YANMAR OPERATION MANUAL COMPRESSORAll Rights Feseived, Copyight VANIMAR GO, LTD.PREFACE (Foreword) PREFACE C Thank you for purchasing a YANMAR Compressor C series. ) 1. Foreword ¢ This Operation Manual has been prepared for your safe and effective use of the compressor. Read thor- ‘ough this Operation Manual and fully understand the safety precautions and precautions regarding the ‘operation, checking and servicing before using this compressor. Keep this Operation Manual at a clearly identified place accessible for the operator to refer to ital any time. #Aiso note that this Operation Manual is subject to change for improving the quality and performances of ‘compressor or for safety. ‘e In this manual, the numericaivalues are based on the St system (Intemational System of Units). ¢ Replacement parts should be our genuine parts or specified parts. Onder a part to your nearest sales or service agent of Yanmar's parts. When ordering a part, clearly specify the Part Name (part description) and Part No., and the Model and manufacturs’s Serial No. of the compressor. ‘# If you should have lost or damaged this Operation Manual, or if you have any questions and advice, please contact us or your nearest sales or service agent (shown in the service network list "YANMAR. Worldwide Service” appended to this manual). ‘* If you transfer this compressor, also transfer this Operation Manual, Final Document and Records of ‘Shop Trial with the compressor to the next owner.CONTENTS yanman G SERIES CONTENTS Page For Safe Use of Your Compressor 1-4, Safety Symbols ... oA 1-2. Term & Symbol Marks 42 1-3. List of Safety Labels... Appearance and Parts Location Specifications .snnsisnnmnmnarnmaninmnnasinniniieninnnnninemnnmnnnennnicaannes Bf Installation 4-4, Installation environment 4-2, Plumbing precautions ... 4-3, Direct alignment procedure .. Lubricating oll and cooling water 5-4. Lubricating oi. 51 5-2, Cooling water 54 Preparations for operation G1, LUDTIOALION «cmt ninnintnnnnnneinnnnnannsnnannensniameniesn 6-2, initia lubrication for each patt nnn nnn vel Operation 7-4, Inspection and preparations prior to starting ses seesniesnnennnineT 72. Trial tun fos a 7-3. Normal operation 72 7-4, Method for storing the compressor for a long period of ti .u..ssssnnnnnnnnnnnnnnnT® 7-5. Operation after a tong period Of T8St ...csuninnnsnnnnainenes smreurnenneine TR Periodic inspection and maintenance 8-4, Table of maintenance and inspection items a4 8-2, Periodic inspection iteMS oes 82 4-3, Maintenance standard table ...csssstssnnnnnninn ssnennnen se S 8-4, Nut and bott torques 88 F-1 (Volume:2pages)CONTENTS 9. Troubleshooting .. 40, Included materials 10-1. List of C-type YANMAR recommended compressor lubricating oils 104 10-2, Valve disassembly and reassembly procedure ... “ oA G2, 10-3. Exploded view of the valve sens 10-6 10-4, Detail drawing of the low pressure vaive mechanism ......... . oA 5 10-5, Detail drawing of the high pressure valve mechanism ......0.cemnsnnnnennnnncens tO 10-6, High pressure vatve installation procedure chart (All C type) 10-7 10-7. Cross section drawing (2 cylinders) .. AB ATTACHED Yanmar's Worldwide Service Network1. For Safe Use of Your Compressor (Safety Symbols) vauman © SI 1. For Safe Use of Your Compressor Be sure fo abide by aN -marked DANGERs, WARNINGs and CAUTIONs described in this Manual. As far as safety is concerned, they are particularly important parts of instructions. 1-1. Safety Symbols The following shows the safety marks used for caution indications in this Operation Manual and safety labels attached to this product and expiains their meaning, It indicates that a danger of possible death or serious injury is very great when the proper precautions is not followed. It indicates that there is a danger of resulting in death or serious injury when the proper precautions is not followed. It indicates that there is the possibifity of resulting in injury or serious damage to the engine when an advice on safety handling or the proper precautions is not followed. @ Where the safety labels are posted is shown in page 1-5. «Tne cautions prefiea wth the Z'\, mark inthis Operation Manual ae especialy inperant fr sate handing of this product. A failure to observe this caution may incur a deterioration of performances or raubotonton of prod, Thats bo sera eben te Hone '® The descriptions captioned by [NOTICE] are for the particularly important items from handiing. If you ignore them, the performance of your compressor may be deterioration leading to a problem. 1-1 (Volume:6pages)1. For Safe Use of Your Compressor (Terms & Symbol Marks) yawaanee C2 SI 1-2. Term & Symbol! Marks 4) The following symbot marks are used in the safety labels shown in this Operation Manual and posted on the engi (1) Caution marks and signal words It indicates that a danger of possible death or serious injury is very [A\PANGER | Great when the proper precautions is not followed. (Z\warnina It indicates that there is a danger of resulting in death or serious injury when the proper precautions is not followed. [ZXcaution] "indicates that theres the possibility of resuling in injury or serious damage to the engine when an advice on safety handling or the proper precautions is not followed. ZA, Itindicates a handing caution which, if not observed, may incur a deterioration of performance or a trouble/accident of this product. (2) Symbol marks (2)Caution masks (yothers Caution on e + + Refer to another page, Pat (OD premocr, ‘Operation Manuat or other Caution on high temperature document, 1-21. For Safe Use of Your Compressor (Basie Precautions) vauman © S' 2) Basic Precautions Strict Observance of the Safety Rules + When running the compressor or servicing it for its maintenance, observe the safety rules, precau~ tions on safety and work procedures. + When carrying out a joint work, work according to the predeter mined signs. Way of pre-work arrangement (1) Aceording to kind of work required (2) Everyone to contemplate and consider (8) Everyone to understand well (4) Fix the most suitable way to work + Wear the proper protective garment, Don't wear oll smudged work clothes because they are prone to catch fire, + Wear protectors such as helmet, safety goggles, safety shoes, protective mask. protective glove, life-ine, etc., depending on the nature of work required, (1) Setely has priority over all the works. (2) Safety is more impor tant than any other duties. 