IYO S 5 5 1 863 M5- 2E,,~-----_/

MG78A AIR COMPRESSOR

INSTRUCTION MANUAL

MATSUBARA IRON WORKS LTD.

Head Office 10th PL, Shin-Os aka Sun Earl Bldg., Kitakan,8-3, Nishinakajima 5-chome, Yodogawa-ku, Osaka, Japan.TEL 06 - 6304 - 7780 FAX 06 - 6304 - 7854

Tokyo Office 4th PL, No.2 Arakawa Bldg.,1-3, Kyobashi 2-chome, Chuo-ku, Tokyo, Japan.TEL 03 - 3243 - 0413 FAX 03 - 3243 - 0415

Shiga Factory 1500- 46, Shibaharaminarni-cho, Higashiomi City, Shiga Pref, Japan.TEL 0748 - 22 - 1313 FAX 0748 - 22 - 1316

SaJety P r e eau t o n s

To ensure proper use of the compressor unit, be sure to read this manual and the otherattached documents carefully before starting installation, operation, maintenance, andinspection. Within this manual, safety precautions are ranked, in order of importance,as either *Danger* or *Caution*.

: An operator may be killed or seriously injured by a hazardouscondition resulting from improper operation.

~c aut ion I : An operator may be suffer minor injuries and/or objects may bedamaged by a hazardous condition resulting from improper.

Under certain conditions, improper operation may result in serious injury and/or damageeven if it is labeled only as *caution*. Even item indicated by either MDanger* or*Caution* should be considered significant. Be sure to give particular care to thoseitems.

n g e r

K!>D a n g e r

1.General• Be sure to read a manual and a safety precaution of the compressor accessories (piping,fitting, receiver, etc.) and tne prime mover (motor, engine, etc.).• Transportation, installation, piping, operation, maintenance, and inspection of acompressor should be done by a specialist. Failure to do so may result in injury.

The strength of piping, fitting, ~tc. should be needed an endurance pressure of4.5MPa or greater.Failure to do so may result in injury and/or these equipments may be burst.

2.Precaution of High pressureThe air is compressed to 3.0MPa by the compressor. This compressed air has a strong

destructive power. Be sure to give care to following items.• Do not disassembly in the pressurised condition.

Failure to do so may result in injury.• Do not rise more than 3.OMP a. If the compressor is running continue in thiscondition, the compressor unit may be burst and an operator may be injurY.· Do not change set pressure of a safety valve to more than the initial set value.

Otherwise, the pressure of the compressor unit should be risen abnormally andthis unit may be burst and an operator may be injury.• When a pressure of the compressor unit is risen abnormally, immediately stopthe operation of the unit and check its cause.

The unit may be burst and an operator may be injury.

3.Precaution of Rotary bodyThis compressor has a rotary body such as flexible coupling, pulley, c~oling fan,

belt , etc.• Do not touch a rotating body and moving body while compressor is running.

Failure to do so may result in injury.Before disassembly, make sure the following items:

The compressor has stopped.The compressor can not run during disassembly.

Failure to do so may result in injury.• Do not start the compressor without a cover of rotary body, belt, or cooling fan.

Failure to do so may result in injury.

4. Precaution of Motor and Starter• Turn off the electric power before starting maintenance or

Electrical shock may result.• Connect cable according to a manual and wiring diagram.

Electrical shock or fire may result.• If there is an abnormality. immediately stop the operation of the unit and turn offthe electric power.

Electrical shock or fire may result.• Do not neglect grounding. Electrical shock may result.• Do not start the uni t wi thout a terminal cover.

Electrical shock may result.

[&cautionl• This is a air cooling type compressor unit. FolIo ins parts become very hot whilethe uni t is running or just after it has stopped.

Do not touch these parts.Fai Iure to do so may resul t in scorching.

ModelMG64A MG78A MG90A MG95A

Cyl inder 0 0 0 0Cylinder cover 0 0 0 0LP air piping 0LP cooling piping 0 0 0HP valve cover 0 0 0HP cooling piping 0 0 0Non-return valve 0 0 0LP valve cover cooling fin 0HP valve holder cooling fin 0

• Keep the exhaust pipe of a safety valve and drainage free of operator.An operator may be injury and his clothes may be soiled.

• The revolution of compressor should be kept the specified direction.The unit may be damaged and an operator may be injury.

• For wiring to motor and starter. select cable sizes suitable.Failure to do so may result in fire.

• Do not touch the edge of screw.Failure to do so may result in injury.

