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Screw Compressor: 185S-6C2

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2. TINO ay NTO 1 YE ul quf 1 4 1 Specification 3 US model 897001 081 NIWA T GE 0261 LIM IV 2 8 0 JAWA DIAS 0 BWd 0 02 44 C6TXU3ddV 0 2 00 1 We NIVST SITIS NV y NIST HI mj dV T 909 ddid 15 LALAO aly TW NETT Wun 1 5 1 Specification 1 4 Internal Components and Part Names 9 10 1112 13 A100417 Export model Funetion 1 Oil separator For separating oil mist mixed in compressed air o 1 For keeping the receiver tank pressure higher than 2 Pressure control valve sensi 0 4MPa 4barl in the tank E For releasing compressed air to the atmosphere when the pressure rises higher than the rated pressure 4 For filtering the dust floating in the intake air For compressor air end 2 Speed regulator For regulating engine revolution speed Air filter For engine For filtering the dust floating in the intake air For automatically bleeding air from fuel pipes Battery For electrically starti
3. 8 5520 09 sJ 75 gt SABA UNEA 1 16 ion t ica Spec 1 2 US model A9vv00lV Jeqqny 2 lt PUPS 010 SUUM v L Jepeoj un 341616 gt JO ploUe oS ZS Lbs IE 1 1018 18 1 166 14 gt H BALA lg 90 osnes nss 1d N 99IAJOS f JojejedesS Q SARA e d 68805 96 OANA 19197 OA E 49181 O1 v 5916 Black lt Black UR Joyesedes 3 16 Black Jeiooo 10 D 2 N By LO eG 5 9809 2 by ssed Ag gt Buidid gt 20 Steel pipe 020 Steel pipe 1 17 1 Specification 1 8 Fuel piping US model is optional Sedimenter Pre filter Fuel pump Fuel tank Fuel filter
4. 4 10 4 4 Others JJ JJJJ JJ JJJJJJJJJJJJJJ J q 4 13 4 5 Explanation of trouble diagnosis 4 14 5 References 5 1 51 Comparison between consumable parts and electrical appliances 5 1 5 2 Engine Wiring Diagram 5 3 1 Specification 11 Specifications PDS1858 6C2 W in mm 128 7 8 270 in mm 74 6 1 895 in mm 66 9 1 700 in mm 59 8 1 520 Ib kg 1 896 860 Ib kg 2 116 960 O O si MPa bar Weight gt Mass Overall length Bonnet only Overall height Operating mass Compressor Free air delivery Working pressure Pressure of pressure control valve cfm m min si MPa bar I2 Burst pressure of safety valve si MPa barl 150 1 03 10 3 Ambient conditions temperature F C 5 to 104 15 to 40 Ambient conditions altitude less than 1 640 1 500 gej O O 21228 B 5 ls e p ERIS YANMAR 4TNV88 BDHKS nl Rated output Gross dn 48 8 3 000 36 4 3 000 inl Rated output Net 3 46 8 3 000 34 9 3 000 Fuel consumption g kW h Engine eee d RPM at unload
5. Pressure and output voltage for reference only RAH Output Pressure Opsi OMPa Obarl DC0 5V Pressure 14psi 0 1MPa 1bar DC0 9V Pressure 85psi 0 6MPa 6bar DC2 9V Pressure 100psi 0 69MPa 6 9bar DC3 3V essure 3 12 Fuel meter Display 08035 STARTING UNLOADER DISPLAY STAR Gos STOP aun ANAL 0 ty 4 e wre toe 3 ow TOR ERROR ary CHANGE CODE am A DISCHARGE TE AD WATER TEM 5 CHARS i E2 WATER TEM J ENGINE OIL PRESS ES DISCHARGE TEMP SENSOR 67 VATER TEMP SENSOR A100359E FUEL LEVEL 7 8 i PC10033E Relation between indicator lamp Ce and residual fuel level Tan Oro oie LED No 3 ON Green ON Green LED No 6 ON Green LED No 7 ON Green 1776 LED No 8 ON Green 19805 Ru 3 16 LED No LED No 5 3 Electric System 3 13 Sending unit Part number 36159 02202 Earth black Unit red white 1 Lo c Y Y 08069 For resistance at float position see No 5 Adjustment and inspection of No 3 1 Controller 3 17 4 Troubleshooting 4 1 Repairing Procedures When performing failure diagnosis pay special attention to the followings observin
6. 3 1 3 2 Alternator Dynamo regulator IC type JJJJ JJ 3 8 eae eet 3 10 3 4 Galely relay s Tssss s 3 11 3 5 Solenoid relay Heater relay 3 12 3 6 Purge starting unloader solenoid valve 3 13 IUUD A E ea 3 14 3 8 Engine oil pressure switch For emergency Stops 3 15 3 9 Fuel air bleeding electromagnetic PUMP J JJ JJ 3 15 3 10 Discharge air temperature sensor Coolant temperature sensor 3 15 3 11 Pressure sensor for Intake negative pressure and for service pressure 3 16 3 12 Fuel meter Display 3 16 3 13 Sending unit 3 17 4 Troubleshooting T Y 4 1 4 1 Repairing Procedures 4 1 4 2 Failures of compressor and engine 4 3 4 3 Operation of emergency switch
7. Repair connection Repair or replace it 4 Troubleshooting 4 3 Operation of emergency switch 4 3 1 Discharge air temperature indication lamp glows and engine stops Check ambient temperature Lower than 104 F 40 C Shortage Check compressor oil level Proper Lower than 248 F 120 C Check Check resistance TRAE TIS indication of of discharge air ira E NE Replace it ace 1 discharge air temperature temperature sensor gauge More than 104 F 40 C More than 248 F 120C Check electric conduction conductance exists Disconnection gt Repair wire connection between controller between and sensor controller and Exists Check belt tension Soiled Check oil cooler fin tubes Normal Fault Check compressor oil filter No difference Replace it Check and confirm the found Abnormality by pass i difference between BY uso aive by pass valve and at the outlet Difference found iAbnormality 2 Disassemble or repair icompressor air end i 4 10 4 Troubleshooting 4 3 2 Engine oil pressure emergency indication lamp glows and engine stops Shortage i Aa NA AA AAAH KANAA HANARNA CHEQUE Check engine oil level Shortage of oil i Replenish or replace Proper Check engine oil filter ilter clogging x Replace 1t Normal
8. Check function engine stop work Faulty engine stop solenoid isolenoid c Faulty fuel air A work d i m 5 bleeding electromagnetic bleeding i Repair or replace it pump i electromagnetic pump It works Check fuel filter Fuel filter clogging gt Normal T i Repair pipes and Check fuel pipes F Cable short Check indicator lamp wire connection Emergency stop Defective controller or Replace controller or faulty cable connection repair cable connection Repair the trouble and get rid of the cause 4 13 4 Troubleshooting 4 5 Explanation of trouble diagnosis Faulty unloader Unloader valve cannot be open Disassemble unloader valve to check function of valve and piston Further check recovery pipe for any clogging Check and confirm that safety valve functions at lower pressure than set pressure for safety valve Check and locate pressure maladjustment or defective safety valve In case of malfunction of safety valve safety valve assembly should be replaced Faulty seat of unloader valve Faulty seat of unloader valve or faulty sliding function of valve and piston Disassemble unloader valve and clean seat surface and check function of valve and piston Check discharge air temperature using digital monitor Check whether actual rise of discharge air temperature stops
9. UA T 75 1 1080 1 3680 1 TH E 20 s S S 09 Bunsesul Jojoeuuoo JO epis eui Jeued jo uo USES si Buiwollo 941 smejedde jo uon VOS 98514 00920 0 9 t W eujus 0020 Q vvy 6 884 Jejonuoo 00676 62897 F O KEI pousos 00060 725 MS 291015 O NM 00050 2 ADD 00791 1 415 OWEN Hed ON Hed ON 2 US model 5 4 This text book contains the most recent information available at the time of printing and the contents of the list are based on information in effect at that time and are subject to change without notice HOKUETSU INDUSTRIES CO LTD 8TH FLOOR SHINJUKU SAN EI BLDG 22 2 NISHI SHINJUKU 1 CHOME SHINJUKU KU TOKYO 160 0023 JAPAN TEL 81 3 3348 7281 FAX 81 3 3348 7289 URL http www airman jp Copyright C 2011 HOKUETSU INDUSTRIES CO LTD All Rights Reserved NPC 0086 PRINTED IN JAPAN 2011 9 25 7 PRINTED WITH SA SOYINK Trademark ol Soybean HOKUETSU INDUSTRIES CO LTD
10. Check engine oil pressure switch 4 Troubleshooting For actuation pressure of oil pressure switch See 1 2 List of set values Check for any defective connection Check and make sure that no disconnection has been found for engine oil pressure switch Switching ON engine oil pressure switch enables engine emergency stop Faulty of engine cooling system When any trouble is not found in thermostat coolant pump can be in disorder For the temperature at which thermostat valve opens refer to 2 12 Check indicator lamp wire connection It sometimes happens that emergency stop circuit is active but warning lamp will not light on because its circuit is in trouble Try to locate its cause 4 15 5 References 5 1 Comparison between consumable parts and electrical appliances Us soi Element Filter Air filter ASS Y For compressor 32100 44900 Air filter element outer 32143 11800 Air filter element inner 32143 13000 Air filter ASS Y For engine Air filter element outer 32100 40700 32143 11700 82148 12900 84220 16101 08402 15140 lt Compressor oil filter ASS Y 37400 16100 Oil filter cartridge 37438 08900 Engine oil filter cartridge cts 5151 43543 01400 Fuel Blven carenidee YANMAR 129907 55801 43540 08100 YANMAR 41650 550800 YANMAR 123325 36140 YANMAR 24311 000120 43550 02900 Sedimenter A
11. SERVICE MANUAL SCREW COMPRESSOR PDS185S 662 HOKUETSU INDUSTRIES CO LTD Preface This service manual explains about the cautions for maintenance jobs and is to serve a guide for the electric system and troubleshooting for service personnel In this book the fundamental matters and other things already mentioned in the Instruction Manual and the Parts Catalog are omitted to avoid duplication Therefore for the operation and handling of this unit we request you to refer to the instruction manual and caution plates and further for the structure and components of the unit please refer to the Parts Catalog separately to be supplied with the unit If you should find any description which does not coincide with the instruction manual and parts catalog we request you to make sure to start the job after clarifying it Service personnel is required to safely take quick and proper countermeasures as well as to use correct technology of maintenance in case of field services and periodical maintenance It is important that service personnel should have proper and sufficient knowledge about the structure and function of the unit and should be well familiar with such technique mentioned in them Regarding the part numbers mentioned in this manual we request you to refer to the Parts catalog separately supplied together with the unit because the parts numbers in this manual are sometimes changed Copies of this s
