Ema. Alin Comp MG78A AIR COMPRESSO INSTRUCT MATSUBARA IRON WORKS LTD. Head Office: 10th FL, Shin-Osaka Sun Earl Bldg., Kitakan, 8-3, Nishinakajima S-chome, Yodogawa-ku, Osaka, Japan, TEL 06 - 6304-7780 FAX 06 - 6304 - 7854 ‘Tokyo Office : 4th FL, No.2 Arakawa Bldg., 1-3, Kyobashi 2-chome, Chuo-ku, Tokyo, Japan, |. 03 - 3243-0413 FAX 03 - 3243 - 0415 Shiga Factory > 1500- 46, Shibaharaminami-cho, Higashiomi City, Shiga Pref, Japan. TEL 0748 - 22-1313 FAX. 0748 - 22 - 1316Safety Precautions qo ensure proper use of the compressor unit, be sure to read this manual and the other attached documents carefully before starting installation, operation, inspection. Within this manual as either “Danger” or “Caution”, (Downers | : An operator may be killed or seriously injured by a hazardous condition resulting from improper operation. intenance, and safety precautions are ranked, in order of importance, Caut : An operator may be suffer minor injuries and/or objects may be damaged by a hazardous condition resulting from improper. under certain conditions, improper operation may result in serious injury and/or damage even if it is labeled only as “caution”. Even item indicated by either “Danger” or “caution” should be considered significant. Be sure to give particular care to those itens. 1. General “Be sure to read a manual and a safety precaution of the compressor accessories (piping, fitting, receiver, etc.) and the prime mover (motor, engine, etc.). - Transportation, installation, piping, operation, maintenance, and inspection of a compressor should be done by a specialist. Failure to do so may result in injury. - The strength of piping, fitting, etc. should be needed an endurance pressure of 4,5MPa or greater. Failure to do so may result in injury and/or these equipments may be burst. 2.Precaution of High pressure The air is compressed to 3.0MPa by the compressor. This compressed air has a strong destructive power. Be sure to give care to following items. + Do not disassembly in the pressurised condition. Failure to do so may result in injury. + Do not rise more than 3.0MPa. If the compressor is running continue in this condition, the compressor unit may be burst and an operator may be injury. = Do not change set pressure of a safety valve to more than the initial set value. Otherwise, the pressure of the compressor unit should be risen abnormally and this unit may be burst and an operator may be injury. + When a pressure of the compressor unit is risen abnormally, immediately stop the operation of the unit and check its cause. The unit may be burst and an operator may be injury. 3.Precaution of Rotary body This compressor has a rotary body such as flexible coupling, pulley, cooling fan, belt, ete. + Do not touch # rotating body and moving body while compressor is running Failure to do so may result in injury ‘Before disassembly, wake sure the following items The compressor has stopped. The compressor can not run during disassembly. Failure to do so may result in injury. + Do not start the compressor without a cover of rotary body, belt, or cooling fan. Failure to do so may result in injury.4, Precaution of Motor and Starter “Turn off the electric poner before starting maintenance or inspection Electrical shock may result ‘ * Connect cable according to a manual and wiring diagram. Electrical shock or fire may result. “If there is an abnormality, immediately st 1 nite iieisistoere y stop the operation of the Unit and tury of Electrical shock or fire may result. + Do not neglect grounding. Electrical shock may result. *Do not start the unit without a terminal cover. Electrical shock may result. Axcaution + This is a air cooling type compressor unit, Folloyi i . Follovin 7 the unit is running or just after it has stopped. evOMe YerY hot while Do not touch these parts. Failure to do so may result in scorching Mode! MG64A NG78A MG90A NG95A Cylinder Cylinder cover LP air piping LP cooling piping HP valve cover HP cooling piping | Non-return valve LP valve cover cooling fin HP valve holder cooling fin iO} JO] jojo} IO} jO} jOJO/O OJOJOJO}. jOJo} O|OJo}o}ojo} lolo + Keep the exhaust pipe of a safety valve and drainage free of operator. An operator may be injury and his clothes may be soiled. +The revolution of compressor should be kept the specified direction. The unit may be damaged