance,
or inspection of this product, always turn OFF the main power to the motor and control power
and other devices. Also, lock and tag out them to prevent the power from being supplied
erroneously during operation.
 When troubleshooting during operation or before performing setup, cleaning, maintenance,
or inspection of this product, confirm that the pressure inside this product and the package unit
is at atmospheric pressure.
 Some refrigerants in use generate bad smell or toxic gases, or may cause deficiency of
oxygen. Before starting work, measure oxygen concentration in the work area as necessary.
Ventilate the area well. Be sure to keep the area well ventilated until the work is finished.
 For the properties of refrigerant and lubricating oil (corrosiveness, decomposability or toxicity),
be sure to obtain the Safety Data Sheet (SDS) and follow the relevant information.
 After using tools always restore to designated place and never leave tools in the package unit
1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power

 Attach lockout/tagout mechanism to the main breakers of motor main power and control power.
Lockout/tagout after power off is a very effective means to secure safety. It can prevent the
power source from being turned on by accident by two or more workers which may cause
injury to other worker(s).
Compound 2-stage Screw Compressor 3225**C 1.1 Strict Requirements and Prohibitions
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2201MYJE-MY-C8-N_2015.04.
Chapter 1 Safety
 If there are any possibilities of danger during works (especially during cleaning, maintenance
and inspection, and troubleshooting), turn "OFF" the motor main power and control power, and
perform lockout/tagout.
 In the following situations, workers may neglect to perform power source shutoff or
lockout/tagout. Clearly notify the workers of the necessity of lockout/tagout.
 It is assumed that workers do not perform lockout/tagout before starting work because it is
troublesome, and only turn "OFF" the main motor and control power.
 It is assumed that workers only turn off the main motor and control power and do not
lockout/tagout the main motor and control power, because they judge that there is no
danger.
1.1.1.4 Do’s about Personal Protective Gear

 Prepare and use protective gear complying with the safety standards of the regulations.
 Check the function of each protective gear before using.
 Wear designated clothes such as work outfits, with their cuffs tightly closed.
 Do not wear any neckties or jewelry as there is a risk of being entangled by a movable part or
rotating part. Put on a helmet as your hair may get entangled.
 Do not have anything in your pocket to prevent objects from falling into the machine.
1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances

 Obtain the Safety Data Sheet (SDS) from manufacturers of hazardous and toxic substances.
Check the SDS and follow the handling instructions recommended by the manufacturers to
handle and store those substances.
1.1.1.6 Do’s about Handling Emergency Situations

 Formulate an emergency action plan complying with the regulations, and post it on a safe
place.
1.1.1.7 Do’s about Waste Oil, Fluid, and Materials

 Disposing of refrigerant and oil used for this product are subject to a number of regulations for
the environmental protection purposes. Follow the local, state, federal acts and regulations
and your company's rules when disposing of such waste oil, fluid and materials.
1.1.1.8 Other Do’s

 Clean the floor around the entire refrigerating/cold storage/gas compression package unit.
Provide a safety passage.
 Walk only on the areas set up as a work floor. Also, do not leave tools and cleaning solutions
in that area.
 If water or oil is spilled on this product or the floor, immediately wipe it off to prevent workers
from slipping and getting injured.
Compound 2-stage Screw Compressor 3225**C 1.1 Strict Requirements and Prohibitions
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2201MYJE-MY-C8-N_2015.04.
Chapter 1 Safety
1.1.2 Prohibitions (Don’ts)

 Do not remove or relocate any safety device, including electrical interfaces.
 Do not disable any safety device by short-circuiting or bypassing without any permission.
 Do not leave this product unsafe and unattended, by removing a safety cover or some other
measures.
 Do not touch, clean or lubricate any part of this product which is moving.
 Do not touch relays or electric systems such as terminal block with bare hands when turning
on the power.
1.2 Warnings
The warning messages described in this manual warn dangerous situations that may arise during work
by using the following four categories.
Neglecting such warnings may cause accidents, resulting in personal injury or even death.
Also, this product or its auxiliary equipment may be heavily damaged. Therefore, be sure to always
observe the instructions of the warnings.
Table 1-1 Warning Symbols and their Meanings
Symbol Meaning
Indicates a hazardous situation which, if not avoided, could very likely cause
serious injury or death.
Indicates a potentially hazardous situation which, if not avoided, may cause serious
injury or death.
Indicates a potentially hazardous situation which, if not avoided, may cause minor
or moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in
property damage.
Compound 2-stage Screw Compressor 3225**C 1.2 Warnings

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Chapter 1 Safety
1.3 Residual Risks

The following information assumes that this product is operated or inspected/maintained while being
used in general refrigerating/cold storage/gas compression package units.
Note that all hazardous sources cannot be predicted for the applications mentioned.
Devise appropriate countermeasures for hazardous sources in your systems.
Table 1-2 Hazardous Sources

Countermeasures in
Countermeasures in
Hazardous sources Predicted hazard cleaning, inspection,
operation
and parts exchange
A Motor and  Caught in due to contact  Install coupling cover  Turn off motor main
compressor coupling and prohibit opening. power and control
Refer to Figure 1-1  Keep away. power, and conduct
lockout/tagout.
B Motor terminals  Electric shock caused by  Keep away.  Turn off motor main
contact with live wires or  Do not open terminal power and control
electrical leakage boxes. power, and conduct
 Do not touch terminal lockout/tagout.
boxes.
C Compressor  Frostbite due to contact  Keep away and do not  Wear protective gear.
low-stage side  Contact with or inhalation of touch.  Work under room
suction casing hazardous substances  Wear protective gear. temperature.
Refer to Figure 1-1 generated by leakage of  Detect gas leakage.
refrigerant or the like
D Compressor  Burn injury due to contact  Keep away and do not  Wear protective gear
intermediate piping  Contact with or inhalation of touch  Work in temperatures
(low-stage discharge hazardous substances  Wear protective gear below 40 °C
port to high stage generated by leakage or  Gas leakage detection
suction port) spout of refrigerant or the like
Refer to Figure 1-1
E Compressor  Burn injury due to contact  Keep away and do not  Wear protective gear.
high-stage side  Contact with or inhalation of touch.  Work at a temperature
discharge casing and hazardous substances  Wear protective gear. of not higher than 40°C.
discharge piping generated by leakage or  Detect gas leakage.
spout of refrigerant or the like
F Check valves/service  Contact with or inhalation of  Sufficient ventilation  Sufficient ventilation
valves and joints on hazardous substances  Indicate valve  Wear protective gear.
each section of the generated by mishandling or open/close state.  Tagout for controlled
package unit leakage  Keep away and do not valve
 Frostbite or burn due to touch.
contact  Wear protective gear.
G Solenoid  Electric shock caused by  Install protective cover  Turn off each breaker
valves/electric valves contact with live wires or on terminals, and and the control power,
on each section of the electrical leakage prohibit opening. and conduct
package unit  Pinched due to contact with  Keep away and do not lockout/tagout.
driving part touch.  Wear protective gear.
 Wear protective gear.
H Electric components  Electric shock caused by  Install protective cover  Turn off each breaker
in each section of the contact with live wires or on terminals, and and the control power,
package unit (oil electrical leakage prohibit opening. and conduct
heater, protective  Pinched due to contact with  Keep away and do not lockout/tagout.
switch, etc.) driving part touch.  Wear protective gear.
 Wear protective gear.
I Package unit oil  Contact with hazardous  Sufficient ventilation  Sufficient ventilation
drains substances generated by  Keep away and do not  Wear protective gear.
leakage or spout touch.  Work at a temperature
 Burn caused by contact with  Wear protective gear. of not higher than 40°C.
high-temperature fluid
J Noises  Damage caused by noise  Wear protective gear. —
Compound 2-stage Screw Compressor 3225**C 1.3 Residual Risks

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Chapter 1 Safety
Figure 1-1 Locations of Hazardous Sources (compressor)
Photo 001 Locations of Hazardous Sources (compressor)
Compound 2-stage Screw Compressor 3225**C 1.3 Residual Risks

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Chapter 1 Safety
1.4 Safety Devices

For safe use and protection of this product, make sure to attach safety devices to this product in
accordance with the regulations and the following instructions.
Safety devices cannot be kept in normal condition unless inspected and maintained at regular intervals.
Their maintenance and inspection need to be performed as an important part of the
maintenance/inspection work project. Provide users of this product with necessary information on the
safety devices, for example, types of the safety devices, installation position, function, and inspection
method of 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 repair or replace
safeties before starting this product.
1.4.1 Emergency Stop Button

 Overview/Function/Purpose
The emergency stop buttons are used to stop the compressor operation immediately if an
emergency occurs in this product.
 Installation Positions
On the control board and in the operation control room
 Stop/Restoration 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/Cycle
The emergency stop buttons must be tested before commissioning and must also be periodically
re-tested after that. 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 Breakers of Motor Main Power and Control Power

(with Lockout/Tagout Mechanism)
Turn off the main motor and control power, and if there is any possibility of danger during work
(especially during cleaning, maintenance, inspection, or troubleshooting), lockout/tagout devices
must be used on the breakers of the main motor and control powers to prevent injuries to workers in
case the power is turned on accidentally during work.
 Methods of Performing and Releasing Lockout/Tagout

Make sure to clearly notify methods of performing and releasing lockout/tagout referring to the
regulations created by Occupational Safety & Health Administration (OSHA) or local governing
body.
The inspection procedures and the inspection interval for the lockout/tagout devices, must be
clearly defined and the information provided to the user of this product.
Compound 2-stage Screw Compressor 3225**C 1.4 Safety Devices

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Chapter 1 Safety
1.4.3 Compressor Protective Devices
 Be sure to adjust the set values and check operation of the protective devices at
the commissioning.
These protective devices are used to protect this product.
 Protecting from discharge temperature rise (DT)
This device activates and stops the compressor operation when the compressor discharge
temperature gets equal to or higher than the set value.
Install a temperature sensing port to the discharge pipe.
 Protecting from oil temperature rise (OT)

This device activates and stops the compressor operation when the compressor oil
temperature gets equal to or higher than the set value.
Install a temperature sensing port to the oil supply pipe of the package unit (after the oil
cooler).
 Protecting from high pressure (HP)

This device activates and stops the compressor operation when the compressor discharge
pressure gets abnormally high due to mishandling of the compressor or suspension of water
supply to the condenser. This device prevents explosion of the equipment and components.
Install a pressure sensing port to the discharge pipe.
 Protecting from intermediate pressure (IP)

This device activates when the intermediate pressure of the compressor gets equal to or
higher than the set value and properly controls the compressor. In some cases, this device
stops the compressor operation. Install a pressure output port to the package unit's
intermediate gas pipe (or compressor's intermediate gas pressure output port).
 Protecting from suction pressure drop (LP)

This device activates and stops the compressor operation when the compressor suction
pressure gets equal to or lower than the set value.
Install a pressure sensing port to the suction pipe.
 Protecting from oil pressure (OP)

This device activates and stops the compressor operation when the differential pressure to
supply oil to the compressor (= lubrication oil supply pipe pressure − compressor discharge
pressure) gets equal to or lower than the set value, due to insufficient lubricating oil, clogged
filter or mixture of refrigerant into the lubrication oil. This device prevents the sliding portion
from being abnormally worn or seized.
Install a pressure sensing port to the package unit's oil supply pump (after the oil pump) and
the discharge pipe.
 Protecting from motor over-current (OCR)

This device activates and applies appropriate control when the current gets equal to or higher
than the set level flows. In some cases, this device stops the compressor operation.
This device is normally installed inside the control panel.

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Chapter 1 Safety
 Connection Positions and Settings

Specify the connection position and setting for each compressor protective device, and make sure
to provide users of this product with them.
Make sure that the set values do not exceed the operating limits shown in Chapter 2, section 2.3.2
and Table 2-2 in this manual.
Compressor protective devices require operation tests and confirmation of the settings calibration
before commissioning as well as at regular intervals.
Specify the inspection methods/intervals of the compressor protection devices, and make sure to
provide users of this product with such information.
 In the operation test, check that alarms and protective devices operate normally
by using devices such as pressure tester. Do not operate the compressor with all
the valves closed, or in any other dangerous conditions.
 If the protection from oil pressure (OP), high pressure (HP) activates, do not
restart operation until the cause of activation is removed.

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2.1 Overview of the 3225**C

The 2-stage compression system, which has hitherto required two units of standard-type screw
compressor for its embodiment, can now be realized by a single unit of compound 2-stage screw
compressor.
Generally, screw compressors use oil injection to keep discharge temperature at a low level during
operation without loss of volumetric efficiency even at high compression ratios. It can, therefore, be
operated with a single-stage compression system even at evaporative temperatures near -40°C.
However, for normal use at low temperatures, a 2-stage compression system is applied in order to
improve kW/RT (ratio of power consumption versus cooling ability). If the 2-stage compression system
is configured with standard-type screw compressors, at least two screw compressor units need to be
installed, one on the high-stage and the other on the low-stage, which inevitably requires double
installation of the entire system including machinery, motors, utilities, etc.
This 2-stage screw compressor is produced to solve this problem. It is a single unit that has two
single-stage compressor units combined into one.
The 3225**C model has a capacity control mechanism for startup load reduction on the high-stage, and
a capacity control mechanism for coping with load change on the low-stage.
In addition, there are four rotor lengths for the low-stage and three rotor lengths for the high-stage.
Moreover, customer is able to select each low-stage and high-stage volume ratio from two
specifications. Employing these combinations of each specification, 3225**C is providing a high
versatility that can satisfy a wide range of operation conditions required by different applications at the
load side. Therefore, the 3225**C models are the long-selling products which last to
more than 30 years since the developed in 1982 as the large sized compound 2-stage screw
compressor.
2.2 Model Designation of the Compressor

This manual describes 3225**C-*B*-51 and 3225**C-*B*-61 models.
The meaning of the type designation, which is engraved on the MODEL column of the compressor
nameplate, is as follows.
*3225**C-*B*-51/61
5: Power frequency (6: 60Hz)
1: Indicates that it is a motor directly connected type.
* Unless specifically specified, machines manufactured in
September, 2010 or after do not have this indication engraved
on their nameplate.
Vi (volume ratio) specified for the high-stage discharge port,
standard value of which is L or M
Means a booster (low-stage machine)
Vi (volume ratio) specified for the low-stage discharge port, standard
value of which is L or M
Stands for Compound (compound 2-stage machine)
Specifications of high-stage rotor length, which is L, M or S
Specifications of low-stage rotor length, which is LL, L, M or S
High-stage rotor diameter of 250
Low-stage rotor diameter of 320
Indicates working fluid
(Example: N = Ammonia, F= Fluorocarbon, P = Propane, HE = Helium)
Compound 2-stage Screw Compressor 3225**C 2.1 Overview of MYCOM 3225**C

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2201MYJE-MY-C8-N_2015.04.
2.3 Compressor Specifications

2.3.1 Standard Specifications
Table 2-1 3225**C Screw Compressor Specifications (1/2)

Model
Items
LLLC LLMC LLSC LLC LMC LSC
Product mass kg 4150 4100 4020 3440 3390 3310
Low-stage swept volume 6740 6740 6740 5700 5700 5700
m3/h
@3550 min-1 /2950 min-1 /5600 /5600 /5600 /4740 /4740 /4740
High-stage swept volume 2840 2380 1900 2840 2380 1900
m3/h
@3550 min-1 /2950 min-1 /2360 /1980 /1580 /2360 /1980 /1580
Working fluid (Refrigerant) - Ammonia, Hydrofluorocarbon, etc.
Design pressure MPa 2.6
Capacity control (Actual load) % 10 to 100
Rotation direction - Counterclockwise viewed from motor

Low-stage suction
- JIS 20K 350A (14”)
flange
Low-stage discharge
- JIS 20K 200A (8”)
flange
High-stage suction
- JIS 20K 200A (8”)
flange
High-stage discharge
- JIS 20K 150A (6”)
flange
Journal lubrication
- JIS 20K 40A (1-1/2”)
(low-stage)
Journal lubrication
- JIS 20K 25A (1”)
(High-stage)
Connected Oil injection
- JIS 20K 20A (3/4”)
pipe size lubrication
Oil return Inlet
- JIS 20K 32A (1-1/4”)
(Rotor casing)
Oil return outlet
(Low-stage Bearing - JIS 20K 32A (1-1/4”)
cover)
Oil return outlet
(High-stage Suction - JIS 20K 20A (3/4”)
cover)
Low-stage capacity
- Load: Rc3/8, Unload: Rc3/8
control
High-stage capacity
control
 Unless otherwise noted, the pressure unit MPa represents the gauge pressure
in this manual.
 For limits of working temperature and pressure, see "2.3.2 Operation Limits" in
this manual.
Compound 2-stage Screw Compressor 3225**C 2.3 Compressor Specifications

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2201MYJE-MY-C8-N_2015.04.
Table 2-2 3225**C Screw Compressor Specifications (1/2)

Model
Items
MLC MMC MSC SLC SMC SSC
Product mass kg 3290 3240 3160 3150 3100 3020
Low-stage swept volume 4760 4760 4760 3820 3820 3820
m3/h
@3550 min-1 /2950 min-1 /3960 /3960 /3960 /3170 /3170 /3170
High-stage swept volume 2840 2380 1900 2840 2380 1900
m3/h
@3550 min-1 /2950 min-1 /2360 /1980 /1580 /2360 /1980 /1580
Refrigerant - Ammonia, Hydrofluorocarbon, etc.
Design pressure MPa 2.6
Capacity control (Actual load) % 10 to 100
Rotation direction - Counterclockwise viewed from motor

Low-stage suction
- JIS 20K 350A (14”)
flange
Low-stage discharge
- JIS 20K 200A (8”)
flange
High-stage suction
- JIS 20K 200A (8”)
flange
High-stage discharge
- JIS 20K 150A (6”)
flange
Journal lubrication
- JIS 20K 40A (1-1/2”)
(low-stage)
Journal lubrication
- JIS 20K 25A (1”)
(High-stage)
Connected Oil injection
- JIS 20K 20A (3/4”)
pipe size lubrication
Oil return Inlet
- JIS 20K 32A (1-1/4”)
(Rotor casing)
Oil return outlet
(Low-stage Bearing - JIS 20K 32A (1-1/4”)
cover)
Oil return outlet
(High-stage Suction - JIS 20K 20A (3/4”)
cover)
Low-stage capacity
control
High-stage capacity
control
 Unless otherwise noted, the pressure unit MPa represents the gauge pressure
in this manual.
 For limits of working temperature and pressure, see "2.3.2 Operation Limits" in
this manual.

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2201MYJE-MY-C8-N_2015.04.
2.3.2 Operation Limits

Table 2-3 Operation Limits of 3225**C
Items Operation Limits

Maximum discharge pressure MPa 1.96
Minimum suction pressure MPa −0.080
Maximum intermediate pressure MPa 0.588
Minimum intermediate pressure - > Suction pressure
Oil supply pressure
･ Maximum journal lubrication pressure MPa Discharge pressure + 0.39
Discharge pressure +0.049 and
･ Minimum journal lubrication pressure MPa
Suction pressure +0.49
･ Minimum oil injection lubrication pressure MPa Suction pressure +0.49
Maximum Suction temperature °C 85
Minimum suction temperature °C −60
Maximum low-stage discharge temperature °C 90
Maximum high-stage discharge temperature °C 100
Maximum oil supply temperature °C 60
Minimum oil supply temperature °C 30
-1
Maximum male rotor rotation speed min 3600
Minimum male rotor rotation speed min-1 1450
Note : Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual.
 If operation at partial load, which is not greater than 30 % of the indicated load, is
continued for a long time except when starting up the machine, abnormal noises
or vibration may be generated. So avoid such operation.
 Repeated startup and stop in a short period is harmful not for the startup devices
and electric machinery but also for the compressor itself. For information on the
start/stop limitations, refer to each instruction manual. Wait at least 15 minutes
after stopping the compressor before restarting it.

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2201MYJE-MY-C8-N_2015.04.
2.3.3 Outer Dimensions
Figure 2-1 Outer Dimension 3225LLLC

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2201MYJE-MY-C8-N_2015.04.
Figure 2-2 Outer Dimension 3225LLMC

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2201MYJE-MY-C8-N_2015.04.
Figure 2-3 Outer Dimension 3225LLSC

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2201MYJE-MY-C8-N_2015.04.
Figure 2-4 Outer Dimension 3225LLC

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2201MYJE-MY-C8-N_2015.04.
Figure 2-5 Outer Dimension 3225LMC

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2201MYJE-MY-C8-N_2015.04.
Figure 2-6 Outer Dimension 3225LSC

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Figure 2-7 Outer Dimension 3225MLC

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Figure 2-8 Outer Dimension 3225MMC

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Figure 2-9 Outer Dimension 3225MSC

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Figure 2-10 Outer Dimension 3225SLC

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Figure 2-11 Outer Dimension 3225SMC

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2201MYJE-MY-C8-N_2015.04.
Figure 2-12 Outer Dimension 3225SSC

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2201MYJE-MY-C8-N_2015.04.
2.4 Structure of Compressor
 For names and locations of each part of the compressor, refer to Section 7.1 "Development
Views, Assembly Sectional Views" and Section 7.2 "Parts Configuration Table" in this manual.
2.4.1 Sectional View Suction port

Suction port
High-stage capacity
control mechanism
Low-stage
capacity control
mechanism
High-stage suction port Discharge port Low-stage

discharge port
Shaft seal block
Low-stage
High-stage compressor compressor
Figure 2-13 3225**C Screw Compressor Sectional Views
The 3225**C model, a compound 2-stage compressor, consists of two compressors, (i) a low-stage
compressor which suctions gas, working fluid, from the refrigerating unit and compresses (pressure-raises)
the gas and (ii) a high-stage compressor which furthermore compresses the gas that has been
pressure-raised by the low-stage compressor and sends the resulting gas to the equipment side.
In each casing (low-stage, high-stage), two screw rotors are supported on both ends by bearings. They are
meshed with each other in a joint assembly. These two screw rotors are a set of a male rotor having 4
protruding lobe profiles (M rotor) and a female rotor having 6 concave lobe profiles (F rotor). They conduct
compressing according to the mechanism explained below.
The standard compressor's M rotor is driven by a 2-pole motor; it operates at 3000 min-1 (50 Hz) or 3600
min-1 (60 Hz). F rotor operates at 2000 min-1 (50 Hz) or 2400 min-1 (60 Hz), conforming to the operation of M
rotor.
* The actual speed of a motor is less than its calculated speed (synchronous speed). This difference is
caused by slipping of the motor rotor.
The shaft of the low-stage compressor's M rotor which is linked with the motor has a shaft seal block that
keeps gas and lubricating oil from escaping from inside the compressor.
For high efficient operation, the 3225**C model has a capacity control mechanism for coping with load
change on the low-stage, and a capacity control mechanism for reducing startup load on the high-stage.
Compound 2-stage Screw Compressor 3225**C 2.4 Structure of Compressor

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2.5 Mechanisms
2.5.1 Basics of the Screw Compressor

The screw compressor is categorized as a positive displacement rotary compressor.
As shown in Figure 2-14, the refrigerant (gas) is continuously compressed by the 3-dimensional spaces
that are formed by a pair of male and female screw rotors (with different sectional profiles) and the
casing, as the spaces change continuously.
The rotor having 4 protruding lobe profiles is called a male or M rotor, and the rotor having 6 concave
lobe profiles is called a female or F rotor. In this manual, they are referred to as M rotor and F rotor.
The compressor is driven by the motor connected to the shaft of the M rotor.
Figure 2-14 Compressor Mechanism
2.5.2 Suction Process

As shown in Figure 2-15, the rotors with different lobe profiles are engaged. As the rotors turn, the
volume between the M and F rotor lobe profiles and the compressor casing gradually increases starting
from the suction side.
As the rotation continues, at a certain point when the volume reaches its maximum, the rotors isolate
the gas (volume), which is enclosed by the rotors and the compressor casing, from the suction port and
then continues rotation.
Figure 2-15 Suction Process
Compound 2-stage Screw Compressor 3225**C 2.5 Mechanisms

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2.5.3 Compression Process

As the rotors rotate further, the volume between the rotor lobes decreases while the sealing line moves
toward the discharge side, which compresses the trapped refrigerant gas.
Figure 2-16 Compression Process
Figure 2-17 Discharge Process

2.5.4 Discharge Process
The volume between the rotor lobes decreases to a level predetermined by the discharge port. With the
rotations of the rotors, the compressed refrigerant gas is pushed out to the discharge port.
2.5.5 About Volume Ratio (Vi)

Volume ratios (Vi) of C-series screw
compressors are indicated in performance tables
or catalogs by using port symbols L and M.
The volume ratio represented by each symbol is
as follows:
L=2.63, M=3.65.
Which volume ratio (L or M) should be used is

decided according to operating conditions. If the
compressor is used with a volume ratio that does
not match operating conditions, operation will go
inefficiently wasting the power.
The relationship between volume ratios and
generally used compression ratios is as follows:
Figure 2-18 Volume Ratio

κ
（Vi）＝ πi ＝Pd/Ps κ= Cp/Cv of refrigerant gas
Vi = Design volume ratio πi = Design compression ratio
As Vi is affected by the constant of the refrigerant gas, its value that corresponds to the compression
ratio will change depending on the refrigerant gas.

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(A) Properly adapted Vi to load condition
(B) Improperly adapted Vi to load condition
Figure 2-19 Relationship between Volume ratio (Vi) and Operation Conditions

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2.5.6 Capacity Control Mechanism

The capacity control mechanism, by moving a slide valve, lets suction gas (immediately before
compressed) bypass and advance to the suction side, to help shorten the rotor portion used for
compression. The slide valve is located at the bottom of the casing in which the rotors mesh together,
and is constructed to move parallel to the rotor shaft. This movement is changed by a cam mechanism
into rotation movement. Its position (namely, capacity control ratio) is indicated externally and, at the
same time, fed back to the automatic control circuit by changing the electric resistance.
Figure 2-21 Slide Valve in the

Main Rotor Casing
Figure 2-20 Capacity Control Mechanism
2.5.7 Bearings and Balance Piston

For the load acting on the rotor perpendicular to the shaft, sleeve-type white metal-lined bearing is used.
For the load acting along the shaft direction, face-to-face combination type of angular contact ball
bearings is used.
Special care is taken to cope with the load acting along the shaft direction. Because the M rotor is a
kind of helical gear and also because the thrust force produced by discharge pressure is larger than
that for F rotor, the load applied onto the M rotor is reduced by using not only a thrust bearing but also a
balance piston that applies pressure from the opposing direction.
2.5.8 Shaft Seal Block

To prevent refrigerant gas and oil leakage, a mechanical seal assembly is used for the shaft seal of the
M rotor.
Mechanical seal assembly is mainly composed of "rotating ring" installed on the rotor shaft and
"stationary ring" installed in the seal cover. Rotating ring rotates with the shaft, and slides each other
with the stationary ring while maintaining a micron class gap. The sliding each other place is called as
the sliding surface.
For example, the BBSE (Balance Bellow Single Seal) which is currently used as standard seal,
employs a stationary ring (mating ring) made of special cast iron, a rotating ring made from carbon, and
O-rings for the packing.