• Do not reconstruct this compressor unit by your hand.This reconstruction is out of our guarantee.

• Maintenance and inspection of a compressor should be done by a specialist.• Replacement parts should be used our products.

L s t of Clamping Nut & Tighten Torque

L.P. Valve H.P. ValveModel

Clamping Tizht en Torque Reference Clamping Tighten Torque ReferenceINut Kgf . Cm N'm Nut Kgf' Cm N'm

G64A M8 115 1 1. 3 M6 60 5.9 Hexagonnut

G78A M 1 2 365 35.8 M8 115 1 1. 3

G90A M 12 365 35.8 M8 115 1 1. 3

G95A M 1 2 365 35.8 M8 1 1 5 1 1. 3.

'Model of blank reference. make use of Hard lock nut.

·Tighten torque apply under nut and tighten torque of

a b 0 v e nut a p ply fro m 60% t 0 100%.

Contents

§ 1. GeneralI.Main specification2.Structure and function of parts

§ 2. Precautions on installation1. Installation place2.Air receiver and piping3.Lubricants

§3. Caution before and after starting1. Pz-e r c h e c k i n g

2.Manual rotation3.]ust after starting

§4. Caution during operation1. Air tightness2. Lubricants3.Noise4.Safety valve5.Reat6.Drain

§5. Caution at stopping1.Just before stopping2.Lubricants3.Drainage4.External inspection

§6. Disassembly1. Body2. Valves3.Piston

§7. Reassembly1. Piston2. Valves3.Body

§8. Lubricants1.Kind of lubricants2.Amount of lubricants

§9. Troubleshootingl.Failure to increase pressure2.Abnormal sound3.0verheat

§10. Automatic operation by motor driven§11. Periodic inspection§ 12. Structural drawing of air compressor

Page·. . .. 1

•••••3

·•••• 3

••••• 4

•••••4

••••• 5

••••• 6

·•. •• 9

·... ·10

· '13· ·15· ·16

§ 1. General1. Ma ins pecif icat ion

The main specification of this machine is as follows.

Design No. MG78APJ MG78ADT

Driven V-belt driven Direct drivenmethod by Motor by Motor

Type Vertical, two stages, air cooled

Model No. MG78A

Low pressure cylinderdiameter 88 mminner

High pressure cylinder 80 mminner diameter

Stroke 60 mm

Revolution 1000 min-' 1200 min-'

Piston displacement 21. 9 m3/h 26.2 m3/h

Pressure 3. 0 MPa

Power required Approx. 3. 3 kW Approx. 3. 7 kW

The suffix of Design No. MG78A** shows as follows:MG78A * *--- --

I I LRevolution~Driven method

Model No.

2

2. Structure and function of parts(Refer to §12 Structural drawing of air compressor)

a. Main bodyThis is a vertical, 2 stages compressed, air cooling type compressor.It is designed to match a normal pressure of 3.0 MPa.The features of this compressor are simple structure, rigidity and

good performances.For its structures, the upper part of cylinder is a low pressure area

and its lower part is a high pressure area. The stepped piston performsHsuctionH and NdeliveryH and compressed air by being moved vertically bymeans of a connecting rod.

The air is compressed in the low pressure area for first stage afterhaving passed the air strainer and inlet valve at the inlet of thecompressor. The compressed air is cooled while passing in the air coolingpipe and enters in the high pressure area. The air recompressed in thehigh pressure area is set to a required pressure.

However, it fed again through the cooling pipe due to a high temperatureand is sent to an air receiver.

b. LP valve and HP valveFor its structure, a suction valve seat is located at its lower part

and a delivery valve seat at its upper part to unify suction anddelivery. This is a feature of the Matsubara Compressor. Since a valvearea is widely allowed, it requires a less lift of the valve.Consequently it endures high-speed rotations and does not lower itsefficiency. Since the valve consists of an unified body, it can be easilyremoved for diassembly and repair.

c. High pressure safety valveThis valve is attached to prevent a danger when a pressure becomes

abnormally high. When the pressure increase within 10% of the normalpressure, it is actuated and discharge the compressed air into theatmosphere to prevent a pressure rise. Its working pressure can be easilycontrolled by mean an adjusting bolt.

d. Oi 1 gaugeLubricants fed into the crank case is spattered by the oil scraper

located beneath the connecting rod to lubricate the cylinder, pistonpin, metal, crank pin, main bearing, etc. Oil consumption can be checkedfrom outside with the oil gauge. The upper reference line indicatesstandard oil level.

