Screw Compressor 6C2 Series 185S
Screw Compressor 6C2 Series 185S
Screw Compressor 6C2 Series 185S
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.
1-1
1. Specification
1.2 Set Value
PDS185S-6C2
Item unit
Export model US model
●Emergency stop devices
Actuating pressure of discharge air
°F(℃) 248(120)
temperature switch
Actuating temperature of water
°F(℃) 230(110)
temperature switch
Actuating pressure of oil pressure
psi(MPa)[bar] 7.3(0.05)[0.5]
switch
●Warning devices
Actuating pressure of discharge air
°F(℃) 239(115)
temperature switch
Actuating temperature of water
°F(℃) 221(105)
temperature switch
Battery failure When not charged
Actuating pressure of air filter
psi(kPa)[bar] 0.9(6.23)[0.0623]
indicator
●Set value
Pressure control valve psi(MPa)[bar] 58(0.40) [4.0]
Actuating pressure of safety valve psi(MPa)[bar] 150(1.03)[10.3]
Unload starting pressure psi(MPa)[bar] 100(0.69) [6.9]
Time for starting purge mode operation 10 to112
sec
(At AUTO IDLE operation mode) (Set at 10 sec. ex.works)
●Engine RPM
Rated RPM min-1 3,000
RPM at unload min-1 1,300
●Indications of gauges or instruments
during operation
Discharge pressure gauge
psi(MPa)[bar] 58 to 100(0.40 to 0.69)[4.0 to 6.9]
(at full load)
Discharge pressure gauge
psi(MPa)[bar] 104 to 131(0.72 to 0.90)[7.2 to 9.0]
(at no load)
Discharge pressure gauge
psi(MPa)[bar] 58 to 73(0.40 to 0.50)[4.0 to 5.0]
(at purge operation)
1-2
1. Specification
1.3 Outline drawing
(1) Export model
A100393E
Unit:mm
1-3
1. Specification
(2) US model
A100469
Unit:in.
1-4
1. Specification
(3) US model
A100468
Unit:mm
1-5
1. Specification
1.4 Internal Components and Part Names
1 2 3 4 5 6 7 8 9 10 11 12 13
19 18 17 16 15 14
A100417
Export model
1-6
1. Specification
20 21 22 23 24
31 30 29 28 27 26 25
A100418
Export model
1-7
1. Specification
1.5 Instrument panel
(1) Export model
A100359E
Digital monitor
※In case that discharge air temperature is below 20℃, “---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.
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
1-9
1. Specification
1.5.1 Indicator lamp
[Indicator lamp] Turn the starter switch to “RUN” position. Then the lamp goes on.
[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.
Failure
Item Contents Measures
code
DISCHARGE Lamp flickers when the air temperature at the
A1
TEMP. H outlet of the air-end reaches 239°F (115℃).
WATER TEMP. Lamp flickers when coolant temperature See
A2
H reaches 221°F (105℃). “Troubleshooting”
Belt loosened and/or cut
CHARGE A5
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.
Failure
Item Contents Measures
code
DISCHARGE Lamp displays when the air temperature at
E1
TEMP. H the outlet of the air-end reaches 248°F (120℃).
WATER TEMP. Lamp displays when coolant temperature
E2
H reaches 230°F (110℃).
Lamp goes on when engine oil pressure drops.
ENG. OIL
E3 The function pressure is below See
PRESS.
7.3psi(0.05MPa)[0.5bar]. “Troubleshooting”
It is displayed when air temperature sensor at
DISCHARGE
E6 the outlet port of compressor air end is
TEMP.SENSOR
disconnected.
WATER It is displayed when engine coolant
E7
TEMP.SENSOR temperature sensor is disconnected.
1-10
1. Specification
1.6 Capacity Control Device
(1) Export model
PC11007E
Step Response
When starting operation, starting unloader valve opens. And compressed air is
sent to unloader chamber and speed regulator chamber . Thus pressure
Start in chamber 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 and speed regulator chamber
increases and decrease according to increase and decrease of delivery air
Load operation
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
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 stopping operation, it opens auto relief valve to relieve the compressed
Stop air in separator receiver tank to atmosphere, detecting the pressure inside
compressor air-end.