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2.6 Gas and Oil Flow

The compression process of the screw compressor is as described in the preceding paragraphs.
Gas of the compound 2-stage screw compressor 3225**C is sent from the evaporator, and passes
through the strainer and check valve. It is drawn in from the upper central area (1) of the compressor,
compressed at the low-stage side (2), and then discharged at (3).
(3) and (4) are connected with a pipe. At the mid point of the pipe, that gas is mixed with the gas from
liquid cooler which was used for super-cooling.
Lubricating oil injected at the low-stage is, while kept mixed with gas, suctioned from (4) into the
high-stage.
After being compressed at (5), the gas mixed with lubricating oil is discharged from (6), and is sent from
the oil separator to the condenser.
Even if without intermediate gas cooling, oil provides cooling effect.
So, the high-stage discharge temperature is maintained at a temperature not higher than 90°C.
Figure 2-22 Gas Flow
Compound 2-stage Screw Compressor 3225**C 2.6 Gas and Oil Flow
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 Oil Supply Route

As shown in Figure 2-23, lubricating oil is split into five flows. After completing each role, the oil
flows to the rotor messing part of the high-stage, and in addition to return to the low-stage rotor
meshing part through the external piping. At last, both oil mixed with compressed gas and
discharged from the compressor.
In standard configuration, oil injection is not performed at the high-stage.
Figure 2-23 3225**C Oil Supply Route
Compound 2-stage Screw Compressor 3225**C 2.6 Gas and Oil Flow
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3.1 General Precautions for Installation
 This chapter (Installation) assumes that the compressor is installed to a standard refrigeration /
cold storage/gas compression package unit.
If the package unit you are actually using is not the standard type refrigeration/cold storage/gas
compression package unit, 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 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.
 Before installing the compressor, please read this chapter and related documents attentively
and fully understand their contents.
 Electrical works should be performed only by electrical engineers.
3.2 Installation Works

3.2.1 Unpacking
Confirm whether a compressor does not have abnormality including the damage.
 If there are abnormalities or deficient parts on the compressor, please contact our sales offices
or service centers immediately.
 Unnecessary packing materials should be discarded according to the laws and ordinances, or
your company's rules.
3.2.2 Storage
If you need to store the compressor before installation, perform the followings:
 Store it indoors.
 Infuse nitrogen gas into the compressor and seal it. (Pressure: Approximately 0.15 Mpa )
3.2.3 Transportation
 Dropping of the lifted compressor may cause death or serious injury to the worker.
Do not stand under the lifted compressor.
1. For lifting the compressor within the safety limit, use lifting equipment and tools appropriate for the
mass of compressor.
2. Secure sufficient space for safe lifting.
3. Always check the wire ropes before using them. Thoroughly check the wire ropes for problems
such as kinks, knots and broken strands. Do not perform lifting before confirming the safety of the
wire ropes. If you cannot make a correct evaluation or judgment, entrust an expert to check.
Compound 2-stage Screw Compressor 3225**C 3.1 General Precautions for Installation
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4. To lift the compressor, attach the wire ropes to the appended eye bolts by using appropriate
shackles and hooks. Refer to Figure 3-1 and Photo 002 in next page.
Use the eye bolts only for lifting the compressor. Do not use the eye bolts when lifting the
compressor together with additive equipment.
 The compressor eye bolts must not be used for lifting the package unit. To lift the
package unit, use the lifting chains provided around the base or other lifting means
provided on the base.
5. Check path of compressor installation to make sure it is free of obstacles in consideration of the
compressor size.
6. Before lifting, check that the hook is located above the gravity center of the compressor.
7. Direct all the workers to stay clear of the work site before lifting.
8. Before lifting the compressor, alert all workers in area of dangers during lifting process by signal
(such as calling at the beginning of the work or making a signal by hand). Do not lift the
compressor unless the signals (such as calling out or hand signals) are completely understood by
the workers at site.
9. Slowly reel up the wire ropes until immediately before the compressor leaves the ground.
10. Then, reel 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.
11. Be sure to lift up the compressor slowly. If it is lifted rapidly, it may damage the lifting tools such as
wire ropes or a part of the compressor.
12. When the lifting work starts, observe to see if wire ropes and lifting tools are normal. Be sure that
the compressor is not tilted.
13. When moving the lifted compressor, always use guiding ropes.
14. When moving the compressor, turn away workers from the movement direction and check safety.
15. Do not lift the compressor above the safety passage unless absolutely necessary.
16. Do not lower the compressor on the safety passage. Always keep the safety passage free of
obstacles.
17. Remove any obstacles before lowering the compressor onto the ground. The compressor should
not be tilted or unstable.
18. Before lowering the compressor, announce to the workers around the working area in advance.
19. When lowering the compressor onto two or more blocks, align the tops of blocks so that the
compressor becomes stable horizontally on them.
20. Slowly lower the lifted compressor so that it is not damaged by shock.
Compound 2-stage Screw Compressor 3225**C 3.2 Installation Works

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 Outer Dimensions, Mass and Lifting Position
3225LLLC 3225LLMC 3225LLSC 3225LLC 3225LMC 3225LSC

Product mass (kg) 4150 4100 4020 3440 3390 3310
L (mm) 2960.5 2927.5 2820.5 2863.5 2830.5 2723.5
3225MLC 3225MMC 3225MSC 322SLC 322SMC 3225SSC
Product mass (kg) 3290 3240 3160 3150 3100 3020
L (mm) 2776.5 2743.5 2636.5 2604.5 2571.5 2464.5
Figure 3-1 Outer Dimensions, Mass and Lifting Position of Compressor
Photo 002 Lifting Position

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3.2.4 Preparation for Installation

 Installation Space
Secure sufficient working space for easy operation, cleaning, maintenance, and inspection.
 Illumination
Prepare illumination devices which allow easy operation, cleaning, maintenance, and inspection.
 Ventilation
If natural ventilation is insufficient, install ventilation fans according to the relevant regulations.
 Piping
Table 3-1 List of Connecting Pipes (Compressor)
Item Dimensions Remarks

Suction gas inlet JIS 20K 350A (14")
Low-stage gas outlet JIS 20K 200A (8")
High-stage gas inlet JIS 20K 200A (8")
High-stage discharge gas outlet JIS 20K 150A (6")
Lubricating oil inlet for low-stage bearing (journal) JIS 20K 40A (1-1/2"）
See Figure 3-2.
Lubricating oil inlet for High-stage bearing (journal) JIS 20K 25A (1"）
Oil inlet for oil injection JIS 20K 20A (3/4"）
Oil return inlet JIS 20K 32A (1-1/4"）
Oil return outlet of low-stage JIS 20K 32A (1-1/4"）
Oil return outlet of High-stage JIS 20K 20A (3/4"）
Lubricating oil inlet for low-stage capacity control Rc3/8 same as loading
Lubrication oil inlet for high-stage capacity control Rc3/8 and unloading
D t g C N-h y
20A 100 4 51 75 4-M12×P1.75 21
25A 125 5 61 90 4-M16×P2 24
32A 135 5 71 100 4-M16×P2 30
40A 140 5 76 105 4-M16×P2 22
150A 305 5 216 260 12-M22×P2.5 35
200A 350 5 261 305 12-M22×P2.5 40
350A 540 5 480 480 16-M30×P3 (Special thread) 50
Figure 3-2 JIS20K Flange Dimensions of Compressor (mm)

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3.2.5 Installation
3.2.5.1 Installation
Check that the surface of the package unit, where the compressor is to be installed, is even and
horizontal. If it is uneven and non-horizontal, tightening the bolts may lead to compressor deformation,
which may hinder normal operation.
3.2.5.2 Shaft Alignment between the Compressor and Driving Machine
 Turn off the main power and control power of the driving machine before shaft alignment
work between the compressor and the driving machine. Be careful so that the power of
instruments does not turn on during shaft alignment work. If the power turns on during
shaft alignment work, the driving machine starts moving and there is a risk of being
entangled with the rotating shaft.
 At the time of turning ON/OFF each electric power breaker, make sure to prevent
electric shock.
 For shaft alignment work between the compressor and driving machine, use designated
tools in normal condition. If a worn or damaged tool or a tool unsuitable for the work is
used, there is a risk of being injured.
In the case shaft alignment between this product and the driving machine, be sure that the deviations
within the range shown in the Table 3–2. However, if alignment tolerance of the driving machine side is
more stringent than Table 3-2, please adjust to the request within the allowable value of the driving
machine side.
Table 3–2 Tolerance of Misalignment
Tolerance
Offset 6/100 mm
Angularity 3/100 mm (reference: Φ100 mm)
The Figure 3–3 and 3–4 show how to measure offset and angularity when performing the centering of
the shafts of the driving machine and this product using a dedicated hub, a dial gauge and a magnet
stand.
Figure 3-3 Measurement of Offset Figure 3-4 Measurement of Angularity

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3.2.5.3 Piping Connection

 Refrigerant Piping
Observe the following when connecting the refrigerant piping to the compressor.
 The compressor is one of the few devices installed within the package unit that have moving
components. These moving components are adversely affected by foreign substances within
the system (scale, dust, spatter, etc.). Therefore, when connecting the piping, do not allow any
of such foreign substances to enter inside.
 Some compressors (mainly those for export) are charged with nitrogen gas to prevent rust. Be
sure to release the pressure before starting piping work.
 Be sure not to allow moisture to enter the piping. There is a high risk that it will cause trouble
after the start of operation. Be sure to assemble piping when it is dry.
 Cover flanges are attached to the compressor's low-stage gas outlet and high-stage gas inlet.
After installation, be sure to attach piping (intermediate piping) that links the both connection
ports.
 Improper piping may cause operating problems such as oil not returning to the compressor or
liquid flow-backs.
 When connecting the piping to the compressor, use piping that is the same size as the
compressor connection port. If the pipe size of the piping is smaller than the compressor
connection port, the flow of lubricating oil or refrigerant will be obstructed leading to problems.
 Do not let the mass of the piping connected to the compressor applied onto flanges or joints.
Be sure to prepare proper supports for piping.
3.2.5.4 Equipment and Devices for Protection of the Compressor

 Oil Filter
According to the requirements of the use of the package unit or the standard to apply, install an oil
filter of appropriate filtration precision in the lubrication system of the compressor.
In the case of general applications such as closed-cycle refrigeration systems, we recommend to
use an oil filter with beta ratio in the range of β20 ≥ 150 that conforms to requirements of NAS 1638
class 8 or ISO 4406 17/15/13.
When the package unit requires API 619 4th/5th edition conformity, use an oil filter with beta ratio in
the range of β10≥200.
The oil filter may be clogged just after test operation. We recommend installing two oil filters in
parallel. This will enable replacement of either filter during operation.
 Oil Heater for Oil Separator

To preserve the temperature of the lubricating oil before starting the compressor, install an oil
heater on the oil separator. Make sure to install a protection function (e.g., with thermostat, etc.) to
the oil heater to prevent overheating.
 Suction Strainer
When compatible (inter-soluble) oil is used, the mesh size of suction strainer should be not less
than 200 meshes. When incompatible (non- inter-soluble) oil is used, it should be not less than 100
meshes.
For details about compatible and incompatible oils, see Section 4.1 "Lubricating Oil (Refrigerant
Oil)" in this manual Chapter 4.
During the commissioning, small particles and scale may come from the system. We recommend
installing a finer filter temporarily.

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 Compressor Protective Devices (Safety Devices)

To protect the compressor, install the necessary protective devices as described in Section 1.4.3
"Compressor Protective Devices" in this manual Chapter 1.
3.2.6 Airtightness Test

Perform an airtightness test on the package unit before starting commissioning. To prevent water entry
in the package unit, use nitrogen gas or dry air for the airtightness test.
3.2.7 Lubricating Oil Charge
 TO select the lubricating oil to be used, refer to Section 4.1 "Lubricating Oil
(Refrigerant Oil)" in this manual.
 When refilling lubricating oil, ensure that it is clean and does not contain foreign
matters.
 Be careful that air and water are not mixed in when refilling.
 To ensure that the lubricating oil does not absorb air moisture, keep it indoors in an
airtight container until use.
3.2.7.1 Initial Charge of Lubricating Oil

Depending on the package unit configuration and operating condition, specify the procedure, method
and amount of the initial charge of lubricating oil, and make sure to provide users of this product with
such information.
In determining the procedure and work procedure of the initial charge of lubricating oil, please care oil is
to be filled in the oil filter and oil cooler always.
3.2.7.2 Additional Charge of Lubricating Oil

Specify the procedure of the additional filling of lubricating oil based on the configuration of the package
unit, and make sure to provide users of this product with the information.
3.2.8 Charge of Refrigerant

Depending on the use working fluid and equipment configuration of your package unit, specify the work
procedure that considered safety enough, and conduct the refrigerant initial filling work accordingly.
In addition, specify the procedure of the additional filling of refrigerant, make sure to provide users of
this product with the information.
3.2.9 Check after Installation

Depending on the package unit to which this product is installed, formulate the necessary confirmation
items and methods for package unit after installation and conduct them accordingly before the
commissioning. In addition, make sure to record and keep the results of your confirmation.

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Chapter 4 Operation of Compressor and Unit
Chapter 4 Compressor and Package Unit Operation

4.1 Lubricating Oil (Refrigerant Oil)
Lubrication management is very significant to keep the compressor in a good operating condition.
Take the following notes when managing lubricating oil.
4.1.1 Precautions for Selecting the Lubricating Oil

 Selection of the lubricating oil should depend on the type of the refrigerant, the type of the
evaporator used with the compressor, and the conditions under which the compressor is
operated. Also to be considered when selecting lubricating oil are the properties of the oil that
include not only the viscosity but also such characteristics as compatibility in refrigerant,
separability from refrigerant, low temperature fluidity, high temperature thermal stability, etc.
We therefore recommend contacting our sales offices or service centers for choice of a
specified brand for your system.
 Lubricating oil used for compressors must have a viscosity appropriate for lubricating the
bearings and other components in the compressors. The viscosity to be considered in this case
should be the viscosity the oil shows at the oil inlet of the compressor. The viscosity of the
lubricating oil significantly changes depending on the type of the refrigerant used in combination
with the oil. If the refrigerant dissolves in the oil (or the oil and refrigerant are compatible), the
viscosity of the oil drops to a level remarkably below the level required for operation of the
compressor under some operating conditions. On the contrary, if the refrigerant does not
dissolve in the oil (or the oil and refrigerant are incompatible), the viscosity may become too high
when the supply oil temperature is low. For this reason, the lubricating oil must be selected such
that it is supplied to the compressor with an appropriate viscosity (kinematic viscosity of 13 to 40
mm2/s) in the operating state.
 The circulation of the lubricating oil for the entire system must be considered. After lubricating
and cooling each part of the compressor, the lubricating oil is discharged with refrigerant gas.
Most of the oil which is discharged from this compressor is trapped by the oil separator and is
cycled to the compressor. A small quantity of refrigerant oil goes to the condenser and the
evaporator. The lubricating oil is required to have sufficient fluidity and stability inside each part
in the refrigerating cycle where temperatures differ.
 Note that some lubricating oils cannot be used depending on the combination with the
refrigerant. The following caution is an example case that is required especially attention.
 Be careful since polyolester synthetic oil (POE) must not be used with ammonia
refrigerant.
4.1.2 Recommended Lubricating Oils

When selecting lubricating oil, not only compatibility with refrigerant but also effects on O-rings must be
considered. To prevent compressor malfunctions, we recommend the lubricating oil described below.
4.1.2.1 Recommended Lubricating oils for Ammonia Refrigerant

 Polyalkylene Glycols (PAG) Based Synthetic Oil (compatible oil)
Brand Kinematic viscosity (40°C) mm2/s Manufacturer Type
JOMO Freol PN46 46 JX Nippon Oil and Energy Corporation PAG
Compound 2-stage Screw Compressor 3225**C 4.1 Lubricating Oil (Refrigerant Oil)
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 Mineral Oils (incompatible oils)

Kinematic viscosity
Brand Manufacturer Type
(40°C) mm2/s
SUNISO 3GS 30 Sun Oil Naphthene
SUNISO 4GS 55 Sun Oil base
REFOIL NS 3GS 30 Nippon Oil
GARGOYLE ARCTIC C HEAVY 46 Exxon Mobil
GARGOYLE ARCTIC 300 68 Exxon Mobil
CAPELLA WF46 46 Texaco
CAPELLA WF68 64 Texaco
CP-1009-32 34 CPI Hydrotreated
CP-1009-68 69 CPI paraffinic base
REFLO 46A 46 Petro Canada
REFLO 68A 58 Petro Canada
CAPELLA PREMIUM 67 Texaco
RHT-68 68 Kluber
REFLO XL 59 Petro Canada
 Synthetic Oils (incompatible oils)

Kinematic viscosity
(40°C) mm2/s
Acemire 300 59 Acemire AB
Mycold AB68 53 BVA
ZERICE S46 46 Exxon Mobil
ZERICE S68 68 Exxon Mobil
BERREL FREEZE 46S 46 Matsumura Oil Co., Ltd.
CP-4700-32 31 CPI
CP-4700-68 56 CPI
Gold-Cold 300 53 Golden West
GARGOYLE ARCTIC NH68 64 Exxon Mobil PAO+AB
REFLO SYNTHETIC 68A 62 Petro Canada
Gargoyle arctic SHC 224Note 30 Exxon Mobil PAO
Note
Gargoyle arctic SHC 226(E) 68 Exxon Mobil
Note: Use only a seal of the standard BBSE type.
4.1.2.2 Oils for Systems Using Hydrofluorocarbon (HFC) Refrigerants

 Polyolester synthetic oils (POE) for R404A, R507A and R410A: compatible synthetic
oils
Kinematic viscosity
(40°C) mm2/s
SUNISO SL-68S 67 Sun Oil POE
EMKARATE RL68H 72 Lubrizol
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 Polyolester Synthetic Oil (POE) for R134a: compatible synthetic oil

Brand Kinematic viscosity (40°C) mm2/s Manufacturer Type
JOMO Freol α100 107 JX Nippon Oil and Energy Corporation POE
 When using lubricating oil of a brand not described in this section, or when using
lubricating oil along with refrigerants or gases not described in this Section, please
contact us.
4.1.3 Change of Lubricating Oil Brand

When changing the lubricating oil for another brand for some reason, pay attention to the following:
 The change of lubricating oil brand may cause problems in operating conditions and
the compressor. When changing the lubricating oil brand in use, make sure to
contact us because appropriate steps must be surely followed.
 Package unit composition differs depending on the characteristics of lubricating oil
(compatible/incompatible with refrigerant). As a general rule, changing compatible oil
to incompatible oil or vice versa is not allowed.
 Lubricating oil contains various additives to fulfill necessary lubricating conditions. Types of
additives and their mixing ratio depend on each oil brand. We, therefore, recommend to avoid
mixed use of different brands of lubricating oil. If mixed brands of lubricating oil are used, the
different additives in the lubricating oil may react with each other and produce foreign
substances like slurry.
 If it is necessary to change the brand of lubricating oil, collect as much as oil as possible from
the compressor as well as from the condenser, evaporator, and all other refrigerating unit
components before charging the new lubricating oil. After 100 to 200 hours of operation, replace
the oil again.
 When changing the lubricating oil for one of a different brand, be sure to ask the lubricating oil
supplier whether such change does not cause any problem. In particular, before changing
current lubricating oil for new one by a different supplier, ask both manufacturers for any
possible problems that may result from the lubricating oil change.
 There is no problem in changing the viscosity level within the same brand. However, make sure
that the viscosity grade will not cause problems during operation. (Example ： SUNISO
3GS→SUNISO 4GS)
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4.1.4 Precautions for Handling lubricating oil

 When refilling lubricating oil, ensure that it is clean and does not contain foreign matters.
 Be careful that air and water are not mixed in when refilling.
 To ensure that the lubricating oil does not absorb air moisture, keep it indoors in an airtight
container until use.
4.1.4.1 Precautions for Handling Polyalkylene Glycol (PAG)

PAG oil is much more hygroscopic than mineral oils and any moisture mixed in the oil may lead to rust,
corrosion and wear within the package. When handling PAG oil, pay special attention to the following
points.
 Do not perform oil charging in rainy weather or at a place with high humidity to prevent
absorbing moisture.
 Before charging, remove as much moisture as possible from the system by exhausting it with
a vacuum pump for a sufficient length of time and leaving the system in vacuum condition
overnight.
 Do not open the lid of pail (oil container) until just before charging. Once the can is opened,
finish the oil charge as quickly as possible. (Finish the charge of a single can of oil within 15
minutes.)
 Cover any gaps between the pail opening and the charge hose so that foreign substances or
moisture cannot enter. A more effective way is to substitute any space inside the pail with
nitrogen gas .
 Always charge all oil from the pail. Even if some oil remains, do not use it subsequently.
 If any oil drops on a painted surface, wipe it away as soon as possible. Otherwise the paint
may come off.
4.1.4.2 Precautions for Handling Polyolester (POE) Oil

This type of oil has high hygroscopicity as polyalkylene glycol, and also exhibits hydrolyzability under
high temperature environments. Moisture entry must be avoided. Therefore, special attention must be
paid as with PAG when handling POE.
 Finish the charging in as short a time as possible after opening the pail to minimize exposure
to air.
 Make sure that all oil in a pail is used in a single charging. Any remaining oil must be stored
indoors with the can lid closed tightly. Do not attempt to store it for a long time.
 Because POE can hydrolyze, make sure to perform an oil analysis regularly in the package to
see if any abnormal conditions are present.
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4.1.5 Lubricating Oil Management Criteria

Lubricating oils that are managed by the criteria are classified into the following categories:
(1) Synthetic oils: Polyalkylene glycols (PAG)

(2) Mineral oils: Naphthenic base oils and paraffinic base oils
(3) Synthetic oils: Alkylbenzene (AB) and Polyalphaolefine (PAO)
(4) Synthetic oils: Polyolesters (POE)
 Oil sampling and analysis is recommended every six months.

 If the following control 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 *1 in the following table.
The analysis items and the criteria are shown in the following tables. Please note that these
management criteria may be changed without notice.
Table 4-1 Synthetic Oil (PAG)

Item Criteria
(a) Color phase ASTM color scale: 4.0 or less
(b) Total acid number (TAN) 0.1 mg KOH/g or less
(c) Kinematic viscosity Within ±10 % from that of fresh oil
(d) Water content 2000 mass ppm or less Note1
(e) Degree of contamination Degree of contamination measured by mass method (Millipore value)
shall be 15 mg/100 mL or less
Table 4-2 Mineral Oil and Synthetic Oil (AB, PAO)

Item Criteria
(d) Water content 100 mass ppm or less
Table 4-3 Synthetic Oil (POE)

Item Criteria
(d) Water content 200 mass ppm or less
Note 1: Synthetic oils (compatible with ammonia) are so highly hygroscopic that they can absorb
moisture at the time of sampling. In addition, the ammonia content they have absorbed may
be detected as the water content at the time of the analysis, making it difficult to precisely
measure the water content. Thus, use the criterion value only as a reference.
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4.1.6 Lubricating Oil Replacement Timing
4.1.6.1 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, be sure to sample and analyze the oil after 500
hours of operation.
If it is found as a result of the analysis that the criteria given in Tables 4-1 to 4-3 are not satisfied, the oil
must be replaced.
4.1.6.2 During Normal Operation

Lubricating oils will degrade 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 lubricating oil must be sampled and analyzed every six months. If it is found as a result of the
analysis that the control criteria given in Tables 4-1 to 4-3 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.
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4.2 Precautions for Operation

If the package unit is used in the refrigeration cycle, please keep in mind the contents of this section in
particular.
4.2.1 Prevention of Liquid Flow-back Operation

Liquid flow-back is a phenomenon where refrigerant that did not completely evaporate with the gas
reaches the compressor. Liquid flow-back may cause insufficient lubrication of the compressor,
abnormal vibrations and noises, and abnormal foaming of lubricating oil (too much oil loss). To prevent
liquid flow-back, properly adjust the expansion valve of each liquid cooler.
For details, refer to Chapter 6 "Troubleshooting" in this manual Chapter 6.
4.2.2 Purging of Non-Condensable Gases
 Some types of refrigerants emit bad smells or toxic gases. Make sure to ventilate the
air during work.
 When handling fluorocarbon refrigerants, remember that they are prohibited from
being purged into air by law.
If there is a leak on the low-pressure side of the system, air may enter the package unit.
If non-condensable gas like air enters the package unit, the condensing pressure rises and the energy
consumption increases. This leads to uneconomical operation.
Follow the procedure below to check for non-condensable gases.
1. When the compressor is stopped, allow the cooling water to flow to the unit's condenser for at
least 15 minutes. Check the condensing pressure by using the pressure gauge of the compressor.
2. Check the cooling water temperature.
3. Compare the condensing pressure checked in step 1 above with the refrigerant saturation
pressure that depends on the cooling water temperature (as shown in the table below).
Table 4-4 Typical Refrigerant Temperature and Saturation Pressure
Pressure MPa
Temperature °C
Ammonia R404A R507A R410A R134a
0 0.328 0.509 0.523 0.699 0.192
4 0.396 0.590 0.606 0.807 0.237
8 0.472 0.678 0.696 0.924 0.287
12 0.557 0.775 0.795 1.053 0.342
16 0.652 0.881 0.903 1.193 0.403
20 0.756 0.996 1.021 1.346 0.471
24 0.871 1.121 1.148 1.513 0.545
28 0.998 1.256 1.286 1.693 0.626
32 1.137 1.401 1.435 1.887 0.714
36 1.289 1.559 1.595 2.098 0.811
40 1.454 1.728 1.768 2.324 0.916
■ Unless otherwise noted, the pressure unit MPa represents the gauge pressure in this manual.
4. When the pressure inside the condenser and the refrigerant saturation pressure that depends on
the cooling water temperature are approximately equivalent, non-condensable gases do not exist.
When the pressure inside the condenser is 0.05 MPa or more higher than the refrigerant
saturation pressure that depends on the cooling water temperature, there is a possibility of
non-condensable gases entering the unit. In that case, purge the non-condensable gases from
the condenser.
Compound 2-stage Screw Compressor 3225**C 4.2 Precautions for Operation

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4.3 When Stopping the Compressor for a Long Time

When stopping the compressor for a long period of time, make sure to perform the following steps.
 Turn off the motor main power.

 Turn off the oil heater power and the control power.
 Close the suction stop valve and discharge stop valve.
If the operation stop period is 1 month or longer, perform the following checks.
 Operate the oil pump for 10 seconds per week.