12. 1050 1500 2100 858 4 2477 9 3053 Lifting bail more than M20 10 9 48 48 210 280 345 with spring washer 2100 2800 3450 5 Pressure vessel and pipes 221 2 433 6 752 2 1194 7 1858 4 2477 9 3628 3 4955 8 6283 2 Separator cover 109 8 8 25 49 85 135 210 280 410 560 710 with spring washer 245 485 845 1350 2100 2800 4100 5600 7100 221 2 433 6 752 2 1194 7 1858 4 2477 9 3628 3 4955 8 6283 2 Press cont body 109 88 25 49 85 135 210 280 410 560 710 with spring washer 245 485 845 1350 2100 2800 4100 5600 7100 06 2 221 2 380 5 601 8 929 2 1327 4 1858 4 2477 9 3053 Press cont cover 10 9 E 48 12 25 43 68 105 150 210 280 345 Jwith spring washer 124 245 425 675 1050 1500 2100 2800 3450 106 2 221 2 380 5 601 8 929 2 1327 4 1858 4 2477 9 3053 Flange for pipe First priority 48 48 48 12 25 43 68 105 150 210 280 345 with spring washer 124 245 425 675 1050 1500 2100 2800 3450 221 2 433 6 752 2 1194 7 1858 4 2566 4 43 Flange for pipe less than M20 Second priority 10 9 8 8 X3 8 8 25 49 85 135 210 290
13. 6 Prevention of repeated occurrence of similar trouble Even if you have repaired the trouble unless you get rid of the fundamental cause of the trouble it will repeatedly occur Therefore perform full investigation of the trouble and it is absolutely necessary to remove the basis of the trouble 4 1 3 How to use the failure diagnosis DIn the troubleshooting column something abnormal is mentioned in lined parenthesis In the troubleshooting column the cause of the said trouble is mentioned in dotted parenthesis In the troubleshooting column the countermeasures or treatment are mentioned in the double lined parenthesis 01 under each column means the index of explanation For details see 4 5 Explanation of trouble diagnosis 4 2 4 Troubleshooting 4 2 Failures of compressor and engine 4 21 At start up starter rotates slowly Check battery voltage and specific gravity Faulty Battery specific gravit Normal too low or electrolyte ishort Volt more than 12V Gravity more than 1 26 Check battery cable Normal Re charge and supply water or replace Replace terminal or assembly Repair or replace assembly X1 When starter switch is placed at the START position the battery is not normal if B terminal voltage decreases by 10V 4 2 2 Starter turns but engine will not start TEO NERIS 2 7 Eun Supply Element clogging
14. Cable connection 10005 1 Specification Rated voltage DC12V Continuous rating Coil resistance between No 1 and No 2 terminal 2 1 Solenoid relay functions list See CN1 8 terminal of NO 6 List of function of 30A Fuse No 3 1 Controller Stop solenoid W terminal When starter switch is turned to GLOW or START power is supplied to switch the contact between No 3 and No 4 terminal to ON 50A Fuse Through alternator BAT When the contact between No 3 and No 4 terminal is terminal ON preheating begins 3 12 3 Electric System 3 6 Purge starting unloader solenoid valve Part number 46811 24100 Clip Tube Ass y Coil Ass y Plunger Ass y O ring Return spring Body IN OUT Opened while electricity Re1 4 is supplied NC u PC10037 1 Specification DC12V Power is supplied It is ON NO 2 List of functions For details of functions see NO 6 List of function CN1 7 terminal of No 3 1 Controller 3 13 3 Electric System 3 7 Stop solenoid YANMAR part number 119233 77932 R HOLD COIL COLER RED B COMMON GROUND COLER BLACK PC10012bE 1 Specification Resistance 0 330 10 Holding coil Resistance 24 5 Q 10 List of functions Line 30A Fuse Power supply Suction power supply Suction coil Controller CN1 3 power supply For details of fu
15. 80 C eS Rated load MAX 40A Engine RPM 0 Power input of alternator frequency P terminal signal ON 8 Starter Interior Engine speed for contact Contant disconnection PC10031E between A and Bt inal Engine speed for ermina recovery X For the details see engine service manual List of functions color Starter switch ACC terminal a Ce NIL Signal of start is inputted When starter switch is turned to START and voltage is applied to E terminal the contact between terminal A and B is switched to ON to supply power to starter motor S terminal to turn starter motor When alternator P terminal frequency 3 E B W Starter switch terminal inputted to terminal H exceeds 250 Hz at engine speed of 13501171 the contact between terminal A and B is switched to OFF and power supply to starter motor is cut to stop engine And after starting is secured the contact between terminal A and B is kept OFF to prevent overrun and plunging of pinion gear Ip j 6 H W R Alternator P terminal Input alternator frequency engine rotating speed signal R Starter motor B terminal For excitation terminal of starter motor magnet W Starter motor S terminal switch excitation coil 3 Electric System 3 5 Solenoid relay Heater relay Part number 44327 05000 YANMAR part number 119650 77910
16. Check engine oil pressure switch Normal Check engine Normal Check wire Faulty wire oil pressure gt connection to connection engine oil pressure switch Abnormal 4 Troubleshooting 4 3 3 Engine coolant temperature lamp glows and engine stops More than p Check ambient temperature 104 F 40 C Unsuitable place of gt Relocation installation i Lower than 104 F 40 C AE d e anion dictare Check water quantity and Shortage of coolant an I Replenish or replace quality in radiator l l E Normal Lower than 230 F 110 C Check water PE resistance of temperature water more than temperature 230 F 110 C Check electric conduction conductance exists Disconnection EUER between controller between WIES and sensor icontroller and Exists Faulty spe Check belt tension Tension not acceptable ior faulty belt i Normal 00000 O Check radiator fin tubes Fin tubes much soiled Wash and clean Normal cooling system Repair the trouble and get rid of the cause 4 12 4 Troubleshooting 4 4 Others 441 Indicator lamps will not glow but engine stops Starter switch is not set in contact and blown fuse trouble is exempted Exists Clogging Check air filter for clogging Normal TE MAHOU
17. ON Hed ON 5 3 5 References 4009 I N T A 9 ie 1 A eiod At EV A 2 m crees 1 2 Jeueis 9 4 amp d 1590 1 0 8 2 NMA i i VW T N BN E 7v JOSUSS CWS 9319250 41 bis 6 0 2M penu QUU g 2 1 1 SEN gren Joy eA ploUSoS MS Joreweny T 2a E 3 JUN AGG GU _ 1 euiSu3 i 2 2 V rgo UNI CIO Se N W pieue os dois PES 2 10 11 001 decas 98 1 4380 8 i 80 0 0 9 Ae 9 ES WE pu m 0590 174580 NIME y x 190 WAG
18. US model only function During purge operation every 1 second 5 Adjustment and inspection Perform the detection and inspection of discharge air temperature engine coolant temperature and setting unit by controller in the following steps VRc1 N 2 1 9 coolant temperature VRc2 D h 1 Connect resistance to controller as shown right CN2 9 AX Sir temperature Or use multi speed variable resistance ie Bes CN2 18 A ending unit resistance value 1 0kQ for VRc1 VRc2 and VRc3 CN2 20 Controller 777 PC10027E 2 Gradually lower resistance values of VRc1 and VRc2 and measure them when they reach abnormal values Then check and confirm that they are within the following ranges Set temperature CC F Warning 640 15 Emergency 560 15 Warning 491 15 Emergency 4323 15 Resistance Q Engine coolant VRc1 Discharge air temperature VRc2 3 Sending unit Resistance Q 3 02 0 3 4 3 Electric System 6 List of functions 1 Connection Remark When starter switch is and voltage is applied to CN1 12 terminal interior contact RYO is ON and voltage is outputted out of CN1 2 terminal to make a heater relay function 2 seconds later when coolant temp is lower than 32 F 0 C 20 seconds later the interior contact RYO becomes OFF to cut power supply to heater
19. 20 19181716 1514131211 CN1 CN2 PC10024E 3 1 3 Electric System 1 Exterior connection drawing Key switch ACC 23 used Controller Battery ze CNI 12 CN RYO CNI 2 Heater relay P CN2 8 1 Hy E changes according Alternator L CN2 I1 to water temperature RY1 CNI 8 Fy wnen starter switcn Is ee LE o we p E 7 4 Solenoid valve 5 Ale weed for starting unloader u RY3 CNI 3 X Engine oil pressure switch oe SR Stop solenoid When it drops it goes 7 MEE CN2 7 4l CN1 11 RY5 CNI 10 PL Auto idle functioning 09 indicator Engine coolant temperature CAN CNe 19 RY4 CNI 4 Cylinder discharge air temp D CN2 9 b Abnorm ue ormal output Fuel sending unit t US CNe 18 t CNe 20 CNe 16 Service pressure sensor Vout CN2 7 GND Vc CNe 15 Intake negative pressure Valk CN2 17 GND CN2 6 CNe 1 CN1 6 PC11009E 1 As engine oil pressure switch contact is B the contact is ON when engine shuts down After engine starts the contact becomes OFF due to rise of engine oil pressure Oil pressure detecting circuit of controller functions at circuit of contact A After engine oil pressure switch is kept ON for 2 seconds engine is brought to emergency stop Engine o