8) It is needless to say that "Safety First” means that safety hes Priority over working aticiency. (4) Safety is the foundation, + When working on the engine, use the specified engine for working elficiency fools. Use jigs or fools suitable for particular work because Safety is never contra dictory t0 working off use of @ wrong tool causes an injury. ciency. Se 2 + While at work, do not jump on and off the compressor. + For working, install a work bench fitted to the size of your compressor to secure @ good footing. Don't ‘work in a dangerous position,1. For Safe Use of Your Compressor (Basic Precautions) Be Cautious of Handling of Fuel & Lubricating Oi. + Hfire Is brought close to fuet and/or lubricating ol, there is the possibitiy of catching fire. {Particulary the fuel is highly Bammabie and dangerous.) + Fire should de strictly prohibited in the engine installed place (engine room), + Check for leak of fue! oil and lubricating oi. If you find @ defective point, repair tt and wipe out leaked fuel or lubricating oil, + Store the fue! oil and lubricating oll at the specified place and do not allow persons other than those concerned to handle them, + Unnecessary flammables in the engine installed place (engine room) may cause fire. Therefore, store these flammables in another specified plage, CRT, TLaMMABLES. Be Cautious of Handling of Fuel & Lubricating Oil. + Do not touch a high-temperature region such as the cylinder head or cooler cover of of compressor with bare hands. ig,| "02 tt bring your face tothe safety valve close dung running the compressor, Suc denly, high-pressor air spouts, In that case, you have the injured anxiety, 141. For Safe Use of Your Compressor (List of Safety Labels) yauman © Si 1-3. List of Safety Labeis ‘ This page shows where safely labels are posted for safely use of this compressor: Carefully read the cautions shown on the safety labels to prevent accidents. ‘e if any safety label is stained, damaged or lost, order it fo your nearest Yanmar sales or service agent {shown in the service network lst "YANMAR Workdwide Service" appended io this manual) by clearly ‘specifying its Part No., and post it No. Part No. 1 141616-07270 2 141616-07210 151. For Safe Use of Your Compressor MEMO. 162. Appearance and Parts Location yauman G SERIES 2. Appearance and Parts Location No. Name No. Name 4_} Cooling water inlet 16 | Water Measuring unit 2 _| Cooling water outlet 17 | Thermostat 3_| Cooling water safety vaive 18 | Suction titer 4_ | Cup (suction fiter cover) 19 | Breather cap 87] Gosling water pump 20 | Check valve @_ [Drain separalor 21 | intercooler cover Solenoid vaive 7 | (used for releasing pressure and 22 | Aflercooler cover discharging drain) €_| Oistrainer 23_| High pressure valve cover uation) 9 _| High pressure safety vaive 24 [High pressure valve cover (delivery) 70} Low pressure safely valve 25 [Side cover 44 | Oil level gauge 26 | Cylinder head 12 | Oi sight giass 27 | Oi pressure control valve 73. Yallow plug 2B_| Low pressure valve cover 14 | Oilfiter 29 | Pneumatic valve 46 | Oilfiller pump ‘30 | Delivery port 2-1 (Volume:2pages)2._ Appearance and Parts Location MEMO. 223.__ Specifications 3. Specifications Model name unit | c1es | c220 | c300 | C370 | caso | caso Type 2-Stage compressor, vertical, double-action, water cooled Low pressure 145 180 145 180 Piston stage diameter High pressure Se mom | 115 140 118 140 No. of cylinders 1 2 ‘Stroke mm| 100 | 0 | 100 | 100 | 80 | 100 Stroke volume @ | 1650 | 2035 | 2543 | 3.300 | 4060 | 5.087 Nominal speed sin 41200 Delivery pressure (maximum) | MPa 204 Right hand (clockwise), Dirsetion of rotation viewed from the side opposite to the motor. Power transmission system Direet, flexible shat coupling Cooling system Fresh water cooling using a centlugal pump Bearings Farced lubrication from the gear pump Lubricating system [Low pressure , soins Fed into the air intake port by the ol filer purnp Release system Discharge into the air using a solenid valve Amount of lubricating oil t 78 16.2 (contained in the fitter case) | (contained in the fiter case) 3-1 (Volume:2pages)3.__ Specifications MEMO. 3-24._ Installation yvanman G SERIES 4. installation 4-1. Installation environment 1) Dust-free, wel-ventiiated area where the compressor is not exposed directly to breezes. 2) Vibration-free, level area 2) Allow space around the machine to disassemble it, 4-2. Plumbing precautions (1) Pipe joints Cub this nd at precisely 00" ut ‘To prevent unbalanced forces being placed on this ‘machine, install pipe joints so that their centers are property aligned with the flange face. (2) Assembly procedure for a bite joint 1) Instat a nut and sleeve on the pipe. (Refer to Fig. 1.) 2) Insert the pine into the body of the joint until the: pipe reaches the bottom (B) of the joint body. (Be sure to apply lubricating of! on the contact and rotating areas.) (Refer to Fig. 2.) Areas where lubscating of Is epee 3) Keep the pipe pressed into the body with one hand ‘and tighten the nut with the other hand, using a wrench, Tighten the nut until the wrench becomes difficutt to turn and the pipe cannot be moved freely 44) Then tighten the nut 1-1/2 to 4-144 tums more. (@) Pipe supports Install supports in appropriate areas that allow the pipe and shutoff valves to be inspected, operated. and disassembled without interference. These supports should take heat deformation and displacement into ‘consideration. (4) Pipe resistance The pipes should be as short and sttaight as possible. Do not use a smaller diameter than the diameter of the pipe connected to the compressor. ©) Pipe cleaning After the pipes have been laid, wash any dust out of the inside of the pipes and clean any scale from the welds. (6) Drain trap and air bleeder 1) Be sure to aim the air discharge pipe down and install a drain trap on the bottom of this pipe, When you have no choice but to use a riser, make sure that drain cannot flow into the compressor. 