For details, refer to §8 Lubricants.

3

§2. Precaution on installation

1. Installation placeInstall the unit in the following place:

Free from dust and dirtNot affected by high humidityWell-liftEasy to inspect. d is+ and reassemble. and repair.Keep 30cm and more distance at the fan side from a wall.

It is also desirable to select a stable and vibration free place.Before tighten all the foundation bolts. lay liners under the foundation

as the foundation is horizontally.

2. Air receiver and pipingThe air receiver should be installed as near the compressor as possible.

Steel pipes (STPG). of schedule 40, having an aperture of BA should beused. Connect pipes securely with due care not to allow air leakage.Avoid to arrange pipes at an acute angle.

The strength of piping, fi tting, etc. should be needed an endurancepressure of 4.5 MPa or greater.

3. LubricantsThe unit has been delivered without lubricants. Never fail to supply

lubricants prior to running-in. Detach the crank case cover and pourlubricants up to the upper reference line of oil gauge.For kinds of applicable oil, refer to §8 Lubricants.

§3. Caution before and after starting

1. Pre-checki ngCheck up the entire machine to see if:

Parts are secured.Proper amount of oil is supplied.There is no abnormali ties in piping, etc.

2. Manual rotationWhile gently turning the pulley, check the interior for abnormalities.

Considerable force required at compression, or hooting or bursting soundsat suction indicates good condition, while signs such as something bumpedindicates improper condition, thus requiring an overhaul.

4

3. Just after startingLet a few drops of the oil in the oil cup atop the air inlet case.

(This step must be taken at running-in after installation. It may beomitted in the state of regular service.)

Immediately after pouring oil, clattering sounds may be heard. This means,the valve makes an irregular motion, which will cease soon.

Open the cock of low pr~ssure gauge to see if pressure has been properlyincreased and if there is no air leakage.

When driven by motor or engine without magnetic valve for drainage,after starting the compressor,close the drain valve.

§ 4. Cautions during operation

1. Air tightnessCheck to see if there is neither air leakage nor oil leakage in the air

passages (pipes, couplings, valve seals, etc.)

2. LubricantsBe careful of oil consumption. Check oil consumption 4 to 5 running hours

after running-in as well as each starting.For oi 1 amount, refer to §8 Lubricants.

3. Noi seIf abnormal sounds are heard, immediately stop the machine and

troubleshoot. This is signal warning a serious accident.

4. Safety va I veCheck the valve at least once to see if it functions at required pressure.

5. Rea t

20 minutes or so after starting, temperature of each part rises. If itcontinues to rise, it indicates a trouble in the machine. At the beginning,check usually temperature of every part and the thermal condition of theair compressor shQuld be understood.

6. Drai nIn the case of a long period of run. open the drain valve to discharge

drain.

§ 5. Caution at stopping

1. Just before stoppingLet a few drops of the oil in the oil cup atop the air inlet case. This

is to prevent rust which may occur during a standstill. In regularoperation, therefore, it can be omi tted.

5

2. LubricantsWhen oil level comes down near the lower reference line of oil gauge,

add oil.Oil is contaminated with drain or impurities after a long period of run,

so check for oil co n d i tion. Replace oil, if necessary.For detail, refer to § 8 Lubricants.

3. DrainageWhen driven by motor or engine without magnetic valve for drainage, open

the drain valve to discharge drain.

4. External inspectionWipe off water, oil, dirt, etc. on the machine. It serves to prevent

coming-in of foreign matters, corrosion, etc.

§6. Disassembly (Refer to §12 Structural drawing air compressor)Before disassembly, make sure the following items:

The compressor has stopped.The pressure in the compressor and piping has decreased to atmosphere.The compressor can not run during disassembly.

1. Body

a. Remove the fan cover.

b. Remove the pipes.

c . Detach cylinder c0 v era n d take 0 u tL P va 1v e .Do not forget to remove the packing also.

d. Remove the crank case cover off the crank case.

e. Unscrew the crank pin metal bolts and take out the lower housing ofthe connecting rod.

Be sure to count the number of adjusting liners.

f. Screw the eye bolt on the piston and take out the piston.Be careful not to damage the piston and the piston rings.

g. Remove HP valve cover and take out HP valve.Do not forget to remove the packing also.

h. Remove the fan bel t and the cooling fan.

6

i , Take out the cylinder.

j. Remove the fan pulley.

k. Unscrew the nuts of main bearing case (at the side where the crank shaftis to be removed), and draw out the crank shaft by tapping the shaft endwith a wooden hammer.