1-11
1. Specification
(2) US model
A100449E
1-12
1. Specification
Step Response
When starting operation, solenoid valve (SV1) opens. And compressed air is
sent to unloader chamber and speed regulator chamber .
Accordingly, the pressure in the chamber and rises soon to fully
Start
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 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 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
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
to relieve the compressed air from separator receiver tank to the atmosphere
At unload operation
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
Stop air in separator receiver tank to atmosphere, detecting the pressure inside
compressor air-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.
<Procedure>
① During operation, push on auto idle switch“1”.
② Then the indicator lamp auto idle“2”goes on.
③ In order to stop this operation mode, push again auto idle switch“1”goes out to disengage this
purge control.
1 2
A100444E-3
1-14
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
No. Item Indication Unit Primary set value
values
PSI 86 70 to 100
1 Purge releasing pressure
kPa 60 50 to 70
Waiting time for transfer
2 sec 10 5 to 60
to purge mode operation
Load factor for transfer to
3 % 15 5 to 30
purge mode operation
<Procedures of adjustment>
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
transfer to purge mode operation),according to the set orders.
[Purge releasing [Waiting time for transfer [Load factor for transfer
pressure] to purge mode operation] to purge mode operation]
1-15
1. Specification
1.7 Piping Diagram
(1) Export model
A100361E
1-16
1. Specification
(2) US model
A100446E
1-17
1. Specification
1.8 Fuel piping
US model is optional.
PC11013
1-18
2. Maintenance
2.1 Cautions for Overhauling
2.1.1 Precautions before starting work
(1) 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.
(2) 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.]
(3) 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.
(4) Tools to be prepared
①Measuring instruments (e. g. tester, insulation resistance gauge etc.)
②Tools
③Torque wrenches
④Jigs and specialized tools
⑤Sealing tape
⑥Molybdenum sulfide (tube type)
⑦Lithium extreme pressure type grease
CALTEX MULTIFAK EP1
MULTINOC SDX
⑧Diesel oil
⑨Compressor oil
⑩Cleaning cloths
⑪Literatures (such as manuals etc.)
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.
Kind Low or Middle carbon steel bolt 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・
Tightening Hexagon bolts Socket bolts Hexagon bolts
torque Tightening Tightening
Hexagon bolts torque Socket bolts Hexagon bolts torque
Bolt diameter Width of across Width of across Width of across
lbf・in.(N・m) lbf・in.(N・m)
in. (mm) flat in. (mm) flat in.(mm) flat in.(mm)
[kgf・cm] [kgf・cm]
0.24 (6) 0.39(10) 44.2( 5)[ 51] 0.20 (5) 0.39(10) 88.5( 10)[ 100]
0.31 (8) 0.51(13) 106.2( 12)[ 124] 0.24 (6) 0.51(13) 221.2( 25)[ 245]
0.39(10) 0.67(17) 221.2( 25)[ 245] 0.31 (8) 0.67(17) 433.6( 49)[ 485]
0.47(12) 0.75(19) 380.5( 43)[ 425] 0.39(10) 0.75(19) 752.2( 85)[ 845]
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 without fail. (See following pages.)
Make sure to remove rust and dust before tightening.
2-2
2. Maintenance
2.2.2 Tightening torque of such important quality parts as bolts and nuts
Strength
Tightening torque lbf・in.(N・m)[kgf・cm]
classification
Application parts & portions Torque Coarse thread / fine thread Remarks
Bolt Nut
section M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
1 Air end
44.2 106.2 380.5
10.9 ― 4.8 (5) (12) - (43) - - - - - - for prevention of deformation of outer ring
① ・End cover [51] [124] [425]
44.2 106.2 380.5
12.9 ― 4.8 (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 12.9 ― 8.8 (10) (25) (49) (85) (135) (210) - - - -
[100] [245] [485] [845] [1350] [2100]
2 Mounting
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4
③ ・Mounting bracket 4.8 ― 4.8 - (12) (25) (43) (68) (105) (150) (210) - - with spring washer
[124] [245] [425] [675] [1050] [1500] [2100]
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4
④ ・Vibration isolator ass'y ― 4.8 4.8 - (12) (25) (43) (68) (105) (150) (210) - - with spring washer and thick washer
[124] [245] [425] [675] [1050] [1500] [2100]
4 Lifting portion
159.3 327.4 601.8 929.2 1327.4 1858.4
・Lifting bail (less than M20) 10.9 4.8 6.8 - (18) (37) (68) (105) (150) (210) - - - with spring washer
⑨ [183] [365] [675] [1050] [1500] [2100]
1858.4 2477.9 3053.1
・Lifting bail (more than M20) 10.9 4.8 4.8 - - - - - - - (210) (280) (345) with spring washer
[2100] [2800] [3450]
6 Undercarriage
※1 For larger than M20, tightening torque becomes so big, and so 4.8 or equivalent shall be used.