2) The cooling water pipe should have as few curves and bends as possible, so that airis not trapped. Install air bleaders in locations where air may be trapped. 3) The drain discharge pipe for the compressor should be as short as possible, Be sure to release the rain into the atmosphere. Do not put this pipe together with other drain pipes, The drain may flow backward. @ Operation, inspection, and disassembly 41) Install shutoff valves al an appropriate position in the air discharge pipe and in the cooling water inlot/ outlet pipe. 2) Do not attach any shutoff valves directly to this machine, Install a short the compressor and any shutoff valves. 3) The short pipe connected between @ shutoff valve and this machine should be easily removed. 4) Instaif shutoff valves in places where they can be operated and inspected easily. 1¢ (150 - 200 mm) between 4-1 (Volume:2pages)4._ Installation yvanman G SERIES 4-3. Direct alignment procedure 1) As shown below, secure the diat gauge stand to the coupling on the motor. Make contact between the dia} gauge probe and the rim of the flywheel. Rotate the coupling to read the gauge. 2) Four points should be measured at 800 angles to each other. 2) Adjust the coupling so that the difference in gauge readings at the four points is tess than 0,2 mm, + Horizontal alignment procedure: Move the motor or the compressor horizontally to align them with each other, + Vertical alignment procedure: Insert a foot liner on the bottom of the motor to adjust the vertical atign- ment. INOTICE] ‘Make sure that the base of the stand shared by the motor and compressor is level before aligning the ‘wo units, (For data, refer to the direct-coupled precision information in the manufacturer's test record.) Flyuhest tt Coupting - Motor Side5. Lubricating oil and cooling water yauman G SERIES 5. Lubricating oil and cooling water 5-1. Lubricating oil Use reciprocating compressor oil for tubrication (ISO, VG100 (SAE30) which does not form carbon at high temperature and does not degrade at high pressure. A list of recommended commercially availabie lubricating oils is given in a separate table, by manufacturer. [I] Refer to section "10-1, List of C-type YANMAR recommended compressor lubrication oils’ INOTICE) + If an inappropriate lubricating oi is used, the intemal parts may seize up or premature wear may ‘occur. This can cause the service life of the compressor to be reduced. + Avoid mixing different brands of lubricating ol {If you must mix oits, consuk the oil manufacturer) 5-2. Cooling water Bo sure to use clean soft water (city wate. [NoTICE} + Do not use hard water, I hard water is used, scale will form in the water chambers, such as the oylinder head and water jacket, and the compressor may overheat. + Before adding cooling water, be sure 10 mix in a corrosion inhibitor, By using only clean water, scale, rust, and other problems will be reduced. 5-1 (Volume:2pages)5. Lubricating oil and cooling water MEMO. Be6._ Preparations for operation yvanman G SERIES 6. Preparations for operation 6-1. Lubrication 1) Remove the breather cap and add lubricating ol. Breather Cap 2) Add lubricating oil untitit ceaches the upper limi tine on the oil level gauge located on the bottom of the crankcase, away from the flywheel. C1s/C220/0300 | C370/C480/C550 “Amount of lubricating oil (2) 78 18.2 6-2. Initial lubrication for each part 1) Remove the side cover on the crankcase. 2) Remove the flywtieel cover. Tum the flywheel by hand and lubricate the main bearing, the crank pin and the bottom of the inside of the cylinder (liner section). 6-1 (Volume:2pages)6._ Preparations for operation MEMO.2._ Operation yvanman G SERIES 7. Operation 7-1. Inspection and preparations prior to starting (1) Visual inspection around the compressor 4) Check whether water, oil or airis leaking from this machine 2) Check for loose or missing nuts and bolts. (2) Checking the lubricating off level and add oit if necessary 4) Check the hubricating oil level during operation using the oil level gauge. If the tubricating oil level is low, add oil at the oil filer port when the compressor is stopped. if oit is, added during operation, it may de blown out (Note: The fevel shown by the oil level gauge wil be about 10 - 15 mm different when the motor is stopped or in operation.) 2) Remove the yellow biind plug on the oll sight glass attached to the air intake port, and add about § oc of lubricating oll, (This step should be performed when first starting the machine, immediately after performing @ compressor release adjustment, and when restarting the compressor after a tong period of inactivity) 8) Checking the cooling water Open the compressor's main inlet/outlet valve on the cooling water pipe, and check whether there is enough cooling water using the water measuring unt. (ote: Because a thermostat is installed, the cooling water wil not flow until the outlet temperature exceeds the specified vale.) (4) Checking the compressed air pipe system Make sure the shutoff valve for each air reservoir and compressed air tine is open. (©) Others Make sure no parts, tools, ete. have been lefl on this machine, 7-2. Trial run Atrial run should be performed when first starting the motor and immediately after performing a compres- sor release adjustment (1) Checking the direction of rotation 4) Switch the machine from stop to start briefly using the start and stop pushbutions to rotate the fy- wheel. Then, check whether the direction that the flywheel turns is the same as the direction indi- cated by the arrow on the motor. 