20. conditions Q Lubricating oils E ect gal Engine oil capacity H L level gal L 1 95 1 06 7 4 4 0 ems ce v gt 4 gt gt B d 5 lt n Compressor oil capacity including receiver tank and oil cooler gal L 3 96 15 etc Ambient temperature 5 to 104 F 15 C to 40 C Compressor oil capacity to be filled SHELL SHELL CORENA OIL 5592 HULS ANDEROL 3032 MOBIL RARUS 424 MOBIL RARUS SHC 1024 NIPPON OIL CO FAIRCOL RA32 TEXACO SYN STAR DE32 Coolant capacity gal L Fuel tank capacity for reference only At purge operation At no load gal Hr L Hr At 5096 gal Hr L Hr g At 70 al Hr L Hr 1 66 6 3 At full load gal Hr L Hr 2 51 9 5 1 1 1 Specification 1 2 Set Value PDS1858 6C2 Export model US model Emergency stop devices G s s UE Actuating pressure of discharge air eF C 248 120 temperature switch Actuating temperature of water oF C 230 110 temperature switch ae psi MPa bar 7 3 0 05 0 5 Warning devices 2 Actuating temperature of water 991 105 temperature switch Battery failure S U When not charged ind es iz A US CIE E cator i Time for starting purge mode operation m 10 to112 At AUTO IDLE operation mode Set at 10 sec ex works load Actuating pressure of discharge air RC 239 115 temperature switch RPM at unload 1 300 Indications of gauges or instruments duri
21. engine or any failure of electrical circuit stops engine Check the resistance of discharge air temperature coolant temperature sensor For resistance characteristics of discharge air temperature and coolant temperature sensor See 3 10 Even disconnection of thermo sensor or 1ts short circuit causes engine to stop Check conductance between controller and discharge air temperature sensor coolant temperature sensor Check whether there 1s any disconnection or short circuit in cable connection between controller discharge air temperature sensor and coolant temperature sensor Clarify whether the trouble is caused by faulty cable connection or defective controller When discharge air temperature coolant temperature exceeds the set temperature 248 120 230 110 interior contact RY3 between controller CN1 9 and CN1 3 terminals turns OFF to cut electrical connection to stop solenoid and making engine stop 4 14 Connect variable resister 1k Q as shown in the following figure and gradually lower resistance value of variable resister And when it displays abnormality measure the value and check whether it is within the range of resistance of set temperature See No 5 Adjustment and inspection of No 3 1 VRc1 Engine coolant temperature CN2 19 VRc2 APS VRc3 A Discharge air temperature CN2 9 CN2 18 Sending unit CN2 20 Controller
22. manuals etc Disassembly and assembly Before removing nylon tubes hydraulic fuel hoses it is necessary to clean the inside of machine to prevent from entrance of dirt and foreign matters Perform disassembly work in a dust free location whenever possible When disassembling parts wash their outer surfaces and place them on a clean sheet of paper or cloth taking care not to contaminate or damage them Wash disassembled parts with diesel oil cleaning solvent after checking for contamination or discoloration However do not wash rubber parts with diesel oil Be careful not to damage disassembled parts they are precision built Replace consumables such as oil seals O rings filters oil etc with new items when reassembling parts Apply CALTEX MULTIFAK to O ring surface and MULTINOC SDX to sliding portion of oil seal When reassembling parts place each part in the order of assembly and take care that no parts are missing or misassembled When reassembling an assembled part set part be sure to replace it as an assembly Contamination or rusting may occur due to dust or humidity if parts are left in disassembled or partly disassembled condition for a long time Therefore be careful to prevent dust or rust from affecting parts if you have to leave the repair incomplete for a long period of time Check tightening torque and clearance when assembling parts Check the direction of rotation speed and oil leakage after a
23. torque du due 2 2 2 3 How to adjust regulator and how to replace diaphragm 2 7 2 4 Clean of element in sedimenter 2 10 2 5 Change Oil Separator 2 10 2 6 Change O Ring of Unloader 2 11 2 7 Check O ring and Needle valve of Auto relief valve and Vacuum relief valve 2 11 2 8 Performance check of Pressure control valve 2 12 2 9 Check Pressure control valve O Ring and Piston 2 12 2 10 Change of pellet assembly of by pass valve 2 13 2 11 Clean inside of Fuel Tank 2 14 2 12 Values of Various Adjustments of Engine 2 14 3 Electric System 3 1 1 Control
24. with spring washer 245 485 845 1350 2100 2900 858 4 2477 9 3053 43 Flange for pipe more than M20 1 Second priority 10 9 4 8 4 8 210 280 345 with spring washer 2100 2800 3450 6 Undercarriage 159 3 327 4 601 8 929 2 1327 4 1858 4 2699 1 3628 3 4690 3 Spring bracket 109 48 6 8 18 37 68 105 150 210 305 410 530 with spring washer 183 365 675 1050 1500 2100 3050 4100 5300 159 3 327 4 601 8 929 2 1327 4 1858 4 2699 1 3628 3 4690 3 U bolt 109 48 68 18 37 68 105 150 210 305 410 530 183 365 675 1050 1500 2100 3050 4100 5300 433 6 1194 7 1327 4 2477 9 Hub wheel 109 88 109 49 135 150 280 485 1350 1500 2800 159 3 327 4 601 8 929 2 1327 4 1858 4 2699 1 3628 3 4690 3 Draw bar 109 48 68 18 37 68 105 150 210 305 410 530 with spring washer 183 365 675 1050 1500 2100 3050 4100 5300 159 3 327 4 601 8 929 2 1327 411858 4 2699 1 3628 3 4690 3 Brake 109 48 6 8 18 37 68 105 150 210 305 410 530 with spring washer 183 365 675 1050 1500 2100 3050 4100 5300 106 2 221 2 380
25. 01 8 929 2 1327 4 1858 Vibration isolator ass y _ 48 48 gt 12 25 43 68 105 150 210 with spring washer and thick washer 1241 245 425 675 1050 1500 2100 3 Coupling portion between comp air end and engine 06 2 221 2 380 5 601 8 929 2 1327 4 1858 4 Housing 48 48 12 25 43 68 105 150 210 with spring washer 124 245 425 675 1050 1500 2100 21 33 52 194 7 1858 4 2477 9 3628 6 Coupling for installing flywheel 109129 8 8 25 49 85 135 210 280 410 with spring washer 245 485 845 1350 2100 2800 4100 221 2 433 6 752 2 1194 7 1858 4 2477 9 3628 3 Coupling for installing driving shaft 129 88 25 49 85 135 210 280 410 with lock washer 245 485 845 1350 2100 2800 4100 221 2 433 6 752 2 1194 7 1858 4 2477 9 3628 3 Coupling for installing gear of resin 10 9 88 25 49 85 135 210 280 410 with spring washer and thick washer 245 485 845 1350 2100 2800 4100 4 Lifting portion 59 3 3274 601 8 929 2 1327 4 1858 4 Lifting bail less than M20 109 48 68 18 37 68 105 150 210 spring washer 183 365 675
26. 5 601 8 929 2 1327 4 1858 4 2477 9 3053 1 Stand for storing drawbar 109 48 48 12 25 43 68 105 150 210 280 345 with spring washer 124 245 425 675 1050 1500 2100 2800 3450 3X2 When fixing parts of aluminum are used lockwasher shall be used for avoiding damage 2X3 Nut shall be of S45C equivalent to 8 8 strength classification For larger than M20 tightening torque becomes so big and so 4 8 or equivalent shall be used 2 3 2 Maintenance 2 Mounting 3 Coupling portion between comp air end and engine COMP SIDE ENG SIDE 2 4 2 Maintenance 4 Lifting portion 5 i d 5 Pressure vessel and pipes T 2 Maintenance 6 Undercarriage imei 2
27. Clean or replace L Jt will not work Faulty engine stop gt Repair or replace it Check function engine stop solenoid It works It will not Check function fuel air work bleeding electromagnetic pump It works Check fuel filter Normal Clogging Faulty Repair pipes and TV s s i Check fuel pipes bleed air Normal Repair the trouble Check and confirm engine and get rid of the cause Abnormal 4 3 4 Troubleshooting 4 23 Engine revolutions will drop before pressure rises up to rated one Check whether valve for Close the valve for starting at low temperature f starting at low is open or close temperature Check setting of purge operation load factor at AUTO IDLE operation Less than 100psi 0 69MPa 6 9bar Check function of Solenoid valve opens purge starting unloader Check power supplied between solenoid valve CN1 9 and CN1 7 terminal of at AUTO IDLE operation controller interior contact RY2 Less than 100psi 0 69MPa 6 9bar Solenoid valve closes No conduction exists Trouble of solenoid valve for gt i Repair or replace it ipurge starting i unloader Exists Trouble of x controller or gt or replace it antake negative ipressure sensor Check adjustment of pressure regulator F
28. Grease of poor quality will deteriorate the material A070337 2 7 Check O ring and Needle valve of Auto relief valve and Vacuum relief valve IMPORTANT When reassembling apply sufficient grease to O ring Slot O ring and sliding surface Use CALTEX MULTIFAK EP1 grease or equivalent Grease of poor quality will deteriorate the material Disassemble and clean the component and check O ring 1 2 3 and needle valve 4 Then replace O ring 1 9 and rubber on the needle valve 4 if hardened O 2 O o x O t Vacuum relief valve A070339 2 Maintenance 2 8 Performance check of Pressure control valve IMPORTANT When reassembling apply sufficient grease to O ring Slot O ring and sliding surface Use CALTEX MULTIFAK EP1 grease or equivalent Grease of poor quality will deteriorate the material lt Procedure gt D When closing stop valve and fully opening service valve while the machine is running make sure that the discharge pressure gauge shows the figure between 49 to 68psi 0 34 to C gt 1 0 47MPa 3 4 to 4 7bar a9 When the pressure is lower than 49psi 0 34MPa 3 4bar replace spring 3 with a new one 1 3 3 When the indicator shows excessively higher pressure you will find that the piston does not move smoothly due to fs 4 foreign material and rust stuck inside valve In such a case disassemble the co