※2 When fixing parts of aluminum are used, lockwasher shall be used for avoiding damage.
※3 Nut shall be of S45C ( equivalent to 8.8 of strength classification ).
2-3
2. Maintenance
1 Air end
2 Mounting
⑤
⑥
COMP.SIDE ENG.SIDE
2-4
2. Maintenance
4 Lifting portion
⑨
⑨
⑫
⑬
⑩ ⑪
2-5
2. Maintenance
6 Undercarriage
⑱ ⑲
2-6
2. Maintenance
2.3 How to adjust regulator and how to replace diaphragm
2.3.1 Method of adjustment
D003
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.
Pressure regulator
Pressure adjusting screw
PC10022
① 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.)
② 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.)
2-7
2. Maintenance
2.3.2 Change diaphragm
B
PC11038
⑤ Internal face of body and cap and also both internal face and external face of diaphragm should
be coated with molybdenum sulfide spray.
How to spray molybdenum sulfide paste:The areas in oblique line should be sprayed with this
paste.
Diaphragm should be rolled up
Then it should be Inside of body should
and back face and piston
returned and be sprayed. be sprayed.
should be sprayed.
2-8
2. Maintenance
⑥Install 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.
Shaft
⑧After diaphragm is set in, install the cap and then
assemble speed regulator.
Cap
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
⑨After 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
<Procedure>
ON 1 8
① Turn fuel selector valve“1”to“OFF”position.
② Loosen the drain valve“2”and drain out condensed
water inside.
③ Turn the cup“3”to the left and remove it. OFF
Be careful to remove the cup“3”because it is filled 7
with fuel. Wipe out split fuel completely. 6
④ Remove float“4”inside cup“3”
⑤ Washing element“5”and the cup inside with new
5
fuel.
3
⑥ Replace element“5”and O ring“6”,“7”if they are
found broken or damaged. 4
⑦ After finishing clean, assemble it in reverse
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
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
Separator
casing
Element
Oil separator
Cover
Separator cover
A100463-1 A100371
[Tightening torque of separator cover bolt]
: 0.31 in. (8 mm)
: 433.6lbf・in.(49N・m)[485kgf・cm]
2-10
2. Maintenance
2.6 Change O-Ring of Unloader
<Caution during O-ring replacement>
Supply grease to O-ring“1”・“2”・“3”・“4”after replacement.
When reassembling, apply sufficient grease to O-ring Slot/O-ring 1
and sliding surface.
Use CALTEX MULTIFAK EP1 grease or equivalent. Grease of poor
quality will deteriorate the material.
2
1
A070337
2.7 Check O-ring and Needle valve of Auto-relief valve and Vacuum
relief valve
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”,“2”,“3” Auto-relief valve
4
and rubber on the needle valve“4”, if 3
hardened.
4
2 3
1
2
1
A070339
2-11
2. Maintenance
2.8 Performance check of Pressure control valve
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.
<Procedure>
① 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 1
0.47MPa)[3.4 to 4.7bar].
2
② When the pressure is lower than 49psi(0.34MPa)[3.4bar],
replace spring“3”with a new one. 3
③ When the indicator shows excessively higher pressure, you
will find that the piston does not move smoothly due to
4
foreign material and rust stuck inside valve. In such a case,
disassemble the component for checking and cleaning.
A100372-1
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.