2) ifthe rotation is backward, refer to the motor operation manual, open the motor terminal Dox and switch the wires Be sure to tum off the main power before switching the motor wires. Otherwise, you may receive an electric shock. (2) Checking the oil pressure Make sure the needle on the oil pressure gauge attached to the machine is in the range of 0.35 MPa to 0.45 MPa. However, when first starting the compressor, the oi! pressure may be a litte higher (0.45 MPa - 0.55 MPa) because the oil will be cool. (3) Checking the operation of the cylinder oil pump Make sure that drops of lubricating oil are seen in the oil sight glass, (When first starting, i willtake some time before drops of hibricating oil are seen.) (4 Running-in 4) With the drain discharge valve on the air reservoir open, perform a no-toad operation for 30 minutes. 2) If no abnormality Is encountered during the no-load operation, adjust the opening of the main valve to the air reservoir and perform 2 load operations for 5 - 10 minutes each. The first should be at 4 Mpa, then 2 Mpa, and finaly at the maximum pressure (2.4 or 2.9 Nipa). mM2._ Operation yvanman G SERIES () items to be checked during operation Check for abnormal sounds, abnormal vibrations, abnormal heat, and air, water, or oil leaks in each section. If any abnormatiy is seen, slop the compressor immediately and investigate the problem, Contact the manufacturer or sales company. (6) Operation check of the automatic contro! units ‘Make sure the aulomatic control units (lubricating oil pressure switch, air temperature switch, auto- matic start-stop pressure switch, etc.) operate properly / 4 \ WARNING + Do not put any part of your body into the fywhee! cover during operation, + Before inspecting or maintaining the rotating section or the surrounding area, be sure to stop the compressor. DANGER + Never touch the cylinder head or cootes cover during operation or immadiately afler stopping the compressor + You may have parts of your body or clothing sucked into the compressor and you can be seriously injured because high speed air flows around the air intake port during operation, + Be careful not to place your hands, body or clothing too cose to the air intake port, + Do not put your face close to the safety valve during operation. High-pressure air is blown out without waming and you may be injured 7-3. Normal operation (1) Automatic start-stop operation 1) When the pressure in the air reservoir reaches the pressure switch's lower limit, the switch will close and the compressor will start. At the same time, the solenoid valve (shared by the drain valve and the unloader valve) will operate, and the drain from each stage will be discharged. Then, normal operation wilt start. 2) When the pressure in the air reservoir reaches the pressure switch's upper limit, the switch will open and the compressor will slop. At the same time, the solenoid valve will operate, and the drain from each stage will be discharged. (2) Controt during operation 4) Monitoring various pressures Check the oif pressure, water pressure, and air pressure at each stage. Record the readings. Note any abnormatities 2) These checks are useful for early detection of problems, Monitor the operating time: 3) Record the operating time. It is useful for early detection of problems. Routinely check for abnormal vibration, abnormal sound, or leaks from pipes: Check for abnormat vibrations or noise from each section. Check each section for possible air, water or oil leaks. Ifany abnormaliies are seen, stop the compressor immediately, and investigate the problem. 4) Contact the manufacturer or sales company, 7-4. Method for storing the compressor for a long period of time When the compressor will not be used for an extended period, take the following steps. 1) Store the compressor in a place nat exposed to humidity or dust. 2) Since rust may form or the lubricating oll may be emulsified due to condensation, drain the cooling water completely. 3) Wipe off any dirt on the extemal parts of the compressor. Apply rust preventative oil or clean cil 4) To prevent humidity from getting into the machine, put a plastic cover over the inlet ports, outlet ports, and electrical components. 7-5. Operation after a long period of rest When restarting a compressor that has not been used for three weeks or more, observe the following points. 1) Perform the pracedure in Section 7.1 "inspection and preparations prior to stat 2) Perform a no-load operation as described in Step 1) of item (4) in Section 7.2. 7-2 (Volume:2pages)8._ Periodic inspection and maintenance yvanman G SERIES 8. Periodic inspection and maintenance 8-1. Table of maintenance and inspection items tn onder to maintain the performance of the compressor and keep it in good condition, periodic inspections are needed, ‘The following table describes the inspection and maintenance items and their inspection intervals. Make schedule for periodic inspections according to the conditions in which you will be using the machine. Make ‘sure 0 follow it routinely. Don't skip any of the inspections. INoTICE} The correct inspection intervals will vary according to the conditions in which the machine is used, the quality ofthe lubricating oil, and the method of handling the machine. Therefore, itis dificult to spec- ify absolute inspection intervals, The table below provides some inspection and replacement stan- dards. Based on your use of the machine, increase or decrease these inspection intervals. on inspection item Run time (hp Remarks Location Details /1000]2000] 3000 4000] 8000] 000 8000 [Crankcase Replace oi ° Lup. oil [Oil strainer Clean ° igneck system [Oil fiter Replace o level daily [Oilfiler pure [Replace ° Outer piston sur [Check the outer dia, and Hace |wear in the ting groove ° Piston |e ch ving Replace ° Piston pin bushing [Check wear and replace ° Higwitow Pres. Ir injsassemble and clean ° an MeN a Chee etn an ° system replace Suction fiter element|Replace ° Safety valve ‘Check operation Check valve ‘Check seal and clean ° Took [Cooling water pump|Replaca mechanical seal } wae Thermostat Check and replace ° system [Gooler Remove water scale ° Cr ae check operation ° Pressure gauge (Check and calibrate ‘Atleast once a year others /Appearance Cheat erleeks wales” [Day arf 50 ous, atin us Breather Discharge drain Daily (Gasket, O-ring {Replace Every time they are opened Overhaul Every 3 years oF § 000 hours 8-1 (Volume:6pages)8.