2. ValvesDraw out the split pin of fitting bolt. apply soft object

around the valve seat, and hold the in a valve. Loosen thedisassemble the valve. Put air-tight and adjusting liners,lest they should be lost.

Take care not to damage the valve and valve seat.

such as ragnut tosprings together

3. Pi ston

a. Remove the piston ring. Be careful not to open the ring too much whentaking out, otherwise it may be damaged.

b. Remove the set bolt and draw out the piston pin using the piston pindrawer.

§7. Reassembly (Refer to § 12 Structure view of air compressor)Reassembly should be done in the opposite order of its disassembly.Do not start up the compressor until reassembly works have finished.

1. Piston

a. Mount the connecting rod. Apply oil to the piston pin metal area of theconnecting rod and insert in the piston. At this time, the blind side ofthe piston pin should be on the left side with the timing mark of theconnecting rod on this side, when this is done.

Insert the piston pin in the piston, paying attention to the notch ofthe set bolt. After having inserted it, hit it hard and fix with the setbol t.

b. Place the piston ring at the right position.

2. Val vesReassemble in the opposite order to disassembly.Take care not to allow dust in. .Adju st valve lift referring the table

below.For an ideal valve contact, it should not be separated when the valve is

calmly and vertically set in a dry condition.

Low pressure Low pressure High pressure High pressuresuction valve- delivery valve suction valve delivery valve

0.6 mm O. 8 mm 1.2 mm 1.0 mm

3. Body

a. Set one main bearing case to the crank shaft and put this crank shaftin the crank caSe. Then set the crank shaft in another main bearing case.Be careful not to catch the oil seal in this main bearing case. If the

oil seal is caught in , it feels heavy when the unit is idled.

b. Attach the cooling fan pulley.

c. Install the cylinder.

d. Attach the the cooling fan and the fan belt.

e. Place HP valve and mount HP valve cover.Do not forget to put the packing.

f. Put the piston attached with the connecting rod.At this time, apply enough o.iI to the cylinder, the crank pin and thesurface of the piston. Set the piston ring at the right position, andput the piston in the cylinder, hitting it lightly. If it is necessaryto hit the piston hard to put it in the cylinder, it indicates that thepiston ring is caught somewhere. Pull the piston out and check it.

Forcing the piston in may break a piston ring.

7

8

g. Apply enough oil to the upper and lower housing of the connecting rod.Place the adjusting liners and crank pin metal bolts to the lowerhousing fitting position of the connecting rod, and tighten themsecurely.

After tightening the nuts, rotate the crank shaft to see if it turnssmoothly and also if the lower part of the connecting rod moves rightand Ieft.Ifad jus tin g Ii ne r s are not e n 0u gh , add Iin er s . Ne v er t igh ten up "th ecrank pin to offset the liners. Otherwise the metal may be burnt out.

A clamping torque of crank pin metal bolts and a clearance between thecrank pin metals and the crank pin are as follows.

Clearance betweenthe 0.04"-' 0.10 mmcrank pin metals and the crank pin

Clamping torque of crank pin metal bolts approx. 29.5 N.m

After above adjusting, insert split pins.

h. Attach the crank case cover.

i. Fi t LP valve in. Do not forget to put the packing. Apply oil to thevalve and attach the cylinder cover. Move the piston to see if thepiston top and LP valve lower part come into contact with each other.If a touch occurs, add packing at LP valve lower part.

The clearance between the top of the piston and the bottom of LP valve(top clearance) should be 0.4- 0.6 mm. Be sure to keep this clearance.

j. Mount the pipes and connect the pipes.

k. Attach the fan cover."

§ 8. Lubricants

1. Kind of lubricantsIf used unsuitable lubricants. the lubricant is carbonized and accumulate

on a val ves. In resul t , following troubles cause.Efficiency dropsOverloadValve plate is damaged. etc.

Based on our experimental results. we recommend the following kind of oil.