<Procedure>
① First stop the unit and make sure that there is no residual pressure left in the separator receiver
tank.
② 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.
③ After having drained oil completely, remove the pellet assembly of by-pass valve and O-ring.
④ Replace the pellet assembly and O-ring by new ones. Install O-ring coated thinly with compressor
oil.
⑤ Supply compressor oil through the filler port provided on the receiver tank.
(Refer to operation manual.)
⑥ Start operation and check the function of by-pass valve.
(It functions well when delivery air temperature will not rise abnormally.)
To oil cooler
(when the oil temperature is high)
To oil filter
(when the oil temperature is low)
PC11033
To oil filter
To compressor air-end
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.
<Procedure>
① 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.
④ 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
2-14
3. Electric System
3.1 Control
Part number: 46870 51901 (Export model)
Part number: 46870 54000 (US model)
PC10024E
3-1
3. Electric System
1.Exterior connection drawing
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 oil pressure abnormality detecting circuit functions
10 seconds after it detects alternator generation signal.)
3-2
3. Electric System
2. Timing of each output relay
PC11010E-1
Lamp goes on at
Water temp. H A-2 Thermister - Always 1.0 sec
221°F(105℃)
Charge signal disappears After starting
Charge A-5 - - 5.0 sec
and lamp goes on. engine
Discharge temp. Lamp goes on at
E-1 Thermister - Always 1.0 sec
H 248°F(120℃)
Lamp goes on at
Water temp. H E-2 Thermister - Always 1.0 sec
230°F(110℃)
Emergency
3-3
3. Electric System
4. Functions of each output relay
Mark Name Remark
When coolant temp. is lower than 32°F(0℃),
It goes ON when starter it becomes OFF 20 seconds later.
RY0 Relay for heater relay
SW is ON. When coolant temp. is higher than 32°F(0℃),
it becomes OFF 2 seconds later.
It goes ON for 1 second
RY1 Relay for solenoid relay
when starter SW is ON.
When coolant temp. is lower than 32°F(0℃),
Relay for starting It goes ON when starter or when 120 seconds pass, it becomes OFF.
RY2
unloader SW is ON. When coolant temp. is higher than 32°F(0℃),
it becomes OFF 10 seconds later.
It goes ON when starter
RY3 Relay for solenoid
SW is ON.
Abnormality output
RY4
relay
When switching to purge operation
Purge function relay Blinking during purge ・・・Blinks every 0.5 seconds
RY5
(US model only) function During purge operation
・・・Blinks every 1 second
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
Item Resistance(Ω)
(℃) (°F)
F 3.0±2.0
1/2 32.5
E 110.0±7.0
3-4
3. Electric System
6.List of functions
(1)Connector CN1
Line
Pin No. color Connection Remark
1 R/W CN1-12 Common
When starter switch is “ON”, 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 Y/R Heater relay [A] terminal
2 seconds later [when coolant temp. is lower than 32°F
(0℃), 20 seconds later] the interior contact (RYO)
becomes “OFF” to cut power supply to heater relay and
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
3 W/B Stop solenoid [R] terminal 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.
4 - NIL For outputting signal of abnormality
5 - NIL For outputting signal of abnormality
6 - NIL
3-5
3. Electric System
3-6
3. Electric System
(2)Connector CN2
Line
Pin No. color Connection Remark
1 B Earth
When auto idle is switched “ON” to be electrically
AUTO IDLE switch
2 W connected, it will be switched to purge control
(US model only)
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)
G Engine oil pressure switch
3 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]
4 - NIL
5 - NIL
6 B Earth
Service pressure sensor Vout
7 G Detection of service pressure.
terminal (US model only)
Input alternator frequency
8 W/R Alternator P terminal
(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
9 G/W Discharge air temp. sensor
“OFF” to make engine emergency stop.
●Warning・Emergency stop set temperature
Warning temperature : 239°F(115℃)
Emergency stop temperature: 248°F(120℃)
10 - NIL
11 W/B Alternator L terminal For detecting abnormal charge
12 - NIL
13 - NIL
14 - NIL
Intake negative pressure sensor
15 R Power supply for intake negative pressure sensor
Vc terminal (US model only)
Service pressure sensor Vc
16 R Power supply for service pressure sensor
terminal (US model only)
Intake negative pressure sensor
17 Y Detection of intake negative pressure.
Vout terminal (US model only)
18 G/Y Sending unit For detecting residual fuel
Detection of engine coolant temperature.