__ Periodic inspection and maintenance 8-2. Periodic inspection items 1.Inspection and maintenance of the lubricating oil system 4-1 Replacing the lubricating oil 4) I the lubricating oll is replaced when it is warm (after the compressor has been running), the oli wil flow easily and can be drained easily. Remove the blind plug on the bot- tom of the crankcase and drain the oll 2) Drain the lubricating oll about 0.6 lit) in the of iter. Initial time 80 Rous Interval Successive times | Every 1,000 hours 4-2 Replacing the oil filter (cartridge system) 1) Tum the oil fter by hand to remove it. (counterclockwise) 2) Before installing a new filter, wipe the sealing face on the compressor clean, and apply a small amount of lubricating oil to the gasket face 3) Tum the new oil filter on by hand until it is snug. (clockwise) 4) Make sure the oll does no leak during operation. Initial ime 80 hours Inierval Successive times | Every 3,000 hours: Level Gauge: 41-3 Cleaning the oil strainer 1) Remove the oil strainer case mounting bolt, and pull the case down, 2) Use @ wrench (22mm) to remove the strainer from the case, 3) To prevent dirt from getting inside the strainer, clean any dirt from the mating surface face and wash it in light ol Every 3,000 hours ‘eral | Gor when replacing the lubricating oi) 4-4 Replacing the oil filler pump 1) Remove the pipes. 2) Use a Philips head screwdriver and remove the pump. Interval Every 8,000 hours: 82 ow Fiter oittter eump8._ Periodic inspection and maintenance yvanman G SERIES 2.Checking and maintaining the piston + Remove the low pressure valve cover, and pull out the low pressure valve. + Loosen the nut on the connecting rod bok, and remove the cap. + Use the screw hole on the top of the piston to pull the piston out, Since the rod will be pulled out together with the piston, pull them straight out to prevent the crankpin and the inside of the cylinder ‘from being damaged. 2-1 Checking the outer face of the piston 41) Check the outer surface and check the fit of the rings in their grooves for wear, 2) ff the wear exceeds the working limit. replace the rings. 2-2 Checking and replacing the piston rings and oil ring 1) Check the installation direction of the rings ( the side marked with an R near the gap should face up) and check for wear.The rings on the pistons are as follows. Low pressure stage: Three piston rings High pressure stage: Three piston rings, and one oil ing 2) If the rings are installed upside down or in the wrong order, reinstall them. If the wear exceeds the working limit, replace the rings. 3) When installing the piston rings, put the side marked with an R facing up, and orient the gaps so that they are 1200 away from each other around the piston. Do not put the gaps in a straight line. Interval Every §,000 hours, 2-3 Checking and replacing the piston pin bushing 4) Remove the snap ring. 2) Tap on one of the seal disks (until it extends about 20 ma), and then pull out the other seal disk. Pisin Pin Use the same procedure to pull out both seal disks. Be careful not to damage the disks. ‘Seal Dink 3) Pull out the piston pin, and check the piston pin bushing for Snap Ring wear. 4) ifthe wear exceeds the working limit, replace the pin O Interval Every §,000 hours, ©. we 3.Checking and maintaining the air system 3-4 Checking and cleaning the low and high pressure air vaiv For more details about the disassembly and installation of the air system, refer to the following materials ‘which core with the unit 1440-2 Valve disassembly and reassembly procedure }10-3 Exploded view of the valve 4310-4 Detail drawing of the tow pressure valve mechanism }10-5 Detail drawing of the high pressure valve mechanism Fai |H10.6 High pressure valve installation procedure chart (Al|C type) 1) Remove the valve cover on each stage. Pull out the low-pressure valves and then the high-pressure valves (suction and delivery), 2) Look for carbon or foreign matter stuck on the mating surface of the valves. f carbon or foreign matter is seen, disassemble the valve and clean i. In this case, be careful not to damage the surface of the seat 3) Push the valve plate from the valve seat air passage using a small at-biade screwdriver or a rod (2.5 - 3.0 mm in dia.) Then, check the movement of the plate and the spring. (Three places) If any abnor- ‘mal movement is seen (he valve tits differently, the plate track is Slow, etc), disassemble and clean ‘the plates and the springs. Check the plates for wear, and the springs for damage, settling or fatigue. ifany abnormality (wear, damage, etc.) is seen on plates and springs, replace them with new ones, 838. Periodic inspection and maintenance yvanman G SERIES 3-2 Replacing the air inlet fiter element {the air inlet fiter element is dirty, the alr inlet pressure will be reduced. This will reduce the amount of air delivered by the compressor. Replace the element every 2,000 hours, After seplacing the element, be sure to reinstall the cup (air filter cover) with the arrows pointed correctly. 4.Checking and maintaining the cooling water system 4-4 Checking and cleaning the cooler It the cooter is diy (Scale has formed), it may cause an increase in the discharge air temperature and a tapid build up of carbon. 1) Remove the intercooler cover and the aftercooler cover. 2) Check whether scale is seen on the copper pipe section. If so, clean it using a brush, Every 3,000 hours interval (or when disassembled) a48.