29. Maintenance 2 3 How to adjust regulator and how to replace diaphragm 2 3 1 Method of adjustment A CAUTION Operation with compressed air supply port opened is prohibited When adjusting regulator system install a silencer to the air delivery port and wear earplugs for protection of hearing damage The speed regulator is already adjusted prior to delivery ex works Never change the setting of the regulator by turning bolt and rod recklessly If it is necessary to re adjust the speed regulator due to overhauling or any trouble adjust it in accordance with the following procedures lt Adjustment procedure gt For engine speed and pressure see 1 2 Pressure regulator Pressure adjusting screw Engine governor lever Speed regulator 08021 1 Left screw oO ER Oy I CES High speed 6 gt Low speed side side Right screw PC10022 D Adjust the length of the rod connecting speed regulator so that engine governor lever can be pulled toward high speed side with compressor kept stopping Making the rod length short engine speed increases Adjust this system so that when unload starting pressure exceeds 100psi 0 69MPa 6 9bar by turning pressure adjusting screw speed regulator can start to function to lower engine RPM Tightening the screw the pressure rises and loosening it the pressure drops 2 1 2 Maintenance 2 3 2 Change diaphragm Speed re
30. N m kgf cm Second time 755 2 to 807 2 85 3 to 91 2 870 to 930 Valve clearance Firing order 13 421 Nelcylinderatflywheelside __ Injectiontiming BTDO FIT145 atliftO 098in 2 5mm b ar psi MPa bar 470 14 5 3 24 0 1 32 4 3 1 Compression imited value 370 14 5 2 55 0 1 25 5 1 Working limit psi MPa barl _ Each pope Ieylinder limit 29 to 43 5 0 2 to 0 3 2 to 3 value Temperature for 160 34 7 7141 5 start of release temperature Valve lift More than 0 31 8 0 For the details see service manual supplied by engine manufacturer 3 Electric System 31 Control Part number 46870 51901 Export model Part number 46870 54000 US model LED6 LED11 O ENG SPEED Otow LED7 H H H H DISCHARGE TEMP LEDS LED1O Zo 0 O WATER TEMP QO CHARGE LED4 LED3 LED2 LED E08 O HOUR METER LEDS 2 LED18 1 019 FUEL LEVEL meg O LEDIS Bom Ke Se code Reset switch Panel face Indication selector switch CN1 CN2 654 321 109876 54321 SS so LIEN NE J dod 121110 987
31. ONITOR CHANGE CHANGE CHANGE CHANGE Push Push Whenever indication selector switch is pushed every time indication screen is changed by turns as shown above 15 lt J l IJ COMPRESSURE LOAD FACTOR SERVICE PRESSURE PSI In case that discharge air temperature is below 68 F L is indicated on screen In case the compressor load factor is more than 50 b is indicated on screen The indication of service pressure the compressor load factor is displayed only at the time of purge driving 1 9 1 Specification 1 5 1 Indicator lamp Indicator lamp Turn the starter switch to RUN position Then the lamp goes on Press starter switch GLOW and the GLOW lamp goes on and after preheating is finished the lamp will be off CHARGE Lamp goes on when alternator is not Check wiring charging Check alternator Warning display This displays such trouble of less importance when it occurs during operation but the unit continues operating When any abnormality happens a trouble code lamp flickers In this time when trouble code switch is pressed a failure code will be displayed code DISCHARGE 1 Lamp flickers when the air temperature at the TEMP H outlet of the air end reaches 239 F 115 C WATER TEMP 9 Lamp f
32. PC11013 1 18 2 Maintenance 2 1 2 1 1 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 Cautions for Overhauling Precautions before starting work Work to be performed It is very important to always plan in advance what facilities tools instruments materials oil etc you will need to use the exact locations and methods of performing inspection adjustment or disassembly and the key points of any repair work to be performed Care not to spill oil Use a pan to collect used compressor oil engine oil when changing the oil or attaching or detaching an oil line If a large volume of oil is expected to flow out make sure to drain any accumulated oil from the reserve tank engine oil pan in advance Follow the designated regulations to dispose of compressor oil and engine oil Care when detaching parts When disassembling a complicated part put a matching mark to indicate the position of detached parts for future reference Make sure that the negative cable is detached from the battery terminals before starting repair work Tools to be prepared Measuring instruments e g tester insulation resistance gauge etc Tools Torque wrenches Jigs and specialized tools tape Molybdenum sulfide tube type Lithium extreme pressure type grease e CALTEX MULTIFAK EP1 e MULTINOC SDX Diesel oil Compressor oil 10 Cleaning cloths Literatures such as
33. SS Y YANMAR 129242 55700 YANMAR 129242 55730 YANMAR 24311 000160 YANMAR 24321 000750 36400 21901 36437 01500 36400 19000 built in unloader 36429 00801 built in unloader 03402 25008 03402 25021 21221 02100 03402 10125 03402 10070 21441 04800 21441 04900 85300 17000 03402 15075 03402 25032 22144 07700 35303 03300 Unloader valve 22100 41201 5 1 5 References US model line Built in compressor oil filter Pellet O ring Electrical appliances eee 46870519011 Controller 46870 51901 46870 54000 44346 16400 Safety relay YANMAR 119802 77200 44327 05000 YANMAR 119650 77910 44327 05000 m YANMAR 119650 77910 Purge starting unloader solenoid valve 46811 24100 Fuse 30A FUSE1 44470 02600 Fuse 5A FUSE2 44470 02100 44328 20600 ntake negative pressure sensor Service pressure sensor ____ 44328 20600 445640600 e 5 T b ct lt Discharge air temp sensor 44364 06500 ___ Coolant temp sensor i 44328 21800 Engine oil pressure switch YANMAR 114250 39450 Purge control switch Lo 7 _ 4624221500 Sending unit Fuel air bleeding electromagnetic pump Q Instruments on panel ae o o Starter switch 44322 07300 5 References D 5 2 Engine Wiring 1 Export model AC6EOOLV
34. ace it purge starting unloader iunloader Meas ee iCable disconnected or Check cable between Cable idefectively connected controller and solenoid valve disconnected _ between controller and for purge starting unloader Solenoid va ve for x fases ipurge starting unloader iand fuses Abnormal Check function of controller X1 As the output voltage of intake negative pressure sensor at unload operation is very little it is better to check the function of purge control operation after replacing the sensor with new one if it is found difficult to diagnose the trouble X2 For details of controller functions see No 3 1 Controller 4 8 4 Troubleshooting 4 2 10 Even when the pressure at consumer s side drops it will not recover from purge control operation US model only Purge releasing Check setting of purge pressure too low _ Faulty setting of purge releasing pressure L releasing pressure L 80psi 0 55MPa 5 5bar Service pressure and output voltage e aq will not meet Trouble of service pressure sensor Check output voltage of service pressure sensor See 3 11 Output voltage normal Disconnection or i Check cable connection Cable disconnected faulty contact between between service pressure controller and service sensor and controller pressure sensor Not cable disconnected 4 9 Adjust See 1 6 2
35. aulty adjustment iFaulty adjustment of ipressure Adjustment Re adjust pressure Change pressure gauge for Adjustment replacement one and re adjust pressure gauge Faulty adjustment Fault Check needle valve of Faulty avers Replace pressure pressure regulator regulator assembly Normal 4 4 4 Troubleshooting 4 2 44 Engine will not turn to meet rated revolutions Not at high speed side Faulty adjustment of speed regulator rod Check if engine governor lever stays at high speed side At high speed side Normal Water collected Check sedimenter Normal Normal Check and confirm engine Check adjustment of pressure regulator Normal Abnormal Faulty Faulty adjustment of pressure 4 5 Clogging Check air filter m m sedimenter Clogging ARR NM Check fuel filter gt Faulty fuel filter Paulie e Check fuel pipes Faulty fuel pipes i Replace it Repair the trouble and get rid of the cause Check unloader recovery pipe Clogging Faulty of unloader e for any clogging irecovery pipe i Repair pipe 4 Troubleshooting 4 2 5 Minimum speed not available even upon no load operation Check if engine governor At low speed lever stays at low speed side
36. aulty adjustment of side ispeed regulator rod Re adjust rod Not at low speed side Check and confirm that It bursts at less safety valve functions at pressure lower pressure than set Faulty safety valve it It bursts out at set pressure Faulty adjustment of 5 _ pressure pressure Check function of pressure Adjustment regulator and 1t is properly adjusted Faulty adjustment Change pressure gauge for Adjustment ps replacement one and Faulty pressure gauge gt it pressure gauge etree Faulty adjustment Bleed pressure regulator Faulty diaphragm of Replace pressure d check for air leak x gt ana check for air leak pressure regulator regulator assembly No air leak Check pipe to pressure Air leak regulator for leak aulty pipes parts No air leak Air leak Not at low in good Check if engine speed side governor lever stays at low speed side At low speed side ied Speed regulator Replace the diaphragm is damaged or diaphragm or iair leaks from control pipe repair piping Faulty seat of unloader valve 4 6 4 Troubleshooting 4 2 7 Oil mixed found in delivery air Check compressor oil level Proper level Lower than Rec nde d thant ems ERE specified lever 49psi 0 34MPa u