After that, rotate the compressor shaft (10 rotations or more).
 Measure the package unit pressure once per month.
 Check for refrigerant leakage once per month.
When restarting the compressor after an operation stop period of 1 year or longer, check the system for
refrigerant leak and analyze the lubricating oil. If it is found as a result of the analysis that the control
criteria given in this Chapter, Section 4.1.5 Tables 4-1 to 4-3 are not satisfied, the oil must be replaced.
Also check the motor insulation resistance.
Supply power to the oil heater at least 1 day before operation start.
Before starting the operation, confirm that the refrigerant is not condensed in the package unit by
checking the package unit temperature and pressure.
Compound 2-stage Screw Compressor 3225**C 4.3 When Stopping the Compressor for a Long Time
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5.1 Precautions for Maintenance and Inspection
When reading this Section, also refer to Section 1.1 in this manual Chapter 1.
 When entering the machine room for maintenance services, ensure that sufficient
ventilation has been started and measure the oxygen concentration so that there is
no risk of oxygen deficiency. The ventilation must be continued steadily until the
work is completed.
 For performing the inspection work, be sure to prepare safety shoes, protective
glasses, gas mask and other proper protective equipment and do not fail to use
them whenever they are required.
 After stopping the machine and before working on a regular inspection or overhaul,
be sure to shut off the main motor power, control power, and other power to each
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 the operation (tag-out).
 When the compressor is to be overhauled, check that the internal pressure of this
product is at the atmospheric pressure before starting the work.
 When using lifting devices, e.g. a crane, etc. and/or lifting tools, ensure that they
can sufficiently withstand the load.
 When lifting a heavy load object, do not allow anyone’s body to put under it.
 The work to turn each power supply ON/OFF or operate a lifting unit must be
exclusively performed by qualified personnel.
 When using electric tools, ensure that they are properly managed in accordance
with each instruction manual. Especially before using and while using, be sure to
follow the care instructions on the safety of each instruction manual.
 Be sure to use only genuine parts for replacement. Using parts that are
not genuine can cause damage to this product or other devices during operation.
 Do not convert or modify this product or its components without prior permission
from MAYEKAWA. Otherwise, it can lead to an unexpected accident.
 Exercise sufficient care for handling a heavy load, and use such a lifting device as a
crane or work with an adequate number of personnel commensurate with the
magnitude of 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.
 If two or more people are to work together, be sure to clearly define the work
procedures to
 share a common understanding among all workers before performing the work.
 Not only the work to turn each power supply ON/OFF or operate a lifting device, but
also any type of work requiring qualification must be exclusively performed by
qualified personnel.
Compound 2-stage Screw Compressor 3225**C 5.1 Precautions for Maintenance and Inspection
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2201MYJE-MY-C8-N_2015.04.
 When checking the operation data of units and executing other daily maintenance
services, pay particular attention to avoid touching the area heated to a high
temperature causing skin burns or inadvertently moving the handle of a valve
leading to an erroneous operation.
 In the disassembly/inspection workplace, secure a sufficient space for temporary
storage of the removed parts and tools, replacement parts, and for the
disassembling work as well as safety passages, and then put up necessary off-limit
signs.
 In the workplace, secure a sufficient space and refrain from putting tools directly on
the floor or from haphazardly laying wires.
 Keep the floor clean all the time. Leaving the floor smeared with oil and the like
causes it to be slippery and may result in the fall and injury of personnel. Thus, do
not leave it but wipe it off right away.
 Make sure that the temperature of the high temperature sections such as head
covers and discharge lines has been cooled down to normal ambient temperature,
before working on them.
 When disassembling and reassembling the compressor, use the specified tools
properly. Before starting to use those tools, gain the full understanding of their
characteristics and the method for use.
 During the maintenance service, keep the tools clean all the time. Using those tools
smeared with oil increases the risk of slip and fall, leading to an injury. Also during
the service, there is a risk of foreign matters intruding inside the compressor to
cause its damage.
 Parts are slippery with oil. Fully watch out for the risk of any object falling down.
Pay attention to any parts falling down, which could lead to personal injury.
 Before disassembly, inspections, and handling of the compressor, sufficiently

understand the disassembly and assembly procedures.
This manual is not intended to provide complete disassembly and assembly
procedures for the compressor. Instead, it describes only the important points in
relation to the maintenance service of the compressor.
 If complete disassembly and assembly of the compressor are required, please
contact your nearest sales office or service center of MAYEKAWA.
 When removing a part, be careful not to damage it.
 Place the removed parts on a clean workbench in an orderly manner.
 For cleaning parts, use kerosene and/or machine parts cleaner.
 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.
 When separating the assembled compressor casings, sometimes it is difficult to
separate them due to the gasket stuck. In such a case, never hammer in a screw
driver or flat chisel into the gap. Screw jack bolts using the screw holes to separate
the casing each other. When some gap is observed between them, use a scraper
to remove one side of the gasket from the surface.
 Removed bolts from each part should be classified into each used section to
prevent confusion.
Compound 2-stage Screw Compressor 3225**C 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 Item" and
record the results.
Regularly recording the daily operational data in an operation log makes it possible 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 in this way 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.
Table 5-1 Daily Inspection Items
Inspection item Inspection details Checkpoints and actions

Hours of operation hour Total hours of operation  Used to determine the timing of
Compressor
regular maintenance and

inspection
Suction pressure MPa Difference from the pressure  Cleanliness of the cooling pipe
that corresponds to the surface
specified evaporation  Temperature and flow of the items
temperature to be cooled
Intermediate MPa Difference from the normal  If the pressure is too high (or too
pressure pressure during rated operation low), check the conditions of the
high/low-stages.
Discharge pressure MPa Difference from the  Cleanliness of the condenser
condensation pressure for the cooling pipe
specified cooling water  Mixing of non-condensing gas
temperature  Amount and temperature of the
cooling water
Oil supply pressure MPa Difference from the discharge  Whether the differential pressure is
pressure decreasing or not
 Liquid flow-back operation
 Wear of compressor parts
Pressure loss of the MPa Pressure difference between  Contamination of the lubricating oil
oil filter the inlet and outlet ports of the  Clogged oil filter
oil filter
Suction temperature °C Whether upper or lower limit  Temperature and flow of the items
temperature is not exceeded cooled
Suction degree of °C Whether the degree of  Adjustment of expansion valve
superheat superheat is appropriate or not  Insufficient refrigerant circulation
Intermediate °C Whether upper or lower limit  Adjustment of the intermediate
temperature temperature is not exceeded expansion valve
Discharge °C Whether it is within the upper  Mixing of non-condensing gas
temperature limit temperature  Supply oil temperature, insufficient
amount of oil supply
 Compressor failure
Supply oil °C Whether upper or lower limit  Cleanliness of the cooling pipe of
temperature temperature is not exceeded the oil cooler
Capacity control % Normally operation  Damaged coil of the solenoid valve
loading  Improper manual valve adjustment
of the solenoid assembly
Leak at the mL/hr Amount of leak per hour  Mechanical seal failure
mechanical seal
Noise and vibration - Abnormal noise and/or  Compressor failure
vibration
Compound 2-stage Screw Compressor 3225**C 5.2 Maintenance and Inspection List
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2201MYJE-MY-C8-N_2015.04.
Table 5-1 Daily Inspection Item (continued)

Inspection item Inspection details Checkpoints and actions
Motor current A Whether it is increased from the  Compressor/motor failure
Others
time of the commissioning

Oil level of the oil - Oil level height  Oil loss
separator  Replenish oil
Liquid level of the liquid - Liquid level height  Replenish refrigerant
receiver
Refrigerant leak check - If any leak is found  Inside the machine room and in the
facility on the load side
■ Unless otherwise specified, the pressure unit "MPa" represents the gauge pressure in this
manual.
■ Daily Maintenance Items

1. Oil level height of the lubricating oil
If the oil level of the oil separator has reached the lower limit, charge the lubricating oil.
2. Oil filer element replacement
When the differential pressure between the inlet and outlet ports of the oil filter exceeds 0.1 MPa,
replace the filter element. During the period of initial operation, the pressure difference between
the inlet and outlet ports of the oil filter can quickly become large
3. Cleaning of suction strainer
Inspect the suction strainer when the operating hours of the compressor from the initial operation
starting has exceeded 500 hours.
If the filter used is a temporary filter for initial operation, remove the filter.
Also, as it is common that the differential pressure across the suction strainer can become large
in a short period of time, inspect and clean the suction strainer if the differential pressure is large.
4. Amount of oil leak from the mechanical seal
If the amount of oil leak from the mechanical seal is considered excessive, check the amount of
oil leak per hour. The table below shows the guideline on the acceptable amount of oil leak and
the amount that requires inspection.
If any damage is found on the mechanical seal in the inspection, be sure to replace it.
Table 5-2 Criteria of the Leakage from the Mechanical Seal

3225**C
Acceptable leakage amount (mL/hr) ≤6
Inspection is required (mL/hr) ≥ 18
Note: The values in the above table are only for guidance
purposes, and no guarantee is provided.
5. Contamination on the cooling water side of the condenser and oil cooler cooling pipe.
The degree of contamination and clogging of the cooling pipe can significantly vary depending on
the quality of the cooling water. If any gradual increase in the oil temperature and/or the discharge
pressure is observed during the initial period of operation, check and clean the cooling water side
of the oil cooler and the condenser regardless of the inspection schedule.
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5.2.2 Periodic Inspection

Conduct inspection for the following items according to the specified intervals.
In addition, observe relevant laws and regulations on the inspections and recording of the results that
are provided for other related items such as any safety devices (e.g. gas leak detectors), or other utility
(gas/electricity) protection devices that constitute the cooling package unit together with the
compressor.
Table 5-3 Periodic Inspection Items

Item Inspection interval and Content Remarks
Pressure gauge/pressure Yearly inspection
sensor
Thermometer/temperature Yearly inspection
sensor
Protection devices and Yearly inspection
safety valves
Suction strainer Inspection after 500 hours of initial Perform inspection and cleaning if
operation the differential pressure across the
Yearly inspection and cleaning suction strainer is high.
Lubricating oil Analyze the oil after 500 hours of Replace the oil if the analysis result
initial operation does not satisfy the control criteria
Analyze the Oil every six months given in Section 4.1.5 "Lubricating
oil Management Criteria".
Oil filter element Yearly replacement When the differential pressure
between the inlet and outlet ports of
the oil filter exceeds 0.1 MPa,
replace the filter element.
Cooling water side of the Yearly inspection Clean it if it is heavily contaminated.
oil cooler
Cooling water side of the Yearly inspection Clean it if it is heavily contaminated.
condenser
Mechanical seal Inspection every year or every To be replaced if any abnormality is
8000 hours of operation Note* found.
If it is difficult to stop equipment
except for scheduled inspections,
replace the part at each inspection.
Coupling Inspection every year or every
8000 hours of operation Note*
Note*: The inspection shall be performed according to the operating period or operating hours,
whichever comes first.
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2201MYJE-MY-C8-N_2015.04.
5.2.3 Guidelines for the Timing of Compressor Overhaul

While the overhaul interval for the compressor depends heavily on the conditions of use, type and
condition of the refrigerant and oil, the package unit, and other factors, the table below shows the
recommended interval of overhaul, as a guideline.
Table 5-4 Guidelines for the Timing of Overhaul Based on the Conditions of Use
(standard package)
Guideline for the overhaul
Category of Operating Condition Application Example
timing
Cold storage and Every 5 years or 40,000
Relatively stable operating condition
refrigeration operating hours
Every 4 years or 30,000
Relatively variable operating condition Ice maker/chiller
operating hours
Frequently started/stopped, and Every 3 years or 20,000
Heat pump
relatively changing operating conditions operating hours
Note 1: The above guideline is applicable only when the package unit is used under the standard
operating conditions separately defined. (Refer to Chapter 2, Section 2.3.2 "Operation Limits"
in this manual.)
Note 2: The above guideline is applicable only when the routine and regular inspection services that
are separately defined are performed. (Refer to Section 5.2.1 "Daily Maintenance" of this
chapter.)
Note 3: Inspect the compressor at the intervals of specified period or operating hours, whichever
comes first.
Note 4: The above guideline is for reference only, and not a warranty period.
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5.3 Compressor Disassembly Preparation

Although screw compressors are very reliable machines, it is still necessary to perform overhaul to
inspect internal parts after a certain period of operation.
This chapter 5 explains the essential points of disassembly methods, where to inspect on parts, and
reassembly procedure of the compound 2-stage screw compressor 3225**C.
In principle, overhauling of the screw compressor that require complete disassembly should be
performed in the maintenance factory. If you must do the overhaul work at the installation site due to
unavoidable reasons, use the methods described in the following paragraphs.
However, please note that regular overhaul work requires removal of the compressor from the base
frame. And then, the compressor should be placed on a work bench which has properly size area to
disassembling the compressor.
When moving the compressor from the unit base to the workbench, be sure to follow the instructions
given in Chapter 3, Section 3.1 "General Installation Precautions" and Section 3.2.3 "Transportation" of
this manual.
Note that some parts name given in the text of this manual is followed by a number enclosed in square
brackets [ ], which indicates the part identification number given in assembly sectional views or
development views.
5.3.1 Disassembly Tools and Workplace

Prepare necessary disassembly tools for the compressor by referring to Section 7.5 "Disassembly
Tools" in this manual Chapter 7.
In addition, prepare other necessary tools and materials including general hand tools, GC (green
carbonite) grinding stones, sandpapers of #80 to #100, about #400 to #800 sandpapers, parts cleaner,
lubricating oil, oilcan, empty can to receive drain oil, waste, etc.
If the overhaul work is to be done with the compressor removed from the installation base, prepare the
work bench whose size is at least around 1.5 times the length and the width of the compressor..
In addition, a special stand for the compressor is required in order to safely perform the
removal/fastening of bolts and plugs on the bottom side of the compressor. Refer to Section 5.3.5 of
this chapter.
To the extent possible, choose a dry and clean workplace free from sand or dust. Note that a sufficient
space is required around the compressor. In addition, it is necessary a temporary storage place for
disassembled parts.
Compound 2-stage Screw Compressor 3225**C 5.3 Compressor Disassembly Preparation

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2201MYJE-MY-C8-N_2015.04.
5.3.2 Replacement Parts

Prepare the genuine parts for replacement.
Parts listed in Table 5-5, we recommend to be replaced on the occasion of each compressor overhaul.
When ordering parts, be sure to inform the (a) model name, (b) serial number, (c) part name, (d) code
No. and (e) quantity required, to our sales offices or service centers.
In particular, if the serial number (b) is unknown, the details of the applicable design and manufacturing
specifications cannot be identified, and thus it becomes difficult to choose correct parts. So, make sure
to inform the (b) serial number to us.
Table 5-5 Replacement Parts of 3225**C Overhauling

P/N Part Name Code No. Remarks Q’ty.
6-1 Gasket, Suction Cover (1) CS00600-320N 1
6-2 Gasket, Suction Cover (2) CS00600-3225CN 1
12-1 Gasket, Bearing Head (1) CS01200-320N 1
12-2 Gasket, Bearing Head (2) CS01200-250N 1
17-1 Gasket, Bearing Cover (1) CS01700-3225CN 1
17-2 Gasket, Bearing Cover (2) CS73300-3225CN 1
23 Gasket, Balance Piston Cover CS02300-250N 1
27-1 Main Bearing (1) with O-ring CS0270-GRT 2
27-2 Main Bearing (2) with O-ring CS0270-FRT 2
28-1 Side Bearing (1) with O-ring CS0280-GRT 2
28-2 Side Bearing (2) with O-ring CS0280-FRT 2
30 Balance Piston CS03000-250 To be replaced if any 1
33 Balance Piston Sleeve CS03300-250 abnormality is found. 1
35 O-ring JIS B 2401 P150 PA11-150 1
38-1 Thrust Bearing (1) CS03800-320 2
38-2 Thrust Bearing (2) CS03800-250P 2
39-1 Lock Nut (1) AN21 NG31-021 To be replaced if any 2
39-2 Lock Nut (2) AN17 NG31-017 abnormality is found. 2
40-1 Lock Washer (1) AW21 NG32-021 2
40-2 Lock Washer (2) AW17 NG32-017 2
49 O-ring JIS B 2401 G160 PA12-160 1
50 Oil Seal CS05010-320VD 1
52 Gasket, Seal Cover CS05200-320N 1
59 O-ring JIS B 2401 P32 PA11-032 1
63-1 O-ring JIS B 2401 G170 PA12-170 1
63-2 O-ring JIS B 2401 G190 PA12-190 1
65-1 O-ring JIS B 2401 P140 PA11-140 1
65-2 O-ring JIS B 2401 P155 PA11-155 1
66-1 Cap Seal (1) BE-140 CS06600-3225 1
66-2 Cap Seal (2) BE-155 CS06600-250 1
68-1 Guide Pin (1) NE2506-016 To be replaced if any 1
68-2 Guide Pin (2) NE2506-012 abnormality is found. 1
69-1 Lock Nut (1) AN10, Unloader Piston NG31-010 To be replaced if any 1
69-2 Lock Nut (2) AN08, Unloader Piston NG31-008 abnormality is found. 1
70-1 Lock Washer (1), Unloader Piston AW10 NG32-010 1
70-2 Lock Washer (2), Unloader Piston AW08 NG32-008 1

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2201MYJE-MY-C8-N_2015.04.

73-1 O-ring JIS B 2401 P44 PA11-044 1
73-2 O-ring JIS B 2401 G35 PA12-035 1
75-1 O-ring JIS B 2401 G150 PA12-150 1
75-2 O-ring JIS B 2401 G170 PA12-170 1
78 Ball Bearing, Indicator Cam #6000 CS07800-200 2
79 Snap ring C type External S10 NG12-010 2
82 V-ring, Indicator Cam VH10 NBR CS08200-200B 2
86 O-ring JIS B 2401 G30 PA12-030 1
89-1 O-ring JIS B 2401 P24 PA11-024 2
89-2 O-ring JIS B 2401 P20 PA11-020 2
93-1 Gasket, Suction Flange (1) CS71200-350N JIS 20K 350A(14") 1
93-2 Gasket, Suction Flange (2) CS71200-200N JIS 20K 200A(8") 1
96-1 Gasket, Discharge Flange (1) CS71200-200N JIS 20K 200A 1
100 Mechanical Seal Assembly BBS-E CS10002-320EBS 1
125-1 Set of Micro-switch (1) CS1259-C 1
125-2 Micro-switch (2) CS12500-200 2
129-1 Potentiometer (1) 1612 1k with Wire CS1299-J To be replaced if any 1
129-2 Potentiometer (2) 200-1K with Wire CS1299-E10 abnormality is found. 1
To be replaced if any
202-1 Bevel Gear 1612D ID 6 mm CS20100-1612C6 2
abnormality is found.
150 O-ring JIS B 2401 G220 PA12-220 2
- Gear Coupling Assembly (Current Type) CS1519-M 1
159 Knurled Cup Point Socket Set Screw NA83610-025 1
160 Lock Nut AN15, Drive Hub NG31-015 1
161 Lock Washer AW15 NG32-015 1
165 O-ring JIS B 2401 P40 PA11-040 1
197 O-ring JIS B 2401 P58 PA11-058 1
216-1 Gasket, Lubricating Oil Inlet Flange (1) CS71200-040N JIS 20K 40A 1
216-2 Gasket, Lubricating Oil Inlet Flange (2) CS71200-025N JIS 20K 25A 1
219 Gasket, Oil Injection Inlet Flange CS71200-020N JIS 20K 20A 1
237-1 Tortional Slip Washer (1) CS23700-320 2
237-2 Tortional Slip Washer (2) CS23700-250 2
328 O-ring JIS B 2401 P46 PA11-046 1
Gasket, Balance Piston Lubricating Oil
351 CS71200-020N JIS 20K 20A 1
Outlet Flange
Gasket, Bearing Cover Lubricating Oil
354 CS71200-032N JIS 20K 32A 1
Outlet Flange
Gasket, Main Rotor Casing Oil Return
357 CS71200-032N JIS 20K 32A 1
Flange
2(*SC)
421 O-ring JIS B 2401 P46 PA11-046
(*MC)
431 O-ring JIS B 2401 P140 PA11-140 1 (M*C)
432-1 O-ring JIS B 2401 G165 PA12-165 4
432-2 O-ring JIS B 2401 G130 PA12-130 4
433-1 O-ring JIS B 2401 G165 PA12-165 4

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433-2 O-ring JIS B 2401 G130 PA12-130 4
528 Oil Seal Sleeve with O-ring CS52809-320VD 1
744 O-ring, Oil Seal Sleeve JIS B 2401 G90 PA12-090 1
- Coupling Element -
- O-ring Set 3225C NBR CS7109-0M -
- Gasket Set 3225C CS7118-0M -
In case of replacing the main/side bearings of No.27 and No.28, it is not necessary to prepare the
O-rings of No.432 and No.433 because the main/side bearings have the O-rings.
The sizes of O-ring No.432-2 and No.432-2 have been changed to G130 from G135 in October 2012
as a design modification.
● The part code of the O-ring is the one assigned to NBR which is standard material.
When the material of the O-ring is other than NBR, a different part code is used for
each material.
If you are using O-rings made from other than the standard material, please contact
us when placing an order.

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5.3.3 Refrigerant Gas Recovery

At the time the compressor operation is stopped, the pressure inside the compressor is still high. As
such, it is necessary to lower the pressure down to the atmospheric pressure before starting the
disassembly process. To do this, there are the following methods for example. Perform your recovery
work in an appropriate manner considering site conditions, requirements of regulatory laws and
regulations.
■ Use the bypass valve to release the high pressure gas in the package unit into the low pressure
side.
■ If there is an adjacent compressor to which a permanent bypass line is connected from this
compressor, operate the other compressor and lower the pressure through the bypass line.
■ Operate the refrigerating system and close the supply source valve to turn the gas into liquid, and
recover the liquid at the receiver.
■ Use a refrigerant recovery machine to recover the liquid at the receiver.
In using either method, prepare a working flow sheet of the system beforehand. Check the valves to be
controlled during the recovery work, according to the method to be used, 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: 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.
The gas mask and other protective gears required at each stage of refrigerant recovery work must be
prepared before starting the work.
 Before the work, be sure to check and communicate the work details and procedure
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.
 After closing (opening) a valve for work, conduct lockout/tagout to prevent it from
being handled accidentally during the work.

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5.3.4 Removal of Connections to the Unit
 If high-pressure refrigerant gas or refrigerant-mixed lubricating oil remains inside the

compressor, refrigerant gas may blow off when the closed circuit is opened. This
may result in injury such as frostbite or loss of vision.
Be sure to confirm that there is no residual pressure before opening any pipe
connections.
When removing the compressor from the mounting base frame, the following parts must be
disconnected beforehand:
(1) Coupling to connect the compressor to the driving machine;
(2) Suction and discharge pipes of the compressor.
If the suction strainer is directly connected to the compressor, also remove the strainer;
(3) Oil supply lines to the compressor (Two journal oil inlet ports, one oil injection inlet port, and two
ports for each of the capacity increase and decrease controls);
(4) Electric wiring for capacity control operation (In some cases, the unloader indicator assembly may
be removed with the wiring left as it is. Refer to Section 5.4.1.1 in this chapter.);
(5) Compressor mounting bolts (foot bolts); and
(6) Intermediate connecting piping from the low-stage discharge port to high-stage suction port of the
compressor (In some cases, this piping is not removed, and the compressor is removed with this
piping attached.)
When removing oil lines from the compressor, there is possibility of gas and oil blowing out caused by
residual pressure. And any residual oil in the pipe will flow out. To be prepared for this, either check the
amount of oil outflow by slightly loosening the pipe joint or drain the oil from the oil temperature gauge at
the supply header before removing the pipe.
Work carefully in particular when disassembling the unloader cylinder block since there is residual
pressure and oil fills in the unloader cylinder. Moreover, prepare a larger volume container than the
unloader cylinder volume to receive oil flowing out.
For easy reconnection, disconnected electric wires should be properly marked for identification. Any
wrong reconnection may result in a startup failure or inability to operate the capacity control mechanism.

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5.3.5 Removing and Lifting the Compressor
 The work to lift up or move the compressor must be performed by a qualified operator.
 Make sure that the lifting equipment and wires have sufficient load capacity for the
compressor.
 Never try to perform disassembly or assembly while the compressor is lifted in the air.
As the suction pipe is located immediately above the compressor, lift up or partially remove the pipe
such that it will not interfere with the lifting device.
For the lifting positions of the compressor, refer to Photo 002 or Figure 3-1 in page 3-3 of Chapter 3 in
this manual.
If the planned overhaul work includes separation between low-stage and high-stage blocks of the
compressor, place the compressor on a special stand as shown in Photo 003 and then remove eight or
more hexagon head cap screws around the bottom flange part. Never try to remove these bolts while
the compressor is lifted in the air. Note that these bolts cannot be removed once the compressor is
placed on the work bench.
Photo 003: Loosening Lower Flange Fastening Bolts
5.3.6 Draining Oil from the Compressor

Because considerable amount of oil is in the
compressor, it is necessary to drain the oil
beforehand.
The drain plugs are located on the bottom of
the suction covers [5-1], [5-2] and on the
bottom of the bearing head [11-1].
The most part of the oil will be drained from
these plug holes.
The remaining oil will be drained as
appropriate in the disassembly process on the
surface plate work bench.
The residual oil will mainly remain inside the a)
unloader cylinder, b) balance piston cover [22], Photo 004: Draining Oil from the Bearing Head
c) seal cover [51], and suction covers [5-1] and [5-2].
Have oil pans and waste ready to receive oil to be drained during the disassembly process.

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5.4 Disassembly and Inspection

During the overhaul work, be very careful in handling the parts. As the compressor is a delicate
machine that is operated at very high speed, a minor handling error could result in a situation where the
rotor and other major components must be entirely replaced. Another possibility is that it may cause a
failure or performance degradation when the compressor is operated after the reassembly.
Please fully understand the following sections before starting the work.
In general, the disassembly sequence will follow the flow shown on the left side of Figure 5-1
"Illustration of the disassembly sequence". Note that the sequence shown is an example, and it may
change depending on the situation. For example, it is allowed to separate the low-stage and high-stage
blocks at first, as shown on the right side of the flow.
Also, in the case of the flow on the left side, the sequence of disassembly may be reversed between the
unloader cover/unloader cylinder block and the mechanical seal block.
Figure 5-1 Illustration of the Disassembly Sequence
Compound 2-stage Screw Compressor 3225**C 5.4 Disassembly and Inspection

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5.4.1 Unloader Indicator

Because the type 3225**C has a capacity control mechanism also on the high-stage, there are two
unloader indicator locations. The standard operation method is such that the capacity control is used
only on the low-stage during operation, and the capacity control on the high-stage is used to reduce the
load during the startup phase.
As a different control method may be used depending on the system, refer to the separate electrical
control schematic diagram for the plant.
Figure 5-2 Development View of the Standard Low-stage Indicator for 3225**C
5.4.1.1 Disassembly
■ In Case of Removing the Wiring only
When removing the wiring of the unloader indicator upon removing the compressor, it is necessary
to remove the cover as the indicator has a terminal block for the wiring. Perform the work according
to the following procedure, and after removing the wires, attach the cover to them for protection.
○ Low-stage
a) Loosen the hexagon socket head cap screws [212] that are fastening the indicator glass [141]. In
this, do not loosen the Phillips screws [210] on the same surface. In this way, the assembly
consisting of the parts [141], [202 to 207], [210], and [211] can be removed.
b) By removing the two each hexagon socket head cap screws [147A] and [147B] that are used to
fasten the indicator cover [146B], the cover can be removed.
c) As you can see the terminal block, remove the plastic cover on the block, and then remove the
screws to disconnect the wires.

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○ High-stage
Regarding the high-stage capacity control, the 3225*SC and 3225*LC types have the load
indication of 30 to 100% while the model 3225*LC has the load indication 0 to 100%. Accordingly,
the dial [137] and micro-switch cam [127] of the types *SC and *MC are for the indication of 30 to
100% while the type *LC has the standard dial and micro-switch cam for the 0 to 100% indication,
according to the standard (200UD/G) specification. Otherwise, the mechanism of the indicator is the
same between all types.
a) By removing the three hexagon socket head cap screws [147] that are used to fasten the
indicator cover [146], the cover can be removed.
b) The indicator cover will be removed with the glass [141] and spacer [142] attached. While the
glass and spacer are glued, be careful not to drop these as they may be separated from the
cover.
c) Remove the wiring.
Figure 5-3 Development View of the Standard High-stage Indicator for 3225**C
Photo 005: Removing Low-stage Indicator Photo 006:Loosening Low-stage

Cover Micro-switch Cam Fixing Screw

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Photo 007: Removing High-Stage Indicator Photo 008: Loosening High-stage

Cover Micro-switch Cam Fixing Screw
■ For Further Disassembly (In case of Removing as Unloader Indicator Assembly)
As the indicator is an assembly to be removed as a whole, no further disassembly should be made

unless the purpose of the disassembly is to disassemble this part.
○ High and Low-stages

a) As a result of the previous disassembly process, the micro-switch mounting plate [121], which is
mounting the potentiometer, micro-switch, and micro-switch cam, can be removed.
b) Unscrew and remove the hexagon socket head cap screws [122].
c) Loosen the set screw [128] of the micro-switch cam.
d) After that, the assembly can be removed by pulling it in the axial direction.
Photo 009: Loosening high-stage micro-switch Photo 010: Removing the high-stage indicator
base plate fixing bolt block
5.4.1.2 Inspection
The inspection procedure is described in the "Reassembly" section of this chapter, as it is often the
case that the unloader indicator block is removed as an assembly and later inspected and adjusted
after the overhauled compressor is reassembled and installed on the mounting base. For details, refer
to Section 5.5.15 "Unloader Indicator" in this chapter.

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5.4.2 Unloader Cover

The unloader cover [74-1] [74-2] is mounted with the indicator cam [77-1] [77-2], which converts the
linear motion of the unloader slide valve to a rotational motion, and their mounting parts.
The indicator cam is supported by the ball bearing [78] and fixed to the cover with a bearing gland [80].
To make it airtight, the V-ring [82], spring [83], and spring retainer [84] are also attached.
The indicator cam has a spiral groove of 340° to cover the moving range of the unloader slide valve.
The indicator cam shaft is rotated being pushed by the guide pin [68-1] [68-2] on the top end of the
unloader push rod [67-1] [67-2].
Figure 5-4 Unloader Cover Block
5.4.2.1 Disassembly
a) Unscrew and remove the unloader cover mounting hexagon socket head cap screws [76-1] and
[76-2].
b) Pull the cover out in the direction parallel to the axis of the push rod in the unloader cylinder.
Carefully pull it straight, because if the unloader cover is pulled sideways, the shaft of the indicator
cam may be bent.
c) If the indicator cam will not move normally, check the spiral groove of the indicator cam, bearing,
and guide pin. The disassembly sequence is as follows:
c-1) As the bearing gland [80], which fixes the indicator cam in place, is secured by three
hexagon socket head cap screws [81] on the cylinder side of the unloader cover, unscrew
and remove these bolts.
c-2) Then, the indicator cam can be pulled out with the ball bearing [78] and the snap ring
(retaining ring) [79] attached to the shaft.
c-3) Inside the unloader cover, the spring retainer [84], spring [83], and then V-ring [82] are
assembled in this order. Because the V-ring is tightly engaged with the bore of the
unloader cover, the lip of the V-ring will be damaged when it is once removed, making it
unusable again. Therefore, be sure to replace it with a new one once it is disassembled.