__Poriodic inspection and maintenance 8-3. Maintenance standard table Unit: mm Tinting dearance CaaS C2BOCIO0 370 c4501C550 Tow press. stage O72 084 Outer dia. of piston / Cylinder bore igh press. stage o68 O70 \Width of piston ring / Ring groove Low press. stage a igh press. stage 3.16 ih of of ving Ring groove 348 Diiter dia. of pision pin Taner dia. of pin bush oat Oiler dia, OF piston pin / Taner dia, Of piston pin hole 0.07 Oiiter dia. of erankpin inner dia, of connecting rod bushing O48 Ouiter dia of joumal Taner dia, of joumal bushing 018 Aoal clearance of the erankshat 70 Unit: mm CHBECSTO CEOICTOOICABICSSO Nominal size | Working mit” | Nerinal sae | Warkina iit ovr press. eu 15 a2 is “O42 Valve plate thickness. |Tow press. del i76 as T75 OAS High pressure io “040 10 610 Pion rng thickness (LO“bIesS Sage | EB 045 60 a8 High press. stage | 40 “oat 30 ae Oi Fg WiGkness a oa 50 ae Ton press sage | 40 ae 40 OA? Piston ring width High press. stage | 3.0 “0.08 30 008 Gitting wieth 20 Baz 40 a2 Piston ring groove [Lowpress. slags | 40 iz 40 02 wit igh press. sage | 3.0 oo 36 oo Siting groove width ao aus i oi cyindorbore Tow press. slage | 145 068 780 72 High press. lage | 775 087 740 a7 Gylinder roundness 00 0.10 Tow press Sage | 148 az 780 as Outer da. of piston 42 High press. stage | __118 ae 740 036 Brite dia” of piston pin 38 88 Eg 608 Giiter dia. of piston pin bush Ey 020 s 036 Biston pin hole 35 0.06 3 0.06 Gaile dia. of erankpin % O38 7% 68 inner da, of red bushing 7 035 73 035 Guile dia of crank journal 80 530 86 030 inner dia, of journal bushing 0 030 30 030 Note: The clearance limit and the working limit are reference values. They do not guarantee performance. 858._ Periodic inspection and maintenance yvanman G SERIES 8-4. Nut and bolt torques 4 Torque of the main perts INOTICE} Tighten the following nuts and boits with a torque wrench using the correct tightening method and order. Unit: Nem(kofn) Low pressure valve cover: M12 bott 59 + 4.960 +05) High pressure valve cover: M10 bolt 8444.95.54.) Cylinder head: M12 bolt 7444975 £05) oles cover MB bott 34 £ 3.0 8.5 #0.3) MB nut 2342023 £02) Balance weight mounting bok: M16 boit 196 = 14.7 20+ 1.5) Connecting rod bolt: M14 nut (lubricated) 176 $4.9 (18 £05) Low pressure valve: M12 nut (lubricated) 51430(62+03) Low pressure valve: M10 nut (lubricated) 29.5 22.03.0202) Note: When tightening the nuts and bois, lubricate the bearing surface of the bolts (or nuts) and threaded parts, Do not use other lubricants (e.g. molybdenum disulfide agent). 2.Torque of standard nuts and bolts + The standard torque shown below is only applied to the bolts marked with a [7] on their heads. (IS strength division: 77) + Ifthe bolts do not have a {7}, tighten them using 60% of the torque shown in the table. + ifthe material the bolt screws into is made of light alloy, tighten the bolt using 80% of the torque shown in the table. + When tightening these nuts and botts, do not lubricate the bearing surface of the bolts (or nuts) and threaded part, Standard nuts and botts Screw dia, x pitch | M6 x 1.0 | MB x 4.25 | Miox 45 | M12x 1.75 | M14 x 2.0 Nm) to+4 232 44449 | M449 | 118498 Torque kof) | (1.0401) | @3+02) | @5#05) | G5+05) | 120+1.0) 869. Troubleshooting 9. Troubleshooting No. Problems Possible causes Remedies It takes foo long for the air [pressure to build The pressure does not rise. (Clogged inlet fiter [Ctean or replace etement. Damaged tow/high press. air valve Check, clean or replace. Wom or stuck piston ring Check, repair or replace. Air leaks from pipes Repair. Defective operation of release sole-| noid vaive Check, clean or replace. [Large noise or vibration Foreign matter in the cylinder Remove foreign matter and repair. [Damaged or broken low/high press. air valve [Check and replace. Incorrectly tightened bolts Retighten, Wom bearings Replace, Too much piston clearance ICheck the oylinder, piston and piston rings. Replace as necessary. Frequent build up of |carbon on the vaives Poor centering Readjust Oil consumption is t00 high, (1) YWosn il sing (1) Replace. (2) Too much piston clearance (3) Too much oil in the crankoase (2) Replace the piston or cylinder. (3) Reduce the oil to the specified level. Discharge air temp. is too high (1) Damaged or broken air valve (2) Poor cooling of too little water (3) Defective thermostat operation (4) Check, repair or replace. (2) Check and clean the cooling jacket, cooler and pump, (2) Check and replace. Inappropriate lub. olf Replace with recommended ub. ol lLow-press. siage safety lvave blows, Poorly sealed high press. valve Overhaul, clean or replace. igh press. suc./del. valves reversed Jchange them. IHigh-press. stage safety valve blows. [Shutof valve in the compressed air ine is closed. JOpen the shutoff valve, Resistance in compressed aie line to air reservoir is too high, Reduce line resistance. Incorrect pressure switch setting [Set propery. 9-1 (Volume:2pages)9. Troubleshooting No. Problems Possible causes Remedies 6 {Oil pressure does not rise. Rotates backwards. (Change fo normal rotation Incorrect pressure control valve setting Set property. [Clogged oil strainer fiter Clean or replace. water. Lub. ollwas not added, [Add tub. oi. ; Poorty tightened or loose cylinder {Retighten. 7 [Airis mixed with cooling thead, cooler cover clamping bolt {Replace gaskets, Air leaks from cooler {Check and replace the cooler, ICtoudy (emutsified) lubricating oit Poor installation environment (righ |temperature or humicity) Ventilate well [Supercooled compressor (1) Cooling water intet temperature is too tow, (2) Too much cooling water is supplied. (3) Cooling water fows when compressor stops. (4) The ventilation air from the duct flows directly over the compres sor. (1) Raise the cooling water inlet temperature, 12) Adjust the amount of cooling water, (8) Slop the wates flow when the ‘compressor stops. (4) Change the duct direction. [Shor, intermittent operation [Extend the operating time. [Cooling water leaks Find the Jeaks and repair. Insufficient ventilation in the crank- case ‘Check if breather is clogged Drain is not discharged smoothly. (1) Defective operation of drain discharge solenoid valve (2) There is too much drain. (3) Drain pipe resistance is too bigh. (1) Check and repair or replace. Check the electricat circut, (2) Reduce the operating interval for the solenokd valve intermit- tent timer, (3) Shorten the drain pipe and dis- charge into the air, Water is condensing in the breather section ‘Open the drain valve on the bottom ‘of the breather and discharge the drain10, inchided materials 10. Included materials 10-1. List of C-type YANMAR recommended compressor lubricating oils IDEMITSU KOSAN CO.,LTD. Manufacturer Mineral oft Synthetic Suid ESsO (ExxonMobil EXXCOLUBE 100 RARUS 827 CASTROL (@xonMobill AIRCOL PD100 AIRCOL SN100 ELF (JOMO} DACNIS P100 BARELF CH100 SHELL (Showa Shell Sekiyy K.K.)