NIPPON OIL CORP. FAIRCOL SA100FAIRCOL A100MARINE T-103

COSMO OIL CO.. LTD. COSMOCOSMOCOSMOCOSMO

MARINE 3000MARINE 3005MARINE 3010RECIPRO SX100

JAPAN ENERGY COR. BER ELF CH 100RES I C N 1 0 0

IDEMITSU KOSAN CO.. LTD. D A P H N E M A R I N E COMPRESSOR lOO

ESSO SEKIYU K. K EXXMARNEWREX

XAD F 1 0 0

OBIL OIL CO.• LTD. 827 (VGIOO)4 2 9

MOBILMOBIL

RARUSRARUS

HOWA-SHELL SEKIYU K. K GADINIA OIL 30CORENA OIL APIOOCORENA OIL PIOO

. [J I KOSAN CO.. LTD. FUKKOL MARINE 312COMPRESSOR S100

9

10

2. Amount of lubricants

Initial pouring Replenishing(up to the upper reference I ine) (amount from the lower up to

the upper reference line)

Approx. 1. 1 Q. Approx. 0.5 Q.

*Because oil is contaminated with drain or impurities after a long periodof run, replace the oil wi t h new one as required.*The amount of lubricant can be precisely checked only at a standstill.

§ 9. Troubleshooting

1. Failure to increase pressure

a. Air leakage from pipingPipes, fi t t in g e , air receiver, etc. are liable to be subjected to air

leakage. Check for such a trouble with soapy water or oil and repair it.

b. Damage of the v a IveThe valve may be worn out due to a long time of operation, or it may

catch dust, or it may be damaged by overheating. If the pressure cannot be increased at all, it indicates the damage of the valve. In thiscase, diassemble and check it immediately. If the pressure can not beincreased smoothly, it indicates that the valve seat is damaged bycatching the dust, or that the valve contact is deteriorated bydeformation of the valve due to overheating. In this case, check thefollowing items, operating the unit.

Closing the air inlet port with hand, if the air is returned in thissucking condition, LP suction valve is defective.

If LP gauge indicates a valve lower than a test result, LP deliveryvalve is defective.

If LP gauge indicates too high a value, HP suction valve is or deliveryvalve is defective. The suction valve is mainly defective when the unitis in operation, and the delivery valve is defective when the unit isnot in operation.

c. Clog of the air inletThis trouble can be found by closing the air inlet port with hand.

d. Abrasion of the piston ringWhen the unit is operated for a long time, the piston ring is worn out.Replace with a new one.

11

e. -Too much lubrication oil (Abnormal sound is prolonged.)Reduce the amount of lubrication oil, otherwise the valve may operate

improperly.

f. Insufficient tightening of LP valve seatIf the valve seat is not sufficiently tightened because the cylinder

comes into contact with the cylinder cover, or because the seat packingof LP valve is not inserted, the compressed air may be flow reversely.

This can be found by closing the air inlet port with hand because theair is not sucked in.

If the cylinder cover is removed, it can be confirmed that the valvedoes not come into firm contact with the packing.

Abnormal soundThis is a signal warning a serious accident. Stop the machine immediately

and clear up its cause.

a. The piston top and lower part of LP valve are in contact.

b. A key of a pulley or a flexible coupling is loosened.

c. Clearance is increased due to wear of the piston pin.A sound distinctly heard implies a considerably wear. Move the piston

slowly to check the piston pin and replace it with new one, if necessary.Also check the crank pin metal for wear. Detach the cylinder cover and

check by observing motion of the piston.

d. Clearance is increased due to wear of the crank pin metal.Remove the crank case cover and move the connecting rod vertically for

checking. If there is an abnormali ty, adjust the clearance referring tobe the table below. Replace the crank pin metal wi th new one, ifneces sa r y .

Standard clearance betweenO. 04~ 0.08 mmthe crank pin metals and the crank pin

Limit clearance between0.20 mmthe crank pin metals and the crank pin

e. When catch dust, a knocking or g o n g in g sound is heard.The valve, cylinder, or piston may be damaged. In this case, diassemble

and check it immediately.

ii) Heat generation in the case of proper cooling fan flow rate.The aperture of pipe between the high pressure air outlet and air

receiver may be too small, or the air receiver check valve may beimproper. Check for both cases.

Check to see if compressed air passages of LP valve, HP valve ornon-return valve is blocked by a carbon deposition, etc.

12

3. OverheatAlthough some parts of the air compressor such as the compressed air

outlet, HP valve and air piping, may be too hot to touch by hand, it isnot abnorma 1.

a. The entire compressor is hot.i) Heat generation due to insufficient cooling fan flow rate.

When the cooling fan fails to send a good amount of air, thecompressor is overheated, resulting in the piston seized. Immediately

stop the machine and check to see if an obstacle is in front of thecooling fan or if the fan belt slips.

b. Heated V-pulleyThe V-pulley is heated due to slippage of the belt. The V-belt smells

as rubber is burnt.Adjust belt tension.

