Compressors Tanabe Marine Compressors Service Documents: For H-Series Compressor

TANABE MARINE
COMPRESSORS
SERVICE DOCUMENTS

For H-series Compressor

TANABE PNEUMATIC MACHINERY Co., Ltd.

Contents
1. FTA
1-1. FTA for damage of 1st. stage valve ················································ 1
1-2. FTA Analysis Table for 2nd Stage Suction & Delivery Valve Breakage················· 2
1-3. Fault tree analysis about Scuffing of Piston and Cylinder ························· 3
1-4. Fault Tree Diagram : Deposition of carbon ········································· 4
2. SERVICE NEWS
2-1. Precautions for H-70 Series 2nd Stage Valve Assembly ······························· 5
2-2. Installation Procedure H-70type cylinder head gasket valve seat gasket············· 7
2-3. Technical Bulletin on Pressure Switch(K. K. Saginomiya Mfg. / SNS-C130PGQ) ········ 9

3. MAINTENANCE NEWS
3-1. Position of valve plate and spring on LP valve ··································· 12
3-2. Caution for assembling valves ···················································· 13
3-3. “H” Series Compressors Procedure for Replacement of “Lubricator”············· 14
3-4. Procedure for measuring flow rate lubricating oil from lubricator················· 16
3-5. How to assemble anti-emulsification kit ·········································· 17
3-6. Procedure for checking crank shaft for “bending” condition ····················· 28
Document　№13･2･13002
FTA for damage of 1st. stage valve 19-Apr-13 ：R.OTSUKA
Fenomenon Factor analysis Explain Method of confirmation Result Eval
Ingress of foreign 1 Suction filter is broken by moisture, salt and

Damage of 1st. stage valve Suction filter is broken. Check weather filter broken trace (filter paper,plastic etc.)
matter rubbish.
2
Ingress of foreign matter at assembling. Ingress of foreign matter is occured and left. Check wheter any hazardous damages or dents on 1st. stage valve.
Ingress of foreign matter by 3

The useof oil other than our reccomendedoil shall Check the package of lubricating oil. Also check whetherother bland of
1st stage cylinder,piston Mismatched lub. oil Property and viscosity is inaaplicable.
be forbidden. lubricating oil is around the compressor or not.
damaged.
Adapt operation using mineral oil 4 Using synthetic oil before fulfill 300 hrs of Recommend experience running with mineral oil in
Check the record of replacement and confirm it though the engineer.
has not carried out. operation. less than 300 hrs compressor.
5 Lubricating oil has not replacement Abnormal wear is caused on each parts by
Deterioration lublicating oil. Check the condition on replacement through the engineer.
periodically. lubricating fault.
Short of lubricant by long term 6 After long term stop of compressor (more than Long term stop of compressor makes no oil film on
Confirm with engineer about the condition.
stop. 3 weeks), initial oiling was not neglected. sliding parts.
7
Lubricator is broken. Omission of replacement at every 8000 hrs. Replacement is required at every 8000 hrs. Confirm with engineer the maintenance records.
8 Performed any adjustment ath the inside of Oil level is adjusted in proper oil level at the Remove the cover to check the condition of adjust screw. After the part
lubricator. delivery. Therefore dealt as a black box. replacement, recall the dimounted lubricator and carry out overhaul in TANABE.
9 30 minutes operation shall be needed to fill the

Short of lubricant in lubricator Lubricating oil at line is not fulfilled at
line. During that time, inside of cylinder is under Confirm with engineer the procedure of lubricator replacement.
oil line. lubricator replacement work.
condition oilless.
10 Insufficient of tightening torque for If tigheten the head without using specified Check tightening condition using torque wrench.
Assembling Ingress of cooling water. Poor surface pressure of gasket.
cylinder head. torque. ※M10=70N・m /M12=120N・m
11 If keep using the gasket continuously, it may lead