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Photo 011: Removing the Unloader Cover Photo 012: Ball Bearing for the Indicator Cam
Photo 013: Indicator Cam Mounting Parts Photo 014: V-ring (Black part is NBR/FKM)
5.4.2.2 Inspection
a) Check the packing portion of the indicator cam shaft for any flaw. If the refrigerant leaks without any
flaw observed in this part, it should be due to a defect of the V-ring or installing the V-ring without
sufficient oil.
In this case, replace the V-ring.
b) Check the spiral groove of the indicator cam. If an abnormal flaw or wear is observed, replace it with
a new one.

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5.4.3 Unloader Piston and Unloader Cylinder

Inside the unloader cylinder [60-1] [60-2] is an unloader piston [64-1] [64-2] around which the cap seal
[66-1] [66-2] and O-ring [65-1] [65-2] are fitted. The unloader piston is assembled to the unloader push
rod [67-1] [67-2], which operates the unloader slide valve, with the lock nut [69-1] [69-2].
Figure 5-5 Unloader Cylinder Block Figure 5-6 Unloader Cylinder Block
(Low-stage) (High-stage)
5.4.3.1 Disassembly
a) Screw two M8 eyebolts into the threaded holes of the unloader piston [64-1] [64-2], and pull it fully
towards you.
b) Unbend the locking tooth of the lock washer [70-1] [70-2], which is used to fix the piston on the push
rod, such that the lock nut [69-1] [69-2] can be turned. Then, loosen and remove the lock nut.
c) Now, you can remove the unloader piston.
Photo 015: Release the Locking Tooth Photo 016: Use Lock Nut Wrench
of the Lock Washer (High-stage) to Loosen the Lock Nut
(High-stage)

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b) The low-stage unloader cylinder [60-1] is

fastened by eight long hexagon socket head
cap screws [62-1] to the low-stage bearing
head [11-1] together with the bearing cover
[16].
Even when all the hexagon socket head cap
screws are removed, the unloader cylinder will
not drop off as it is securely engaged with the
bearing cover. Pull out the unloader cylinder
by holding the flange or rib.
Photo 017: Removing the Low-stage Unloader

Cylinder
c) The high-stage unloader cylinder [60-2] is also

fastened by hexagon socket head cap screws
[61] (× 2) and [62-2] (× 6). The high-stage
unloader cylinder is to be pulled out similarly
to Step b) for the case of low-stage cylinder.
However, if the cylinder is to be further
disassembled, leave the two bolts [61]
fastened. Remove the bolts [24] and [62-2]
fastening the balance piston cover [22] and
remove the unloader cylinder together with
the balance piston cover. In this, as oil
remains in the balance piston and side
bearing part, be careful of the oil that will Photo 018: Removing the Balance Piston
come out when the balance piston cover is Cover and Unloader Cylinder
removed. If the gasket [23] is sticking and it together
does not come off, screw in two M8 eye bolts
to the two forcing screw threads on the
balance piston cover to separate the gasket.
5.4.3.2 Inspection
a) Both the O-ring [65-1] [65-2] and cap seal
[64-1] [64-2] that are on the periphery of the
unloader piston [64-1] [64-2] must be replaced
by new ones.
b) As it is often seen that the inside of the
unloader cylinder has flaws or is contaminated
by oil residue, thoroughly clean the area and
use fine sandpapers to finish the surface.
Photo 019: Removing the Cap Seal

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No. Part Name

101 Mating ring
Stationary
102 Insert lock pin
rings
103 O-ring
100
109 Seal collar
Rotating
111 Seal collar set screw
rings
112 O-ring
528 Oil seal sleeve
529 Set screw for oil seal sleeve
744 O-ring
48 Retainer, oil seal
49 O-ring
50 Oil seal
Photo 020: Seal assembly 20 Spring pin
Figure 5-7 Development View of BBSE-type Mechanical Seal Assembly and Rerated Parts
5.4.4.1 Disassembly
a) Of the eight hexagon socket head cap screws [53] securing the seal cover [51], remove six bolts
leaving two diagonally opposite bolts.
b) Loosen the remaining two screws alternately and evenly, a little at a time. When the screws are
loosened to some extent, the seal cover will be pushed by the spring force of the seal to create a
gap under the cover. The gap will not be created if the gasket is sticking to both surfaces. In this
case, free the cover by screwing M8 eye bolts into the jacking screw threads on the seal cover to
separate it.
c) As the oil inside will flow out through the gap, be ready to receive the oil with a container.
d) Pull out the seal cover in the direction of the rotor shaft axis. Inside the cover, there is the mating
ring fitted with the O-ring. In this, carefully remove the seal cover for the mating ring not to be
damaged by touching the shaft.
e) Remove the O-ring [49] between the seal cover and oil seal retainer [48].

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f) After the seal cover has been removed, wipe clean the shaft and then check its surface. If any flaw
is found, use a fine sandpaper to smoothen the surface. This correction is intended to prevent
possible damage of the internal O-ring when the mechanical seal is pulled out.
g) Loosen the set screws [111] securing the seal collar [109] about three turns. Do not remove the set
screws completely. Loosen them such that their ends are retracted from the surface of the seal
collar. These two screws are located 90° apart from each other.
h) Pull out the mechanical seal assembly by holding the seal collar with your fingertips. While
removing the assembly, make sure that the ends of the set screws do not touch the shaft surface.
Any scratch on the shaft will cause leakage.
i) Pull out the oil seal sleeve [528] after removing the two set screws [529] .
j) Screw two M8 eye bolts into the screw holes in the seal retainer and pull out the seal retainer while
keeping it in the right angle with the shaft.
k) Remove the oil seal [50] that is atacched into the oil seal retainer.
Photo 021: Removing the Seal Cover Photo 022: After Removal of the Seal Assembly
5.4.4.2 Inspection
a) Although it is instructed that the mechanical seal must be replaced after abnormality is found in the
inspection, only visually checking the sliding surface may be insufficient in determining any
abnormality. It is thus recommended to always replace it with a new one, similarly to the case of
O-rings and gaskets, if the inspection is done in such a way.
Also, if it is difficult to stop the compressor operation except for scheduled inspections, we
recommend to replace the mechanical seal assembly with a new one at every inspection of this
block.
However, even if the assembly is to be replaced without exception, it is still necessary to visually
check the condition of the sliding surface between the mating ring and the seal collar. If any
unevenness or flaw is observed on the sliding surface, analyze the condition to determine whether it
is due to aging, overheating, or other reasons in order to take necessary corrective actions.
b) Replace the O-rings every time the mechanical seal assembly is inspected because they normally
swell and deform over time.
c) Check the wear of the oil seal sleeve in the area it rubs against the oil seal lip.
If wear is evident, replace both the oil seal [50] and oil seal sleeve [528] with new parts. Since the oil
seal is made of a special material, only genuine oil seals must be used for the replacement.
Information on the O-ring [744] for the oil seal sleeve

A design modification was made in March 2010 to insert an O-ring [744] in the oil seal sleeve.

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5.4.5 Bearing Cover

The bearing cover [16] should be removed when the low-stage thrust bearing block is inspected or the
rotor is pulled out for inspection.
5.4.5.1 Disassembly
a) Unscrew and remove all the hexagon socket head cap screws [18-1]. The bearing cover remains
attached to the bearing head [11-1] with two alignment pins [19-1].
b) For safety, screw two stud bolts into appropriate top bolt holes.
c) There are two jacking screw holes in the opposite positions. By screwing in two left and right M8 eye
bolts evenly, the bearing cover will be separated from the bearing head. When some gap is
observed between them, use a scraper to remove one side of the gasket [17-1] from the body.
d) Further screwing in the eye bolts will disengage the bearing cover from the alignment pins.
 At this point, if the bearing cover is not properly supported, it may fall or drop down
onto the rotor shaft to cause damage on it. So, be sure to protect the shaft with a
blanket or other protective covering before starting the work.
Photo 023: Removing the Bearing Cover Photo 024: Removing the Bearing Cover

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5.4.6 Separating High-stage and Low-stage Blocks

The high-stage and low-stage blocks should be separated before inspecting the gear coupling,
high-stage thrust bearing, main bearing, pulled out rotors, etc.
As explained at the beginning of Section 5.4 of this chapter, the separation may be done at the initial
step of the overhaul work.
5.4.6.1 Disassembly
a) As it is explained in the Section 5.3.5, the bolts on the bottom side must be removed by
placing the compressor on a special stand before starting the disassembly work.
b) Remove the hexagon socket head cap screws [18-2] that fasten the high-stage bearing head [11-2]
to the low-stage suction cover [5-1].
c) As the gasket [17-2] is sticking to both surfaces of the high-stage bearing head and the low-stage
suction cover, use the bolts [18-2] that have been removed to screw them into the jacking threads in
the bearing head to evenly push the suction cover to separate the two blocks.
d) The gear coupling assembly [151 to 161] for power transmission is located inside, on the side of the
M rotor shaft.
As the drive side and driven side of the coupling can be separated along the shaft axis, move the
main body exactly along the shaft axis to separate them.
Photo 025: Screwing in the Bolts to Push and Photo 026: Separating the High-stage and
Separate Low-stage Blocks
5.4.7 Gear Coupling

The gear coupling, which is used as a power transmission means, is divided into the high-stage and the
low-stage blocks, with each block attached to the corresponding M rotor shaft, and these two blocks are
directly connected by a drive sleeve.
5.4.7.1 Disassembly
a) The drive sleeve [151] can be removed by hand after the high-stage and low-stage are separated.
b) On the high-stage (driven) side, first loosen the knurled cup point socket set screw [159] on the
driven hub used for locking, and then pull out the driven hub. The driven hub can be easily pulled
out, as clearance fit is used.
c) To remove the low-stage drive hub [152], release the locking teeth of the lock washer [161] and
loosen the lock nut [160].
d) There are two screw holes in the drive hub.
Screw M8 eye bolts into these screw holes and pull out the drive hub. It can be easily pulled out, as
clearance fit is used.

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5.4.7.2 Inspection
Check the hub and sleeve for possible deformation of the gear teeth and wear on each tooth flank.
If it is found abnormal, replace the whole gear coupling assembly. At the same time, investigate the
cause of the abnormality.
Photo 027: Current Gear coupling parts Photo 028: Low-stage Gear Coupling
Gear coupling mechanism of 3225**C models

The gear coupling of 3225**C uses a coupling hub and drive sleeve. While the old couplings (before the
design modification made in February 2011) have a stop on both outer ends of the sleeve to prevent the
sleeve from dropping off, the stops are placed on the inside of the drive sleeve after the design
modification (compatible with the old type).
After this design modification, the drive sleeve stopper [154] and stop ring [155] are no more used.
The gear coupling assembly consists of the items The gear coupling assembly consists of the
151, 152, 153, 154*2, 155*4, and 159. items151, 152, 153, and 159.
Figure 5-8 Conventional Method (Before the Figure 5-9 New Method (After the Design
Design modification in Feb. 2011) modification in Feb. 2011)

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5.4.8 Removing Oil Injection Pipe

The oil injection pipe [85] is located at the bottom of the low-stage suction cover [5-1].
5.4.8.1 Disassembly
Remove the oil injection pipe gland [164], and then hold a M20 bolt screwed into the screw hole on the
head of the oil injection pipe to pull out the pipe.
Photo 029 Removing Oil Injection Pipe Photo 030 Removing Oil Injection Pipe

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5.4.9 Balance Piston

During the operation of a screw compressor, both
the rotation rate and the thrust load of the M rotor
are higher than those of the F rotor. Accordingly,
the service life of the thrust bearing for the M rotor
will be significantly shorter than that of the F rotor,
if no special measures are taken. As such, in
order to reduce the thrust bearing load on the M
rotor side, a hydraulic piston is used on the shaft
end of the rotor drive shaft to cancel the thrust
load.
◆ Note that no balance piston is used on the
low-stage. Because the low-stage pressure
condition is lower than high-stage, the service
life difference of the bearings is not so Figure 5-10 Balance Piston Block
significant compared to the high-stage.
5.4.9.1 Disassembly
a) Remove the snap ring [32] retaining the
balance piston [30] on the shaft using external
snap ring pliers.
b) Pull the balance piston straight out by
screwing two eye bolts into the screw holes.
While the rotor shaft has a balance piston key
[31], it is unnecessary to remove the key.
Photo 031
c) To prevent rotation of the balance piston sleeve [33], there are
hexagon socket head set screws [34] screwed from both the M rotor
side (balance piston)and F rotor side. So, loosen the set screw on
the F rotor side, and place the M rotor side screw under the suction
cover as shown in Photo 032.
d) Remove the snap ring [37] securing the balance piston sleeve using
the internal snap ring pliers. As the snap ring is pressed out by the
internal O-ring [35], slightly pushing it can easily remove the snap
ring.
e) Remove the balance piston sleeve and O-ring.
As clearance fit is used to engage the outside of the sleeve with the
suction cover, you can easily pull it out.
Photo 032 As there is an O-ring spacer [36], also remove the spacer.
5.4.9.2 Inspection
While you will be able to find some trace of wear on the inside surface of the balance piston sleeve,
such wear is not abnormal as it is caused because the clearance between the balance piston and the
sleeve is narrower than the clearance between the rotor shaft and the bearing.
Because enough clearance is given to the outside of balance piston sleeve in order not to apply the
bearing load to the balance piston, no further development of the wear is expected.
However, you should still carefully check the condition because when the side bearing is significantly
worn, the balance piston may also be worn.

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5.4.10 High-stage Suction Cover and Side Bearings

If the work sequence is such that the thrust bearing block is disassembled first and then the suction
cover is removed, there is a risk that, when the suction cover is separated from the main rotor casing,
the rotor may also be pull out and dropped. As such, in the procedure described in this manual, the
suction cover is removed first, and then the thrust bearing is disassembled.
 In this procedure to remove the suction cover before disassembling the thrust bearing
block, it is necessary to sufficiently loosen the lock nut that are securing the thrust
bearing while the rotor is supported by both the main and side bearings, in order not to
damage the rotor during the disassembly process.
5.4.10.1 Disassembly
a) Remove the hexagon head bolts [45-2] and the conical spring washers [46-2] that are used to fasten
the thrust bearing gland [43-2], and then remove the gland.
In case of a former model which uses a rotation stopper fitting instead of a conical spring washer,
extend the bent plate of the rotation stopper and remove it from the hexagon head blot [46-2], and
then remove the hexagon head bolt and the thrust bearing gland.
Photo 033 Removal of Hexagon Head Bolts Photo 034 Loosening the Lock Nut
b) Unbend the rotation stopper tooth of the lock washer [40-2] holding the lock nut [39-2] which retains
the inner race of thrust bearing [38-2] on the rotor shaft and loosen the lock nut using a lock nut
wrench.
c) As the height of the high-stage main rotor casing is low, the casing is installed like a bridge to
connect between the suction cover and the bearing head. As such, the main rotor casing will be
supported only by one side (i.e., overhang) when the suction cover is removed. To avoid this, either
place squared timbers or use a lifting device to properly support the main rotor casing.
d) Loosen and remove the hexagon socket head cap screws [2-2] securing the high-stage suction
cover [5-2] to the high-stage main rotor casing [1-2].
e) As the gasket [6-2] of the suction cover is sticking to the surface of the flange, screw two hexagon
socket head cap screws [2-2] that have been removed into the screw holes in the main rotor casing
flange to evenly push the suction cover. When some gap is observed between them, use a scraper
to remove one side of the gasket from the surface.
f) When it comes to the position the alignment pins are disengaged, pull out the suction cover at once
along the rotor axis.
g) As the high-stage suction cover is installed with an O-ring [328] and O-ring gland [326-2] in the
opening for the push rod to pass through, remove them. As the four bolts fastening the O-ring gland
are small (M5), be careful not to lose them.

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h) The side bearing [28-2] has been press fit from the balance piston cover side of the suction cover.
Remove the snap ring [29-2] using internal snap ring pliers.
i) Either push out the side bearing from the main rotor casing side using some block or pull it out using
a special tool such as shown in Photo 034. For the details of the special tool, refer to Section 5.5.2
in this chapter.
Photo 033 Pulling Out the Suction Cover Photo 034 Removing the Side Bearing
5.4.10.2 Inspection
a) Check the oil inlet path to the balance piston part of the suction cover by spraying air or the like.
b) We recommend unconditional exchange of the side bearings on the occasion of the compressor
overhaul, but for confirmation of the compressor condition and system operating condition, carefully
check the sliding part metal surface of the side bearings.
If the metal surface is turned gray or any foreign matter is embedded, also carefully check the wear
of the rotor shaft.
c) The inside surface of the main rotor casing should have no problems because sufficient clearance is
provided. However, if any trace of scraping by the end of the rotor is found, it should be determined
that the thrust bearing is defective. It is also necessary to check the operational condition, such as
whether the system is operated for a long time with a high intermediate pressure.

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5.4.11 Low-stage Suction Cover and Side Bearings

Similarly to the case of the high-stage, the lock nut fastening the thrust bearing should be loosened
before removing the suction cover.
a) Remove the hexagon head bolts [45-1] fastening the thrust bearing gland [43-1] and O-ring [150].
As conical spring washers [46-1] are used together, be careful not to lose them.
b) Unbend the tooth of the lock washer [40-1], and loosen the lock nut [39-1].
c) Loosen and remove the hexagon socket head cap screws [2-1] securing the suction cover [5-1] to
the main rotor casing [1-1].
d) Drive in the alignment pins [3-1] to the main rotor casing side as shown in Photo 35. If it is not
feasible, screw in suitable bolts to the jacking screw holes on the flange to push the suction cover
evenly.
e) At this time, the alignment pins will also be disengaged. Even after the alignment pins are
disengaged, as the rotor shaft and side bearing are still engaged together, pull out the suction cover
carefully along the shaft axis (Photo 36).
f) Remove the snap ring [29-1] holding the side bearing using internal snap ring pliers.
g) Either push out the side bearing from the main rotor casing side using some block or pull it out using
a special tool such as shown in Photo 037. For the details of the special tool, refer to Section 5.5.2
in this chapter.
Photo 035 Photo 036
Photo 037
5.4.11.2 Inspection
Inspect the suction cover and side bearings in the same way as for the high-stage.

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5.4.12 Thrust Bearing Block
5.4.12.1 Disassembly of High-stage Thrust Bearing Block
Table 5-6 Component Parts of the High-stage

Thrust Bearing Block
P/N Name Q'ty
38-2 Thrust bearing (2) 2
39-2 Lock nut (2) 2
40-2 Lock washer (2) 2
42-2 Thrust bearing alignment spacer (2) 2
43-2 Thrust bearing gland (2) 2
45-2 Hexagon head bolt 8
Figure 5-11 High-stage Thrust Bearing Block 46-2 Conical spring washer (2) 8
237-2 Torsional slip washer (2) 2
250-2 Thrust washer (2) 2
The high-stage thrust bearing block of 3225**C has no spacer for the thrust bearing outer race. While
the thrust bearing outer race spacer is used to support (i.e., ensure a sufficient support width for) the
outer race of the thrust bearing, 250 or higher models use no spacer for the thrust bearing outer race
because the case (bearing head) side has sufficient margin to the support it.
a) Remove the lock nut [39-2] that has been loosened. Then, remove the torsional slip washer [237-2],
lock washer [40-2], and thrust washer [250-2].
b) The clearance fit is applied to two gaps between the outer race of the thrust bearing and the bearing
head, between the inner race of the thrust bearing and the rotor shaft.
Prepare a 1 or 2 mm diameter aluminum wire, make the tip of the wire flat by hammering, and
slightly bend the tip to make a hook. Then, insert the tip of the wire between the outer race and the
ball retainer of the thrust bearing [38-2] to hook and pull out the bearing. In this way, the bearing can
be easily removed.
c) The whole thrust bearing will be removed helped by the surface tension of the oil on the side face.
If you have failed to remove the whole bearing at once, put the components in the order of the
removal.
d) Inside the thrust bearing is an alignment spacer [42-2] for the inner race on the rotor shaft side. The
M rotor side has a marking of "M", and the F rotor side has a marking of "F".
Neatly arrange the parts removed, i.e., the
thrust bearing gland, thrust washer, thrust
bearing, and thrust bearing alignment spacer,
separately for the M rotor and F rotor as shown
in Photo 040.
You must be very careful because if an
assembly error is made to result in a wrong
combination of parts after failing to neatly
arranging and separating the parts, it can lead
to performance degradation and/or dragging
accident due to overheating caused by being
too narrow clearance, for example.
Photo 040

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5.4.12.2 Disassembly of Low-stage Thrust Bearing Block
Figure 5-12 Low-stage Thrust Bearing Block Photo 041
Unlike the high-stage, the low-stage thrust bearing block of 3225**C is using an oil supply spacer for
the combined surface. This is to facilitate lubrication of the ball bearing because as the rotor diameter
becomes larger, the rotor shaft diameter become larger. Thus, a larger thrust bearing is required and
the ball rotation speed increases accordingly. Furthermore, as with the high-stage, the low-stage thrust
bearing block of 3225**C has no spacer for the thrust bearing outer race.
a) Remove the lock nut [39-1] that has been loosened. Then, remove the torsional slip washer [237-1],
lock washer [40-1], and thrust washer [250-1].
b) Similarly to the case of the high-stage, remove the thrust bearing [38-1] and the thrust bearing
alignment spacer [42-1].
5.4.12.3 Inspection (High-stage and Low-stage)

a) The thrust bearing is normal if the bearing balls are found fully glossy after the thrust bearing has
been fully washed and cleaned. It is abnormal if the ball surface has tarnish streaky pattern.
b) Support the inner race with your hand and rotate the outer race. If you feel abnormal vibration on the
hand, the rolling contact surface of the inner or outer race or some balls may be in an abnormal
condition. So, carefully check the conditions. You could feel some irregular click even with a small
foreign matter that has entered during the removal process. In such a case, it should return to the
normal condition when high pressure air is used to blow out the foreign matters after washing and
cleaning the unit. If the bearing is determined to be defective, it must be replaced with new ones.
c) If the inner race and outer race can be easily separated, the wear is considered excessive. If so, you
cannot reuse the bearing.
d) After washing the bearing, you should be able to hear a clattering sound when the bearing is rotated
by hand. Such a sound is due to the motion of the ball within the backlash or play, or the gap
between the retainer and the ball. Such a sound will not be heard if the bearing is held horizontal
and turned. If some lubricating oil is applied after washing the bearing, the sound should not be
heard when the bearing is turned. If you can still hear the sound, the bearing is abnormal.
e) If any abnormality is seen in the thrust bearing in the above inspection, replace with new ones.
In addition, carefully check the reason whether due to mere aging or any problem with the operating
condition and/or lubricating mechanism.
f the compressor has been operated for more than 20,000 hours without replacing the thrust bearing,
it is recommended to replace the bearing with a new one for safely continuing the operation until the
next overhaul, even if no abnormality is found in the above described inspection.
 As the bearing used for the compressor is a specially designed combined-type bearing, the
accuracy and material are different from normal ones of the same part number that may be
found in the catalogue of a bearing manufacturer. Be sure to use only genuine
parts for replacement. Otherwise, it will not be covered by the warranty.

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5.4.13 High-stage Rotors and Main Rotor Casing
a) While you can pull out the rotor either from the M or F side, you should be very careful in the work as
either rotor is very heavy.
When pulling out the M rotor (or F rotor) first, pull out about 2/3 of the full length of the rotor by
holding the shaft upward and turning it in the CW (or CCW) direction.
 You should carefully note that the rotor must be rotated in the specified direction
while pulling it out. If the M (F) rotor is not turned during the pulling out process,
the F (M) rotor can also be pulled out together.
b) As a preparation, use a nylon belt or other lifting belt that will not blemish the lifting surface to
support the center of the rotor. Then, pull out the rotor while slightly lifting up the rotor using the belt.
Photo 042 Pulling Out the F Rotor Photo 043 Lifting Up the F Rotor
Photo 044 Pulling Out the M Rotor Photo 045 Lifting Up the M Rotor
c) The pulled out rotor should not be directly

placed on the floor. Use appropriate wood
boards to support the rotor as a cushion to
prevent blemishing or use V-blocks to support
the shaft to prevent blemishing of the outer
surface (See Photos 046 and 048.)
Photo 046

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5.4.13.2 Inspection
a) No abnormality should be observed on the surface of the rotor lobes under normal operations.
Regarding the contact surface of the teeth, black luster should be seen on the root area of the M
rotor lobes and on the tip area of the F rotor lobes.
In other cases, when the suction gas or oil is contaminated by fine dust, there may be fine linear
scratches on the shaft surface, in the direction perpendicular to the shaft axis. If any such flaw is
found, use a fine sandpaper or grindstone to smooth the surface.
b) In case of ammonia refrigerant or gas compressor, the non-contact surface of the rotor may be
discolored by rust or deposits. Use sandpapers or others to finish the surface according to the
degree of the problem.
c) Then, check the bearing areas of the rotor shaft. Two types of finishing are used: one is the
induction hardening (polish finishing) for the standard specification, and the other is the hard
chrome plating (polish finishing), as a special specification. The most suitable finish is selected
according to the type of refrigerant and operation conditions.
Very little wear will be present unless the compressor is operated for a long time using dirty oil or
any hard matter is buried in the metal of the inner circumference of the bearing.
d) Check the portion of the shaft on which the thrust bearing is mounted for any trace to show that the
inner race of the bearing has rotated.
If the lock nut that fastens the inner race of the thrust bearing is loosened, or if the bearing is
abnormally worn, the inner race will become rotate. If any trace of rotation is seen, correct the
problem. Depending on the degree of the rotation trace, it might be necessary to replace the rotors
with new ones.
e) Check the inner surface of the main rotor casing.
There is a narrow clearance between the periphery of the rotor and the main rotor casing. Any slight
flaw present on the tip of the rotor teeth or on the inner surface of the main rotor casing, due to small
foreign matters, will not be a problem.
If there is any trace to show that the tips of the rotor teeth have hit the inner surface of the main rotor
casing, it is an abnormal condition. In such a case, the possible cause is that the main bearing
and/or side bearing is worn out. Take proper actions by finding the cause of the problem, such as
contamination of the lubricating oil or entrance of foreign matters.
5.4.14 Low-stage Rotors and Main Rotor Casing

Perform the work similarly to the case of the high-stage unit. The work should be very carefully
performed as the low-stage rotors are heavier than the high-stage rotors.
Also perform the inspection work similarly to the case of the high-stage unit.
As the low-stage M rotor is installed with a mechanical seal, do the work very carefully not to damage
the shaft. It is recommended to apply a protective tape on the shaft surface.
Photo 047 Pulling Out the Low-stage M Rotor Photo 048

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5.4.15 High-stage Bearing Head and Main Bearings

On the rotor mounting side of the bearing head [11-2], there is a gas discharge port as determined by
the operating conditions of the compressor. This discharge port affects the performance of the
compressor.
In addition, the bearing head has the main bearing that supports one end of the rotor.
a) Remove all the hexagon socket head cap
screws [2-2] fastening the main rotor casing
and the bearing head. Support the foot of the
main rotor casing using squared timbers.
b) Use jacking bolts to evenly push the block.
Once some gap is produced between the
main rotor casing and the bearing head, use a
scraper to detach the gasket from the bearing
head and put it on to the main rotor casing
side.
When the alignment pins are disengaged, the
bearing head is separated from the main rotor Photo 049 Loosening the Fastening Bolts
casing.
c) The main bearing [27-2] is lightly press fit into the bearing head. When removing the main bearing,
first use internal snap ring priers to remove the snap ring [29-2]. Then, either use a plastic block or
other suitable element to push the bearing from the rotor side or use a special tool such as shown in
Photo 051 to pull out the bearing. For the details of the special tool, refer to Section 5.5.2 in this
manual.
Photo 050 Removing the Snap Ring Internal Photo 051 Removing the Main Bearing
d) The unloader slide valve can be removed as an assembly by pulling it out from the bearing head
side. If no specific abnormality is found, no further disassembly is required.
e) The guide block stem [88-2] is screwed in from the bottom of the main rotor casing, and the guide
block [87-2] is engaged from the top. To replace the O-rings [89-2], remove the guide block stem.
5.4.15.2 Inspection
a) We recommend as well as the side bearings, unconditional exchange of the main bearings on the
occasion of the compressor overhaul, but for confirmation of the compressor condition and system
operating condition, carefully check the sliding part metal surface of the main bearings.
If the metal surface is gray or any foreign matter is buried, also carefully check the wear of the rotor
shaft.