| CORENA Olt P100 ‘CORENA IL AP100 TEXACO (ChevronTexaco) REGAL OIL R&O N100 Cetus DE 100 CALTEX (ChevronTexaco) RPM COMPRESSOR OIL 100 | Cetus DE 100 MOBIL, (ExonMobil)| MOBIL RARUS 427 MOBIGARD 1 SHE MOBIL RARUS 827,820 BP (NIPPON OIL, CORPORATION)| ENERGOL RC100 ENERSYN RX100 NIPPON Ol. CORPORATION | FAIRCOL A100 FAIRCOL SA100 DAPHNE MARINE. DAPHNE ALPHA MARINE COMPRESSOR 100 COMPRESSOR 100 FUJI KOSAN CO., LTD. JOM) RECIC 100 COSMO OIL CO, LTD. ‘COSMO RECIPRO 100 Tonen General Sekiyu KK. COMPOL A100 FUKKOL ‘SHINLUB. COMPRESSOR $100 COMPRESSOR OIL $B100 10-1 (Volume:spages)10, _Iincided materials yvanman G SERIES 10-2, Valve disassembly and reassembly procedure Valves are the most important parts of the compressor. If defective valves are used in the compressor, i vill not only damage the valves but also cause serious problems such as broken pistons or damaged cylin- ders. Before disassembling or reassembling the parts, be sure to read this manual thoroughly to understand the design of valves and how to operate the compressor carefully, 1.Tools No. Name Tow presure valve High pressure vaive “Torque:48 ~ S4N-m Torque:28 ~ 81N-m 4 fForque wrench (6.9 ~ 5.5kgh-m) (28 ~ 3.2kgtm) Apply lub, oi Apply lub. ci. Socket wrench (nominal) 18 6 Boxwrench (nominah 3 5 Hexagonal nut 4 {or tocking temporarily) wiz Mio © [Small atblade screwdriver. Used in commen: 6. [Valve locking jig 2.Precautions (1) Do noi put a valve directly in the jaws of a vise. (2) Secure the vaive with the vaive locking jig 50 that the seat and the guard cannot turn, and then tighten the nut Ifthe seat or the guard tum backwards, the pin will break. @) Be sure to tighten the wing nut by hand. I itis tightened with a toot, the guard may be deformed by over tightening it. 3.Valve disassembly procedure (1) Remove deposits (carbon) from the surface, valve air passages, and the threaded parts of the nuts ‘ang bolts. Then apply (ubricating oil to the threaded parts, (2) Secure the valve mounting plate in the vise so that the valve mounting plate is higher than the top of the vise (8) Put the valve on the valve mounting plate, and secure the vaive with the valve presser plate and the wing bot (4) Loosen the nut using a socket wrench, (8) Place the disassembled valve parts in a tray to avoid fosing them. InoTicel To prevent problems from occurring due to incorrect reassembly of the parls, check the order that the parts are removed, and their orientation, and record this information. 10-210, Included materials yvanman G SERIES Socket Wench Valve Preeaure Plate ave Mounting Plate 4Nalve reassembly procedure (1) Refer to section "40-3 Exploded view of the valve" and reassemble the parts. Pay attention to the feassembly order and orientation of the parts. Then, temporarily lock the valve using the temporary ‘nut, Then, check the following items to see if the valve is reassembled property. a) The seat and guard should be parallel. Make sure size A described in sections “10-4 Detail drawing of the fow pressure valve mechanism” ‘and “10-8 Detail drawing of the high pressure valve mechanism" is fess than AJO.imm at the four positions at equal distances, ») The guard should not have any backlash. ©) Ifthe guard can be rotated tefl and right a litle by hand. a knock pin shouid be used to stop it from fuming 4) The vaive plate should not be trapped. Push the seat lightly with @ screwdriver passed through the air hole on the seat side, and make sure the seat can be lifted. (2) Putthe valve oa the mounting plate, and secure the valve with the valve presser plate. Replace the temporary nuts with normal nuts, and tighten them to the following torques. Low pressute valves : 48 - 54 N-m (4.9 -§.5 kgFm) Apply lubricating oil High pressure valves : 28 - 91 N-m (2.8 - 3.2 kgm) Apply lubricating oil (8) Remove the valve trom the jig, and check again to make sure the vaive plate is not trapped. “Torque Viteneh ‘Sox Virenen 10-810, inchided materials 10-3. Exploded view of the valve Low Prosaure Vote Pin (63.8), Pin (623) Fin (61.8) Valve Piste (suo 3 Spacer Qe SZ, 8 k Bot 2 vanman G SERIES High Pressure Valve susua ine ona se fee a : = GES = Valve Ser SS OY e_ YP 2 —© valve Piste valve 5 i Pin (923) Pin 8) 10-410, inchided materials vanman G SERIES 10-4, Detail drawing of the low pressure valve mechanism wg 195 __,| Low pressure valve mechanism No. Name Parts No. Qtyiass'y 1 | Seat uc.) 90370-11120 1 2 | Seat el) 10370-11710 1 3 | BotMi2 90370-11130 1 4 | Valve plate (suc.) 90370-11140 1 5 | Valve spring uc.) 90370-11150 4 6 | Spacer 190370-11160 2 7 | Valve plate (del) 90370-11170 1 8 | Valve spring (del) 90370-11180 2 @ | Nut 190370-11220 4 30 | Pin 03.8 90370-41380 2 1 | Pin 628 190370-11200 1 12 | Pin 618 90870-11240 4 10-510, inchided materials vanman G SERIES 10-5. Detail drawing of the high pressure valve mechanism Tritt __ #8 \ (3 @ High pressure suction valve mechanism Te Nae PaRENG THAST Top Seat 7e0570-71076 7 2 Guard 90370-71020 7 3 Bolt M10 190370-71060 7 4 Valve plate 190370-71030 7 S| Valve spring (90370-71040 7 6 Spacer 490370-71050 7 7 Nut 190370-71080 4 8 Pin 623 190370-71070 1 opin its ieosre TTI 4 High pressure suction valve mechanism No. Name Parts No_ CyAssy 1 | Seat 80870-71716 7 2 Guard ‘180376-71130 7 3 Bot Mid {90370-71060 7 ‘4_| Valve plate 90370-71030 1 5__|_Valve spring 90370-71040 2 6 | Spacer 90370-71050 4 7 [Nut 90370-71080 4 @_ [Pin ads 190370-71070 i o_ [Pin ots 190370-14210 7 10-610, _Incided materials yvanman G SERIES 10-6. High pressure valve installation procedure chart (All C type) SRotanor ‘Since the suction valve act te delivery have diferent lengths, be cavetl nt to mic them up) Aalve Set Bot orgie "2322 Nam (2340.2 gt) ‘Cone bise Spring (Pay akenton to the intataton direction) Suction Vaive Pertype Snap Ring ‘Mechanism vind Digh Pressure Cover AiDelivery valve Mechanism sto-cng ut Torque : 28st Nem (2340.2 ket) Instaifation procedure 4) First, reassemble paris @ to @ outdoors. 