Cylinder head gasket and valve seat gasket
surface pressure drop, and cause of ingress of Check maintenance record and confirm it with engineer.
were not replaced at overhauling work.
cooling water and impaired of air tightens.
12 Insufficient of overlap width projection for Sureface pressure in side of air and cooling water Measure thickness of 1st stage valve and depth of cylinder head fitting
1st. stage valve. may lead impaired of proper values. portion.
13 Excessive of overlap width projection for 1st Sureface pressure in side of air and cooling water Measure thickness of 1st stage valve and depth of cylinder head fitting
stage valve. may lead impaired of proper values. portion.
14 Request engineer to check whether oil level increase or not when compressor is
Leak from pinhole made by cast. Penetration leakage occured. Imperceptible leakage is caused.
in stop.
15 Request engineer to check whether oil level increase or not when compressor is
Penetration leakage occured. Imperceptible leakage is caused.
in stop.
16 Clearance leakage occured from cylinder head

Joint surface of gasket is rough. If the surface is rough, air tightness is impaired. Check the surface roughness where will be seat.
joint.
17 Clearance leakage occured from cylinder

If the surface is rough, air tightness is impaired. Check the surface roughness where will be seat.
joint.
Seize of valve plate by 18 If the assembling is upside down, lubricating oil

Piston ring assembly direction is wrong. Check the direction of piston ring identifying mark.
lubricating oil. comsumption is increase by pumping action.
19 In case of using 7 inches of old type with grommet

Others Omission of aaplication on material seat. worked sealing material shall be applied.Apply Check application condition of sealing material.
grease for 6 inches on gasket.
20
Penetration leakage occurred from gasket. leak from inside of gasket. Check lines and creases on the surface of gasket.
21 Leak can be caused when water pressure exceeds 0.06MPa for compressor is in stop.
Water pressure is high.
designed value. 0.1MPa for compressor is in operation.
22 Recompression may cause temperature rise inside of

Maintenace Back flow of 1st stage valve. Valve seat is inapplicable. Check whether any wear or damage on the seat.
cylinder.

Valve plate is inapplicable. Check whether any wear or damage on the seat.
cylinder.

Valve spring is inapplicable. Check whether any wear or damage on the seat.
cylinder.

Valve seat gasket is inapplicable. Whether the contact is even or not.
cylinder.
No maintenance or maintenance 26 Maintenance and Inspection are needed by

Cause defective operation. Check maintenance record and confirm it with engineer.
interval is improper. maintenance table.
27
Break of piston ring. Desorption of piston was performed wrong. Piston ring is broken when insert piston. Check piston and piston ring by visual confirmation.
28 Narrow side assembling for 1st stage valve's

Gasket direction is wrong. H-70 of grammet gasket has direction. Check gasket direction for assembling.
sealing part.
Component(plate,spring etc.) 29 Component assembling is wrong or not correct

Cause defective operation. Check quantitiy,assembling position and way of assembling.
assembling is wrong. quantity of parts.
30 Insufficient of tightning torque is caused slack

Valve's tightening torque is not manage. Check the tightning torque by torque wrench.
valve seat and valve guard.
31 Valve plate is not assembling correct

Valve plate is moved and damaged. Check the valve plate assembling position.
position.
32
Corrosion of keeping. Valve is rusted under the bad condition keeping. Check the appearance of keeping valve.
Short of cooling 33 Measure the inlet temperature of cooling water to see the temperature
Temperature at cooling water inlet Temperature at cooling water inlet exceeded
water Short of cooling water. difference.
is high. 45℃.
※shall be in the range of 36℃～45℃.
34 Measure the inlet & outlet temperature of cooling water and see the difference.
Temperature difference between cooling water
Short of cooling water Short of cooling water. ※ Maximum delivery temperature is under 50℃ and temperature difference in
inlet and outlet is 10℃ and over.
inlet & outlet shall be in 10℃.
Tempreature at suction air is 35 Valve is high temperature by short of cooling

Temperature at suction air exceeded 50℃. Measure the temperature of suction air is under 45℃.
high. water.
36 Use of low qualified product instead of a Imitation of main parts in large amounts is
Use of imitation Check the appearance, process, logo, embossed character, and etc.
genuine. distributed.
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Document　№13･2･13004　　
FTA Analysis Table for 2nd Stage Suction & Delivery Valve Breakage 24th May, 2013 : Takano
Case Factor Analysis Explaination Method of Confirmation Result Evaluation
Breakage of 2nd stage Suc. & Del. Ingress of 1 The carbon and rust generated in the inside of compressor, get Check the condition of carbon & rust generation in the inside of com pressed
Carbon & rust have generated.
valve foreign matter peeled off and bit into the valve. air flow passage.
2 Fragments generated at when piston & cylinder getting burn-out