and an operator may be injury. + For wiring to motor and starter, select cable sizes suitable. Pailure to do so may result in fire + Do not touch the edge of screw. Failure to do so may result in injury. on Do not reconstruct this compressor unit by your han This reconstruction is out of our guarantee . «Maintenance and inspection of @ compressor sl + Replacement parts should be used our products. ould be done by a specialist.List of Clamping Nut & Tighten Torque + L.P. Valve HP. Valve Model Clamping |__Tighten Torque | Reference | Clasping| Tighten Torque _| Reference Nut | Ket-ca| oN Nut Kef sca] Wem MG64A MB 11s] 11.3 M6 60 5.9 | Hexagonnut MG78A M12 | 365| 35.8 Ms iis | 11.3 MGS0A M12 | 365| 35.8 MB 11s | 11.3 MGO5A M12 | 365) 35.8 Ms 115 | 11.3 “Model of blank reference, make use of Hard lock nut. -Tighten torque apply under nut and tighten torque of above nut apply from 60% to 100%,_— §1 §2 §3 84 $5. § 6. $7. §8 $9. § 10. gu $12. Contents General 1.Main specification 2.Structure and function of parts Precautions on installation 1. Installation place 2. Ahir receiver and piping 3. Lubricants Caution before and after starting 1. Pre-checking 2. Manual rotation 3. Just after starting Caution during operation I.Air tightness 2. Lubricants 3. Noise 4. Safety valve 5. Heat 6.Drain Caution at stopping 1. Just before stopping 2. Lubricants 3. Drainage 4. External inspection Disassembly 1. Body 2. Valves 3. Piston Reassembly 1. Piston 2. Valves 3. Body Lubricants 1.Kind of lubricants 2.Agount of lubricants Troubleshooting 1.Failure to increase pressure 2. Abnormal sound 3. Overheat Automatic operation by motor driven Periodic inspection Structural drawing of air compressor 3 peas aaa meee 15 een aareeno) sores 10$1. 1 General Main specification The main specification of this machine is as follows Design No. MG7BAPS MG78ADT Driven method V-belt driven Direct driven by Motor by Motor Type Vertical, two stages, air cooled Wodel No. MG7BA Low pressure cylinder _ 88 on inner diameter High pressure cylinder - : 80 om inner diameter Stroke 60 on Revolution 1000 min™* | Piston displacement 21.9 w/b 26.2 a/b Pressure 3.0 MPa Power required Approx. 3.3 kW Approx. 3.7 kW The suffix of Design No. MG78A** shows as follows: MG7BA * ee pevalution Driven method Model No.2. Structure and function of parts (Refer to §12 Structural drawing of air compressor) Main body This is a vertical, 2 stages compressed, air cooling typo cospre, It is designed to match a normal pressure of 3.0 MPa. The features of this compressor are simple structure, rigidity ang good performances. For its structures, the upper part of cylinder is a low pressure are, and its lower part is a high pressure area. The stepped piston perforsy “suction” and “delivery” and compressed air by boing moved vertically yy means of a connecting rod. The air is compressed in the low pressure area for first stage after having passed the air strainer and inlet valve at the inlet of the compressor. The compressed air is cooled while passing in the air cooling pipe and enters in the high pressure area. The air recompressed in the high pressure area is set to a required pressure. However, it fed again through the cooling pipe due to a high tenperature and is sent to an air receiver. LP valve and HP valve For its structure, a suction valve seat is located at its lower part and a delivery valve seat at its upper part to unify suction and delivery. This is a feature of the Matsubara Compressor. Since a valve area is widely allowed, it requires a less lift of the valve. Consequently it endures high-speed rotations and does not lower its it can be easily efficiency. Since the valve consists of an unified body, removed for diassembly and repair. c. High pressure safety valve This valve is attached to prevent a danger when a pressure becomes abnormally high. When the pressure increase within 10% of the normal pressure, it is actuated and discharge the compressed air into the e easily atmosphere to prevent a pressure rise. Its working pressure can be © controlled by mean an adjusting bolt. d. Oil gauge Lubricants fed into the crank case is spattered by ‘the oil scraper located beneath the connecting rod to lubricate the cylinder, piston a pin, metal, crank pin, main bearing, etc. Oil consumption can be chee from outside with the oil gauge. The upper reference line indicates standard oil level For details, refer to §8 Lubricants.