37. d equally in the body using an assembly tool Important Once diaphragm is settled in turn slowly the tool for secure installation When turning the tool hold the diaphragm not to be afloat After diaphragm is set in install the cap and then assemble speed regulator Important Before installing the cap make sure again that the portion of diaphragm shown in right figure is seated intact If diaphragm is afloat it can cause diaphragm to be caught in when installing cap If the shaft is turned after installation is Clearance finished it could damage diaphragm Take care Body After re assembling the speed regulator adjust it according to the adjustment method of speed regulator See 2 3 1 2 9 2 Maintenance 2 4 Clean of element in sedimenter lt Procedure gt D Turn fuel selector valve 1 to OFF position Loosen the drain valve 2 and drain out condensed water inside Turn the cup 3 to the left and remove it Be careful to remove the cup 3 because it is filled with fuel Wipe out split fuel completely D Remove float 4 inside cup 3 Washing element 5 and the cup inside with new fuel Replace element 5 and O ring 6 7 if they ar
38. e found broken or damaged 4 After finishing clean assemble it in reverse Es procedure 2 If air is found still in fuel pipe place starter switch to RUN position and loosen air bleeding bolt 8 to bleed air After finishing air bleeding tighten the air bleeding bolt 8 Drain the condensate in container 9 and then 9 dispose of condensate according to the designated regulations A100117 2 5 Change Oil Separator IMPORTANT When changing the oil separator both cover and element must be replaced with new ones Even before the periodic interval time of replacement replace the oil separator whenever the oil consumption increases and also oil is found mixed in the discharge air When consumption of the oil is still unusual even after cleaning strainer in the scavenging orifice change the oil separator with a new one O ring gt Element Separator Oil separator Sa he A100463 1 A100371 Tightening torque of separator cover bolt 0 31 in 8 mm r 433 6lbf in 49N m 485kgf cm 2 10 2 Maintenance 2 6 Change O Ring of Unloader lt Caution during O ring replacement gt Supply grease to O ring 1 2 3 4 after replacement IMPORTANT When reassembling apply sufficient grease to O ring Slot O ring and sliding surface Use CALTEX MULTIFAK EP1 grease or equivalent
39. ecause it is faulty Normal 13 to 15V i Di ted check and confi Check charging warning lamp Cable disconnected i res waning lamp circuit L terminal circuit avs controller CN2 11 terminal Not cable disconnected Repairing alternator because it 1s faulty 3 9 3 Electric System 3 3 Starter YANMAR part number 129242 77010 Magnetic switch 5 terminal B terminal Magnetic switch a 28 x PC10036E PC10030E Cable connection 1 List of ons B Battery For supplying power to starter which enables starter pinion to turn For supplying power to make starter pinion to spring out and also a little power to make pinion turn for smooth engagement between pinion gear and ring gear when they are in contact W Safety relay B terminal 2 Judgement of starter functions ames method by measuring battery terminal Normal Value at full load operation During normal operation at normal temperature 7 7V 400A and pinion RPM lower than 1 400min 3 10 3 Electric System 3 4 Safety relay Key switch Part number 44346 16400 OFF oN Battery DC12V 11011 ConnectorA Connector B PC10003E 1 Specification 2 Chart of function Rated voltage DC12V ST ST ES Range of voltage at which unit is used DC10 to 15V Starter switch ON Range of temperature at which 22 176 F SER unit is used 30
40. eration Low temp start valve lt Orifice In the speed regulator 3 D Starting unloader valve Speed regulator Pressure regulator Separator PC11007E Response When starting operation starting unloader valve opens And compressed air is sent to unloader chamber A and speed regulator chamber Thus pressure in chamber A and rises smoothly and closes unloader valve completely at low pressure And at the same time engine speed drops by function of speed regulator Consequently load at start up will be saved Air volume sent to unloader chamber A and speed regulator chamber increases and decrease according to increase and decrease of delivery air pressure Thus according as unloader valve position and engine speed change free air delivery is sleeplessly and automatically regulated from 0 to 100 When air consumption decreases and compressed air in separator receiver tank exceeds rated pressure it closes unloader valve by function of pressure regulator and speed regulator and reduces engine speed down to unloaded speed Further when interior of compressor air end becomes extremely high vacuum during unloaded operation it causes vacuum noise In order to prevent vacuum noise which occurs in compressor air end it detects secondary pressure in pressure regulator to open vacuum relief val
41. ervice manual are intended to be distributed to limited numbers of our customers The unauthorized reproduction or distribution of this service manual is prohibited Table of Contents 1 Specification 1 1 1 1 Specifications 1 1 1 2 SetValue J JJ JJJJJJJJJJJJJJJJJJJJJ 1 2 1 3 Outline drawing 1 3 1 4 Internal Components and Part Names 1 6 1 5 Instrument panel 1 8 1 6 Capacity Control Device 1 11 1 7 Piping Diagram 1 16 1 8 Fuel piping 1 18 2 Maintenance 2 1 2 1 Cautions for Overhauling 2 1 2 2 Tightening
42. g general cautions 411 Safety caution 1 Removing such cap and or plug for receiver tank fuel tanks and pipes where pressure is loaded stop the machine and relieve all the interior pressure Install measuring instruments connected firmly 2 When doing the job with co worker s together make sure to give signal to the other person s and do not allow other persons to come near to the job site 3 Take care not to touch hot portions and not to be involved in turning portions 4 1 2 Caution during failure diagnosis 1 Do not make haste to disassemble the unit If the unit is disassembled urgently DYou may disassemble the other portions which are not related with the trouble The cause of trouble may be missing The unnecessary reparations require more spare parts and man hours and reparation costs will increase more What is worse you will lose reliance or trust from clients operators and users Therefore it is absolutely necessary to investigate the trouble more carefully in advance and to follow the required procedures for failure diagnosis 2 Ask the clients about the trouble in details In order to prevent misunderstanding and incorrect judgment about the trouble it is necessary to ask users or operators about the following questions DIs there any other disorder than the trouble he has informed Anything abnormal occurred before this trouble Did this trouble happen unexpectedly Or the unit had been operated in bad condit
43. gulator Bellophragm type lt Procedure gt D Remove the speed regulator from the bracket and disassemble it Replace diaphragms with new ones 20 Check A to D shown in figure for any burrs Diaphragm is delivered in different state from the p d i AUN onem s state in which it should be installed So install diaphragm which should be turned inside out as p shown in the following Fig Delivered state State to be installed e PC06037 Locking nut Washer Diaphragm Seal Internal face of body and cap and also both internal face and external face of diaphragm should be coated with molybdenum sulfide spray Shaft focis PC11038 How to spray molybdenum sulfide paste The areas in oblique line should be sprayed with this paste Diaphragm should be rolled up and back face and piston s T ded 2 should be sprayed returned and be sprayed be sprayed Inside face of body X Jointed portion should should be sprayed be sprayed enough till middle line 11037 1 2 8 2 Maintenance OInstall diaphragm to shaft and piston and fasten it with a locking nut Tightening torque 70 8bf in 8N m 80kgf cm Important Be careful not to tighten the locking nut excessively Excessive tightening can cause washer to turn together and twisting diaphragm The diaphragm will be damaged in shorter period Put in diaphragm to be settle
44. id ae NAL Onin TSA Faulty pressure sone icontrol valve Too much Check discharge air pressure More than 49psi 0 34MPa 3 4bar Check separator collection Clogging orifice pu strainer Not collection Clean or replace it No clogging 4 2 8 Discharge air is insufficient Clogging is large Check air filter for clogging rar purge Repair or replace it Air leak Check purge solenoid valve for any air leak Normal Not shrunk Check if engine speed side i governor lever adjustment gt Re adjust rod stays at high iof rod i speed side Faulty seating Faulty pressure Replace it regulator Pressure drop f me Wd defects of Re selection of airline i and repair air leak at high speed side Too long narrow and air leaking Check whether pressure N Check air ormal rises up to the rated one line up to smoothly soon after service valves are closed quickly from full load operation ia Check fuel filter Check fuel pipes Check and confirm engine Normal Difference is Check difference in pressure IF mm E 7 7 between at front and rear of n re gt oil separator Unloader valve does Replace defective mot open well parts by new ones Normal 4 Troubleshooti