Ingress of foreign matter caused by Disassmble the valve to check whether any dents on the seat, plate, and the
and piston & piston ring getting break being bit into the
burning out of piston & cylinder relatives.
valve.
3 Ingress of foreign matter at assembly Check whether any foreign matter has got stuck in the valve when at assembly
Ingress & remaining of foreign matter at maintenance work.
work. and installation of parts.
Non-conformance Valve is used in high 4 Check whether the cooling water temperature is under 50 degC.
of usage state temperature. Valve gets exposed in high temprature due to insufficient of
Cooling water temperature is high. (Cooling water inlet temperature should be 36 - 45 degC, and the temperature
cooling.
difference between outlet & inlet should be in 10 degC or less for target.)
Insufficient in quantity of 5 Insufficient in quantity of water Valve gets exposed in high temperature due to insufficient of Check whether the cooling water tempemperature difference betweeen outlet &
cooling water supply. cooling. inlet is in 10 degC or less.
6 Water stain has dipositted on the cylinder jacket & the Check whether the temperature difference between outlet & inlet of cooling
Flow passage area has become narrow. relatives, and it causes the cooling water flow passage water is in 10 degC or less.
narrowed. Check the condition of cooling water passage such as a cylinder jacket.
7 If oil scraper ring & piston ring had installed in wrong

Valve plate has been adhered by lube
direction, it will cause lube oil to splash up the inside of Check the installation direction of oil separator ring & piston ring.
oil.
cylinder.
Non-conformance 8 If the nut gets loosened, and the valve will vibrate and break Check whether the tightening torque is proper.
At valve assembly Valve clamp nut Improper tightening torque.
at valve in the valve port. (Specified torqe= H-70: 25 N・m　H-60: 12 N・m )
maintenance
9 The number of valve springs; H-70 Suction valve: 1, H-70
Wrong number of valve springs had been
Valve spring Delivery valve: 3, H-60 Suction valve: 3, H-60 Delivery Check the instruction manual for air compressor
installed at suction & delivery valve.
valve:4
10 If work with taking a hold by vice bench or work without

Special tools are not been used at Use special tools for works assembling & reassembling 2nd stage suc. & del.
Deformation & break of valve holding with tools, the valve will become a deformed or cause
disassembling & assembling. valve.
a break of knock pin.
If any additional modification such like a grinding work had

11 performed, it will be excluded from our warranty. In this
Valve plate Performed lapping work (grinding work Check the thickness of valve plate.
regard, any cases grind work has performed on it, the
on the surface). The thickness of valve plate; H-70: 1.25mm, H-60: 1.5mm
permissive use limit for thickness of new part shall be 90%.
If it will below 90%, we propose its replacement with new one.
Non-conformance At installation into valve 12 Bolt gets loosened, and the valve will vibrate and break in Check whether the tightening torque is proper.
Valve set bolt Improper tighghtening torque.
at valve holder the valve port. (Specified torque: 25 N・m)
installation
13 Since margin for screw thread catch of valve set bolt gets
No clearances between valve set bolt & Check whether there is a clearance between valve set bolt and valve clamp nut
smaller, the frictional force will not be secured, and it will
valve clamp nut (H-70 only). (Check whether genuine thin nut, valve clamp nut x2 has been used).
effect the valve set bolt to get loosened.
Since reaction force of valve set spring does not have