When the set temperature of emergency stop
becomes higher, the interior contact (RY3) between
CN1-9 and CN1-3 terminals turns “OFF” to cause
19 Y/B Coolant temp. sensor
engine to emergency stop.
●Warning・Emergency stop set temperature
Warning temperature : 221°F(105℃)
Emergency stop temperature: 230°F(110℃)
20 G/B Earth
※:Abnormal oil pressure detection circuit of controller starts to function in 10 seconds after it detects
alternator generating signal with CN2-8 terminal.
3-7
3. Electric System
3.2 Alternator [Dynamo regulator (IC type)]
YANMAR part number: 129423-77200
Cable connection
PC10028E-1
(1)List of functions
Line
Pin No. color Connection Remark
3-8
3. Electric System
(3) Diagnosing when battery charging warning lamp lights
Abnormal
Measure battery voltage : less than 12V
Recharging battery.
when engine stops.
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 Repairing alternator because it is
voltage at 1,500min-1. faulty.
Normal: 13 to 15V
3-9
3. Electric System
3.3 Starter
YANMAR part number: 129242-77010
PC10036E PC10030E
Cable connection
(1)List of functions
Line
Pin No. color Connection Remark
3-10
3. Electric System
3.4 Safety relay
Part number:44346 16400
PC11011
PC10003E
(1) Specification (2) Chart of function
3-11
3. Electric System
3.5 Solenoid relay・Heater relay
Part number:44327 05000
YANMAR part number:119650-77910
Cable connection
PC10005
(1) Specification
Rated voltage DC12V
Continuous rating 1min
Coil resistance (between No.1 and No.2 terminal) 13Ω
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 IN OUT
(Rc1/4) (Rc1/4)
・Opened while electricity
is supplied (NC) PC10037
(1) Specification
Rated voltage DC12V
Function Power is supplied. It is ON (NC)
3-13
3. Electric System
3.7 Stop solenoid
YANMAR part number:119233-77932
PC10012E
(1) Specification
Rated voltage DC12V
Rated current 36.5A
Suction coil
Resistance 0.33Ω±10%
Rated current 0.49A
Holding coil
Resistance 24.5Ω±10%
※For details of functions, see“No.6 List of function (CN1-7 and CN1-8 terminal) of No.3.1
Controller”.
3-14
3. Electric System
3.8 Engine oil pressure switch (For emergency stops)
Part number:44328 21800
PC10013
Specification
Setting pressure 7.3psi(0.05MPa)[0.5bar]
Contact type B contact switch (Contact “OFF” in excess of set pressure)
・10 seconds after engine starts.
Time lag
・2 seconds during operation ※
※When such situation under operation pressure continues longer than 2 sec.
It brings engine to emergency stop.
Specification
Rated voltage 12V
Operating current 1.5A (MAX)
More than 0.11 to 0.29gal/min
Delivery capacity
(0.4 to 1.1 L/min)
PC10014
PC08033
3-15
3. Electric System
3.11 Pressure sensor (for Intake negative pressure and for service pressure)
Part number:44328 20600
PC08035
3.12 Fuel meter (Display)
A100359E
PC10033E
3-16
3. Electric System
3.13 Sending unit
Part number:36159 02202
PC08069E
3-17
4. Troubleshooting
4.1 Repairing Procedures
When performing failure diagnosis, pay special attention to the followings, observing general
cautions.
4-1
4. Troubleshooting
NO
OK 1 2 3
NO
OK
NO OK
OK
② In the troubleshooting column the cause of the said trouble is mentioned in dotted parenthesis.
③ In the troubleshooting column the countermeasures or treatment are mentioned in the double lined
parenthesis.