45. il pressure abnormality detecting circuit functions 10 seconds after it detects alternator generation signal 3 2 3 Electric System 2 Timing of each output relay ON Power supply FF Starter switch 1 0 M Stop solenoid For pulling in RY 1 Stop solenoid For holding When coolant temp is lower than 32 F 0 C it holds 20 seconds I J When coolant temp is higher than 32 F 0 C it holds 2 seconds a ad Glow RY 0 When coolant temp is higher than32 F 0 C it holds 10 seconds When coolant temp is lower than 32 F 0 C it hold till temp Solenoid valve rises higher than32 F 0 C or it holds till 120 seconds pass for starting unloader RY 2 It detects at 5 seconds after charge signal disappears 4p Engine start Detection of abnormal charge Discharge air temp t detects at 2 seconds after oil press SW starts Water temp P It does not detect for 10 seconds after engine starts A Time lag Abnormality oil pressure It detects at 20 seconds after oil press disconnects Detection _ of disconnection Resetting of abnormal warning to be Warning Engine stop done by switching OFF key SW PC11010E 1 3 Warning emergency display and emergency stop functions Detecting timing Discharge temp P Lamp goes on at E Lam
46. ion decreases and compressed air in separator receiver tank exceeds rated pressure it closes unloader valve by function of pressure regulator and speed regulator and reduces engine speed down to unloaded Suction port closing speed Further when interior of compressor air end becomes extremely high unload operation vacuum during unloaded operation it causes vacuum noise In order to prevent vacuum noise which occurs in compressor air end it detects secondary pressure in pressure regulator to open vacuum relief valve thus preventing interior of air end from becoming high vacuum When the certain set time it can be changed has passed at lower pressure than the set negative pressure detecting the negative pressure inside the compressor air end with an intake negative pressure sensor PRS1 solenoid valve SV1 opens and it closes unloader valve At the same time it functions Purge control 7 Apud to relieve the compressed air from separator receiver tank atmosphere and thus it lowers the pressure Thus the compressor power is saved When air consumption increases and the pressure used for load drops below the set pressure services pressure sensor PRS2 detects it and it disengages the purge control solenoid valve SV1 closes to start full load operation When stopping operation it opens auto relief valve to relieve the compressed air in separator receiver tank to atmosphere detecting the pressure inside compressor ai
47. ions before When and how did this trouble occur amp Had he repaired the unit before this trouble occurred Did he not experience similar trouble before 3 Inspection items before starting diagnosis Sometimes such trouble may be caused owing to routine mishandling of the unit Before starting failure diagnosis check the following items The engine runs short of engine oil or its oil is not dirty Q Check each wire connection for any disconnection Check the other portions for any damage 4 Confirmation of trouble Discuss with user s and or operator s sufficiently about the trouble As a result judge whether their judgment is based on the numerical comparison or sentimental basis Make him them understand well the reparation or correction you have finished Then check and confirm by yourself the cause of the trouble Note Never proceed any investigation or measurement which may cause further greater damage 4 1 4 Troubleshooting 5 Procedures of diagnosis When you become well experienced you can find out the cause easily during the process of confirmation 4 But easy understanding could cause unexpected failure So check and judge it according to the following procedures Q Check the easiest thing or portion first Investigate the most possible cause Check the other things connected to the trouble Check for the possibility of any other troubles Start proper and careful investigation on this trouble
48. ith CN2 8 terminal reg Power supply for intake negative pressure sensor 3 7 3 Electric System 3 2 Alternator Dynamo regulator IC type YANMAR part number 129423 77200 EY m Cable connection PC10028E 1 1 List of functions 5A Fuse It detects battery voltage and it controls rotor coil Through joint connector electromagnetic current Controller CN2 11 terminal It makes warning lamp go on when battery charging function is abnormal Controller CN2 8 terminal cr nator O rotating speed signal For diagnosing P terminal check the generating voltage between P E terminal and it is normal LLL the voltage detected is about DC2 2V 2 Judgement of alternator functions omm method by measuring battery terminal Normal Value at full load 8atfullleaadoperation Measure the battery terminal voltage at 13to 15V 1 500min 1 3 8 3 Electric System 3 Diagnosing when battery charging warning lamp lights Abnormal Measure battery voltage less than 12V when engine stops Recharging battery Normal 12V Abnormal same voltage as battery Measure the voltage of voltage when stopping Repairing alternator because it is alternator BAT terminal faulty during operation Normal 13 to 15V Abnormal Check and confirm battery higher than15 5V voltage at 1 500min Repairing alternator b
49. ithout fail See following pages Make sure to remove rust and dust before tightening For specified sections 2 2 2 Maintenance 2 2 2 Tightening torque of such important quality parts as bolts and nuts RUE Tightening torque Ibf in N m kgf cm Application parts amp portions zi Nut Torque Coarse thread fine thread Remarks section Mg M8 M10 M12 M14 M16 M18 M20 M22 M24 1 Air end 442 106 2 380 5 10 9 _ 48 5 12 43 for prevention of deformation of outer ring D e 12 9 _ 48 5 12 43 for prevention of deformation of outer ring 51 124 425 292 0 566 4 2 Plate holding pinion gear 12 9 _ 10 9 33 64 for prevention from loosening 325 640 88 5 221 2 433 6 752 2 1194 7 1858 4 Others 426 88 10 25 49 85 135 210 100 245 485 845 1350 2100 2 Mounting 06 2 221 2 380 5 601 8 929 2 1327 4 1858 4 Mounting bracket 48 48 12 25 43 68 105 150 210 with spring washer 1241 245 425 675 1050 1500 2100 06 21 80
50. ive pressure becomes higher than the set pressure the AUTO IDLE lamp flickers at short intervals When this condition continues for a certain time the solenoid valve functions to start purge mode operation Consequently the pressure inside separator receiver tank drops and reduces the power of compressor air end In this stage the lamp AUTO IDLE flickers at longer intervals 3 Next when the pressure for load down to the purge releasing pressure owing to the increase of air consumption the solenoid valve operation gets Lamp goes on OFF and it is transferred to normal operation In this stage the lamp AUTO IDLE goes on Lamp flickers at longer intervals 1 Specification 1 6 2 Setting of AUTO IDLE control purge control pressure timer How to change set value of auto idle pressure timer is shown below Range of set Item Indication 1 Primary set value values 86 70 to 100 Purge releasing pressure Waiting time for transfer 10 5 to 60 to purge mode operation Load factor for transfer to 15 5 to 30 purge mode operation lt Procedures of adjustment gt When auto idle switch is pressed longer than 5 second first L Purge releasing pressure is displayed Each time auto idle switch is pressed each indication will be selected Then each time it is pressed one time T Waiting time for transfer to purge mode operation is switched to b Load factor for transfe
51. lickers when coolant temperature See H reaches 221 F 105 C Troubleshooting Belt loosened and or cut Faulty generation of alternator Emergency display When any trouble takes place during operation this displays and it stops as an emergency stop When any abnormality happens a trouble code lamp flickers In this time when trouble code switch is pressed a failure code will be displayed code DISCHARGE Ei Lamp displays when the air temperature at TEMP H the outlet of the air end reaches 248 F 120 C WATER TEMP E2 Lamp displays when coolant temperature H reaches 230 F 110 C ENG OIL Lamp goes on when engine oil pressure drops PRESS The function pressure is below See 7 3psi 0 05MPa 0 5bar Troubleshooting It is displayed when air temperature sensor at SUE Ss OR the outlet port of compressor air end is disconnected WATER ET It is displayed when engine coolant TEMP SENSOR temperature sensor is disconnected 1 10 1 Specification 1 6 Capacity Control Device 1 Export model From air fi Start Functions of J Load operation magnetic valve Auto relief valve CLOSE Vacuum relief valve Unload operation CLOSE Stop CLOSE Pressure control valve ca To compressure air en Service valve Load operation Suction port closing unload op
52. lue prior to delivery 86psi 0 59MPa 5 9bar to cut power supply to the solenoid for purge starting unloader mode and then switched to normal node operation Auto idle lamp changes from blinking to lighting For pulling stop solenoid When starter switch is ON and voltage is applied to CN1 12 terminal interior contact RY1 is ON and voltage is outputted out of CN1 8 terminal to make the solenoid relay function Thus power is supplied to W terminal of stop solenoid and it pulls interior plunger 1 second later the interior contact RY1 becomes OFF to cut power supply to solenoid relay Then stop solenoid is switched to holding circuit EN 00 electrical connection found When auto idle switch is ON and power is supplied to CN2 2 terminal interior contact RY5 becomes ON to make auto idle function indicator go on Power supply for auto idle function lamp lighting Power supply 3 6 3 Electric System When auto idle is switched ON to be electrically connected it will be switched to purge control mode No electrical connection found When engine oil pressure drops engine oil pressure switch turns ON to electrical connection When electrical connection interior contact RY3 between CN1 9 and CN1 3 terminal turns OFF to cause emergency stop to engine Set pressure of emergency stop oil pressure below 7 3psi 0 05MPa 0 5bar 2 Connector CN2 AUTO IDLE switch US m