Check whether the edge face of valve set spring coincides with cooler cover
14 All valve set springs has been effectiveness, a clearance will be produced by alternate load
Valve set spring groove-worked part (In case of H-60 series, cooler tube plate step-worked
installed in the same direction. comes from compression, then the clearance will gradually
part).
become wider.
15 U nut has not been used for fixing ・Check whether U nut is used.
U nut U nut is used for preventing nut gets loosened.
valve holder & valve set bolt. ・Check whether the tightening torque is proper.(Specified torque= 25 N・m )
16 Since valve gets rickety by a clearance produced between valve Check whether the edge face of valve set spring coincides with cooler cover
At installation into cylinder Completed assembly without installing
& cylinder, leads a fatigue breakdown due to the repeated groove-worked part (In case of H-60 series, cooler tube plate step-worked
valve seat gasket.
loading. part).
17 Mixed up the parts such as valve Check whether the edge face of valve set spring coincides with cooler cover
Different size of valve holders has been used on the sides
holders, spring holders, valve flanges groove-worked part (In case of H-60 series, cooler tube plate step-worked
suction & delivery.
of sides delivery and suction. part).

18 Bolts had been tightened uneaven which effectiveness, a clearance will be produced by alternate load
Valve flange bolt Check whether the valve frange bolt has been tightened evenly.
installed at 4 potisions. comes from compression, then the clearance will gradually
become wider.

19 effectiveness, a clearance will be produced by alternate load Check the tightening torque is proper.
Improper tightening torque.
comes from compression, then the clearance will gradually (Specified torque: 70 N・m)
become wider.
Corroded by 20 Since drain is carried from drain trap to HP valve, the valve
Drain is not discharged. Check whether there shall be no drain retention in the drain separator and
drain Non-conformance of device Drain trap malfunction. plate & spring get corroded by the moisture contained in the
the drain is discharged out of the machine promptly.
drain.
21 Since the auto drain valve is taking a long time for opening, Check whether quantity of drain at the inside of suction valve port has
Non-conformance of installation The period of auto drain discharging is
the drain discharging does not catch up the quantity of drain abnormal increase.(The standard for intermittent timer to discharge for 5 to
condition long.
generated. 10 seconds in interval of 10 to 15 minutes)
22 Cooling water temperature is low (super When air temperature gets down (decrease in the amount of Check whether our recommended cooling water inlet temperature is met (Inlet:
cooled). saturated vapor), the quantity of drain generation increase. 36 - 45 degC, The temperature difference between outlet and inlet: 10 degC).
23 Drain flows back from drain pipe and another equipments, and
Drain flowbacks from the piping. Check whether the construction does not make a flow back of drain.
flows in by extending to the valve port and cylinder.
Non-conformance 24 The packing condition has not been kept

Rust generated on sliding parts prevent the operation of the Check the packing condition (packed with oiled paper, and put it into plastic
of storage the condition of it delivered from
valve. bag with pressure bonding) has not been changed.
condition Tanabe.
25 Using products which are not a genuine Imitation of the main parts have been distributed in large
Use of imitation Check the appearance, dimension, processing method, and the relatives.
of Tanabe. quantities in the market.
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Fault tree analysis about Scuffing of Piston and Cylinder 2013/6/10 ：Inagaki
Situation Factor Analysis Explanation Method of Confirmation Result Evaluation
Scuffing of piston Ingress of 1 Whether any damages on 1st stage suction and delivery valve.
From 1st stage valve Broken component parts of suction and delivery valve drops in the cylinder
- cylinder foreign matter Whether any harmful damages and dents on the zenith of piston.
into cylinder 2 Whether any damages on 2nd stage suction valve.
From 2nd stage suction valve Broken component parts of suction valve dropped in the cylinder
Whether any harmful damages and dents on the step of piston 2nd stage side.
3 Whether any breakages on 2nd stage delivery valve.
From 2nd stage delivery valve Broken component parts of delivery valve dropped in the cylinder
Whether any harmful damages and dents on the step of piston 2nd stage side.
4 Whether any harmful damages such as a hit, crack, dent, and bulge on the inside of cylinder and the outer periphery
At assembly work Ingress and remaining of foreign matter can be occurred at the inside of cylinder
of piston.
5 Whether any traces caused by suction filter breakage (filter paper, plastic, and etc.) are left.
By suction filter is broken Suction filter can be saturated and can get broken
Exchange suction filter every 2000 hours.
6 Check whether any traces of filter breakage, and confirm replacement records.
By oil filter is broken Oil filter can be saturated by dust and can get broken
Exchange oil filter every 2000 hours.
Decrease of Increase in gas Reverse flow at a valve 7 There is no O-ring for separating suction and
Temperature rise in cylinder by recompressing. Check the presence and the status of O-ring.
clearance gap temperature of cylinder (Recomressing) delivery in 1st stage valve.
between piston 8
and cylinder Inappropriate valve seat Temperature rise in cylinder by recompressing. Check the status of the valve seat whether there are any damages such as abrasion and scratch.
9
Inappropriate valve plate Temperature rise in cylinder by recompressing. Check the status of the valve plate whether there are any damages such as abrasion and scratch.
10
Inappropriate valve spring Temperature rise in cylinder by recompressing. Check the status of the valve spring whether there are any damages such as abrasion and scratch.
11
Inappropriate valve seat gasket Temperature rise in cylinder by recompressing. Check the trace of contacts on the gasket whether they are uniform.
12 Measure suction air temperature (installation environment temperature).