10. Automatic operation by motor driven(Refer to Fig-l Flow sheet of Automatic operation)This automatic operation device is that the motor is stopped and started

by the pressure switch on the air receiver.

1. Description of performance

a. Stopping operationWhen the pressure inside the air receiver reaches a specified upper

limit, the contact of the pressure switch is opened, and the magneticswitch is actuated to stop the motor. At the same time, since thecurrent to magnetic valve is shut off, the valve is opened, and thedrainage and residual air are discharged into the atmosphere. The non-return valve is closed to prevent the reverse flow of the compressedair inside the air receiver.

b. Starting operationWhen the pressure inside the air receiver reaches a specified lower

limit, the contact of the pressure switch is closed, and the magneticswitch is actuated to start the motor. The timer on delay works and themagnetic valve is closed later. The operation of the compressor opensthe non-return valve to fill the air receiver with air.

2. Pressure swi tchThe working pressure (a lower and upper limit) are adjusted.This pressure can be easily adjusted by the "adjusting bolt.

3. Magnetic valveAt stopping, the magnetic valve is opened, and the drainage and residual

air are discharged into the atmosphere. The starting load is decreased bythis valve opening.

4. Notea. When the working pressure is unsui table, the majori ty of this cause is

that the air leakage in the air passages between the air receiver andthe pressure swi tch. -Ch e c k and repair it.

b. Since the pressure switch may be damaged by a dust or drainage in theworking air, the lead pipe to the pressure switch should be selected aposition with less dust and drainage.

c. The pressure switch acts sensitively. The working pressure is unsuitableby the pressure fluctuation. The working pressure never leads on the

piping between the compressor and the air receiver.

13

14

J--HMAIN SWITCH I0 0 0 '

CD AUTO & HANUAL EXCHANGE S~ITCH

9TON SWITCH

v

® 1 ST STAGECOMPRESSION AREA

COMPRESSED AIRTO ATMOSPHERE

ORAl It. E & RE

Fig~l Flow sheet of Automatic operation

AIR RECEIVER

l

'"'" I

15I:: -- Pe r i 0 d i c I n s p e c t i o n

Pe r i 0 d i c i n s p e c t i o n i s recomme n d e d i n o r d e r t 0 U 5 e t h eco m p r e 5 5 0 r w i t h o u t a t r o u b I e a t any t i ID e. Al t h 0 u g h i t i sd i f f i c u 1 t t 0 5 t a n d a r d i z e the p e r i 0 d i c i n s p e c t i on du e t 0

t h e a p p I i c a t i o n 0 f t h e compre S 5 or, i t s 5 e r v i c e c 0 nd i t i on,

q u a 1 i t y 0 f i t s 1 ub r i can t a nd i t s h a n d 1 i n g. t h e con t e n t 5

0 f i t S i n s p e c t i on a n d the i r f r e que n c i e s are a 5 f 0 1 1 o w s.

Pe i rod i c i n s p e c t i o n 1 i s t

Inspection item Operation term Remarks

ion Inspection Job contents Every 200 hr 400 hr 1000 hr 2000 hrday (3 months) (6 months) (I year) (2 years)

~-CaJ]ts Crankcase Check of Quantity of0oil

Change of lubricants 0

la· - ting Piston Check and replacement0parts of piston ring

Removal and cleaning0of piston

Check of piston pin 0

connecting Check of piston pin0rod metal

Check of crank pin0metal

Check of crank pin0metal bolt

- Main Check of main bearing--=o...'::;}g parts0bearing

Crankshaft Check for wear 0 I

~ ;;ystem Valves Removal", check and Notebcleaning of valves

Replacement of valves 0

Safety Check of discharge Notebvalve pressure and cleaning

Non-return Check, cleaning and Note)valve replacement of valve 0

seat

Air Check and cleaning Notebpassage

~; -"-s Various Check for leakage0pipes

Appearance Check looseness ofbolts and nuts 0Check for oil leak

- e) Ca r b on d e p 0 s i t i o n v a r i e s d e p end i n g on q u a I i t y o f1 u b r i can t .

De t e r m i n e pro per c h e c k per i o d a f t e r ch e c k i n g c arbond e p 0 S i t i on.