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2201MYJE-MY-C8-N_2015.04.
b) Check the condition of the surface of the bearing head on the rotor side, where the discharge port is.
Properly mend the surface if any flaw is observed. If the entire surface has significant flaws, either
the thrust bearing is defective or the end clearance adjustment is poor.
If oil compression has been caused during the operation, carefully and thoroughly check the area of
the discharge port in particular. If the continued use is in doubt at all, perform the penetrant testing
(color check) to determine if it can be used or not.
c) With the unloader slide valve mounted in position, check the step height between the slide valve
and the main rotor casing surfaces. Usually, the surface of the slide valve should be lower than the
surface of the main rotor casing.
If the top surface of the slide valve has a trace of hitting the rotor, the probable cause is that the slide
valve is worn or the rotor shaft/bearing is worn. Please contact our sales offices or service centers.
d) Check the properness of the slotted guide pin [68-2] at the tip of the unloader push rod [67-2] that
engages with the indicator cam [77-2].
5.4.16 Low-stage Bearing Head and Main Bearings

a) Unscrew and remove all the hexagon socket head cap screws [2-1].
b) Drive in the alignment pins [3-1] from the bearing head side to the main rotor casing side.
c) Use the jacking screw holes on the flange to separate the bearing head and the main rotor casing.
d) Separate them carefully along the shaft axis, as the unloader push rod [67-1] is engaged.
e) The main bearing [27-1] can be easily pulled out by removing the snap ring [29-1] and then lightly
tapping it from the rotor side via a pad. Otherwise, use a special tool to pull it out.
f) Remove the slide valve as an assembly, using the same procedure as for the high-stage unit.
Carefully perform the work, as you are handling a heavy object.
Photo 052 Removing the Snap Ring Internal Photo 053 Removing the Slide Valve
Assembly
5.4.16.2 Inspection
The inspection must be performed similarly to the case of the high-stage.

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5.5 Reassembly
 During the reassembly work, be very careful in selecting the correct replacement
O-rings of the specified standard, not to make a mistake regarding the size, material, for
fixed use, for sliding use, etc. Using a wrong O-ring can lead to oil leak or other
problems.
 Some gaskets are not symmetrically shaped. In such a case, be careful not to misplace
the gasket. If the gasket is misplaced, it can lead to a significant problem such as
blocking any oil supply route on the casing.
After completing the disassembly and inspection procedures, start the assembly process.
First, read again Section 5.1 "Precautions for Maintenance and Inspection" in this Chapter 5.
Before starting the assembly, check the replacement parts once again.
Like gaskets, all O-rings that have been removed during the compressor disassembly must be replaced
with new ones.
The reassembly sequence is mostly the reverse of the disassembly sequence. First of all, clean the
work bench and the tools to be used.
Immediately prior to the assembly, use washing agent (e.g., kerosene, parts cleaner) oil to clean the
parts to be assembled, dry them with compressed air, and sufficiently apply lubricating oil, etc. For this,
prepare a sufficient amount of clean lubricating oil for the reassembly. Also, apply oil on both sides of
the gasket.
Because the assembly procedure is mostly similar between the high-stage and low-stage sides, the
following sections provide explanations that are commonly used for both stages. For this purpose, the
part number given in the common explanations will omit the distinction between high-stage and
low-stage by means of a hyphenated suffix (the suffix of [**-1] for low-stage and [**-2] for high-stage
part number will be omitted).
Please fully understand the details in this Section 5.5 for correct assembly work.
Table 5-7 Tightening Torques for Hexagon Socket Head Cap Screws
Torque unit M6 M8 M10 M12 M14 M16 M20 M24
N･m 10 25 50 90 140 240 450 750
kgf cm 100 250 500 900 1400 2400 4500 7500
When fastening the hexagon socket head cap screws, use the tightening torque specified in the above
table.
Compound 2-stage Screw Compressor 3225**C 5.5 Reassembly

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2201MYJE-MY-C8-N_2015.04.
Figure 5-13 Illustration of the Assembly Sequence (Example)

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2201MYJE-MY-C8-N_2015.04.
5.5.1 Unloader Slide Valve and Guide Block

a) Attach two O-rings [89] on the guide block stem [88] and screw in the guide block stem securely
from the bottom of the casing. Then, mount the guide block [87] in the casing.
b) If the slide valve assembly has been disassembled, first make sure that the alignment position
between the slide valves [54] and [55] is accurately reproduced and then tighten the hexagon
socket head cap screws [58] with spring washers [267] at the specified torque. The outer diameter
of the spring washers used here is less than normal spring washers for hexagon socket head cap
screws. So, be careful not to mix up with other washers.
c) After using a grind stone or fine sand paper to lightly finish the circumference of the assembly,
mount the assembly in the main rotor casing. Then, slowly push-in the push rod while aligning the
groove of the slide valve with the guide block.
d) After it is assembled, hold the unloader push rod and move it for several times to check that it
moves smoothly. Then, carefully check the joint with the main rotor casing that there is no step
between them.
If there is a step, check it by reversing the orientation of the guide block first. If the step is still
present, it should be due to imperfect assembling, and it must be reassembled.
◆ A slight step between the surfaces of the unloader slide valve and the main rotor casing is
allowed if the slide valve side is lower.
 If the step is such that the surface of the unloader slide valve is higher than the
surface of the main rotor casing, it is considered the problem of assembly. In such a
case, it must not be left uncorrected. Be sure to reassemble it. Otherwise, the
periphery of the rotor can make contact with the slide valve, resulting in a severe
damage.
e) The low-stage slide valve assembly has an oil injection pipe guide [168] on the opposite side of the
push rod. Do not forget to install the O-ring [59] (Photo 055).
Photo 054 Installing the Slide Valve Photo 055 O-ring for the Oil Injection Pipe
(low-stage) Guide

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5.5.2 Bearing Head and Main Bearings

The main bearing (O-ring type) [27] is installed by a light press fit.
a) Align the notch on the main bearing with the spring pin [14] that is driven in into the bearing head
[11], and then push it in with a pad. For the alignment, it is convenient to use a tool such as a guide
bar.
b) After the bearing has been inserted, install the snap ring [29] to retain the bearing in position (Photo
056). Securely install the snap ring to be fully seated in the ring groove, by pushing the snap ring
with a guide bar or the like, or by lightly hitting the guide bar with a hammer while placing the guide
bar on the snap ring.
Photo 056 High-stage Bearing Head Photo 057 Low-stage Bearing Head
c) On the low-stage bearing head [11-1], install the O-ring [197] in the part where the push rod passes
through. Then, use hexagon socket head cap screws [166-1] to install the O-ring gland [326-1].
When press fitting the bearing, it is recommended to prepare a collared plastic cylinder (spacer) that
exactly fits inside the inner diameter of the bearing and also a collared weight that fits inside the
plastic cylinder as shown in Figure 5-14. Then, hit the top of the weight for easy press fitting of the
bearing. Instead of the above, special tools are also available from us for the high-stage and
low-stage main and side bearings. These tools are similar to the above described weight, and the
surface finish of which is improved to eliminate the need of a plastic spacer (Refer to Chapter 7,
Section 7.5). You are welcome to place an order if necessary.
Figure 5-14 Example Tool for Press Fitting the Bearing

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5.5.3 Bearing Head and Main Rotor Casing
 Since the bearing head gasket [12] is not symmetrically shaped, carefully check the
orientation when installing the gasket.
 If you place the bearing head gasket by just hanging it on the stud bolts, the gasket
will protrude into the inside of the rotor casing when the casing is assembled. Apply
sufficient amount of oil, etc. to the gasket to make it fully attached to the surface to
prevent protruding upon the assembly.
a) In case of the low-stage, after fitting the unloader

push rod [67-1] into the hole of the bearing head
[11-1], slide either the bearing head or the main
rotor casing [1-1] to mate them together.
b) Lightly fastening two bolts [2] in symmetrical position.
Next, drive in the alignment pins [3] to fix the position
by using a copper or an aluminum hammer.
c) After tightening the bolts [2], check that the bearing
head gasket is not protruding into the inside of the
casing.
d) Also, move the slide valve back and forth to check
that it works normally.
e) As the full height of the high-stage main rotor casing
is lower than that of the bearing head, both centers
will not be aligned when they are placed on the work
bench. Therefore, either use a pedestal as used in
the disassembly process or lift the rotor casing using
a crane or other device to align the centers.
The assembly procedure after mating the both Photo 058 Low-stage Rotor Casing
casing flanges is same as the high-stage. and Bearing Head
f) The bottom bolts that cannot be fastened on the work
bench are to be fastened later on.
 Be sure to check for possible protrusion of the gasket after the bearing head and
rotor casing have been assembled together. If you forget to check it out, it may lead
to a measurement error in the end clearance adjustment process, as the gasket may
be placed in between the rotor end and the bearing head surface. Furthermore, if the
compressor is operated after the end clearance is erroneously adjusted and fixed in
this condition, it may compromise the performance.

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5.5.4 Installing the Rotors

Note on the rotor profile of 3225**C
The rotor profile has been changed from the A profile to O profile from the production in November
1993. The biggest difference is the existence of lobe tip edge, as the A profile with lobe tip edge has
been changed to the O profile, which has no lobe tip edge.
The rotor must be sufficiently reworked. If any slight flaw is observed on the shaft surface in the area of
attaching the bearing or seal, use a sand paper to correct and finish the surface. After finishing the
surface to attach the seal, apply protective tape on the surface.
Both the M rotor and F rotor have a specific engagement position, and the position is marked by
carving.
In order to make it easier to match the positions when the rotor is installed into the main rotor casing, a
number is marked on the lobe tip: the M rotor has the marking on the discharge side, and the F rotor
has the marking on the suction side.
Photo 059 Mating Mark on the M Rotor Photo 060 Mating Mark on the F Rotor
a) Apply sufficient amount of lubricating oil on

the main bearing in the bearing head and on
the bearing area of the rotor shaft.
b) While it is easier to mate the markings if the F
rotor is first installed into the casing, it is not a
mistake to install the M rotor first, as shown in
the photo to the right.
c) Regardless of which rotor is installed first, the
lobe of the M rotor with the carved marking of
"1" must be set in between the F rotor’s lobes
that are marked "1" and "2". As it affects
smooth engagement of the lobes as well as
the balance, be sure to mate the markings as
described above.
Photo 061 Installing the M Rotor
 As the circumference of the rotor is touching the main rotor casing in this condition,
any rotation of the rotor should be kept to the minimum required. Otherwise, the
lobes tip of the rotor may be worn.

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5.5.5 Suction Cover and Side Bearings

a) Similarly to the main bearing, the side bearing (O-ring type) [28] is machined to the size that will
allow light press fitting to the suction cover.
Press fit the bearing by aligning the notch position of the bearing with the spring pin [8] for
positioning the bearing driven-in on the suction cover. During the press fitting process, check that
the notch position of the bearing is at the pin position. If the position has been shifted, pull out the
bearing and try the press fitting process again.
b) After the bearing has been installed, install the snap ring [29] to retain the bearing. Make sure that
the snap ring is fully seated in the ring groove either by pushing the ring with a guide bar or tapping
the head of the guide bar while applying the bar on the ring.
Photo 062 Installing the High-stage Side Photo 063 Installing the High-stage Snap Ring
Bearing
Photo 064 Installing the Low-stage Bearing Photo 065 Installing the Low-stage Snap Ring

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5.5.6 Balance Piston Sleeve

The high-stage suction cover shall be further installed with the balance piston sleeve.
a) First install the snap ring for the O-ring retainer [37], and then install the spacer [36].
b) After setting the O-ring [35] in position, install the balance piston sleeve [33].
Insert the chamfered side of the balance piston sleeve towards the O-ring already placed. Also,
align the notch of the balance piston sleeve to the rotation stop/oil supply port.
Photo 066 Installing the O-ring Photo 067 Installing the Balance Piston
Sleeve
c) Attach the set screw [34] for the balance

piston sleeve detent, and attach a remaining
set screw from the opposite side (F rotor side)
to secure the set screw which is attached
earlier.
d) Insert the snap ring [37] to retain the balance

piston sleeve. As it should be difficult to fit the
snap ring into the groove due to the elastic
force of the O-ring, either push the side of the
ring by a guide bar or tap the head of the
guide bar to fit the ring securely into the Photo 068 The Balance Piston Sleeve Detent
groove.
e) Install the O-ring [73] on the unloader push

rod (Photo 069).
Photo 069

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5.5.7 Installing the Suction Cover

a) The gasket of the suction cover [6] is not symmetrically shaped, both for the high-stage and
low-stage.
Apply oil on both sides of the gasket, and attach it to the main rotor casing side while carefully
checking the position of oil supply holes.
Photo 070 (High-stage) Photo 071 (Low-stage)
b) On the high-stage side, pass the unloader push rod through the hole at the bottom of the suction
cover.
Slide (or use a lifting device to move) the suction cover in parallel along the shaft axis to engage the
rotor shafts with the side bearings. At this time, be careful not to damage the inside surface of the
side bearing by the shaft end.
As the low-stage unloader push rod is out to the bearing head side, be careful only with the rotor
shaft end in this work.
c) After the suction cover has been pushed in up to the flange surface, lightly fasten some of the bolts
[2].
d) Using a copper hammer or an aluminum hammer, drive in the alignment pins [3].

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e) Tighten the hexagon socket head cap screws evenly up to the specified tightening torque. The bolts
on the bottom side (about 6 bolts) are to be tightened during the final assembly stage, on the special
stand used in the disassembly process.
f) For both the high-stage and low-stage blocks, move the unloader push rod back and force by hand
to check that it is working normally.
g) Hold and rotate the M rotor shaft to check if it works normally.
In addition, check that the rotor has an axial play (i.e., the rotor can move in the axial direction).
h) On the low-stage, push in the oil injection pipe [85] installed with the O-ring [86] to the suction cover
(Photo 076). Then, install the oil injection pipe gland [164] installed with the O-ring [165].
Photo 076 Photo 077

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5.5.8 Thrust Bearing Block
(Low-stage) (High-stage)
Figure 5-15 Thrust Bearing Block
Table 5-8 Components of the thrust bearing block

Q'ty
P/N Part Name
Low-stage High-stage
42-1, 42-2 Thrust bearing alignment spacer (1), (2) 2 2
38-1, 38-2 Thrust bearing (1), (2) 2 2
250-1, 250-2 Thrust washer (1), (2) 2 2
40-1, 40-2 Lock washer (1), (2) 2 2
237-1, 237-2 Torsional slip washer (1), (2) 2 2
39-1, 39-2 Lock nut (1), (2) 2 2
150 O-ring, JISB2401 G220 2 -
43-1, 43-2 Thrust bearing gland (1), (2) 2 2
46-1, 46-2 Conical spring washer (1), (2) 8 8
45-1, 45-2 Hexagon head bolt (1), (2) 8 8
 The torsional slip washer [237] and lock washer [39] must be replaced with new ones.
 If the removed thrust bearing is to be installed as it is, check the marking of "M" or
"F" on the thrust bearing alignment spacer and assemble it in the same combination
as it was disassembled. This is important in controlling the end clearance on the
discharge side of the rotor.
 Even if the same bearing is installed, the work must be very carefully done as the
dimension can change if any foreign matter such as a chip of paint or dust is pinched
by the alignment spacer.
 In determining the installation direction of the thrust bearing, there are two methods
depending on the existence of an alignment "V" marking on the outer circumference
of the bearing. Install the bearing according to the following procedure provided for
each case.
The assembly sequence for this block is as illustrated in Figure 5-15. The important points to be noted
in the procedure are described below:
a) Check the marking of either "M" or "F" on the thrust bearing alignment spacer to ensure that the
units are assembled in the same combination of parts.
The front and back of the thrust alignment spacer must be distinguished when it is installed. The
larger chamfering side is on the inner machine side, and the smaller chamfering side is on the thrust
bearing side.

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b) If thrust bearing has a "V" marking on the

outer circumference, it means that the
installation direction of the bearing will
sensitively affect the end clearance
adjustment. In this case, the bearing must be
installed with the pointed end of the marking
pointed toward the inside of the machine.
If there is no "V" marking, it means that the
direction of the bearing installation will not
affect the end clearance adjustment. However,
in order to clearly determine the orientation
(whether it is on the inside or outside of the
machine), first combine both bearings with
Photo 078
the bearing number carving facing the outside
of the machine. Then, use a blue whetstone to write the above "V" marking on the bearing to show
the inside direction of the machine. Then, install the bearing (Photo 078).
c) After the thrust bearing has been installed, attach the thrust washer, lock washer, and torsional slip
washer. Then, tighten the lock nut at the specified torque or within the specified range of the
tightening angle (refer to Chapter 7, Section 7.3 "Tightening Torques for Bolts and Nuts" in this
manual) to secure the inner race of the thrust bearing on the rotor shaft.
Photo 079 Tightening the High-stage Lock Nut Photo 080 Tightening the Low-stage Lock Nut
Tightening the lock nut while keeping the setting position between the lock nut wrench hooks
and the lock nut grooves may cause to make the rotor run-out to enlarge due to uneven
tightening forces.
Change the setting position between the lock nut wrench hooks and lock nut grooves about four
times when fastening the lock nut.
d) Turn the M rotor shaft by hand, to make sure that rotation of rotors is smooth.
 As clearance fit is used for the inner race of the thrust bearing, this tightening work is
very important because the bearing is secured only by the tightening force of the
lock nut.

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 When the thrust bearing has been replaced, the dimensional difference between the
sides of the inner race and outer race varies even if it is within the tolerance of the
applicable standard specification.
As such, if the thickness of the thrust bearing alignment spacer that has been used is
insufficient, and if the lock nut is securely tightened from the first, the end clearance
between the rotor shaft end and the end face of the discharge side bearing head will
be lost. Furthermore, as the balls are pressed against the rolling contact surface to
create impression on the surface, it will damage the bearing. To avoid this, gradually
tighten the lock nut while rotating the rotor to make sure the outer race is free, until
the lock nut is fully tightened. If it comes to require more force to turn the rotor while
the lock nut is being tightened, the thickness of the spacer is considered insufficient.
5.5.8.1 End Clearance Measurement

At this point (i.e., after the thrust bearing block has been fully assembled), measure the clearance
between the bearing head end face and the rotor end face on the discharge side. This clearance is
called as the end clearance.
In particular, this measurement must be made when the thrust bearing has been replaced. Even if the
same bearing is used, the measurement should be made for verification.
If the measured clearance does not satisfy the range specified in Table 5-9, proper adjustment must be
made.
Table 5-9 Specified Range of End Clearance (unit: mm)
Rotor Low-stage
Model High-stage
profile S M L LL
A 0.06 to 0.08
3225**C 0.70 to 0.76 0.73 to 0.79 0.77 to 0.83 0.81 to 0.87
O 0.08 to 0.011
a) For pressing the rotor shaft on to the discharge side, hit the rotor shaft strongly from the suction side
while putting a jig (Teflon block).
b) Prepare the thrust bearing gland to be readily mounted. Mount a dial gauge on the suction side axial
end of the rotor, and set the indication needle to zero point while the rotor is fully pressed onto the
discharge end face (Photos 081 and 082).
Figure 5-16 End Clearance Measurement Preparation

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c) Without inserting the conical spring washer, tighten the four fastening bolts of the bearing gland
sequentially and evenly up to the specified tightening torque (Photo 083). Tightening each bolt at
once at the specified torque must be avoided because it will result in uneven tightening. So, repeat
to sequentially tighten the bolts for several times.
d) Then, read the dial gauge indication. This value shows the actual end clearance. If the end
clearance is outside the specified value, perform the adjustment work described in the next section.
If the end clearance is within the specified value, turn the M rotor shaft by hand and confirm the
smooth turning without uneven tightening. And then perform the measurement of the run-out of the
rotor shaft described in next section (3).
Table 5-10 Tightening Torques for the Thrust

Bearing Gland
Tightening torque
Compressor
N･m kgf cm
High-stage 60 600
3225**C
Low-stage 120 1200
Photo 083
Figure 5-17 Measurement of the End Clearance
5.5.8.2 End Clearance Adjustment Procedure

(1) When the end clearance is less than the specified value
In this case, a shim (thrust adjustment liner) must be inserted between the thrust alignment
spacer [42] and the inner race of the thrust bearing to increase the end clearance.
The thickness of the shim must be determined by the difference between the specified end
clearance and the measured value.
◆ Although the thrust adjustment liner is not shown in the sectional view and development
view, you can place an order to us indicating the model name.
(2) When the end clearance exceeds the specified value

If any shim (thrust adjustment liner) has been inserted between the thrust bearing alignment
spacer and the inner race of the thrust bearing, and the thickness corresponds to the difference
between the measured end clearance and the specified value, just remove the shim.
If no shim is used or the thickness of the shim is insufficient to compensate for the excess end
clearance, use a surface-grinding machine (or ask a vendor) to make the thrust bearing
alignment spacer [42] thinner by the amount of the end clearance difference between the
measured and specified values. After the surface grinding is done, use a micrometer to measure
the thickness of the spacer for the entire circumference to make sure the thickness is uniform.

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(3) Measuring the run-out of the rotor shaft

(low-stage M rotor)
If the end clearance adjustment has been
successfully completed, then measure the
run-out of the low-stage M rotor shaft
using a dial gauge at the point of the
mechanical seal attachment and turning
the shaft by hand (Photo 084).
A run-out of up to 0.03 mm is acceptable
for all models. The run-out occurs if the
thickness of the thrust alignment spacer is
not uniform or the marking on the thrust
bearing is not properly positioned. And it Photo 084
occurs if fastening the lock nut performed
without changing the position of the lock nut wrench (i.e., the uneven fastening of the lock nut).
The run-out also becomes significant if any small foreign matter is present in between relevant
parts.
If the run-out exceeds the allowable value, disassemble the unit again even if the end clearance
is within the specified limits, and adjust the relative position of the alignment spacer and thrust
bearing.
This adjustment is very important as any run-out affects the function and service life of the
mechanical seal.
5.5.8.3 Tightening after Finishing the End Clearance Adjustment

a) Remove the thrust bearing glands [43-1] of the low-stage.
b) Attach the O-rings [150] to removed thrust bearing glands. Without inserting the conical spring
washers in the same manner as in the case of the end clearance measurement/alignment,
clearance, tighten the hexagon head bolts i n a diagonal sequence, a little at a time, and finally
tighten them to the specified torque.
The procedures after this are same both low-stage and high-stage.
c) Remove one of the hexagon bolts fastening the thrust bearing gland [43], insert the conical spring
washer [46], tighten the bolt at the specified torque, and repeat this procedure for all other hexagon
head bolts.
d) Bend the tooth of the lock washer to set it in the notch of the lock nut fastening the inner race of the
thrust bearing to prevent loosening (Photos 085 and 086). The these steps c) and d) may be
performed in reverse order.
Conical spring washer has been adopted instead of the plate type lock washer from October, 2001.
When using the conical spring washers for the compressors produced before this modification, the
hexagon head bolt heads may interfere with the low-stage bearing cover inner face.
In case of overhauling the compressor produced before October, 2011, do not change the lock
washer [46] to the conical spring washer.

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5.5.8.4 Installing the Balance Piston

On the high-stage side, install the balance piston
[30] (Photo 087).
Then, use the external snap ring pliers to install
the snap ring [32], and fix it in position.
Check that the snap ring is fully seated in the
groove.
Photo 087
5.5.9 Balance Piston Cover
and High-stage Unloader Cylinder
a) Before installing the balance piston cover on
the high-stage suction cover [5-2], install the
O-ring [328] in the part of the high-stage
suction cover where the push rod passes
through. Then, use hexagon socket head cap
screws [166-2] to install the O-ring gland
[326-2].
b) Install the unload spacer (for 30% load) [420]
on the high-stage push rod. In the case of
3225*LC, no unloader spacer is used
(because the full length of the unloader
cylinder has been reduced to make
adjustment unnecessary). Photo 088 O-ring Gland
c) In the case of 3225**C, as the high-stage side
also has the unloader cylinder [60-2], the
work will become easier if the unloader cylinder is first installed on the balance piston cover [22] and
then the resulting assembly is installed on the high-stage suction cover [5-2].
d) Install the O-ring [63-2] in the O-ring groove on the machined surface of the balance piston cover
along which the unloader cylinder is installed (Photo 089).
The mounting position of this O-ring has been changed in Oct. 1996 to the current position shown in
Photo 089 from the previous chamfered part in the corner of the balance piston cover. The low-stage
bearing cover was similarly changed at the same time.
Photo 089 Photo 090 Steel Rod for Positioning

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e) Align the position of the balance piston cover with the unloader cylinder. As shown in the above
Photo 090, using a steel rod for positioning makes it easier to align the position of bolt holes.
As no gasket is used on the mating flange between the balance piston cover and unloader cylinder,
evenly and thinly apply liquid gasket (made of special synthetic rubber) on the surface of the flange
of the unloader cylinder inside from the center of the bolt holes.
f) As the O-ring of the balance piston cover is already installed, lightly tap the flange surface with a
soft hammer to install it as shown in Photo 091.
g) When joining the flanges, also align the bolt hole positions if any positioning steel rod is not used.
Then, insert two hexagon socket head cap screws [61] in the positions shown in Photos 092 and
093 to fasten the unloader cylinder to the balance piston cover.
Bolt positions for fastening

the cylinder and cover
Photo 091 Photo 092 Photo 093
h) Install the O-ring [73-2] in the O-ring groove on the tip of the unloader push rod [67-2], at the
position where the unloader piston is installed.
i) Attach the O-ring [65-2] without lubricating oil on the unloader piston [64-2], and then install the cap
seal [66-2] on it. It can be smoothly installed by slightly folding the cap seal along the circumferential
direction. Also, using a small and smooth spatula (Photo 094) will facilitate the assembling work.
j) Install the unloader piston fitted with the O-ring and cap seal in the unloader cylinder. One side of
the unloader piston is with screw holes for eye bolts, while the other side does not have such holes.
First, to make it easier to fit the cap seal on the unloader cylinder wall, lightly press one side of the
piston onto the chamfered area of the unloader cylinder by hand, changing the side of the piston for
several times. Finally, apply lubricating oil to the unloader cylinder, then, push and install the piston
with the screw holes side of the piston facing the unloader cover. After the installation, check that
the cap seal is not broken or pinched.
Photo 094 Photo 095

k) Push the unloader piston into the unloader cylinder and set it in the middle of the cylinder, pull the
unloader push rod [67-2] toward you, and install the balance piston cover with the gasket fitted as
shown in Photo 095 onto the high-stage suction cover (Photo 096). Pushing the piston into the push
rod and temporarily fastening the lock nut [69-2] in the course of the work will make later work
easier.

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Photo 096 Photo 097
m) After joining the flanges together, tighten the hexagon socket head cap screws [24] of the balance
piston cover at the specified torque of 90 N･m and tighten the hexagon socket head cap screws
[62-2] of the unloader cylinder at the specified torque of 240 N･m.
n) Use the eye bolts to pull the piston toward you (Photo 098), once remove the temporarily fastened
lock nut, install the lock washer [70-2] and lock nut [69-2], and then tighten the lock nut at the
specified torque of 140 N･m. To prevent loosening, bend the tooth of the lock washer at the notch of
the lock nut (Photo 100). Lastly, use the eye bolts to check the smooth movement of the piston
(Photo 101).
Photo 098 Photo 099
Photo 100 Photo 101

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5.5.10 Bearing Cover

a) Before installing the bearing cover [16], check that
the teeth of the lock washer of the thrust bearing part
have been properly bent to prevent rotation and that
the hexagon head bolts fastening the thrust bearing
gland are with conical spring washers.
b) For ensuring the safety, screw two stud bolts in the
upper bolt holes on the flange of the low-stage
bearing head [11-1].
c) After applying sufficient amount of oil, etc. on the
flange surface of the bearing head as well as on
both sides of the gasket (1) for the bearing cover
[17-1], hang the gasket from the upper stud bolts
and attach the gasket onto the flange surface (Photo
102).
Photo 102
 The bearing cover gasket is not symmetric because there is a hole for lubricating
oil line to the mechanical seal block in the left (seal) side.
Be careful that do not mistake the direction of the gasket when attaching onto the
bearing head flange surface. Mistaken the direction of the gasket causes the
lubrication failure to the shaft seal block.
Photo 103 Photo 104
d) While lifting the bearing cover using a lifting hook on the eye bolt, install the bearing cover carefully
not to make contact with the M rotor shaft or the push rod (Photo 103). Once the cover is on the stud
bolts, the lifting hook may be removed.
e) After correctly setting the position of the alignment pins, lightly tap the flange at different places
alternately using a copper hammer or soft hammer to install the cover in position (Photo 104).
f) When the cover has come to the position the bolts can be screwed in, screw in two or three
hexagon socket head cap screws [18-1] and evenly tighten them to reduce the clearance and make
the cover contact the body. Then, tighten all the bolts at the specified torque of 450 N･m.