4-2
4. Troubleshooting
4.2 Failures of compressor and engine
4.2.1 At start-up, starter rotates slowly
※1
Battery specific gravity
Check battery voltage and Faulty Re-charge and supply
too low or electrolyte
specific gravity. water or replace
short
Normal
Volt: more than 12V
Gravity: more than 1.26
Faulty Replace terminal or
Check battery cable. Faulty cable assembly
Normal
Repair or replace
Faulty starter motor assembly
※1:When starter switch is placed at the “START” position, the battery is not normal if B terminal
voltage decreases by 10V.
4-3
4. Troubleshooting
4.2.3 Engine revolutions will drop before pressure rises up to rated one
Check whether valve for Open Close the valve for
starting at low temperature Forgot to close valve starting at low
is open or close. temperature
※ Closed
Exists Trouble of
controller or Repair or replace it
intake negative
pressure sensor
※ Items in dotted square show failure diagnosis items for US model auto idle operation
mode.
4-4
4. Troubleshooting
4.2.4 Engine will not turn to meet rated revolutions
Not at high
Check if engine governor
speed side Faulty adjustment of
lever stays at high speed Re-adjust rod
side. speed regulator rod
At high speed side
Clogging
Check air filter. Faulty air filter Clean or replace it
Normal
Water collected
Check sedimenter. Water mixed in fuel Separate water
Normal
Clogging
Faulty element in
Clean or replace it
sedimenter
Clogging
Check fuel filter. Faulty fuel filter Replace it
Normal
4-5
4. Troubleshooting
4.2.5 Minimum speed not available even upon no-load operation
No air leak
It functions
Not at low in good
Check if engine speed side Check function order. Faulty
governor lever stays of speed adjustment Re-adjust rod
at low speed side. regulator of rod
4-6
4. Troubleshooting
4.2.7 Oil mixed found in delivery air
Too much Arrange oil level to
Check compressor oil level. Oil level too high
specified lever
Proper level Lower than
49psi(0.34MPa)
[3.4bar] Faulty pressure
Check discharge air pressure. Replace spring
control valve
More than
49psi(0.34MPa)[3.4bar]
Check separator collection Clogging
Not collection Clean or replace it
orifice and strainer.
No clogging
Faulty oil separator Replace it
Too long,
narrow and
Check whether pressure
Normal Check air air leaking Pressure drop
Re-selection of airline
rises up to the rated one line up to and defects of
smoothly soon after air tools and repair air leak
air leaking
service valves are closed
quickly from full load Normal
Re-selection of air
operation.
compressor
Late
Clogging
Check fuel filter. Faulty fuel filter Replace it
Normal
Faulty Repair pipes and
Check fuel pipes Faulty fuel pipes
bleed air
Normal
Faulty Repair the trouble and
Check and confirm engine. Faulty engine
get rid of the cause
Normal
Difference is
Check difference in pressure large
Faulty oil separator Replace it
between at front and rear of
oil separator.
Normal
Unloader valve does Replace defective
not open well parts by new ones
4-7
4. Troubleshooting
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 Service air piping
Repair air piping
air leak. leaking
No air leak
Lower than
Check setting of purge 15% Faulty setting of purge
operation load factor (b). Adjust (See 1.6.2)
operation load factor (b)
15%
Set time is too Faulty setting of the
Check setting of the time long time required for
required for switching to switching to purge Adjust (See 1.6.2)
purge operation (T). operation (T)
10sec Disconnection or
Cable
defective contact of
Check AUTO IDLE switch disconnected
cable connection Repair connection
cable connection. between controller-auto
Not cable disconnected idle switch-ground
※1 connection
Check intake negative Abnormal output
pressure sensor output voltage found Trouble of intake
voltage of “Key ON when negative pressure Replace it
stopping” and “At sensor
unload”(See 3.11)
Key ON when stopping:DC0.5V
At unload:less than DC0.5V
Cable Disconnection and
Check cable connection
disconnected faulty contact between
between intake negative
controller and intake Repair connection
pressure sensor and
negative pressure
controller.
sensor
Not cable disconnected
At no load:
Check electrical connection to electrically Trouble of solenoid
solenoid valve for connected
valve for purge/starting Repair or replace it
purge/starting unloader. unloader
At no load:
electrically connected
Cable disconnected or
Check cable between Cable defectively connected
controller and solenoid valve disconnected between controller and
solenoid valve for
Repair connection
for purge/starting unloader,
and fuses. purge/starting unloader,
and fuses
Not cable disconnected
※2
Abnormal
Check function of controller. Trouble of controller Repair or replace it
※1: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.