Suction air temperature is high Temperature of suction air exceeding 45℃. It falls to insufficient cooling.
※　It shall be 45℃ or less. (Reference: SM A265 1.3.1 1)
Cooling water inlet temperature is 13 Cooling water temperature at inlet exceeding Measure cooling water inlet temperature.
It falls to insufficient cooling.
high 45℃. ※　Cooling water temperature shall be in the range of 36 to 45℃.
14 Water temperature difference between inlet and Check the difference of cooling water temperature between inlet and outlet.
The cooling water is in short supply It falls to insufficient cooling.
outlet is in 10℃ or more. ※　The outlet temperature shall be in 50℃ or less. The difference between inlet and outlet shall be under 10℃.
Local temperature rise occurred by 15 The water jacket is not filled with the cooling
It falls to insufficient cooling. Confirm air-bleeding condition by filling water jacket with cooling water.
means of air pocket in water jacket water.
The water jacket is filled with 16 The cooling water contains much calcium and
It falls to insufficient cooling. Check the state in the water jacket.
deposits sludge.
Degradation of Ingress of drain into 17 Check for the actuation of the magnetic valve.
Malfunction of a magnetic valve Decrease lubricity by ingress of water.
lubricity the cylinder Check for the setting of the drain timer.
18 Operating conditions of the auto drain trap is
Decrease lubricity by ingress of water. Check for the operation of auto drain trap.
not good
19 Check the size, length, and pathway of drain piping.
The pipe for drain is clogged. Emission performance of the drain is reduced by the pressure loss.
Check whether there are any clogs in the piping.
20 Check whether there has been occurred a back current of drain by removing drain piping when at the compressor is in a
The pipe for drain is gathered to one. Decrease lubricity by leaking water into lubricating oil.
stop.
21 There is no "water leg" - drain collector -
Decrease lubricity by ingress of water. Check the line where after the delivery piping.
equipped at outlet of compressor.
Non-compliant of the 22 Viscosity and the other properties do not Check the lubricating oil brand.
We cannot ensure without our recommendable lubricating oil.
lubricating oil brand conform the compressor Also check whether there are any other lubricating oils around there.
No experience operation 23 Using synthetic oil despite the operation time
We recommended using the mineral oil during the initial operation of 300 hours. Check the record of replacing lubricating oil.
with mineral oil is not reach 300 hours.
24 Insufficient of tightening torque for cylinder If tightened head without using regular torque, designed surface pressure cannot be Check tightening condition using torque wrench.
Ingress of cooling water Improper gasket surface pressure
head secured. ※ M10=70M・m / M12=120N・m
25 Cylinder head gasket and valve seat gasket were not If continuously keep using the gasket, it may lead the surface pressure drop, and cause an Check maintenance records.
replaced at overhauling. ingress of foreign matter and also cannot keep the air sealing anymore. Check whether only valve seat gasket has held the stock in large quantity.
26 Insufficient of overlap width projection for Surface pressure at the gas side and cooling water side become less able to keep the
Measure the thickness of 1st stage suction & delivery valve and depth of cylinder fitting portions
1st stage delivery valve proper value
27 Excessive of overlap width projection for 1st Surface pressure at the gas side and cooling water side become less able to keep the
Measure the thickness of 1st stage suction & delivery valve and depth of cylinder fitting portions
stage delivery valve proper value
28 Check whether oil level has been increasing when compressor is in stop
Leak from pinhole made by casting Penetration leakage is occurring from cylinder Imperceptible leakage can be caused by going around of defective part
Check whether emulsification has occurred
29 Penetration leakage is occurring from cylinder Check whether oil level has been increasing when compressor is in stop
Imperceptible leakage can be caused by going around of defective part
head Check whether emulsification has occurred
The contact surface with a gasket is 30 Clearance leakage is occurring from cylinder
If the surface is rough, air tightness can be impaired Check surface roughness of a portion where will be a seat
rough head joint surface
31 Clearance leakage is occurring from cylinder
If the surface is rough, air tightness can be impaired Check surface roughness of a portion where will be a seat
joint surface
32 Insufficient of cleaning for cylinder head In case of gasket left on joint surface at the replacement, air tightness can be impaired
Check maintenance records
joint surface due to cooling water leakage
33
Others Penetration leakage is occurring from gasket Can be leaked from inside of gasket Check lines and creases on the surface of gasket
34
Cooling water pressure is high If exceeded the design value, it could occur a leakage Check whether the cooling water pressure exceeding the design value (0.4MPa)
Deterioration on the 35 Lubricating oil has not been replaced