53. mponent for checking and cleaning A100372 1 2 9 Check Pressure control valve O Ring and Piston After disassembling and cleaning pressure control valve check ring 1 2 and piston 4 When the rubber of these parts is found hardened or damaged replace them After replacement run the machine to check its function air leak or any disorder 2 12 2 Maintenance 2 10 Change of pellet assembly of by pass valve By pass valve fitted on this unit is of full bore type While the unit is used for normal operation it is not to perform periodical replacement of the Inner pellet assembly but when such trouble as excessive rise of compressor oil temperature it becomes necessary to replace it in accordance with the following procedures lt Procedure gt D First stop the unit and make sure that there is no residual pressure left in the separator receiver tank After checking and confirming that the temperature of compressor oil has become amply low open drain valves on separator receiver tank and oil cooler to empty compressor oil completely 8 After having drained oil completely remove the pellet assembly of by pass valve and O ring Replace the pellet assembly and O ring by new ones Install O ring coated thinly with compressor oil Supply compressor oil through the filler port provided on the receiver tank Refer to operation manual Start operation and check the function of by pa
54. nctions see No 6 List of function CN1 7 and CN1 8 terminal of No 3 1 Controller 3 Electric System 3 8 Engine oil pressure switch For emergency stops Part number 44328 21800 PC10013 Specification 7 3psi 0 05MPa 0 5bar B contact switch Contact OFF in excess of set pressure 10 seconds after engine starts 2 seconds during operation Time lag When such situation under operation pressure continues longer than 2 sec It brings engine to emergency stop 3 9 Fuel air bleeding electromagnetic pump Part number 43650 02700 YANMAR part number 129612 52100 Specification Rated voltage 12V Operating current 1 5A MAX More than 0 11 to 0 29gal min 0 4 to 1 1 L min Delivery capacity PC10014 3 10 Discharge air temperature sensor Coolant temperature sensor Part number 44364 06500 R1 8 S pesce Ms mm ss PC08033 Note Take care not to tighten excessively Less than 17 7lbf in 2N m 20kef cml For temperature characteristic of resistance see No 5 Adjustment and inspection of No 3 1 Controller 3 15 3 Electric System 3 11 Pressure sensor for Intake negative pressure and for service pressure Part number 44328 20600 Trouble diagnosis of pressure sensor itself Check and confirm that output voltage between 2 3 is DCO 5 0 1V when 5V is applied between terminals at an Power Earth Dsupply atmospheric pressure Output
55. ng 4 2 9 Purge control operation will not start even if AUTO IDLE purge control switch is pressed US model only Check service piping for any Air leak air leak No air leak 22272 leaki Repair air piping Lower than 15 pes dap eration load factor b Check setting of purge operation load factor b Adjust See 1 6 2 Set time is too Faulty setting of the time required for Check setting of the time long x mw required for switching to switching to purge Adjust See 1 6 2 purge operation operation T i Check AUTO IDLE switch cable connection Not cable disconnected Cable disconnected efective contact of able connection Repair connection between controller auto idle switch ground iconnection Check intake negative voltage of Key ON when megative pressure Replace it stopping and At Sensor U Key ON when stopping DC0 5V At unload less than DC0 5V Disconnection and i Cable i Check cable connection faulty contact between intake negative disconnected _ i icontroller and intake Repair connection pressure sensor and i i inegative pressure i controller Not cable disconnected At no load electrically connected Check electrical connection to Trouble of solenoid solenoid valve for valve for purge starting Repair or repl
56. ng engine 1 6 For checking engine cooling water level and for replenishing cooling water ES 10 11 Fuel pre filter For filtering dust and foreign matter mixed or to be mixed in the fuel oil 12 13 15 16 18 5 7 1 1 1 1 1 1 1 1 1 0 1 3 4 5 6 7 8 1 Specification 31 30 29 28 A100418 Export model Funetion For cooling compressor oil circulating in the system For driving the compressor For filtering compressor oil circulating in the system For keeping compressor oil at proper temperature For compressing intake air 25 Separator receiver tank From this portion where condensate is drained out of separator receiver drain valve tank Compressor oil filler port For supplying and replenishing compressor oil 22 NC Scale for measuring compressor oil level 1 7 1 Specification 1 5 Instrument panel 1 Export model Error code Reset switch When this switch is pushed on while lamp is blinking it shows error code When starter switch is placed to STOP displayed screen is reset STARTING UNLOADER STOP RUN START MANUAL CUT SPEED UO DISCHARGE TEMP chance P HOUA METER Hr CN sss F o MEM r A100359E Discharge air pressure gauge Starter switch For indication of working For starting and pressure stopping engine Digital monit
57. ng operation ended COS Ee ger psi MPa bar 58 to 100 0 40 to 0 69 4 0 to 6 9 psi MPa bar 104 to 131 0 72 to 0 90 7 2 to 9 0 1 2 psi MPa bar 58 to 73 0 40 to 0 50 4 0 to 5 01 itch 2 psi kPa bar 0 9 6 23 0 0623 gi ted 23 40 4 0 Actuating pressure of safety valve psi MPa bar 150 1 03 10 3 EN TUI 90 1 2 1 Specification 1 3 Outline drawing 1 Export model 3 6 001V 3Hnssdd 1884 SE 0 71 0161 I3 INI mee gi O C I 89 6 00 FATWA 39IAH3S dO Y3LN39 175 0 0 Obed 7106 NVI Tans HOLVIQVS 9090191110 LSNVAXS Sed TIO dWOON TIONS HOJVIQOVMH Y71000 SNI 1OOO vd pun 1 8 1 Specification 2 US model 697001 8S Nia Hi 8 6S LIN dY ONION JAWA 1785 feo XOddd 08 8449 TTXUSdd9 es 288 881 699 1 ve NIC NIV HI dV y nmm THI
58. odel only 4 5 7 Ure Vout Detection of service pressure terminal US model only Alternator P terminal input frequency engine rotating speed signal Detection of discharge air temperature When it is higher than the emergency stop actuating set temperature interior contact RY3 between CN1 9 and CN1 3 terminals will be turned G W Discharge air temp sensor OFF to make engine emergency stop Warning Emergency stop set temperature Warning temperature 239 F 115 C Emergency stop temperature 248 F 120 C EUN NUN 11 12 13 14 5 Alternator L terminal For detecting abnormal charge E 1 Intake negative pressure sensor terminal US model only 16 Ve Power supply for service pressure sensor terminal US model only es R Intake negative pressure sensor Vout terminal US mods only Detection of intake negative pressure Detection of engine coolant temperature When the set temperature of emergency stop becomes higher the interior contact RY3 between 19 IB Aeneas CN1 9 and CN1 3 terminals turns OFF to cause engine to emergency stop Warning Emergency stop set temperature Warning temperature 221 F 105 C Emergency stop temperature 230 F 110 C Abnormal oil pressure detection circuit of controller starts to function 10 seconds after it detects alternator generating signal w
59. or When power is supplied revolution speed lamp lighting is indicated Jig gt Wig 1188 18 ENG SPEED DISCHARGE TEMP MENTOR WATER TEMP HOUR METER min CHANGE Hr Push COl Push Push Whenever indication selector switch is pushed every time indication screen is changed by turns as shown above XIn case that discharge air temperature is below 20 C L is indicated on screen 1 8 1 Specification 2 US model Error code Reset switch When this switch is pushed on while lamp is blinking it shows error code When starter switch is placed to STOP displayed screen is reset m T 2 Paru YO LN TERIS T TEMP F LEVEL VANGE AIR PRESSURE DISCHARGE TEMP H 2 WATER TEMP H 2 ENGINE OIL PRESS 6 DISCHARGE TEMP SENSOR WATER TEMP SENSOR e A100444MMD Auto idle switch with indicator lamp Discharge air pressure gauge Starter switch This switch is used when fuel For indication of working For starting and consumption is minimized at no load pressure stopping engine operation Digital monitor When power is supplied revolution speed lamp lighting is indicated 13108 gt IB gt JH gt ENG SPEED DISCHARGE TEMP WATER TEMP HOUR METER 1 MONITOR CF MONITOR CF MONITOR Hr M
60. p goes on at Charge 5 Charge signal disappears After starting 5 0 sec and lamp goes on engine Discharge temp Lamp goes on at Emergency 3 Lamp goes at Water temp H 230 110 C Always 1 0 sec Pressure Lamp when 10 seconds after Eng oil press E 3 SW A contact pressure is lower than 2 0 sec 7 3psi 0 O5MPa 0 5bar 5 Discharge temp E 6 Themis Disconnected and lamp After starting sensor goes on engine Water temp Themis Disconnected and lamp After starting sensor goes on engine Emergency Compressor continues to run Warning Compressor stops 3 3 3 Electric System 4 Functions of each output relay When coolant temp is lower than 32 0 It goes ON when starter it becomes OFF 20 seconds later SW is ON When coolant temp is higher than 32 F 0 C it becomes OFF 2 seconds later Relay for heater relay It goes ON for 1 second Relay for solenoid relay when starter SW is ON When coolant temp is lower than 32 0 Relay for starting It goes ON when starter or when 120 seconds pass it becomes OFF unloader SW is ON When coolant temp is higher than 32 F 0 C it becomes OFF 10 seconds later It goes ON when starter SW is ON Relay for solenoid Abnormality output relay When switching to purge operation Purge function relay Blinking during purge lt lt Blinks every 0 5 seconds