※2: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
Adjust (See 1.6.2)
releasing pressure (L) releasing pressure (L)
80psi(0.55MPa)[5.5bar]
Service pressure
and output voltage
Check output voltage of will not meet Trouble of service
service pressure sensor pressure sensor Replace it
(See 3.11)
Output voltage normal
Disconnection or
Check cable connection Cable disconnected faulty contact between
controller and service Repair connection
between service pressure
sensor and controller. pressure sensor
Not cable disconnected
4-9
4. Troubleshooting
4.3 Operation of emergency switch
4.3.1 Discharge air temperature indication lamp glows and engine stops.
More than
104°F(40℃) Unsuitable place of
Check ambient temperature. Relocation
installation
Lower than 104°F(40℃)
Shortage
Check compressor oil level. Shortage of oil Replenish or replace
Proper
Lower than 248°F(120℃)
Check Check resistance Abnormal
indication of Faulty sensor Replace it
of discharge air
discharge air temperature
temperature sensor.
gauge.
5
4 Normal
More than No
Check electric conduction
248°F(120℃)
conductance exists Disconnection
Repair wire connection
between controller between
and sensor. controller and
sensor
6
Exists
Faulty controller Repair it.
Soiled
Check oil cooler fin tubes. Fin tubes much soled Wash or clean
Normal
Faulty
Check compressor oil filter. Filter clogging Replace it.
Normal
No difference
Check and confirm the found Abnormality by-pass Check by-pass valve
difference between valve
temperature at the inlet of
by-pass valve and at the
outlet.
Difference found
Abnormality
Disassemble or repair
compressor air end
4-10
4. Troubleshooting
4.3.2 Engine oil pressure emergency indication lamp glows and engine stops
Shortage
Check engine oil level. Shortage of oil Replenish or replace
Proper
Faulty
Check engine oil filter. Filter clogging Replace it
Normal
4-11
4. Troubleshooting
4.3.3 Engine coolant temperature lamp glows and engine stops
More than
104°F(40℃) Unsuitable place of
Check ambient temperature. Relocation
installation
Lower than 104°F(40℃)
Soiled
Check radiator fin tubes. Fin tubes much soiled Wash and clean
Normal
Repair the trouble
Faulty of engine
and get rid of the
cooling system
cause
9
4-12
4. Troubleshooting
4.4 Others
4.4.1 Indicator lamps will not glow, but engine stops.
(Starter switch is not set in contact, and blown fuse trouble is exempted.)
Not exists
Check fuel Shortage of fuel Supply fuel
Exists
Clogging
Check air filter for clogging. Element clogging Clean or replace it
Normal
It will not
Check function engine stop work Faulty engine stop
solenoid. solenoid Repair or replace it
It works
Clogging
Check fuel filter Fuel filter clogging Replace it
Normal
Faulty Repair pipes and
Check fuel pipes Faulty fuel pipes
bleed air
Normal
4-13
4. Troubleshooting
4.5 Explanation of trouble diagnosis
No. Item Cause Remedy
1 Faulty unloader. Unloader valve cannot be Disassemble unloader valve to check
open. function of valve and piston. Further
check recovery pipe for any clogging.
2 Check and confirm Check and locate pressure In case of malfunction of safety valve,
that safety valve maladjustment or defective safety valve assembly should be
functions at lower safety valve. replaced.
pressure than set
pressure for safety
valve.
3 Faulty seat of Faulty seat of unloader Disassemble unloader valve, and clean
unloader valve valve or faulty sliding seat surface and check function of valve
function of valve and piston. and piston.
4 Check discharge air Check whether actual rise of
temperature, using discharge air temperature
digital monitor. stops engine or any failure
of electrical circuit stops
engine.
5 Check the resistance For resistance Even disconnection of thermo sensor or
of discharge air characteristics of discharge its short-circuit causes engine to stop.
temperature/coolant air temperature and coolant
temperature sensor. temperature sensor, See
3.10.