§ 2. Precaution on installation 1. Installation place Install the unit in the following place: Free from dust and dirt Not affected by high humidity Woll-lift Easy to inspect, dis~ and reassemble, and repair. Keep 30cm and more distance at the fan side from a wall. It is also desirable to select a stable and vibration free place. Before tighten all the foundation bolts, lay liners under the foundation as the foundation is horizontally. 2. Air receiver and piping The air receiver should be installed as near the compressor as possible. Steel pipes (STPG), of schedule 40, having an aperture of 8A should be r leakage. used. Connect pipes securely with due care not to allow Avoid to arrange pipes at an acute ang: The strength of piping, fitting, etc. should be needed an endurance pressure of 4.5 MPa or greater. 3. Lubricants The unit has been delivered without lubricants. Never fail to supply lubricants prior to running-in. Detach the crank case cover and pour lubricants up to the upper reference line of oil gaug For kinds of applicable oil, refer to §8 Lubricants. § 3. Caution before and after starting 1, Pre-checking Check up the entire machine to seo if: Parts are secured. Proper amount of oil is supplied. There is no abnormalities in piping, etc. 2. Manual rotation Vhile gently turning the pulley, check the interior for abnormalities. Considerable force required at compression, or hooting or bursting sounds dition, while signs such as something bumped at suction indicates good c indicates improper condition, thus requiring an overhaul.3. S4. 1 Just after starting Let a few drops of the oil in the oil cup atop the air inlet ca (This step must be taken at running-in after installation. It may be omitted in the state of regular service.) Inmediately after pouring oil, the valve makes an clattering sounds may be heard. This g, irrogular motion, which will ns, cease soon. Open the cock of low pressure gauge to see if pressure has been properly increased and if there is no air leakage. When driven by motor or engine without magnetic valve for drainage, after starting the compressor,close the drain valve. Cautions during operation (yy; py Air tightness Check to see if there is neither air leakage nor oil leakage in the air passages (pipes, couplings, valve seals, etc.) Lubricants Be careful of oil consumption. Check oil consumption 4 to 5 running hours after running-in as well as each starting. For oil amount, refer to §8 Lubricants. Noise If abnormal sounds are heard, troubleshoot. This immediately stop the machine and is signal warning a serious accident. Safety valve Check the valve at least once to see if it functions at required pressure. Heat 20 minutes or so after starting, temperature of each part rises. If it continues to rise, it indicates a trouble in the machine. At the beginning. check usually tomporature of overy part and the theraal condition of the air compressor should be understood. Drain In the case of a long period of run, open the drain valve to discharge drain. Caution at stopping Just before stopping Let « few drops of tho oil in the oil cup atop the air inlet case. THF is to prevent rust which may occur during # standstill, In regular operation, therefore, it can bo omitted2 S6. Lubricants When oil level comes down near the lower reference line of oil gauge, add oil. Oil is contaminated with drain or impurities after a long period of run, so check for oil condition. Replace oil, if necessary. For detail, refer to §8 Lubricants. Drainage When driven by motor or engine without magnetic valve for drainage, open the drain valve to discharge drain. External inspection Wipe off water, oil, dirt, etc. on the machine. It serves to prevent coming-in of foreign matters, corrosion, ete. Disassembly (Refer to §12 Structural drawing air compressor) Before disassembly, make sure the following items: The compressor has stopped. The pressure in the compressor and piping has decreased to atmosphere. The compressor can not run during disassembly. Body a. Remove the fan cover. b. Remove the pipes. c. Detach cylinder cover and take out LP valve. Do not forget to remove the packing also. d. Remove the crank case cover off the crank case. e. Unscrew the crank pin metal bolts and take out