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The standard mechanical seal assemblies used in the current shaft seal of standard
screw compressors are of the BBSE (balance bellows single) type. There are other cases where the
BOS (balance O-ring single) type seals are used, according to the specification by the customer.
Figure 5-18 BBSE-type Mechanical Seal
a) Before installing the mechanical seal, clean the seal

installation area on the rotor shaft. In particular,
immediately prior to the assembly, check again that
no flaw is present on the step area of the shaft where
the seal is to be installed.
b) Install the oil seal [50] on the seal retainer [48]. The
installation orientation of the oil seal has been
reversed in November 2002 as a design change.
While the oil seal had been installed with the oil seal
lip facing the direction of the atmosphere, the
direction was reversed. This is because excessively
high pressure should be avoided by helping the
escape of oil from the seal box. Photo 105
Using a Teflon block or the like as a pad (Photo 105),
lightly hit the pad to push the oil seal evenly into the
retainer until it is fully seated. Once the oil seal is
fully inserted, you can easily sense it as the hitting
sound as well as the response will change.
After the installation, check that the level difference
with the retainer is uniform and that the oil seal is
evenly inserted by observing the condition from the
opposite side.
c) Insert the O-ring [744] into the inner circumference of
the oil seal sleeve [528], and install the sleeve into
the oil seal retainer with an O-ring inserted as shown Photo 106
in Photo 106.

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d) Install the oil seal retainer with the oil seal and sleeve along the rotor shaft using two M8 eye bolts
as shown in Photo 107. At this time, position the oil escape hole of the retainer on the upper side of
the rotor shaft, and accurately align the notch in the retainer with the position of the spring pin [20]
that is driven in into the bearing cover to prevent its rotation.
After the installation, check the position by slightly turning the retainer to the left and the right using
the eye bolts. If the position is correct, the retainer will not rotate.
e) Secure the oil seal sleeve using two set screws [529] on the rotor shaft (Photo 108).
Photo 107 Photo 108
f) Then, insert the O-ring for the seal retainer [49] (Photo 109).
 You should be particularly careful on this point, as the O-ring for the oil seal retainer
[49] is often forgotten to be installed.
g) Insert the O-ring [112] on the inner circumference of the seal collar [109], and install the seal collar
on the rotor shaft. Before the assembly, apply sufficient lubricating oil onto the rotor shaft and wash
out dust and stains. Push in the seal collar carefully not to damage the O-ring [112] by the step on
the rotor shaft (Photo 110). After installing the seal collar, push it by hand and check it’s normal
movement in the axial direction.
h) Fasten the seal collar on the rotor shaft by screwing the two seal collar set screws [111] at the
countersinks on the rotor shaft (Photo 111). Failing to fasten the screws at the countersink positions
will damage the rotor shaft, and it can cause a leakage.
Photo 109 Photo 110 Photo 111
i) Install the O-ring [103] for the mating ring and the mating ring [101] on the seal cover [51]. (Photo
112)

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j) Apply oil on the seal cover gasket [52] and attach it to the seal cover flange by carefully aligning the
oil hole position on the gasket and the one on the flange.
◆ In the case of the standard internal oil supply system, oil is first sent from the bearing cover to
the seal cover through the oil supply hole machined on them, then from the notch in the seal
cover to the upper part of the seal cover through a groove, and lastly supplied from the oil supply
hole in the seal cover to the upper part of the sliding surface of the mechanical seal.
k) Install the seal cover with the gasket such that the oil drop tube comes to the bottom side.
At this time, carefully install the seal cover not to hit the mating ring in the seal cover with the rotor
shaft. For this, hold the seal cover at the right angle to the rotor shaft or only slightly incline it such
that the top side follows the bottom side.
m) At a midway point, the sliding surface of the seal ring comes in contact with that of the mating ring.
At this point, use a taper gauge (Photo 113) to check the clearance between the surfaces of the seal
cover gasket and the bearing cover flange. This clearance is called "fastening margin" of the seal,
and is used as a guideline in determining the sliding surface pressure between the rotating ring and
stationary ring of the seal. In case of the BBSE type seals for 3225**C, make sure that this value is
in the range of 3.5 to 4.5 mm.
Photo 112 Photo 113
n) If it is confirmed that the fastening margin of the seal

is appropriate, firmly press the seal cover onto the
bearing cover. While you will feel the reaction of the
seal bellows, keep pressing the cover and fasten
two hexagon socket head cap screws [53] evenly to
secure the seal cover at opposite positions
separated by 180°. When there is no clearance
between the surface of the flange and gasket, fasten
all other bolts at the specified torque of 240 N･m.
o) After fastening the seal cover, remove the plug on
the top of the seal cover, and supply oil approx. 600
mL into the seal cover while rotating the rotor shaft
(Photo 114).
This oil refilling work is very important to maintain
the airtightness in the shaft seal block when
vacuuming after compressor overhauling.
After the refilling work, make sure to attach the
removed plug on the seal cover. Photo 114

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5.5.12 Low-stage Unloader Cylinder

The installation of the low-stage unloader cylinder may be done either after the bearing cover
installation described in Section 5.5.10 or after the installation of the mechanical seal.
a) Check that the O-ring [73-1] is inserted in the O-ring groove on the tip of the unloader push rod
[67-1], at the position where the unloader piston is installed.
b) Install the O-ring [65-1] and cap seal [66-1] on the unloader piston [64-1].
c) Install the unloader piston fitted with the O-ring and cap seal in the unloader cylinder [60-1]. The
work procedure is the same as that for the high-stage side as described in Section 5.5.9, item j).
d) Insert the O-ring [63-1] in the O-ring groove on the part of the bearing cover [16] in which the
unloader cylinder is installed (Photo 115).
◆ The assembly method of this O-ring [63-1] has been changed in the design change dated Oct.
29, 1996. While the O-ring is inserted to the triangular part on the flange surface of the bearing
cover that makes contact with the unloader cylinder in the previous method, the O-ring is
inserted in the O-ring groove in the current method.
e) Install the unloader cylinder in the bearing cover (Photo 116), and fasten the eight hexagon socket
head cap screws [62-1] at the specified tightening torque of 450 N･m.
Photo 115 Photo 116
f) Set the lock washer [70-1] and lock nut [69-1] on the unloader push rod, and fasten the lock nut at
the specified torque of 180 N･m.
At this point, in the case of 3225M*C, be careful not to excessively pull the unloader piston toward
you as it is explained in the caution in the next section.
To prevent loosening, bend the tooth of the lock washer on the tightening side at the notch of the
lock nut (Photo 117). Lastly, use the eye bolts to check the movement of the unloader piston (Photo
118).
Photo 117 Photo 118

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5.5.13 Unloader Cover
Photo 119 Installing High-stage

Unloader Cover
Figure 5-19 Unloader Cover Block Photo 120 Inserting Spacer
a) Use eye bolts to move the unloader piston back and forth to check the normal operation again. In
doing this, be careful not to pull the unloader piston up to the extreme position.
 You should be careful because if the low-stage unloader piston is pulled beyond a
limit, the slide valve may be disengaged from the guide block in some models
(3225M*C).
b) To prevent disengagement of the slide valve from the guide block on the 3325M*C models, the
spacer [423], of which outer circumference has O-ring [431] inserted, must be installed in the
low-stage unloader cylinder beforehand. (Photo 120)
c) Assemble the ball bearing [78] on the shaft portion of the indicator cam [77]. When fitting the
bearing onto the shaft, push the inner race of the bearing. Pushing the outer race may damage the
bearing. Push the bearing to the stepped portion of the indicator cam and retain the bearing with the
external snap ring.
d) Sufficiently apply oil on the unloader cover [74], and install the V-ring set [82] in it. One of the rings
of the V-ring set (i.e., dark colored one) is made of rubber to improve the sealing performance, and
is placed as the second item from the outside as shown in Fig. 5-19. The orientation of the V-ring
must be such that the apex of the V-shape faces the outside and the lips face inside.
e) Install the spring [83] and the spring retainer [84] into position. Then, insert the shaft of the indicator
cam assembled in Step b) above into the V-ring. Lastly, fasten the bearing gland [80] onto the
unloader cover to retain the bearing.
f) After making sure that the indicator cam rotates smoothly, attach the O-ring [75] to the unloader
cover.
g) Install the unloader cover on the unloader cylinder [60]. Making sure that the guide pin [68] of the
unloader push rod [67] is well engaged in the spiral groove of the indicator cylindrical cam, push-in
the unloader cover. With the oil supply hole for the unloader operation up, secure the unloader
cover by fastening the hexagon socket head cap screws [76] at the specified torque (90 N･m for
both high-stage and low-stage).

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5.5.14 Coupling the High-stage and Low-stage Blocks
【157】 Driven hub key 【160】 Locknut

【159】 Self-locking knurled hexagon socket set screw 【161】 Lock washer
【153】 Driven hub 【152】 Drive hub
【151】 Drive sleeve 【158】 Drive hub key
Figure 5-20 Gear Coupling Block
a) Attach the driven hub [153] of the gear coupling on the high-stage side, and fasten the M12
hexagon socket set screw [159] to hold the driven hub key [157].
This hexagon socket set screw is knurled and provided with anti-loosening.
b) On the low-stage, attach the drive hub [152], lock washer [161], and lock nut [160] in this order.
Tighten the lock nut at the specified torque or within the specified range of the tightening angle (refer
to Chapter 7, Section 7.3 "Tightening Torques for Bolts and Nuts" in this manual). Then, bend the
tooth of the lock washer at the notch of the lock nut.
c) Set the drive sleeve on the low-stage drive hub.
d) Screw in two stud bolts into two of the upper bolt holes in the low-stage flange.
e) After applying sufficient amount of oil, etc. on both sides of the bearing cover gasket (2) [17-2], hang
the gasket from the upper stud bolts and
correctly attach the gasket onto the flange
surface.
f) After slightly lifting up the high-stage block
from the surface table using a lifting device,
slowly move the block to approach the
low-stage side.
At this time, the gear coupling can be
engaged smoothly if the M rotor shaft on the
low-stage side is rotated clockwise and
counterclockwise alternately for a small
amount (Photo 121).
Photo 121

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g) Once the gear coupling has been successfully engaged, push the high-stage unit onto the low-stage
unit along the rotor shaft axis. Then, insert 4 to 6 hexagon socket head cap screws [18-2] into the
bolt holes, while avoiding the bolt holes that are adjacent to the left and right alignment pins, and
temporarily fasten them evenly to eliminate the clearance between the low-stage and high-stage
flanges.
h) After the flange surfaces have contacted, slightly loosen the bolts that have been temporarily
fastened. Then, drive in the left and right alignment pins [19-2] (Photo 122).
i) Rotate the low-stage M rotor using a special tool or something to check that no abnormality is found.
Photo 122 Photo 123
j) Tighten the hexagon socket head cap screws at the specified torque of 450 N･m (Photo 123). The
lower bolts must be tightened with the compressor placed on a special stand as in the case of
disassembly (Photos 124 and 125). Do not forget to attach bottom drain plugs while the compressor
is placed on the special stand.
Photo 124 Photo 125

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5.5.15 Unloader Indicator

The unloader indicator contains micro-switches, a micro-switch cam, and a potentiometer. These parts
are used to detect the change in the rotation angle of the indicator cam shaft, which converts the axial
position change of the unloader slide valve into rotational position change, convert the change into an
electric signal, and send the signal to the package unit and/or the controller of the refrigeration system.
To check the unloader indicator after inspection, adjustment, or parts replacement, coordination with
the controller side will be required. Even in a case where the compressor is carried out of the
installation site for overhaul, the indicator assembly is often removed from the compressor (to be kept
at the site) and the inspection/adjustment and parts replacement are performed at the site. Thus, this
section provides a detailed procedure, which may be helpful after the reassembly work.
 When removing the indicator block or performing inspection/adjustment or parts

replacement, be sure to shut down the control power and use lock-out and tag-out
procedures. If the power is not shut down, there is a risk of electric shock.
The high-stage side of 3225**C is implemented with an indicator assembly that is identical to the one
used in a standard single stage machine (except that the dial and micro-switch cam for the 3225*MC
and the 3225*SC are special to the high-stage of the 3225*M/SC types, for the range of 30 to 100 %).
The low-stage side of 3225**C is implemented with an indicator assembly that is identical to the one
used in 1612**C, specially designed for the low-stage use, with the addition of a bevel gear to convert
the axial direction to the lateral direction, for the indicator and dial.
5.5.15.1 Potentiometer
The potentiometer of the standard-type indicator is a rotary instrument for measurement over a full turn.
It senses the continuously variable position (indicated load of 0 % to 100 %) of the unloader slide valve,
and feeds the sensed position as electric signals to the control side of the package unit or refrigerating
system.
While the expected service life of the potentiometer will significantly vary depending on the installation
environment of the compressor (e.g. corrosive gas atmosphere, moisture, or the like.) and operational
conditions (e.g. frequent partial load operations, frequent start/stop operation, vibration, etc.), the
potentiometer is a consumable part that requires regular replacement according to the situation.
■ Disassembly
Refer to Section 5.4.1.1 in this manual for the disassembly procedure for the potentiometers on the
low-stage and high-stage sides.
■ Inspection
a) Check at the terminal block that the lead wires of the potentiometer are not loosened.
b) Check for any crack or other defects in the soldering of the lead wires of the potentiometer.
c) Manually rotate the shaft of the potentiometer and measure the resistance value using a circuit
tester to check that the resistance value changes smoothly.
5.5.15.2 Micro-switches and Micro-switch Cam

The unloader indicator uses two micro-switches and one micro-switch cam to detect the commanded
0 % (30 % for the high-stage of 3225*M/SC) and 100% capacity control positions of the unloader slide
valve.
If the micro-switch fails or any of these connections becomes loose for some reason, correct position
detection cannot be made, and it causes a problem in the operation control of the compressor.

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■ Disassembly
Refer to Section 5.5.2.1 in this manual for the disassembly procedure for the potentiometers on the
low-stage and high-stage sides.
■ Inspection
a) In the normal condition where the hydraulic line for the capacity control of the compressor is not
opened, set the unloader piston to the no load and full load positions from the manual capacity
control circuit and check the operation of the control circuit to see if the micro-switch can detect the
0 % (30 %) and 100 % positions of the micro-switch cam (i.e., by checking the operation of the
relevant relays and contacts).
b) After shutting down the control power and carrying out the lock-out and tag-out procedures, remove
the indicator glass and check that the micro-switch mounting screws [126] are not loosened.
c) Check that the hexagon socket set screw [128] securing the micro-switch cam [127] are not
loosened.
d) After checking that the wiring for the micro-switch has been removed, turn on and off the switch to
check the normal switching operation of the micro-switch using a circuit tester.
e) If the hydraulic line for the capacity control of the compressor is opened for overhaul or other work,
use nitrogen gas or compressed air to set the unloader piston to the no-load and full load positions
and check if the micro-switch can detect the 0 % (30 %) and 100 % positions of the micro-switch
cam.
f) Carry out other visual inspection including any indication of water intrusion in the indicator, any rust
on switch terminals, any wear of the switch roller or micro-switch cam, and so on.
5.5.15.3 Reassembly
To carry out the reassembly, follow the disassembly procedure in reverse. Lastly, correctly set the
needle position according to the following procedure:
a) If the hydraulic line for the capacity control of the compressor is opened for the purpose of overhaul
or other work, use nitrogen gas or compressed air to set the unloader piston to the no-load position.
Then, set and fix the indicator dial needle to the origin of the figure to show the rotation on the dial.
Next, set the piston to the full load position. Make sure the indicator dial needle points to the end
point of the figure on the dial.
b) In the normal condition where the hydraulic line for the capacity control is not opened, use the
manual capacity control circuit to move the piston. While the control power is turned on, the
indicator cover must be mounted to prevent possible electric shock. Then, after the piston position is
fixed, control power is turned off, and the lock-out and tag-out procedures are completed, remove
the indicator cover and secure the indicator dial needle in position.

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Figure 5-21 The High-stage Unloader Indicator for 3225**C
Table 5-11 Component Parts of the High-stage Unloader Indicator for 3225**C
P/N Part Name Q'ty P/N Part Name Q'ty
121 Micro-switch base plate 1 136 Hexagon socket set screw, M3 × 14 3
Hexagon socket head cap screw, M6
122 3 137 Dial, 30 to 100 % 1
× 20
123 Micro-switch base plate 1 137 Dial, 0 to 100 % 1
124 Philips Screw, M3 × 10 2 138 Philips Screw, M3 × 5 2
125 Micro-switch 2 139 Indicator dial needle 1
126 Philips Screw, M3 × 25 4 140 Philips Screw, M3 × 10 1
127 Micro-switch cam, 30 to 100 % 1 141 Indicator glass 1
127 Micro-switch cam, 0 to 100 % 1 142 Indicator glass spacer 1
128 Hexagon socket set screw, M4 × 8 1 143 Electric cable gland 1
129 Potentiometer 1 144 Bracket, 125L 1
130 Potentiometer mounting plate 1 145 2
× 15
131 Philips Screw, M3 × 5 3 146 Unloader indicator cover (2) 1
132 Terminal block 1 147 3
× 15
133 Philips Screw, M3 × 20 2 148 Plug 1
134 Dial plate support [2] 2 214 Spring pin 2 dia. × 8 1
135 Dial plate support [1] 2 265-2 Spring washer, M3 7
Note: For the items 127 and 137, the range of 30 to 100 % is specified for 3225*MC or 3225*SC
and the range of 0 to 100 % is specified for 3225*LC.

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Figure 5-22 The Low-stage Unloader Indicator of 3225**C (Type 1612C)
Table 5-12 Component Parts of the Low-stage Unloader Indicator for 3225**C
P/N Part Name Q'ty P/N Part Name Q'ty
121 Micro-switch base plate 1 143 Electric cable gland 1
122 3 144 Bracket, 125L 1
× 25
123 Micro-switch base plate, 125L 1 145 2
× 15
Unloader indicator cover [2],
124 Philips Screw, M3 × 10 2 146 1
1612LSC
125 Micro-switch 2 147A 2
× 60
126 Philips Screw, M2.5 × 25 4 147B 2
× 95
127 Micro-switch cam, 0 to 100 % 1 149 Micro-switch insulating plate, 125L 1
128 Hexagon socket set screw, M4 × 8 1 202 Bevel gear [2]. 6 dia. 2
129 Potentiometer 1 203 Indicator dial needle shaft 1
130 Potentiometer mounting plate 1 204 Indicator dial needle shaft holder 1
131 Philips Screw, M3 × 5 3 205 Countersunk screw, M5 × 14 4
132 Terminal block 1 206 Indicator glass spacer 1
133 Philips Screw, M3 × 20 2 207 Indicator glass holder 1
134 Dial plate support [3] 2 210 Philips Screw, M5 × 15 4
136 Hexagon socket set screw, M3 × 14 3 211 Countersunk screw, M3 × 5 2
137 Indicator dial [B], 0 to 100% 1 212 4
× 30
138 Philips Screw, M3 × 5 2 213 Spring pin 2 dia. × 8 1
139 Indicator dial needle 1 265-1 Spring washer, M2.5 2
140 Philips Screw, M3 × 10 1 265-2 Spring washer, M3 2
141 Indicator glass 1 - - -

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Table 6-1 describes typical trouble symptoms of compressors, their causes and actions to be taken.
The explanations of this Chapter are assumed that the compressor is used in the general refrigeration
cycle.
Table 6-1 Troubleshooting
01: Compressor does not start up

Direct cause Root cause Action
Power source is off. Mostly caused by forgetting to Use a check sheet for post-inspection
turn on after inspection. actions and implement finger pointing
and call check to prevent forgetting.
Main motor failure Mostly caused by activation of Refer to the operation manual of the
overload protection circuit. motor for details including other
causes and actions.
"Micro-switch and Micro-switch failure Replace.
micro-switch cam" of the
indicator do not sense Loosening of micro-switch or Adjust the position of the cam and
capacity control of 0%. micro-switch cam set screw switch, and tighten them.
due to vibration. Use thread locking agent when
necessary.
When compressor's vibration is
unusually high, see Item No. 12
"Compressor generates abnormal
vibration and/or sound".
Defective capacity control Improper adjustment of oil flow Readjust.
oil supply line control valve (throttled
excessively).
Leak/clogging in piping or Remove cause, and check oil for
solenoid valve contamination/replace oil.
Oil pressure not detected Failure of oil pressure Identify defective devices, investigate
protection device, pressure causes of failure and take necessary
sensor, relay, etc. actions.
Then, replace failed device(s).
Pressure pipe is clogged. Remove clogging, and check oil for
contamination/replace oil.
Cooling water circulation Failure of devices such as Identify defective devices, investigate
is not confirmed. cooling water pump and causes of failure and take necessary
related circuits actions.
Circulation route is clogged. Remove the clogging.
Failure of magnet, relay, Aging degradation Replace with new one.
etc. in compressor startup
circuit Poor installation environment Replace ventilation fans, etc. if
defective.
Improve temperature, humidity and
ventilation at the installation site.
02: Compressor stops immediately after startup

Low pressure protection Insufficient refrigerant flow To correct insufficient refrigerant,
circuit activates.  Insufficient refrigerant check leak, stop leak and then add
refrigerant.
* Also pay attention to moisture
entering into the system.

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02: Compressor stops immediately after startup (continued)

Low pressure protection Insufficient refrigerant flow To correct insufficient liquid supply,
circuit activates.  Insufficient liquid supply inspect expansion valve and liquid
supply strainer. Take necessary
actions.
In addition, inspect devices and
parameters (set values) of the
expansion valve aperture adjusting
mechanism, and take necessary
actions.
Heat exchange failure in heat If there are any problem (insufficiency)
exchanger in heat exchange, such as
malfunction of defrosting, investigate
the cause and take necessary
actions.
In case of malfunction of pressure
control valve, replace the valve or
remove the cause.
Failure of low pressure Identify defective devices, investigate
Motor overload Motor overload that occurs just after startup is mostly caused not by the
refrigeration cycle but by the motor. Refer to the instruction manual of
the motor.
03: Unusually low pressure (decrease of suction pressure)

Refer to direct cause, Same as left Same as left
"Low pressure protection
circuit activates", in Item
02 above.
04: Low oil pressure (low lubricating oil supply pressure)

Oil filter element is Contamination of lubricating oil Remove clogging, and check oil for
clogged. contamination/replace oil.
* Pressure difference
between the outlet port Internal defects of compressor Check for oil contamination and
and inlet port is large. conduct vibration/noise diagnosis.
Overhaul compressor if necessary.
Insufficient oil in oil Oil heater is not functioning, Inspect oil heater alone, inspect
separator. refrigerant dissolves relays, etc. on related circuits, and
excessively when the machine replace parts as necessary.
is stopped, and oil loss occurs
at startup.
Insufficient oil return due to Correct insufficient refrigerant

insufficient refrigerant circulation, and return oil from
circulation load-side heat exchanger.
* Supply lubricating oil temporarily.
Troubles such as clogging in oil Remove causes of the trouble, and
return passage restore the system.

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04: Low oil pressure (continued)

Insufficient oil in oil Extensive oil leak Inspect machine room and around the
separator. compressor, and take necessary
actions.
Check if there is oil floating in cooling
water system.
→If there is, check for oil leak from
heat transmission tube of oil cooler
and take necessary actions.
If piping is damaged due to excessive
vibration, take measures to reduce
vibration (including measures for
resonance vibration).
Oil pressure detection Failure of oil pressure Identify defective devices, investigate
function is defective. protection device, pressure causes of failure and take necessary
Pressure pipe is clogged. Remove clogging, and check oil for
05: Intermediate pressure is unusually high.

High suction pressure Heat load on load side is Inspect the conditions on load side
higher than design value. (warehousing volume,
opening/closing of doors, etc.), and
take necessary measures.
Malfunction of suction pressure In case of pressure sensing failure,
control mechanism replace the pressure sensor.
* In some cases, pressure pick-up
position is improper. → Change the
position.
If there is a problem in device(s) on
the control circuit, find the defective
device(s) and replace it.
If parameter (set value) on the control
circuit is improper, optimize it.
In case of malfunction of pressure
control valve, replace the valve or
remove the cause.
Malfunction of compressor's See Item No. 11 "Capacity control
capacity control malfunction".
Liquid flow-back from Failure or internal leakage of Repair or replace.

intermediate liquid cooler. intermediate liquid supply
expansion valve
There is problem in Malfunction of capacity control See Item No. 11 "Capacity control
compressor's high-stage. on compressor's high- stage malfunction".
Excessive wear or sliding Overhaul compressor and replace

damage of the part(s) on parts.
compressor's high- stage Replace the whole quantity of
lubricating oil.

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06: Unusually high pressure (abnormal discharge pressure)

Heat exchange failure in Heat transmission tubes and/or Clean and wash.
condenser (heat fins are contaminated or Depending on the contamination
exchanger) blocked. level, use chemical cleaning.
Failure or water dripping in fan Identify defective devices, investigate
motor, thermo switch, water causes of failure and take necessary
spraying pipes, cooling water actions.
pumps, etc. Then, replace failed device(s).
Faulty adjustment of cooling In case of manually adjusted valve,

water/brine readjust the valve.
When an automatic control valve
(including wax valve) is used,
investigate the cause and take
necessary actions.
Other causes of insufficient Inspect filters installed on the
flow of cooling water, etc. circulation route for clogging and
contamination, and take necessary
actions.
Inspect for leaks in circulation routes,
and take necessary actions.
Inspect water supply
routes/mechanisms, and take
necessary actions.
If frozen, take measures such as
improvement of heat insulation or
increase of temperature.
Deficiency in heat exchanger If the symptom is caused by change in
performance operating conditions, re-examine the
conditions for improvement.
If the symptom is caused by change in
installation environment, improve the
environment if possible.
In either case, if improvement
measure is difficult to be made, add
more heat exchangers or increase
their sizes.
Non-condensable gases Leak on low pressure side Perform a leak check, and take
mixed into the system * There are also cases where necessary measures.
the symptom was caused by Air-purge the heat exchanger.
corrosion in suction
temperature gauge protection
Refrigerant is excessive. In some cases, insufficient Properly adjust the refrigerant charge.
cooling is judged as caused by
insufficient refrigerant and, as
a result, refrigerant is charged
repeatedly.
Capacity of heat changer is If the symptom is caused by change in

insufficient. operating conditions, re-examine the
conditions for improvement.
If improvement is difficult, add heat
exchangers or increase their sizes.

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06: Unusually high pressure (continued)

Discharge pressure Failure of high pressure Identify defective devices, investigate
detection function is protection device, pressure causes of failure and take necessary
defective. sensor, relay, etc. actions.
clogging of pressure pipe Remove clogging, and check oil for
Outlet shut-off valve of oil Operator forgot to restore after Open the valve or perform emergent
separator is closed. shut down operation. stop.
Human error Be sure to conduct tagout while
handling valves.
Be sure to check valves before
starting the compressor.
07: Discharge temperature is abnormally high.

Overheated during Insufficient refrigerant flow See the causes listed in item 02
operation above.
Heat load on load side is Inspect the conditions on load side
higher than design value. (warehousing volume,
opening/closing of doors, etc.), and
take necessary measures.
Failure of low pressure Identify defective devices, investigate
Non-condensable gases Leak on low pressure side Perform a leak check, and take
mixed into the system necessary measures.
Air-purge the heat exchanger.
Oil supply temperature is Heat exchange failure in oil For water-cooling system, see "Heat
high. cooler exchange failure in heat exchanger" in
06 above.
For liquid cooling system, check liquid
supply expansion valve, temperature
sensor and related
relays/wiring/terminals, and take
necessary actions.
Oil temperature rise protection Check temperature protection device,
feature does not function. temperature sensor and related
relays/wiring/terminals, and take
necessary actions.
Defective discharge Failure of temperature Identify defective devices, investigate
temperature protection device, temperature causes of failure and take necessary
detection/protection sensor, relay, etc. actions.
feature. Then, replace failed device(s).
Insufficient oil supply See "Low oil pressure" in Item Same as left
04 above.