6 Check conductance Check whether there is any Connect variable resister (1kΩ) as
between controller and disconnection or shown in the following figure and
discharge air short-circuit in cable gradually lower resistance value of
temperature connection between variable resister. And when it displays
sensor/coolant controller, discharge air abnormality, measure the value and
temperature sensor. temperature sensor and check whether it is within the range of
coolant temperature sensor. resistance of set temperature.
Clarify whether the trouble (See No.5.Adjustment and inspection of
is caused by faulty cable No.3.1)
connection or defective
controller. When discharge
air temperature/coolant
temperature exceeds the set
temperature
[248°F(120℃)/230°F(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
4. Troubleshooting
4-15
5. References
5.1 Comparison between consumable parts and electrical appliances
Part Number
Item
Export model US model
●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) 32100 40700 ←
Air filter element (outer) 32143 11700 ←
Air filter element (inner) 32143 12900 -
Oil separator 34220 16101 ←
O-ring for oil separator 03402 15140 ←
Compressor oil filter ASS'Y 37400 16100 ←
Oil filter cartridge 37438 08900 ←
41290 01100
Engine oil filter cartridge (YANMAR:119005-35151)
←
43543 01400
Fuel filter cartridge (YANMAR:129907-55801)
←
Fuel pre-filter ASS'Y 43540 08100 -
43541 02400
Element -
(YANMAR:41650-550800)
O-ring (YANMAR:123325-36140) -
O-ring (YANMAR:24311-000120) -
43550 02900 ←
Sedimenter ASS'Y (YANMAR:129242-55700)
Element (YANMAR:129242-55730) ←
O-ring (YANMAR:24311-000160) ←
O-ring (YANMAR:24321-000750) ←
●Air control
Speed regulator 36400 21901 ←
Diaphragm 36437 01500 ←
Pressure regulator 36400 19000 ←
Auto relief valve / Vacuum relief valve (built-in unloader) (built-in unloader)
Needle valve 36429 00801 ←
O-ring 03402 25008 ←
O-ring 03402 25021 ←
O-ring 21221 02100 ←
Unloader valve 22100 41201 ←
O-ring (2 pieces) 03402 10125 ←
O-ring 03402 10070 ←
O-ring 21441 04800 ←
O-ring 21441 04900 ←
Pressure control valve 35300 17000 ←
O-ring 03402 15075 ←
O-ring 03402 25032 ←
Spring 22144 07700 ←
Piston 35303 03300 ←
5-1
5. References
Part Number
Item
Export model US model
●Oil line
By-pass valve ASS'Y
- -
(Built-in compressor oil filter)
Pellet 37231 02100 ←
O-ring 03402 25045 ←
●Electrical appliances
Controller 46870 51901 46870 54000
44346 16400
Safety relay (YANMAR:119802-77200)
←
44327 05000
Solenoid relay (YANMAR:119650-77910)
←
44327 05000
Heater relay (YANMAR:119650-77910)
←
Purge/starting unloader solenoid valve - 46811 24100
Fuse 30A(FUSE1) 44470 02600 ←
Fuse 5A(FUSE2) 44470 02100 ←
Intake negative pressure sensor - 44328 20600
Service pressure sensor - 44328 20600
Discharge air temp. sensor 44364 06500 ←
Coolant temp. sensor 44364 06500 ←
44328 21800
Engine oil pressure switch (YANMAR:114250-39450)
←
Purge control switch - 46242 21500
Sending unit 36159 02202 ←
Fuel air-bleeding electromagnetic pump 43650 02700 ←
●Instruments on panel
Starter switch 44322 07300 ←
Pressure gauge 36141 15503 36141 18600
5-2
5. References
5.2 Engine Wiring Diagram
(1) Export model
A100392E
5-3
5. References
(2) US model
A100445E
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.
2006年 2月 27日 初版
2003年 4月 20日 改訂
発行 北 越工業株式会社
本社工場
新潟県燕市下粟生津3074
TEL 0256-93-5571
FAX 0256-94-7567
(無断複写・転載を禁ず)
NPC-0086
PRINTED IN JAPAN 2011. 9