2) Use the end screw of valve set bolt @ , and twist the whole mechanism to the right to squeeze it into the cylinder. 3) Install high pressure valve cover @ with O-ring @ installed in it 10-7sol Low Pressure Valve Mechantsre Piston ‘Valve Mechaniem High Pressure Delivery ‘vate Mechanism Res Cooler Cooling Water Pump connecting od A Fitar Pump ‘High Pressure Suction ae - Py |S ae brieating 08 Pump (suapuyAd Z) Huymeup uosyIas SSOlD “2-01 Ol ‘sjeuaqeu! papnjouy SaaS 2 YeNNWAYanmar's Worldwide Service Network Domestic Office YANMAR CG, LTD. m Yanmar (Head office) 1-82, Chayamachi, Kits-ku, Osaka, Japan §30-8311 Yanmar {Tokyo} 7-1, -chome, Yaesu, Chuo-ku, Tokyo, Japan 104-5468, hyo ape © Export Dept. Marine Country Code: 81 Phone: 33275-4009 Fax. 3-3275.4060 @ Large Power Products Operations Division 1-5, 1-Chome, Nagasu Higashi-don, Amagasaki, Hyogo, Japan 660-2685 © Quality Assurance Dept. County Code: 81 Phone: 68409-8017 Fax: 66458-4009 YVANMAR ENGINEERING GO, LTD. @ Tokyo Office 4-1, 2-Chome, Yaesu, Chuo-ku, Tokyo, Japan 104-6496 Country Code! 81 Phone 33242-6950 Fax: 9-0242.8960 Web: wanw yanmar co jiyer Osaka Office (Head Office! 7-1, 7-Ghome, Nagasu Rigashi-dori, Amagesaki, Hyogo, Japan 560-8585 Country Code: 81 Phone 65459-3048 Fax: 6-6481-101 ‘Web wnu yanmar. jive! (Bein 19, oy 2012) a @ a o ° Overseas Office ‘Yanmar Europe B.V. Brugplein 11, 1332 BS Amore-de Vaart, Netherlands. Country Code: 31 Phone: 36-5493200 Fax. 98-6498209 ‘Yanmar Asia (Singapore) Corp. Pte. Ltd. (YASC) 4 Tuas Lane, Singapore 838673 Country Code: 85 Phone: 6595-8200 Fax: 68825189 Yanmar America Corp. 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Room 1208, 0.0. vw Bavding, 302-308, Hennessy Read, Wanchai, Hong Kong, China Phone: 2833-0082 Fax 2004-7763 E-mail endo@yanmarhk com hk © Cistar Tech HK Ltd. 3iF,, 81 Hing Wah Sireat \West Lai Chi Kok, Kewloon Hong Kong. China Phone: +85227750161 Fax: +86227726054 E-mail nfo@icstarhk corn Web. wawe'starhk com ‘@ Charter Technical Services Lt Room 1207-8, C.C. Wo Bulding 302-308, Hennessy Road, Wanchai, Hong Kong, Chine Phone, 2803-964 Fax. 2603-5701 PHILIPPINES (Country Code: €3) (D YANUAR ENGWEERING CO.,LTD, PHILIPPINES LIAISON OFFICE Bldg 3, Bortaphil South, Bayaninan St, siose Abad Sentos Avenue, Clark Freeport Zone 2023 Pampanga Philppines. Phone d5-A90-1541 / 4542 Fax: d5-809-1548 ® Seapowers Trading & Industrial services 316-A Mamet Cebuyao, Laguna, Philippines Phone’ 917-500-2017 Fax 49-02-0785, E-mail seapowers@pldtdsl net MALAYSIA (Country Code: 60) ® Pan Sarawak Co., Sdn. 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Vashi New Bombay-400 703, india Phone: 22-55912289 / 27882524 Fax: 22-56912284 | 27892528 E-mal: INFO@INDAUST.COM SINGAPORE (Country Code: 65} ® Yanmar Asia (Singapore) Corp. Pte. Ltd. (YASC) ‘Tuas Lane, Singapore 638613 Phone: 6861385 Fax 5862.5189 ® Chong Lee Leong Seng Co., (Pte) Ltd. 28 Tuas Avenue 2, Singapore 63454 Phone: 6264-2923 Fax 6861-8785 KOREA (Countty Code: 42) @ Hwalll Trading Co., Ltd. #83, 2-GA, Namheng Dong, Young Do-es, Busan, Korea Phone. 51.412.5986 Fax 514148762 E-mail hwall@lwvail. oo kr @ PLUS Service Co. Room 2806, Centum Leasess Mark B/D, 1514 U-Dong, Haoundae-gu, Busan, 612-288, Korea Phone: 81-745-8201-~2/4 Fax: 81-74-8203 E-mail. plusbusan@nanafos.com ® CHIBA MARINE KOREA Go., Ltd. 4-80, Chungrak-Dong, Yeongdo-gu, Busan, Korea Phone. §1-418-8098 Fax 51.478.5380 Exmail. chibako@korea.com THAILAND (Country Code: 66 @ Siam Consotium Service Co., itd. 403-107. 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'48-50 Export Drive Brooklyn 2025, Victoria, Australia Phone: 3.9314.3722 Fax 3.9914.3799 E-mail waterside-eng.com @ Jaitco 40106 Kurrabe Road, Neuve Bay, N.S.WV 2080, Australia Phone, 290008548 Fax. 2-90631726 @ Japan Marine Engineering Co., Ltd. 475 Wertigal Road Mocrabian Victoria Australia 3189 Phone’ +61-9-9555-5277 Fax +61-3-0555-5344 E-mail sales@jmeaust com.au 4a @ GOLTENS PAPUA NEW GUINEA (Country Code: 675) @ Lutheran Shipping PO. Box 1459, Lae, Papue New Guinea Phone 42.8190 Fax 42-5808 Telex NE 44172 NORTH AMERICA U.S.A, (Country Code: 1) ® Yanmar America Corp. (VA) Georgia Office 404 nteretonal Parkway, Adeirsvile, GA 30103,U.S,0. Phone: 1-770-877-9804 Fax: 1-770-877-9009 @ YANMAR AMERICA CORPORATION. NEW YORK BRANCH Parker Plaza (GF, 400 Kelby Street, Fort Lee, NJ 07024 US A, Phone. 201-592-8800 Fax: 201.692.8503 E-mail HWstanabe@yanmar com @ Marine Turbo & Diesel Inc. 1000 7th Strost, Richmond, Ca, 94601, USA Phone: 510-236-3525 Fax $19.2353678, @® GOLTENS New York Corp. 460 Van Brunt Sveet, Brockiyn, NY 11291 U.S.A, Phone: 718-985-7200 Fax 718-802-1147 smi Co. Ink 2325 NE. Miami Court - Mian, Florida 33137 USA, Phone: 206-576-441 Fax 305-678-3827 E-mail morten lindkvist@goltens.com TRANSMARINE PROPULSION SYSTEM, Inc 5424 West Crenshaw Tampa, Florida, 33634 U S.A. Tel: 1-813-830-9180 Fax1-812-830-0181 UNITED WORLD ENTERPRISE, INC 16310 Wintiee Houston, Texas 77087 U.S.A, Phone: 1-713-641-1915 Fax. 1-713-.041.2717 SEER BRASIL (Country Code: 55) @ Metalock do Brasil Ltda Rua Visconde do Rio Branco 20/26, 11013-030, Santos, SP. Brasil Phone’ 13-3222-4086. Fax. 13-8222-4088 E-mail. santos@metalock com br Web; http siwwarmetalock com ir= LALO MAL) C185, C220, C300, C370, C450, C550 ‘st edition: June 2003 1st edition 1st rev.: October 2012 lgsued by: YANMAR CO.,LTD. Large Power Products Operations Div. Quality Assurance Dept. Edited by: YANMAR TECHNICAL SERVICE CO., LTD.YOSSIudINOD VYANMAR YANMAR CO., LTD. a hitestiwww.yanmar.co.jp sate