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08: Leak from mechanical seal

Initial leak after In some cases, immediately In case of initial leak, although leak
replacement until sliding after replacement, the amount might increase temporarily, it
surfaces settle compressor-specific operating will decrease gradually. Check that
conditions and the pressure leak does not increase continuously.
receiving conditions of Duration of initial leak depends on
machined sliding surface is design/operating conditions. It is
unstable. approximately 200 hours, as a rough
indication.
Sliding surface is Started and stopped too many If heat load is less than the level set
roughened due to times. by the equipment's design conditions,
overheating. * In case of standard review the operating conditions and
equipment, "four or more set control such that equipment is
times per hour" is considered started/stopped less frequently.
"frequent/too many". In case of capacity control
malfunction, see "Capacity control
malfunction" in item No. 11.
Excessive refrigerant solved In case of liquid flow-back, remove the
into the lubricating oil, resulting cause(s).
in decreased viscosity of oil. If oil heater or devices on its control
circuit are defective, replace the
defective part.
Overheated operation See the causes in item 02,
"Insufficient refrigerant flow".
Oil supply temperature is high. See the causes in item 07, "Oil supply
temperature is high".
Machine is stopped for a User-specific conditions, such If machine is sometimes stopped

long time. as intermittent heat load longer than a week, take either of the
(No oil film on sliding following measures: (i) Manually
surfaces) operate oil pump alone and turn the
rotor shaft of the compressor.
(ii) Attach an oil pot for supply oil to
the seal cover.
Deteriorated part(s) Hardened O-ring If deteriorated over time, replace.
For other specific causes, see the
causes/action for symptom
"Overheating of sliding surface".
Swelled O-ring In case of liquid flow-back, remove the
* This occurs when the cause(s).
lubricating oil of refrigerating If oil heater or devices on its control
machine contains large circuit are defective, replace the
amount of refrigerant. defective part.
Deteriorated seal ring/mating If deteriorated over time, replace.
ring For other specific causes, see the
causes/action for symptom
"Overheating of sliding surface".
Incompatibility of Unsuitable lubricating oil was If possible, review the operating
lubricating oil and selected, or operating conditions.
operating conditions (such conditions have changed after If not, see "4-1 Lubricating Oil
as working temperature installation of the equipment. (Refrigerant Oil)" to select suitable
range or refrigerant) lubricating oil and replace the whole
quantity.

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08: Leak from mechanical seal (continued)

Poor contact of sliding Foreign matter attached to Replace the whole quantity of
surfaces sliding surfaces, due to lubricating oil.
contaminated lubricating oil. Install bypass filter to oil supply line.
Faulty assembly of parts Disassemble, replace parts and
Human error reassemble.
Use assembly check sheet to ensure
confirmation.
09: Squeaking of mechanical seal

During initial period after As the sliding surfaces are very Squeaking itself does not cause leak
exchange for new hard and dense, they need from seal or deterioration in sealing
mechanical seal, squeaks time to fit together. function.
may be heard from sliding Normally, squeaking is heard for
surfaces until they fit several dozens of hours, however, it
together. may last longer in rare cases.
→In this case, contact our service
center.
10: Capacity control position is indicated incorrectly

Inaccurate reading of Screw for securing indicator Manually operate the compressor's
compressor indicator needle is loose. capacity control to indicate 0%
gauge. position, and tighten the screw again.
Indicator's bevel gears are If deteriorated over time, replace.
worn. If the wear is caused by excessive
vibration of the compressor, take
measures to reduce vibration and
then replace the bevel gears.
Inaccurate reading of The cam groove of Often caused by continued operation
capacity control indicator compressor's indicator cam is with load on a certain point.
on the control panel. worn. →Replace the indicator cam.
* The currently shipped indicator cam
has its grooved portion
strengthened.
The guide pin of the Currently, this pin is also improved in
compressor push rod is worn. resistivity against wear. If the indicator
cam is replaced with the improved
version, replace the pin with the
countermeasure part.
Failure of potentiometer If the part is deteriorated over time or
loaded at a certain point during
operation for a long time, replace it.
If the wear is caused by excessive
vibration of the compressor, take
measures to reduce vibration and
then replace the potentiometer.
Improper zero span adjustment Readjust.
of E/E positioner

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10: Capacity control position is indicated incorrectly (continued)

Inaccurate reading of E/E positioner or/and indicator If deteriorated over time, replace.
capacity control indicator is faulty. If there are specific causes such as
on the control panel. surge current, remove the cause or
take proper action.
Loosened terminals or Tighten the terminals if loosened.
defective wires Replace defective wires.
11: Capacity control malfunction

↑ See the causes for Same as left Same as left
"Inaccurate reading of
capacity control indicator
on the control panel".
"Micro-switches and Micro-switch failure Replace.
micro-switch cam" of the Loosening of micro-switch or Adjust the position of the cam and
indicator do not sense micro-switch cam screw due to switch, and tighten them.
"100%" position and/or vibration. Use thread locking agent when
"0%" position. necessary.
When compressor's vibration is
unusually high, see Item No. 12
"Compressor generates abnormal
vibration and/or sound".
Failure of capacity control Mostly caused by coil burnout. If deteriorated over time, replace.
solenoid valve or related If the symptom is caused by wet with
relays water, etc., remove the cause(s) and
then replace defective part(s).
For details, refer to the instruction
manual of solenoid valve.
Internal leakage of Oil compression due to If the symptom is caused by long
capacity control solenoid temperature rise inside duration of low-load operation, review
valve unloader cylinder and improve the operating method.
Arrange inline check valve and oil
bypass route on the capacity control
oil supply line.
Defective capacity control Improper adjustment of oil flow Readjust.
oil supply line control valve
Leak/clogging in solenoid valve Remove cause, and check oil for
gland or oil supply piping contamination/replace oil.
Unloader piston does not Damage on the cap seal of the Check oil for contamination/replace
move. piston oil.
(Though this is one of the Replace O-ring, cap seal, etc.
causes of "Defective Cap seal is pinched. Replace O-ring, cap seal, etc.
capacity control oil supply Cap seal is worn. Check oil for contamination/replace
line", it is listed separately oil. Replace O-ring, cap seal, etc.
here.) There is residual refrigerant Stop the compressor. By operating the
gas inside unloader cylinder. oil pump, repeat load/unload
operation to purge refrigerant gas
from unloader cylinder.
In case of liquid flow-back, remove the
cause(s).
If oil heater or devices on its control
circuit are defective, replace the
defective part.

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12: Compressor generates abnormal vibration and/or sound.

Shaft poorly aligned with If the shaft vibration value of Conduct shaft alignment again.
motor axial direction is high, it may be If this occurs frequently in monocoque
caused by this. unit, perform hot alignment (operate
the compressor at rated speed to raise
the temperature and make adjustment
before it cools down).
M rotor shaft runout Lock nuts and/or thrust bearing If lock nuts are not loose and parts
excessively. glands are tightened unevenly. such as thrust bearing are free of
defects, tighten the glands evenly.
Thrust bearing glands get Lock washer tooth not bended, or
loosened. thrust bearing rolling elements (balls)
are worn.
→ Check the thrust bearing. If any
defect is found, replace it, and then
reassemble it after adjusting end
clearance and checking shaft runout.
Rotor dynamic balance is If no other causes are found for
disturbed. abnormal vibration, or if on-site
overhaul only has been repeatedly
performed for a long time, this may be
the cause.
→ Overhaul the compressor at a place
where a dynamic balance
measurement/adjustment system is
available, such as the MAYEKAWA
Moriya Factory.
Oil compression Continuous low-load operation During low-load operation, lubricating
with capacity control not oil is difficult to be discharged. As a
greater than 30% result, oil that stays between the
engaged rotors increases and gets
compressed.
→ Avoid continuous low-load
operation as far as possible.
* Especially when the fluid is light gas
(He, NH3, etc.), continuous operation
of merely 10 minutes can cause bad
effect. The maximum limit should be
30 minutes even for fluorocarbon
fluids.
Liquid flow-back during Refrigerant liquefies and stays There are many probable causes,
startup inside upstream piping when such as a leak inside liquid supply
* Loud abnormal noise at equipment is stopped. solenoid valve on the load side,
startup. insufficient heat exchange (refrigerant
* If this is heard, the evaporation) in heat exchanger, or
compressor may get trapping due to mis-piping in the piping
damaged instantaneously. line.
→ Identify the cause(s) and take
necessary measures. Then overhaul
and inspect the compressor.

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12: Compressor generates abnormal vibration and/or sound (continued)

Liquid flow-back during Aperture of liquid In case of temperature-type expansion valve,
operation supply expansion check the condition of temperature sensitive
* Notable frosting on the valve is large cylinder and capillary tube. If any defect is found,
suction side. take necessary actions.
* In many cases, If orifice gets unsuitable due to the change in
flow-back of mist operating conditions, replace the orifice with
(steam) rather than proper size one(s).
liquid occurs.
* Sometimes, gas-liquid In case of electronic expansion valve, check
separator devices attached on the expansion valve aperture
(accumulator) is control mechanism (circuit) such as temperature
attached to prevent sensor, converter, controller (overheating
this symptom. regulator). If any of them is found defective,
replace it.
* See also the causes in In the same way as with temperature-type
item 02, "Insufficient expansion valve, if orifice gets unsuitable due to
refrigerant flow" the change in operating conditions, replace the
orifice with proper size one(s).
Rapid change from Set control parameters so as to prevent rapid
no-load operation to changes.
full-load operation Otherwise, make adjustment by throttling the
aperture of the capacity control increase-side oil
quantity adjusting valve.
Expansion valve Avoid rapid change in heat load that exceeds the
aperture control cannot set value of follow-up range of "heat exchanger on
keep up with rapid load side (evaporator)" and "expansion valve".
change in heat load on For details, refer to the instruction manuals
the load side. related to devices/control on load side.
Heat exchange failure In case of frosting (icing), conduct manual

in heat exchanger on defrosting.
load side Set defrosting interval shorter.
・Related to defrosting If a device which is specific to the defrosting type
fails, remove the cause(s) and replace the
device(s).
If a piping route which is specific to the defrosting
type gets blocked, remove the cause(s) and take
necessary actions.
* Especially when handling hot gas defrosting
systems, thoroughly read and understand the
contents of the instruction manuals for the units
associated with devices/control on the load side.
Heat exchange failure If ventilation around the heat exchanger is
in heat exchanger on obstructed for any reason such as piled up load,
load side improve the conditions.
・Load side conditions * Ensure the flow of heating medium through the
heat exchanger on the load side.
Heat exchange failure Check for any blocked heat transmission tubes or
in heat exchanger on fan motor(s) failure. If any problem is found, take
load side necessary actions.
・Heat exchanger
conditions

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12: Compressor generates abnormal vibration and/or sound (continued)

Foreign substances Welding spatter, etc. Check suction strainer and/or oil filters. Replace
entering the flowing from upstream element if defective.
compressor side Overhaul the compressor.
Tools and/or waste Collect foreign substances and identify their
cloth left uncollected sources. Then take necessary actions.
after overhauling
Damaged thrust Deterioration over time The time for replacement depends largely on
bearings. (operated beyond operating conditions (low pressure or high
recommended time of intermediate pressure will make the life shorter,
replacement) etc.) and/or oil management conditions. In case of
a typical refrigeration application which basically
operates in a stable continuous mode, inspect and
replace them every 40,000 hours or 5 years,
whichever comes first.
For details, see Chapter 5, Section 5.2.3 in this
manual.
Operation with liquid Refer to causes of "Liquid flow-back during
flow-back startup" and "Liquid flow-back during operation" in
item 12.
Entry of foreign Refer to causes of "Foreign substances entering
substances the compressor" above.
Excessive thrust stress Re-examine operating conditions, and improve if
other than above possible.
・High suction If difficult to improve, review maintenance interval.
pressure/intermediate
pressure exceeding
the level set by
operating conditions
Faulty assembly Tighten lock nuts by using specified torque or
* Lock nuts tightened torque angle (see Chapter 7, "7.3 Tightening
insufficiently, lock Torques for Bolts and Nuts" in this manual).
washer tooth not
bended, rotation Be sure to record data on the assembly check
stopper not set to sheet to prevent omission of work steps.
thrust bearing gland,
gland not assembled,
etc.
Resonance vibration This occurs when the In many cases, this symptom is caused by change
frequency of vibration in installation environment (such as change in
comes close to the piping routes or additive installation of devices in
natural frequency of the machine room, oil level change, etc.)
any component in the →If occurrence of resonance vibration is a
entire vibrating system, suspected, contact our service centers.
including pipes and
supports.

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2201MYJE-MY-C8-N_2015.04.

7.1 Development Views, Assembly Sectional Views
Figure 7-1 3225**C Development View (Low-stage)
Compound 2-stage Screw Compressor 3225**C Development Views

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2201MYJE-MY-C8-N_2015.04.
Figure 7-2 3225**C Development View (High-stage)
Compound 2-stage Screw Compressor 3225**C Development Views

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2201MYJE-MY-C8-N_2015.04.
Compound 2-stage Screw Compressor 3225**C Assembly Sectional Views

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2201MYJE-MY-C8-N_2015.04.

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2201MYJE-MY-C8-N_2015.04.

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2201MYJE-MY-C8-N_2015.04.

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2201MYJE-MY-C8-N_2015.04.
7.2 Parts Configuration Table
Table 7-1 Parts Configuration Table

1-1 Main Rotor Casing (1) CS00100-3225C1S 3225S** 1 (S*C)
1-1 Main Rotor Casing (1) CS00100-3225C1M 3225M* 1 (M*C)
1-1 Main Rotor Casing (1) CS00100-3225C1L 3225L** 1 (L*C)
1-1 Main Rotor Casing (1) CS00100-3225C1LL 3225LL* 1(LL*C)
1-2 Main Rotor Casing (2) CS00100-250S 250S** 1 (*SC)
1-2 Main Rotor Casing (2) CS00100-250M 250M** 1 (*MC)
1-2 Main Rotor Casing (2) CS00100-250L 250L** 1 (*LC)
2-1 Hexagon Socket Head Cap Screw NB35424-080 M24×80 52
3-1 Alignment Pin NE2025-080 Φ25×80 4
4-1 Eye Bolt NB600-30 M30 2
4-2 Eye Bolt NB600-30 M30 1
5-1 Suction Cover (1) CS00500-3225C1 3225**C 1
5-2 Suction Cover (2) CS00500-3225C2 3225**C 1
6-1 Gasket, Suction Cover (1) CS00600-320N 320*** 1
6-2 Gasket, Suction Cover (2) CS00600-3225CN 3225**C 1
7-1 Eye Bolt NB600-16 M16 2
7-2 Eye Bolt NB600-36 M36 1
8-1 Spring Pin (1) NE3206-018 Φ6×18 2
8-2 Spring Pin (2) NE3206-012 Φ6×12 2
10-1A Plug NF06-020 R3/4 1
10-1B Plug NF06-015 R1/2 1
10-2A Plug NF06-010 R3/8 1
10-2B Plug NF06-032 R1/4 1
10-2C Plug NF06-020 R3/4 1
10-2D Plug NF06-015 R1/2 1
10-2E Plug NF06-015 R1/2 1
10-2F Plug NF06-015 R1/2 1
11-1 Bearing Head (1) CS01100-3225C1 3225**C 1
11-2 Bearing Head (2) CS01100-3225C2 3225**C 1
12-1 Gasket, Bearing Head (1) CS01200-320N 320*** 1
12-2 Gasket, Bearing Head (2) CS01200-250N 250*** 1
13-1 Eye Bolt NB0600-036 M36 2
13-2 Eye Bolt NB0600-012 M12 1
14-1 Spring Pin (1) NE3206-018 Φ6×18 2
14-2 Spring Pin (2) NE3206-012 Φ6×12 2
15-1A Plug NF06-010 R3/8 1
15-1B Plug NF06-032 R1"1/4 1
15-1C Plug NF06-020 R3/4 1
16 Bearing Cover CS01800-3225C 3225**C 1
17-1 Gasket, Bearing Cover (1) CS01700-3225CN 3225**C 1
17-2 Gasket, Bearing Cover (2) CS73300-3225CN 3225**C 1
Compound 2-stage Screw Compressor 3225**C Parts Configuration Table

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2201MYJE-MY-C8-N_2015.04.

20 Spring Pin NE3203-016 Φ3×16 1
22 Balance Piston Cover CS02200-250 250V** 1
23 Gasket, Balance Piston Cover CS02300-250N 250*** 1
24 Hexagon Socket Head Cap Screw NB35412-030 M12×30 11
25-1 Male Rotor (1) 3225S*C O-profile,
CS02520-3225*** 1 (S*C)
26-1 Female Rotor (1) induction hardening
25-1 Male Rotor (1) 3225M*C O-profile,
CS02520-3225*** 1 (M*C)
25-1 Male Rotor (1) 3225L*C O-profile,
CS02520-3225*** 1 (L*C)
25-1 Male Rotor (1) 3225LL* O-profile,
CS02520-3225*** 1(LL*C)
25-2 Male Rotor (2) 3225*SC O-profile,
CS02520-3225*** 1 (*SC)
25-2 Male Rotor (2) 3225*MC O-profile,
CS02520-3225*** 1 (*MC)
25-2 Male Rotor (2) 3225*LC O-profile,
CS02520-3225*** 1 (*LC)
27-1 Main Bearing (1) O-ring type CS0270-GRT 320*** 2
27-2 Main Bearing (2) O-ring type CS0270-FRT 250*** 2
28-1 Side Bearing (1) O-ring type CS0280-GRT 320*** 2
28-2 Side Bearing (2) O-ring type CS0280-FRT 250*** 2
29-1 Snap Ring (1) C type internal NG11-200 H200 4
29-2 Snap Ring (2) C type internal NG11-160 H160 4
30 Balance Piston CS03000-250 250*** 1
31 Key, Balance Piston CS03100-250 250*** 1
32 Snap Ring C type external NG12-080 S80 1
33 Sleeve, Balance Piston CS03300-250 250*** 1
34 Set Screw NA83608-020 M8×20 2
35 O-ring PA11-150 JIS B 2401 P150 1
36 Spacer CS03600-250 250*** 1
37 Snap Ring C type internal NG11-160 H160 2
38-1 Thrust Bearing (1) CS03800-320 320*** 2
38-2 Thrust Bearing (2) CS03800-250P 250*** PPS 2
39-1 Lock Nut (1) NG31-021 AN21 2
39-2 Lock Nut (2) NG31-017 AN17 2
40-1 Lock Washer (1) NG32-021 AW21 2
40-2 Lock Washer (2) NG32-017 AW17 2
42-1 Spacer, Thrust Bearing Alignment (1) CS04200-B320 320*** 2
42-2 Spacer, Thrust Bearing Alignment (2) CS04200-250 250*** 2
43-1 Thrust Bearing Gland (1) CS04300-320S 320*** 2
43-2 Thrust Bearing Gland (2) CS04300-250S 250*** 2
45-1 Hexagon Head Bolt NB111020-055 M20×55 8

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2201MYJE-MY-C8-N_2015.04.

46-1 Conical Spring Washer CS04600-320 M20 8
- Lock Washer (1) Set (old, plate type) CS0469-G 320*** 8ps/set -
46-2 Conical Spring Washer CS04600-250 M16 8
- Lock Washer (2) Set (old, plate type) CS0469-F 250*** 8ps/set -
48 Retainer, Oil Seal CS04800-320VDS 320V** 1
49 O-ring PA12-160 JIS B 2401 G160 1
50 Oil Seal CS05010-320VD SA1J 95×120×13 1
51 Seal Cover CS05100-320 320*** 1
52 Gasket, Seal Cover CS05200-320N 320*** 1
54-1 Unloader Slide Valve (1-1) (L Port) - 3225S*C 1 (S*C)
54-1 Unloader Slide Valve (1-1) (M Port) - 3225S*C 1 (S*C)
54-1 Unloader Slide Valve (1-1) (L Port) - 3225M*C 1 (M*C)
54-1 Unloader Slide Valve (1-1) (M Port) - 3225M*C 1 (M*C)
54-1 Unloader Slide Valve (1-1) (L Port) - 3225L*C 1 (L*C)
54-1 Unloader Slide Valve (1-1) (M Port) - 3225L*C 1 (L*C)
54-1 Unloader Slide Valve (1-1) (L Port) - 3225LL*C 1(LL*C)
54-1 Unloader Slide Valve (1-1) (M Port) - 3225LL*C 1(LL*C)
54-2 Unloader Slide Valve (1-2) (L Port) - 3225*SC 1 (*SC)
54-2 Unloader Slide Valve (1-2) (M Port) - 3225*SC 1 (*SC)
54-2 Unloader Slide Valve (1-2) (L Port) - 3225*MC 1 (*MC)
54-2 Unloader Slide Valve (1-2) (M Port) - 3225*MC 1 (*MC)
54-2 Unloader Slide Valve (1-2) (L Port) - 3225*LC 1 (*LC)
54-2 Unloader Slide Valve (1-2) (M Port) - 3225*LC 1 (*LC)
55-1 Unloader Slide Valve (2-1) - 320S** 1 (S*C)
55-1 Unloader Slide Valve (2-1) - 320M** 1 (M*C)
55-1 Unloader Slide Valve (2-1) - 320L** 1 (L*C)
55-1 Unloader Slide Valve (2-1) - 320LL* 1(LL*C)
55-2 Unloader Slide Valve (2-2) - 250S** 1 (*SC)
55-2 Unloader Slide Valve (2-2) - 250M** 1 (*MC)
55-2 Unloader Slide Valve (2-2) - 250L** 1 (*LC)
59 O-ring PA11-032 JIS B 2401 P32 1
60-1 Unloader Cylinder (1) - 3225S*C 1 (S*C)
60-1 Unloader Cylinder (1) - 3225L*C 1(M*C)(L*C)
60-2 Unloader Cylinder (2) - 250S,250L 1 (*SC)(*LC)
60-2 Unloader Cylinder (2) - 250M 1 (*MC)
63-1 O-ring PA12-170 JIS B 2401 G170 1
63-2 O-ring PA12-190 JIS B 2401 G190 1
64-1 Unloader Piston (1) CS06400-3225CK 3225**C 1
64-2 Unloader Piston (2) CS06400-250T 250*** 1
65-1 O-ring PA11-140 JIS B 2401 P140 1

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2201MYJE-MY-C8-N_2015.04.

65-2 O-ring PA11-155 JIS B 2401 P155 1
66-1 Teflon Cap Seal CS06600-3225 SUNR-BE-140(S4101) 1
66-2 Teflon Cap Seal CS06600-250 SUNR-BE-155(S4101) 1
67-1 Push Rod, Unloader Slide Valve (1) CS06700-3225C 3225S*C 1 (S*C)
67-1 Push Rod, Unloader Slide Valve (1) - 3225L*C,M*C,LL*C 1(M*C)(L*C)
67-2 Push Rod, Unloader Slide Valve (2) - 3225*SC 1 (*SC)
67-2 Push Rod, Unloader Slide Valve (2) - 3225*MC 1 (*MC)
67-2 Push Rod, Unloader Slide Valve (2) - 3225*LC 1 (*LC)
68-1 Guide Pin (1) NE2506-016 Φ6×16 1
68-2 Guide Pin (2) NE2506-012 Φ5×12 1
69-1 Lock Nut (1) NG31-010 AN10 1
69-2 Lock Nut (2) NG31-008 AN08 2
70-1 Lock Washer (1) NG32-010 AW10 1
70-2 Lock Washer (2) NG32-008 AW08 2
71 Lock Nut NG31-012 AN12 1
72 Lock Washer NG32-012 AW12 1
73-1 O-ring PA11-044 JIS B 2401 P44 1
73-2 O-ring PA12-035 JIS B 2401 G35 1
74-1 Unloader Cover (1) CS07400-3225C 3225**C 1
74-2 Unloader Cover (2) CS07400-250S 250*** 1
75-1 O-ring PA12-150 JIS B 2401 G150 1
75-2 O-ring PA12-170 JIS B 2401 G170 1
77-1 Indicator Cam (1) - 3225S*C 1 (S*C)
77-1 Indicator Cam (1) - 3225M*C 1 (M*C)
77-1 Indicator Cam (1) CS07700-3225C 3225L*C 1 (L*C)
77-2 Indicator Cam (2) CS07700-250S 250S** 1 (*SC)(*LC)
77-2 Indicator Cam (2) - 250M** 1 (*MC)
78 Ball Bearing CS07800-200 #6000 2
79 Snap Ring C type external NG12-010 S10 2
80 Bearing Gland CS08000-200 200*** 2
82 V-ring CS08200-200B VH10 NBR 2
83 Spring CS08300-200 200*** 2
84 Retainer, Indicator Cam Spring CS08400-200 200*** 2
85 Oil Injection Pipe - 3225S*C 1 (S*C)
85 Oil Injection Pipe - 320M** 1 (M*C)
85 Oil Injection Pipe - 320L** 1 (L*C)
86 O-ring PA12-030 JIS B 2401 G30 1
87-1 Guide Block (1)
CS08700-320 320*** 1
88-1 Stem, Guide Block (1)
87-2 Guide Block (2)
CS08700-250 250*** 1
88-2 Stem, Guide Block (2)
89-1 O-ring PA11-024 JIS B 2401 P24 2
89-2 O-ring PA11-020 JIS B 2401 P20 2
91 Shaft Key CS09100-320 320*** 1

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2201MYJE-MY-C8-N_2015.04.

92-1 Suction Flange (1) with hole CS71300-350 JIS 20K 350A (14") 1
92-1 Suction Flange (1) without hole CS71300-P350 JIS 20K 350A (14") 1
92-2 Suction Flange (2) with hole CS71300-200 JIS 20K 200A (8") 1
92-2 Suction Flange (2) without hole CS71300-P200 JIS 20K 200A (8") 1
93-1 Gasket, Suction Flange (1) CS71200-350N JIS 20K 350A (14") 1
93-2 Gasket, Suction Flange (2) CS71200-200N JIS 20K 200A (8") 1
94-1 Hexagon Head Bolt NB12030-080P3 M30P3×80 16
95-1 Discharge Flange (1) with hole CS71300-200 JIS 20K 200A (8") 1
95-1 Discharge Flange (1) without hole CS71300-P200 JIS 20K 200A (8") 1
95-2 Discharge Flange (2) with hole CS71300-150 JIS 20K 150A (6") 1
95-2 Discharge Flange (2) without hole CS71300-P150 JIS 20K 150A (6") 1
100 Mechanical Seal Assembly CS10000-320BE BOS-E1 1
100 Mechanical Seal Assembly CS10002-320EBS BBS-E 1
100 Mechanical Seal Assembly CS10001-320BBS BBS3 1
120-1 Unloader Indicator Assembly (1) CS12000-1612F 1612**C 1
120-2 Unloader Indicator Assembly (2) CS12000-3225 3225C (2) 30-100% 1
125-1 Micro Switch Set (1) CS1259-C 125L** 1
125-2 Micro Switch (2) CS12500-200 200*** Z15GW 2
127-1 Micro Switch Cam (1) CS12700-125F 125L** 0-100% 1
127-2 Micro Switch Cam (2) CS12700-322530 3225*SC/*MC (2) 1
127-2 Micro Switch Cam (2) CS12700-200F 3225*LC (2) 1
129-1 Potentiometer (1) CS1299-J 1612 1k with lead wire 1
129-2 Potentiometer (2) 200-1k CS1299-E10 with lead wire 1
137-1 Indicator Dial (1) CS13700-1612CA 1612**C 1
137-2 Indicator Dial (2) CS13700-3225C 3225*SC/*MC (2) 1
137-2 Indicator Dial (2) CS13700-200 3225*LC (2) 1
202-1 Bevel Gear CS20100-1612C6 1612 ID 6mm 2
150 O-ring PA12-220 JIS B 2401 G220 2
- Gear Coupling Assembly (Current Type) CS1519-M 151+152+153+159 1
151+152+153+159
- Gear Coupling Assembly (Old Type) CS1519-M -
+154+155
151 Drive Sleeve 3225**C IUS-A-30 1
152 Drive Hub CS15100-3225C 3225**C IUS-A-30 2
154 Stopper, Drive Sleeve 3225**C IUS-A-30 2
155 Stop Ring - FRS-130 4
157 Key, Driven Hub & Drive Hub CS15700-3225CH 20×12×84 2
M10×16 knurled,
159 Set Screw NA83610-025 1
with anti-loosening
160 Lock Nut NG31-015 AN15 1
161 Lock Washer NG32-015 AW15 1
164 Retainer, Oil Injection Pipe CS16400-3225C 3225**C 1
165 O-ring PA11-040 JIS B 2401 P40 1
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168 Pipe Guide, Oil Injection CS16800-3225C 3225L*C,M*C,S*C 1
168 Pipe Guide, Oil Injection - 3225LL*C 1(LL*C)
197 O-ring PA11-058 JIS B 2401 P58 1
Flange, Lubricating Oil Supply (1)
215-1 CS71300-040MK JIS 20K 40A (1"1/2) 1
with hole
215-1 without hole CS71300-040 JIS 20K 40A (1"1/2) 1
Flange, Lubrication Oil Supply (2) with
215-2 hole CS71300-025MK JIS 20K 25A (1") 1
215-2 CS71300-025 JIS 20K 25A (1") 1
without hole
Gasket, Lubricating Oil Supply Flange
216-1 (1) CS71200-040N JIS 20K 40A 1
Gasket, Lubricating Oil Supply Flange
216-2 (2) CS71200-025N JIS 20K 25A 1

218 Flange, Injection Oil Supply with hole CS71300-020MK JIS 20K 20A (3/4") 1
218 Flange, Injection Oil Supply without hole CS71300-020 JIS 20K 20A (3/4") 1
219 Gasket, Injection Oil Supply Flange CS71200-020N JIS 20K 20A 1
220 Hexagon Head Bolt NB12012-035 M12×35 4
237-1 Torsional Slip Washer (1) CS23700-320 320*** 2
237-2 Torsional Slip Washer (2) CS23700-250 250*** 2
245- Spring Washer ND330-12 M12 5
250-1 Thrust Washer (1) CS25000-320 320*** 2
250-2 Thrust Washer (2) CS25000-250 250*** 2
Special Spring Washer for Hexagon
267-1 Socket Head Cap Screw ND330-16 M16 4
Special Spring Washer for Hexagon
267-2 ND330-12 M12 4
Socket Head Cap Screw
326-1 Gland, O-ring (1) CS32600-3225C 3225**C 1
326-2 Gland, O-ring (2) CS32600-3225C2 3225**C 1
328 O-ring PA11-046 JIS B 2401 P46 1
329 Spring Pin NE3204-010 Φ4×10 1
Flange, Balance Piston Oil Return
350 Piping with hole CS71300-020MK JIS 20K 20A (3/4") 1
Flange, Balance Piston Oil Return
350 CS71300-020 JIS 20K 20A (3/4") 1
Piping without hole
351 Gasket, Balance Piston CS71200-020N JIS 20K 20A 1
Flange, Bearing Cover Oil Return Piping
353 CS71300-032MK JIS 20K 32A( 1-1/4”) 1
with hole
Flange, Bearing Cover Oil Return Piping
353 CS71300-032 JIS 20K 32A (1-1/4”) 1
without hole
354 Gasket, Bearing Cover CS71200-032N JIS 20K 32A 1
Flange, Rotor Casing Oil Return Piping
356 CS71300-032MK JIS 20K 32A (1-1/4”) 1
with hole
Flange, Rotor Casing Oil Return Piping
356 without hole CS71300-032 JIS 20K 32A (1-1/4”) 1
357 Gasket, Rotor Casing CS71200-032N JIS 20K 32A 1
420 Spacer, Unload Position (High-stage) CS42000-250S30 250S** 30 % load 1 (*SC)
420 Spacer, Unload Position (High-stage) CS42000-250M30 250M** 30 % load 1 (*MC)

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2201MYJE-MY-C8-N_2015.04.