16

§ 12. Structural drawing of air compressor

Sectional view of air compressor

Structural drawing of LP valve and HP valve

illl

, II

I I

~M'tTSXB,\RAitTYPE : IfRlIC.JL2STNHRCOOlfDJf~ J.I: : ITm - tgIHJi?tIPMODEL :m '" : MG78A

-® 0.0 .1 ~I V~E\\W\\I I SECTIONAL VIEWOF

-®Q) JJ_ I \~~~ I AIR COMPRESSOR

:49J ~ ~ JI ~te.~~Jl IT ~ r1D ~

STANDARDfilE~W;;f,;:;' ~'<.:7 I~ "tl I J ti!l-----1'fI' I r YI rH~'\A -, -, ~ I(j)-

14 ~-.:y "--Y

41 @~

0N~

9 ,KITAGAWA

~ MATSUBARA IRON196 .1 I 18 240 WORKS LTD.234 278 .3t.~19 ~~~IPfl

I -'"-...J

D;~~;GI F' 12400000NOPART NO N A M E MATERIAL OTY NO PARI NO N A M E MATERIAL OTY£~ tfb =I ~

""f,f; M • JH'X ~~ Jb it -it "t f,f; M • Jm

LP PRESSURE GAUGE SET COOLING FAN PLASTIC1 6012060010 ll\JIJItJ.t --- 1la 32 1121131010 l~to/7 :::; .g.m:r.U~ 1

6209512512 L.P.PRESSURE GAUGE VALVE SET 33 1121131040 COOLING FAN V-PULLEY N022 (ftlIlItJWlli~w1

--- lla 1il!IJ:>7 :'>IIlV:1- U N02 FC200 1

I I3 1105004122 LP VALVE CLAMPING BOLT S45C 1 34 1121131050 COOLING FAN SHAFT

SS400 1ll\II# laitm:i~ ~ )t!IJ:>7:.>lIltll

4 1121104100 LP DELIVERY VALVE COVER FC200 1 35 3012620299 FAN SHAFT BEARING(BIG)SUJ2 1ll\IIIJIIIl# 11 )jl!IJ:> 7 :'>lIltll~ -(;Id

Ii

5 1103004061 LP DELIVERY VALVE SUS 1 36 3012600299 FAN SHAFT BEt,RING(SMALL) SUJ2 1~III1HIJ# 1il!IJ:>7 :'>lIltll~ 'I')

6 1121104012 LP VALVE SEAT FC250 1 37 1121131070 FAN SHAFT BEARING CASE FC200 1iltlI#1!i ,j';!II:>7 :'>lIltll~?" -;<.

7 1121104081 LP SUCTION VALVE HOLDER S45C 1 38 1124031110 COOLING FAN COVER SET PLATE SS400 1ll\IIII!lA# ~ ,f>!IJ:>7 :'>:lJi~lIliiHt~

8 1121104040 LP SUCTION VALVE SUS 1 39 1124033110 LP AIR COOLING PIPE C1220T 1ll\JIII!lA# ~II:!t'~)j';!IJ~ MATSU.BARAJt9 1105003012 AIR INLET CASE FC200 1 40 3327120310 COOLING FAN V-BELT RUBBER 1:!t'lKAO~ ,j';!IJ:>7 :.>IIlV"'-iH :lb. -:;z ~ J~ ..,

10 1105003101 AIR STRAINER SPHC 1 41 1121131140 COOLING FAN V-PULLEY N01FC200 1 TYPE : IrnTICAll STAll IJR COO.IJ)

:!t'~Aol\IilltB ,j';!IJ:>7 :.>1IlV:1-I) N011f~ 'tt : ITH1- f&lni~lji

LUBRICATING OIL PIPE CRANK SHAFT11 1121129010 :tll)-':$Ilii~-(:1 C1220T 1 42 1121110010 ?5:.>?" SF590A 1 MODEL:

12 3082002526 PISTON PIN METAL SUJ2 SET 43 3042400307 MAIN BEARINGSUJ 2 2 1f~ * MG78A

1::;<.0 :.>1£;1!li~ 1la :HII~ SECTIONAL V1EW1101015140 AIR VENT PIPE CAP SPHC 44 1105014010 MAIN BEARING CASE NO 1 FC200 213 :!t'~I!t~i~-{:1*." el:1 1 ::UI~?"-:;(N01 OF

14 1121112010 CONNECTING ROD SF440A 1 45 1103012021 CRANK PIN METALWJ 2 SET AIR COMPRESSOR:J'+?5'-I:'>~ Del ~ ?5:.>?1:::.> ;I!1i~ 1!ill