61. r end 1 13 1 Specification 1 6 1 AUTO IDLE control Purge control This model is equipped with auto idle control operation mode This operation mode is recommendable for such use not so much air consumption is required and it is used continuously and also power consumption under unloaded operation is required to be saved Use this mode depending upon the need and demand For the selection of this mode switch on AUTO IDLE on the operation panel Select this operation mode freely according to required air consumption lt Procedure gt D During operation push on auto idle switch 1 2 Then the indicator lamp auto idle 2 goes on In order to stop this operation mode push again auto idle switch 1 goes out to disengage this purge control GLOW STOP guy MANUAL P P 9 a1 70 E cuase Q9 HOUR METER Hr DISCHARGE TEMP H E2 WATER ENGINE OIL PRESS DISCHARGE TEMP SENSOR ET WATER TEMP SENSOR A100444E 3 Function of auto idle control Purge control Conditions of auto idle lamp D First engine speed drops to the minimum speed by pressure regulator owing to reduction of air consumption Later the air consumption is reduced further the unloader valve gradually closes and intake negative pressure increases In this stage Lamp flickers at short intervals the pressure sensor detects the intake negative pressure Then when the intake negat
62. r to purge mode operation according to the set orders gt Aid 81145 Purge releasing Waiting time for transfer Load factor for transfer pressure to purge mode operation to purge mode operation UP DOWN UP DOWN UP DOWN t 4 Press 1 22 ADJUSTMENT So Press 3 9 Press 2 times ERROR times after time after after COE setting job a setting job setting job is finished is finished 1 15 ion t ica Speci 1 D 1 Export model iping 1 7 P 319 001V Leet UR JSAISO91 Joyesedes 2 N _ 2 Steel pipe lt 020 Steel pipe are BURNS OLO esou Z L L lt lt UM v L 9 gt t 8 1 eunsseJgd 8 o3ne3 91156914 3 16 Black gt ely OD 89S VO Joyejedeg But LO M edid 998018 Jepeojun Suni pue Alv Black lt 06 Black Q6 ZEN Q6Black 00 9 h 50107750905 OG aS Peg pela Co EIEIO Joje nse4 peeds 9 1 oin
63. relay and Heater relay A terminal 3 W B Stop solenoid R terminal complete engine preheating For holding stop solenoid When starter switch is ON and voltage is applied to CN1 12 terminal interior contact RY3 is ON and voltage is outputted from CN1 3 terminal to supply power to R terminal for holding stop solenoid When starter switch is OFF or emergency stop system functions the interior contact RY3 becomes OFF to cut power supply to the stop solenoid and consequently engine stops For outputting signal of abnormality For outputting signal of abnormality 3 5 5 mw 3 Electric System Purge starting unloader solenoid valve US model only Solenoid relay CN112 ________ 12 Auto idle function indicator US model only CN1 12 US model only Starter switch ACC terminal Through 5A Fuse When starter switch is ON and voltage is applied to CN1 12 terminal interior contact RY2 between CN1 9 and CN1 7 terminal becomes ON to supply power to solenoid for purge starting unloader to open the valve Thus this unit automatically starts starting unloader operation when it starts up consequently saving load at start up When controller CN2 8 terminal receives input of alternator generation signal after engine starts controller timer begins to function and 10 seconds later after whichever shorter time passes between the time till water temperature
64. rises higher than 32 F 0 C when it is lower than 32 F 0 C and the time of 120 seconds later the interior contact RY2 becomes OFF to cut power supply to the purge starting unloader operation and then switched to normal mode operation from starting unloader mode Functions during AUTO IDLE purge control operation When auto idle switch is switched on during operation auto idle lamp goes on and switched to purge control operation When this switch is pressed on again auto idle lamp goes out and this mode is released When air consumption decreases and pressure regulator begins to function engine speed drops and at the same time unloader valve of compressor air end gradually begins to close and suction load increases Compressor load factor is shown as monitor indication See 1 5 2 based on the suction load which is detected by suction load sensor When the load factor becomes lower than the specified value set value prior to delivery 15 See 1 6 2 auto idle lamp blinks at short intervals When this situation continues for a certain time set time prior to delivery 10 seconds the interior contact in controller RY2 becomes ON to make solenoid for purge function to start purge Thus receiver tank pressure drops to save machine power At this time the auto idle lamp blinks at long intervals Further when air consumption increases and the pressure at load becomes lower than the purge releasing pressure set va
65. ss valve It functions well when delivery air temperature will not rise abnormally O ring Pellets ASSY To oil cooler when the oil temperature is high 4 To oil filter when the oil temperature is low gt ura PC11033 To oil filter P To compressor air end Actuating temperature By pass valve fully closing temperature 180 37 F 82 3 C 192 36 F 89 2 C 2 13 2 Maintenance 2 11 Clean inside of Fuel Tank Condensate is caused and accumulated at the bottom of fuel tank owing to churning of dust or dirt mixed when fuel oil is fed and water drop caused while fuel oil tank is used for a long time When any condensate is found afloat and fuel filter gets clogged too fast fuel oil tank should be cleaned after condensate is removed from fuel oil tank even before the specified cleaning interval time lt Procedure gt D Open drain valve to remove fuel oil from fuel tank 2 Remove side cover under door 3 Remove fuel pipes and wires connected to fuel tank Remove belt holding fuel tank and remove tank 5 Insert cleansing nozzle through fuel filler port or drain port for cleaning tank 6 After cleaning job is finished install fuel tank from which water or the like should be completely removed PC11008 2 12 Values of Various Adjustments of Engine PDS1858 6C2 YANMAR 4TNV88 BDHKS Ibf in Firsttime 1364 6 to 416 6 41 2 to 47 1 420 to 480 Tightening torque of head bolts
66. ssembly Before starting the machine after disassembly run it at low idle to check for unusual noises etc to prevent engine or generator damage 2 1 2 Maintenance 2 2 Tightening torque 2 2 1 General bolts and nuts tightening torque Fasten all the bolts and nuts with the specified tightening torque when assembling High tensile strength bolt SS400B etc SCM435 etc Strength and 4 6 6 8 4T 6T 8 8 12 9 7T 12T sorting Width of across flat Socket bolts Hexagon bolts Tightening torque Ibf in N m kgf cm Tightening torque Ibf in N m kgf cm Socket bolts Hexagon bolts Width of across Width of across flat in mm flat in mm Hexagon bolts Width of across Bolt di t gt flat in mm in mm 442 5 51 88 5 10 100 106 2 12 124 221 2 25 245 221 2 25 245 488 6 49 485 380 5 43 425 752 2 85 845 601 8 68 675 1 194 7 135 1 350 938 1 106 1 055 1 858 4 210 2 100 1 283 2 145 1 450 2 566 4 290 2 900 1 814 2 205 2 050 3 628 3 410 4 100 2 477 9 280 2 800 4 955 8 560 5 600 3 053 1 345 3 450 6 283 2 710 7 100 For general sections such as bonnet Applied sections and frame IMPORTANT The above torque values in the table shall be applicable for the bolts and nuts used for machine Generally the abovementioned tightening torques should be followed but in some points different torque is specified So use the tightening torque w
67. ve thus preventing interior of air end from becoming high vacuum When stopping operation it opens auto relief valve to relieve the compressed air in separator receiver tank to atmosphere detecting the pressure inside compressor air end 1 11 1 Specification 2 US model Functions of pasen vate Start OPEN P Load operation CLOSE CLOSE Purge control OPEN gt Pressure control valve From air filter Auto relief valve To compressure air end Orifice In the speed regulator 3 3 Speed regulator i 1 12 A100449E 1 Specification Response When starting operation solenoid valve SV1 opens And compressed air is sent to unloader chamber A and speed regulator chamber Accordingly the pressure in the chamber A and rises soon to fully close unloader valve at low pressure And then engine speed drops with the function of speed regulator and it starts automatically starting unloader operation Thus it can reduce the load at start up After starting operation SV1 valve closes after 10 seconds have passed The air volume sent to the chambers A and from pressure regulator Load operation increases or decreases according to the rise and drop of discharge air pressure Thus according as unloader valve position and engine speed change free air delivery is steplessly and automatically regulated from 0 to 100 When air consumpt

Screw Compressor: 185S-6C2

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