421 O-ring PA11-046 JIS B 2401 P46 2(*SC)(*MC)
423 Spacer, Unload Position (Low-stage) CS42300-3225MSC 3225M*C 1 (M*C)
431 O-ring PA11-140 JIS B 2401 P140 1 (M*C)
432-1 O-ring PA12-165 JIS B 2401 G165 4
432-2 O-ring PA12-130 JIS B 2401 G130 4
433-1 O-ring PA12-165 JIS B 2401 G165 4
433-2 O-ring PA12-130 JIS B 2401 G130 4
528 Sleeve with O-ring, Oil Seal CS52809-320VD 320V** 1
529 Set Screw NA83606-008 M6×8 2
605 Plug NF06-025 R 1" 1
607-A Plug NF06-008 R 1/4 1
607-B Plug NF06-008 R 1/4 1
744 O-ring PA12-090 JIS B 2401 G90 1
- O-ring set CS7109-0M NBR 3225C -
- Gasket set CS7118-0M 3225C -
The sizes of O-ring No.432-2 and No.432-2 have been changed to G130 from G135 in October 2012
as a design change.
 The part code of the O-ring is the one assigned to NBR which is standard material.
When the material of the O-ring is other than NBR, a different part code is used for
each material.
If you are using O-rings made from other than the standard material, please contact
MAYEKAWA when placing an order.

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2201MYJE-MY-C8-N_2015.04.
7.3 Tightening Torques for Bolts and Nuts

Table 7-2 List of Tightening Torques
 Hexagon socket head cap screw
Torque
P/N What is tightened Q’ty. Size
N·m kgf·cm
Main Rotor Casing (1) to
2-1 750 7500 52 M24×80
Suction Cover (1) and Bearing Head (1)
Main Rotor Casing (2) to
2-2 750 7500 44 M24×60
Suction Cover (2) and Bearing Head (2)
18-1 Bearing Cover to Bearing Head (1) 450 4500 20 M20×70
18-2 Suction Cover (1) to Bearing Head (2) 450 4500 24 M20×65
24 Balance Piston Cover to Suction Cover (2) 90 900 11 M12×30
53 Seal Cover to Bearing Cover 240 2400 8 M16×40
58-1 For Securing Unloader Slide Valve 240 2400 4 M16×50
58-2 For Securing Unloader Slide Valve 90 900 4 M12×40
61 Unloader Cylinder (2) to Balance Piston Cover 240 2400 2 M16×40
Unloader Cylinder (1) to
62-1 450 4500 8 M20×170
Bearing Cover and Bearing Head (1)
Unloader Cylinder (2) to
62-2 240 2400 6 M16×90
Balance Piston Cover and Suction Cover (2)
76-1 Unloader Cover (1) to Unloader Cylinder (1) 90 900 8 M12×35
76-2 Unloader Cover (2) to Unloader Cylinder (2) 90 900 8 M12×30
81 Bearing Gland (1) (2) to Unloader Cover 10 100 6 M6×15
162 Push Rod, Unloader Slide Valve (1) 90 900 5 M12×50
166-1 O-ring Gland (1) to Bearing Head (1) 10 100 4 M6×15
166-2 O-ring Gland (1) to Suction Cover (2) 6 60 4 M5×12
 Hexagon Head Bolt

Torque
N·m kgf·cm
45-1 Thrust Bearing Gland (1) 120 1200 8 M20×55
45-2 Thrust Bearing Gland (2) 60 600 8 M16×45
94-1 Suction Flange (1) JIS 20K 350A 200 2000 12 M30×80
94-2 Suction Flange (intermediate pipe) (2) JIS 20K 200A 140 1400 12 M22×55
97-1 Discharge Flange (intermediate pipe) (1) JIS 20K 200A 140 1400 12 M22×55
97-2 Discharge Flange (2) JIS 20K 150A 160 1600 8 M22×55
217-1 Journal Lubrication Flange (1) JIS 20K 40A 40 400 4 M16X45
217-2 Journal Lubrication Flange (1) JIS 20K 250A 40 400 4 M16X45
220 Oil Injection Flange JIS 20K 20A 40 400 4 M12X35
Oil Return Outlet Flange on Suction Cover (2)
352 40 400 4 M12X35
JIS 20K 20A
355 Oil Return Outlet Flange on Bearing Cover JIS 20K 32A 40 400 4 M16X45
Oil Return Inlet Flange on Main Rotor Casing (1)
358 40 400 4 M16X45
JIS 20K 32A
Compound 2-stage Screw Compressor 3225**C Tightening Torques for Bolts and Nuts
7-34
2201MYJE-MY-C8-N_2015.04.
 Lock Nut
Tightening torque (N·m)

Standard Maximum
39-1 Thrust Bearing (1) Note 1 2259 2824 2 AN21

39-2 Thrust Bearing (2) Note 1 1186 1483 2 AN17
69-1 Unloader Piston (1) 180 - 1 AN10
69-2 Unloader Piston (2) 140 - 1 AN08
71-1 Unloader Slide Valve (1-1) 408 510 1 AN12
160 Gear Coupling Drive Hub Note 1 810 1012 1 AN15
Note 1: When tightening a lock nut, if it is difficult to use a torque wrench, manage the tightening
torque of the lock nut controlling the tightening angle range as explained below.
 Tightening Angle Range of Lock Nuts for Rotors

a) After tightening the lock nut by hand, further tighten the lock nut by using a lock nut wrench until the
rotor starts to turn. Take care not to over-tighten.
b) Put a mark on the lock nut at the right side edge of the rotor groove where the stopper tongue of the
lock washer fits in, as shown in Figure 7-9.
c) From this marking position, tighten the lock nut in such a way that rotation can be stopped within the
tightening angle range shown in Table 7-3.
When measuring the angle, use an angle gauge which is set to the diameter of rotor shaft.
Table 7-3 Tightening Angles Specified

for Lock Nuts of Rotor
Model Angle range
First time 250 (High-stage) 30°to 40°
tightening 320 (Low-stage) 25°to 35°
Rotor groove (slot) Second time 250 (High-stage) 20°to 30°
Marking tightening 320 (Low-stage) 15°to 25°
where stopper tongue of
the lock washer fits * When tightening lock nut, tightening start position
differs between the first time tightening and the
tightening for the second time or after. Therefore,
angle ranges are specified also for the second
time tightening.
Figure 7-9 Position where mark is put
Photo 126 Angle gauge (example)
Compound 2-stage Screw Compressor 3225**C Tightening Torques for Bolts and Nuts
7-35
2201MYJE-MY-C8-N_2015.04.
7.4 About the O-rings Used

7.4.1 List of O-rings Used
Table 7-3 List of O-rings Used
Location JIS B 2401
P/N
attached place description in functional aspect Size
35 Sleeve, Balance Piston same as left P150
49 Seal Retainer same as left G160
59 Oil Injection Pipe Guide Oil Injection Pipe P32
63-1 Bearing Cover Unloader Cylinder (1) G170
63-2 Balance Piston Cover Unloader Cylinder (2) G190
65-1 Unloader Piston (1) same as left P140
65-2 Unloader Piston (2) same as left P155
73-1 Unloader Push Rod (1) Unloader Piston (1) P44
73-2 Unloader Push Rod (2) Unloader Piston (2) G35
75-1 Unloader Cover (1) same as left G150
75-2 Unloader Cover (2) same as left G170
86 Oil Injection Pipe same as left G30
89-1 Guide block Stem (1) same as left P24
89-2 Guide block Stem (2) same as left P20
150 Thrust Bearing Gland (1) same as left G220
165 Oil Injection Pipe Gland same as left P40
197 Bearing Head (1) Unloader Push Rod (1) P58
328 Suction Cover (2) Unloader Push Rod (2) P46
421 Unload Spacer (2) same as left P46
431 Unload Spacer (1) same as left P140
432-1 Main Bearing (1) same as left G165
432-2 Main Bearing (2) same as left G130
433-1 Side Bearing (1) same as left G165
433-2 Side Bearing (2) same as left G130
744 Oil Seal Sleeve same as left G90
■ Attached place means parts which they have grooves or with taper cutting for attaching O-ring.
7.4.2 O-ring Materials Used for Screw Compressor
Table 7-4 List of O-ring Materials Used for Screw Compressor

(excluding mechanical seal)
Working fluid O-ring material
Ammonia
NBR
Hydrofluorocarbon (HFC)
FKM
CO2
HNBR
Trifluoromethane (R23)
Propane
Propylene
FKM
Natural gas
City gas
Helium
Compound 2-stage Screw Compressor 3225**C About the O-rings Used

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2201MYJE-MY-C8-N_2015.04.
7.5 Tools for Disassembly

Table 7-5 List of Tools for Disassembly (example)
Parts Center
Tool name Illustration size, etc.;
Code No.
Ratchet wrench 1/4” SG261-08
Adjustable wrench 250 mm SG231-250

75 mm SG112-075
Screwdriver Phillips
125 mm SG112-125
75 mm SG111-075
Screwdriver Flat blade
125 mm SG111-125
ST-1 SG311-01
Snap ring pliers External
ST-3 SG311-03
Snap ring pliers Internal RT-4 SG312-04

M8×200
Eye bolt two-peace-set UHT0016
2 mm SG241-02
Across 3 mm SG241-03
flats 4 mm SG241-04
5 mm SG241-05
6 mm SG241-06
Allen wrench key
8 mm SG241-08
10 mm SG241-10
14 mm SG241-14
17 mm SG241-17
19 mm SG241-19
AN-08 SAS111-08
AN-10 SAS111-10
AN-12 SAS111-12
Lock nut wrench
AN-15 (L) SAS112-15
AN-17 SAS111-17
AN-21 SAS111-21
5-25 N･m -
Torque wrench
for assembly 20-100 N･m SG132-0900
60-420 N･m SG132-4200
Assembly and 250S/L CS70300-250
Disassembly Tool,
Main/Side Bearing 320S/L CS70300-320
Compound 2-stage Screw Compressor 3225**C Tools for Disassembly

7-37
Contact Information_2015.04.
Contact Information
Sales Offices/Service Centers

 Sales Offices in Japan (as of April 21, 2015)
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
Chugoku 2-3-40, TAKAYADAI, HIGASHIHIROSHIMA CITY, TEL: 082-491-1830
Branch HIROSHIMA 739-2117 FAX: 082-491-1838
Shikoku 410-1, OTAKAMI-MACHI, TAKAMATSU-CITY, KAGAWA 761-2117 TEL: 087-868-3400
Branch FAX: 087-868-3399
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 21, 2015)
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 21, 2015)
Telephone and
Description Location
facsimile No.
NORTH AMERICA
MAYEKAWA CANADA INC. 12180 RIVERSIDE WAY, TEL: (1) 604-270-1544
(VANCOUVER OFFICE) RICHMOND, B.C., V6W 1K5, CANADA 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, FAX: (1) 773-516-5071
IL 60007, U.S.A.
MAYEKAWA U.S.A. INC. 250 WEST NYACK ROAD,SUITE TEL: (1) 914-301-9770
(NEW YORK OFFICE) 230,WEST NYACK, FAX: (1) 914-332-0400
NY 10994, U.S.A.
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. 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 & ANUFACTURING)
MAYEKAWA U.S.A. INC. 3222 PASADENA FREEWAY TEL: (1) 281-447-2599
CHEMICAL PROCESS DIVISION PASADENA, FAX: (1) 281-447-6623
(HUSTON SERVICE OFFICE) TX 77503, U.S.A.
MAYEKAWA U.S.A. INC. 1770 ST. JAMES PLACE, SUITE 408, TEL: (1) 832-547-2320
CHEMICAL PROCESS DIVISION HOUSTON, TX 77056, U.S.A.
(HUSTON SALES &
ENGINEERING OFFICE)
EUROPE and 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, FAX:(49)89-5527-989-19
DEUTSCHLAND
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

Contact -2
Telephone and
facsimile No.
MAYEKAWA. S.L. CALLE MONTEVIDEO 5, NAVE 13 TEL: (34) 91-830-0392
POL. INDUSTRIAL CAMPORROSO FAX: (34) 91-830-0397
28806 ALCALA DE HENARES,
MADRID, SPAIN
MAYEKAWA FRANCAISE SARL 9, RUE MICHAEL FARADAY, 78180 TEL: (33) 1-30-58-26-00
MONTIGNY-LE-BRETONNEUX, FAX: (33) 1-30-58-19-37
FRANCE
N.V. MAYEKAWA EUROPE KOROVY VAL ST., 7, OFFICE 228, TEL: (7) 499-230-01-76
MOSCOW REPRESENTATIVE 119049, MOSCOW,RUSSIA FAX: (7) 499-230-21-12
OFFICE
MAYEKAWA-SVEDAN SP. Z 0.0. UL. DRUSKIENNICKA 8/10, 60-476 TEL: (48) 61-842-0738
(MPL) POZNAN, POLAND FAX: (48) 61-848-5837
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, FAX: (20) 22-503-2801
NORTH 90th St. THE 47th BUILDING -
4th FLOOR, OFFICE 419, EGYPT
MAYEKAWA INTERTECH AG ALI & SONS BUSINESS CENTER TEL: (971) 2-5102-451
- ABU DHABI OFFICE No.201 FAX: (971) 2-5102-571
ALI KHALFAN RASHED AL MUTAWA
AL DHAHIRI BLDG. PLOT No.29, AL
AIN ROAD, UMM AL NAR, ABU DHABI
U.A.E. P.O. BOX 129865
MAYEKAWA MIDDLE EAST FZCO P.O.BOX 61349, PBU: RA08-UC05, TEL: (971) 4-888-6363
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, TEL: (359) 2-8910130
（BULGARIA） SOFIA, 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 TEL: (39) 051-726-364
（BOLOGNA OFFICE） DI RENO, FAX: (39) 051-726-804
BOLOGNA, ITALY
MAYEKAWA SOUTH AFRICA (PTY) WEST END, UNIT 3 PRIME PARK, TEL: (27) 21-551-1434
LTD. PRINTERS WAY, MONTAGUE FAX: (27) 86-546-3618
(CAPE TOWN OFFICE) GARDENS 7441, 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

Contact -3
Telephone and
facsimile No.
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 TEL: (62) 31-531-6613

(SURABAYA OFFICE) FLOOR SUITE 702B, JL. JEND. FAX: (62) 31-532-4341
BASUKI 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 CORP. 4/F UNIT A AND B SUNTREE TOWER, TEL: (63) 2-706-0473
13 MERALCO AVENUE, SAN FAX: (63) 2-706-0475
ANTONIO, ORTIGAS CENTER, PASIG
CITY 1605, PHILIPPINES
MAYEKAWA PHILIPPINES CORP. ROOM 4, LEAH DAPROZA BUILDING TEL: (63) 83-552-3282
(GENARAL SANTOS OFFICE) FISCAL DAPROZA AVENUE FAX: (63) 83-301-2698
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 TEL: (886) 7-821-0886

(KAOHSIUNG OFFICE) DIST., FAX: (886) 7-821-4688
KAOHSIUNG CITY,80672
TAIWAN , ROC
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, ROC
MAYEKAWA (TAIWAN) CO., LTD. 8F, NO, 421, SUNG-SHAN ROAD, TEL: (886) 2-2727-9711
(TAIPEI HEAD OFFICE) TAIPEI, TAIWAN 11083, REP. OF FAX: (886) 2-2759-8484
CHINA
MAYEKAWA (TAIWAN) CO., LTD. NO. 80-2, SEC.3, HUANJUNG RD., TEL: (886) 4-2251-4128
(TAICHUNG BRANCH) TAICHUNG, TAIWAN, 40755, FAX: (886) 4-2251-4129
REP. OF CHINA
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., LTD. 201700 PLANT 1, NO.39, WEST TEL: (86) 21-6920-7718
XIQING ROAD, FAX: (86) 21-6920-7719
QINGPU, SHANHAI, P.R. CHINA
MAYEKAWA CHINA MFG.CO., LTD. RM.1205, TIANLHEFULI BUSINESS TEL: (86) 20-8527-6161
(GUANGZHOU BRANCH) MANSION, No.4, HUA TING RD, FAX: (86) 20-8527-6165
GUANGZHOU, 510610, 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

Contact -4
Telephone and
facsimile No.
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, 116100,
DALIAN, P. R. 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
MAYEKAWA HOLDING BANGNA-TRAD RD, K.M.6.5,
(THAILAND)CO., LTD. BANGKAEW BANGPLEE,
SAMUTPRAKARN 10540, THAILAND
MAYEKAWA (THAILAND) CO., LTD. 1/7 TRANG-PALIAN RD., MUANG, TEL: (66) 75-224-784
(TRANG BRANCH) TRANG 92000, THALAND FAX: (66) 75-224-351
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, FAX: (82) 55-299-7678
GYEONGSANGNAM-DO 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
LATIN AMERICA
MAYEKAWA ARGENTINA S.A. DR. JOSE VALENTIN GOMEZ 151, TEL: (54) 11-4627-6660
(BUENOS AIRES OFFICE) LOT42, HAEDO-PARTIDO DE MORON, FAX: (54) 11-4628-1511
BUENOS AIRES, CP B1706FMA,
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. GUILLERMO TEL: (593)4-262-9108
PAREJA C.C.STEFANY LOCAL #4, TEL: (593)4-262-6407
CALLA.LA GARZOTA 1 MZ.28 SOLOR FAX: -
13, GUAYAQUIL, ECUADOR
MAYEKAWA COLOMBIA S.A.S TRANSVERSAL 93 NO.53-48 TEL: (57) 1-430-9980
INTERIOR 37, PAQUE INDUSTRIAL EL TEL: (57) 1-224-3028
DORADO, BOGOTA, COLOMBIA FAX: (57) 1-437-0988

Contact -5
Telephone and
facsimile No.
MAYEKAWA COLOMBIA S.A.S. DIRECCION CR 43B No. 8 SUR 10 TEL: (57) 4-313-4343
(MEDELLIN OFFICE) OFICINA 404 EDF. OVIEDO FAX: (57) 4-313-4343
MEDELLIN, COLOMBIA
MAYEKAWA DO BRASIL RUA LICATEM 250, BLOCO B/C, TEL: (55) 11-4654-8000
EQIPAMENTOS INDUSTRIAIS JARDIM PEROVA-ARUJA-SP FAX: (55) 11-4654-8002
LTDA. CEP:07428-280, BRASIL
MAYEKAWA DO BRASIL LTDA. RUA DR. JOSE PEROBA, 275 - SALA TEL: (55) 71-3341-0737
(BAHIA BRANCH) 902 EDIFICIO METROPOLIS - BAIRRO FAX: —
STIEPE, SALVADOR –
BA,CEP:41770-235, BRASIL
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 - FAX: —
LTDA. (CUIABA BRANCH) CENTRO CUIABA-MT, CEP 78055-560,
BRASIL
MAYEKAWA DO BRASIL RUA XV DE NOVEMBRO, 2175 6 TEL: (55) 41-3383-1518
EQIPAMENTOS INDUSTRIAIS ANDAR 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 TEL: (55) 17-3227-0235
EQIPAMENTOS INDUSTRIAIS OLIVEIRA, FAX: (55) 17-3227-3120
LTDA. (OESTE PAULISTA 344 JARDIM PINHEIRO SAO JOSE DO
BRANCH) RIO PRETO-SP, CEP 15091-330,
BRASIL
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: (55) 51-3477-5212
LTDA. CANOAS-RS, BRASIL
(RIO GRANDE DO SUL BRANCH)
MAYEKAWA DO BRASIL AV. GOVERNADOR CARLOS TEL: —
EQIPAMENTOS INDUSTRIAIS LINDENBERG, 873/107 CENTRO FAX: —
LTDA. (LINHARES BRANCH) CEP:29900-020 LINHARES-ES,
BRASIL
MAYEKAWA DO BRASIL RUA PROFESSOR MARIETA TEL: (55) 22-2772-6069
EQIPAMENTOS INDUSTRIAIS PEIXOTO, FAX: (55) 22-2759-3112
LTDA. (MACAE) 62 CENTRO - MACAE – RJ,
CEP 27910-250, BRASIL
MAYEKAWA DO BRASIL AV.LUIZ CARLOS PRESTES, TEL: (55) 21-2431-3600

EQIPAMENTOS INDUSTRIAIS 350-SALA 313-EDIFICIO BARRA FAX: (55) 21-2430-8882
LTDA. TRADE II,
(RIO DE JANEIRO BRANCH) BARRA DA TIJUCA, RIO DE
JANEIRO-RJ
CEP:22775-055, BRASIL
MYCOM CENTROAMERICA S.A BODEGA #63, CONDOMINIO TEL: (506) 2441-4464

COMERCIAL TIERRA DOS, EL FAX: (506) 2441-4465
CACIQUE DE RIO SEGUNDO,
ALAJUELA, COSTA RICA

Contact -6
Telephone and
facsimile No.
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
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 FAX: -
(MARACAIBO OFFICE) 6, ZONA INDUSTRIAL IIETAPA,SAN
FRANCISCO
EDO.ZUILIA, VENEZUELA
MYCOM VENEZUELA AV. MUNICIPAL DE PTO. LA CRUZ, TEL: (58) 261-765-1059

SALES & SERVICE, C.A. EDIF. 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 FAX: -
6, 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, FAX: (52) 77-73-20-5762
(CUERNAVACA OFFICE) C.P.62578, 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. TEL: (52) 3336-15-5765
S.A. DE C.V. VALLARTA SAN LUCAS FAX: (52) 3336-15-1307
(GUADALAJARA OFFICE) GUADALAJARA, JALISCO, 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 TEL: (52) 662-216-2047
S.A. DE C.V. BENAVENTE #38 COL. LOS ARCOS FAX: (52) 662-216-2047
(HERMOSILLO OFFICE) CD. 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
MAYEKAWA DE MEXICO, CERRADA DE RIO AMATAN 106-A COL. TEL: (52) 993-315-4025
S.A. DE C.V. CASA BLANCA PRIMERA SECCION,
(VILLAHERMOSA OFFICE) VILLAHERMOSA, TABASCO,
C.P.86060, MEXICO

Contact -7
2201MYJE-MY-C8-N_2015.04
MAYEKAWA MFG. CO., LTD.

3-14-15 Botan, Koto-ku, Tokyo 135-8482, JAPAN
TEL : (81)-3-3642-8181 FAX: (81)-3-3643-7094
URL : http://www.mayekawa.com

3225 C Instruction Manual: Compound 2-Stage Screw Compressor

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2201MYJE-MY-C8-N_2015.04.

Compound 2-stage Screw Compressor

3225LLLC-*B*-51 3225LLLC-*B*-61 3225LLMC-*B*-51 3225LLMC-*B*-61 3225LLSC-*B*-51 3225LLSC-*B*-61

3225**C Instruction Manual 2201MYJE-MY-C8-N_2015.04. Nov. 14, 2014

Compound 2-stage Screw Compressor 3225**C

Warranty and Disclaimer

"Liquid flow-back operation" is ･･･

Compound 2-stage Screw Compressor 3225**C

Intended Use of This Product

For Safe Use of This Product

Compound 2-stage Screw Compressor 3225**C

About This Manual

Construction of This Manual

Compound 2-stage Screw Compressor 3225**C

Warranty and Disclaimer

"Liquid flow-back operation" is ･･･

Compound 2-stage Screw Compressor 3225**C

Intended Use of This Product

For Safe Use of This Product

Compound 2-stage Screw Compressor 3225**C

About This Manual

Construction of This Manual

Compound 2-stage Screw Compressor 3225**C

Chapter 2 Compressor Specifications and Structure

Compound 2-stage Screw Compressor 3225**C

2.5 Mechanisms ............................................................................................... 2-18

Chapter 4 Compressor and Package Unit Operation

Compound 2-stage Screw Compressor 3225**C

4.2 Precautions for Operation ........................................................................... 4-7

Chapter 5 Maintenance and Inspection

Compound 2-stage Screw Compressor 3225**C

5.4.10.1 Disassembly .............................................................................................. 5-29

Compound 2-stage Screw Compressor 3225**C

Chapter 7 Related Documents

Compound 2-stage Screw Compressor 3225**C

1.1.1.2 Do’s on Maintenance

1.1.1.3 Do’s on Lockout/Tagout after Shutting Off the Power

1.1.1.4 Do’s about Personal Protective Gear

1.1.1.5 Do’s about Handling of Hazardous and Toxic Substances

1.1.1.6 Do’s about Handling Emergency Situations

1.1.1.7 Do’s about Waste Oil, Fluid, and Materials

1.1.1.8 Other Do’s

1.1.2 Prohibitions (Don’ts)

Table 1-1 Warning Symbols and their Meanings

Compound 2-stage Screw Compressor 3225**C 1.2 Warnings

1.3 Residual Risks

Table 1-2 Hazardous Sources

Compound 2-stage Screw Compressor 3225**C 1.3 Residual Risks

Figure 1-1 Locations of Hazardous Sources (compressor)

Photo 001 Locations of Hazardous Sources (compressor)

Compound 2-stage Screw Compressor 3225**C 1.3 Residual Risks

1.4 Safety Devices

1.4.1 Emergency Stop Button

1.4.2 Breakers of Motor Main Power and Control Power

 Methods of Performing and Releasing Lockout/Tagout

3225LLLC-B-51 3225LLLC-B-61 3225LLMC-B-51 3225LLMC-B-61 3225LLSC-B-51 3225LLSC-B-61

Compound 2-stage Screw Compressor 3225C 2.1 Overview of MYCOM 3225C