15 1121115110 CRANK CASE COVER N02 FC200 1 46 1124011320 HP PISTON OIL SCRAPER RING FC250 1?5:'>?~ 11 N02 ;iiJIt";<. ~ :.>$i!i!l! I) :.>?' ']b )::= ff ~rnm!ROD REAMER BOLT HP PISTON TAPER RING .::c. 5(\,16 1121112060

D ," t' U-"m:i~ ~ SCM435 2 47 1124011310 ilJII::J. 0:'> 5'-i~I):'>'J FC250 1 *~.rrWT 00 ~17 1121115120 BAFFLE PLATE SPHC 1 48 1103011101 HP PISTON RING FC250 2!ft'J$t$l!i~;;tt~ I;III::J. ~:.> I) :.>?'

STANDARD18 6101040100 OIL GAUGE PLASTIC

2 49 1121111020 PISTON PIN SCM415 1ld!ililt .g.m:r.IA~ t::;(~:.> 1£ t~4!ff~19 1121113010 CRANK CASE FC200 1 50 1124011010 PISTON FC250 1? 5:'> ?:i: 1:::;(0:'>

20 1105012151 ROD OIL SCRAPER S45C 1 51 1124011100 LP PISTON RING FC250 2$d!IUll ll\III::;<'~:'>I):'>~

21 1121115010 CRANK CASE COVER NOl FC200 1 52 1121101011 CYLINDER FC250 1?5:'>?~ 11 NOl :;I)J9'

22 1121105040 HP SUCTION VALVE SUS 1 53 1121102011 CYLINDER COVER FC200 1illIII!lA# :"') :'>9:IJi~

23 1121105010 HP VALVE SEAT FC250 1 54 ---At/Hi-Ii --SCALE

24 1121105040 HP DELIVERY VALVE SUS 1 55 --- -- R Ii;iiIIIJHIJ# UG.16.2001

25 1121105080 HP SUCTION VALVE HOLDER S45C 1 56 --- --;i;IIII!lA# j:

HP DELIVERY VALVE COVER .KITAGAWA26 1121105100 ilJI~IIl# 11 S45C 1 - --- --27 1121108010 HP VALVE COVER FC200 1 - --- -- MATSUBARA IRON

;ii1I#:lJi~ WORKS LTD.NON RETURN VALVE SET28 5121121000 ~J!::# --- lla - --- -- .j(*~29 5103020201 HP SAFETY VALVE --- SET - --- -- ti!J.i~IJiJTillI:fi~# 1\11

30 1121133210 HP AIR COOLING PIPE C1220T 1 - --- -- WORKS;ii1I:!t'f;\)f>!II~COOLING FAN COVER No.

31 11 240311 00 )j';!II:> 7 :'>:lJi~ SPHC 1 - --- -- if

'I

III

ce

LP delivery valve springi[l;II Di tlH:t- A 7' !) :; :i

P suction valvefi adjusting liner"'II®A#-IJ 7 i' ~m~'5 --{:t

~ 5' C 'on volve spring~=:-.iiA#-A 7' I):; j-

19.Nuti[l;II#-*Ht:t '!) r-

LP delivery valve cover1[1;II Di tI)#- iI

050 LP delivery valveittlIDitl)#-

LP suction valve holderi[l;lIo.&A#-~

LP delivery valvelift adjusting lineri~ff Of tI)#-I) 7 HmY'5--{:t

L()

CD LP valve seati[l;ff#-@:

LP suction valvei[l;ff°'&A#-

0105

LP valve clamping boltittfftHfliiiR)1; r-

LP valve air tight liner1[1;II#-~\if:'5--{ :t

LP valve (assembly)iff ff ff (7t irm D~ )

Nut;§;ff #-MHt-:h r-

HP delivery valve spring;§;lIo± tI)#-:;z 7' I) :; j-

032HP delivery valve cover;§;lIo± tI)#-lI

HP suction valvelift adjusting liner;§;II 0.& A #-I) 7 i' ~PoJ~'5-{:t

HP delivery valve;§;IIO±tI)#-

oCD

HP delivery valvelift adjusting liner;§;lIo± tI)#-I) 7 HI!1~'5--{:t

HP valve seat~II#-@:

HP suction valvei'iiiIIOJiA#-_J socii n valve spring~-=-;...;r:;Z7"):;j- 032 HP suction valve holderi'iiiIIO.&Att~

HP valve (assembly)~ ff ff (7t irm D~ )

Structural drawing ofLP valve and HP valve

E IT#-}£rY~ JI#-t~@ ~