the lower housing of the connecting rod. Be sure to count the number of adjusting liners. f. Screw the eye bolt on the piston and take out the piston. Be careful not to damage the piston and tho piston rings. g. Remove HP valve cover and take out HP valve. Do not forget to remove the packing #lso h. Remove the fan belt and the cooling fani. Take out the cylinder. j. Remove the fan pulley. k. Unscrew the nuts of main bearing case (at the side where the crank shaty is to be removed), and draw out the crank shaft by tapping the shaft end th a wooden hammer. Valves Draw out the split pin of fitting bolt, apply soft object such as rag around the valve seat, and hold the in a valve. Loosen the nut to disassemble the valve. Put air-tight and adjusting liners, lest they should be lost. Take care not to damage the valve and valve seat. springs to; 3. Piston a. Remove the piston ring. Be careful not to open the ring too much when taking out, otherwise it may be damaged. b. Remove the set bolt and draw out the piston pin using the piston pin drawer. § 7. Reassembly (Refer to §12 Structure view of air compressor) Reassembly should be done in the opposite order of its disassembly. Do not start up the compressor until reassembly works have finished. 1. Piston a. Mount the connecting rod. Apply oil to the piston pin metal area of the At this time, the blind side of de with the timing mark of the connecting rod and insert in the piston. the piston pin should be on the left connecting rod on this side, when this is done. Insert the piston pin in the piston, paying attention to the notch of the set bolt. After having inserted it, hit it hard and fix with the set bolt b. Place the piston ring at the right position.2. Valves Reassemble in the opposite order to disassembly Take care not to allow dust in. Adjust valve lift referring the table below. For an ideal valve contact, it should not be separated when the valve is calmly and vertically set in a dry condi ion. Low pressure |Low pressure | High pressure suction valve | delivery valve | suction valve High pressure delivery valve 0.6 om 0.8 om 1.2 om 1.0 om Body a, Set one main bearing case to the crank shaft and put this crank shaft in the crank case. Then set the crank shaft in another main bearing case. Be careful not to catch the oil seal in this main bearing case. If the oil seal is caught in, it feels heavy when the unit is idled. b. Attach the cooling fan pulley c. Install the cylinder. 4. Attach the the cooling fan and the fan belt. e. Place HP valve and mount HP valve cover. Do not forget to put the packing. f. Put the piston attached with the connecting rod. At this time, epply enough oil to the cylinder, the crank pin and the surface of the piston. Set the piston ring at the right position, and put the piston in the cylinder, hitting it lightly. If it is necessary to hit the piston hard to put it in the cylinder, it indicates that the piston ring is caught somewhere. Pull the piston out and check it. Forcing the piston in may break a piston ring.&. Apply enough oil to the upper and lower housing of the connecting ray Ower . housing fitting position of the connecting rod, and tighten thes Place the adjusting liners and crank pin metal bolts to the } securely. Mfter tightening the nuts, rotate the crank shaft to see if smoothly and also if the lower part of the connecting rod mov. and left. it turns 9 right If adjusting Liners are not enough, add liners. Never tighten up the crank pin to offset the liners. Otherwise the metal may be burnt out, A clamping torque of crank pin metal bolts and a clearance b etveen the crank pin metals and the crank pin are as follows. } Clearance between vhe crank pin metals and the crank pin 0.04~0.10 am Clamping torque of crank pin metal bolts | approx. 29.5 Nea After above adjusting, insert split pins. h. Attach the crank case cover. i. Fit LP valve in. Do not forget to put the packing. Apply oil to the velve and attach the cylinder cover. Move the piston to see if the piston top and LP valve lower part come into contact with each other. Tf @ touch occurs, add packing at LP valve lower part. The clearance between the top of the piston and the bottom of LP valve (top clearance) should be 0.4~0.6 mm. Be sure to keep this clearance J. Mount the pipes and connect the pipes. k. Attach the fan cover,