Abnormal wear can be resulted on respective parts due to lubricating fault Check the condition of oil replacement
lubricating oil periodically.
Run out of oil film 36 No implementation of initial oiling at the time Long term stop of compressor makes no oil film on sliding portions, requires initial
Check the state of implementation of initial oiling after long term stop of compressor
cause of long term stop for starting compressor after long term stop.※ oiling
※more than 3 weeks
Short of lubricating oil 37 Lubricating oil in the line has not been filled In order to fill the line, required around 30 min of running. If no lube oil had been
Confirm replacement procedure for lubricator
at lubricator oil line when at lubricator replacement filled in the line, it meant no lube oil at the inside of cylinder all during that time
38
Damage of lubricator Omission of replacement at every 8000 hours Replacement is required at every 8000 hours Check the maintenance records
39 Performed an adjustment at the inside of Prohibited any adjustment at customer's site since lubricator had adjustment at the proper
Perform parts replacement, and recall the parts to carry out overhauling
lubricator oil quantity when at the delivery
Break of piston 40
Desorption for piston was performed wrong Piston rings can be broken when inserting piston Visually confirmation
ring
Use of imitation 41 Use of low qualified products instead of
Imitation of main parts are distributed in large amount. Check the appearance, measurement, logo, embossed character, and etc.
products genuine products
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Fault Tree Diagram：Deposition of carbon 2013/9/12 ：Inagaki
Situation Analysis of Factor Explanation Result Evaluation
Deposition of Run back of 1st stage delivery 1

Expansion by heat Inappropriate valve seat Can be rise of temperature into cylinder by recompressing.
carbon valve
Run back of 2nd stage suction
valve 2
Inappropriate valve plate Can be rise of temperature into cylinder by recompressing.
and delivery valve
3
Inappropriate valve spring Can be rise of temperature into cylinder by recompressing.
4
Inappropriate valve seat gasket Can be rise of temperature into cylinder by recompressing.
Temperature high at coolant 5 Excessive coolant inlet temperature Can be short of coolant
inlet over 45℃ ※　Shall be in 36℃～45℃
6 10℃ temperature difference between Can be short of coolant

Short of coolant
inlet and outlet of coolant ※　Delivery temp. shall be max at 50℃ or below. Temp. difference at suction and delivery shall
Rise of temperature occurred at 7

Compressor is not filled with coolant Can be short of coolant
a portion by air pocket
Quality of water is 8
Contains too much sludge and calcium Can be short of coolant
incompatibility
Suction temperature is too 9 Suction air temperature (Ambient Temp.) Can be short of coolant
high. exceeds 45℃. ※　Suction air temperature (Ambient temperature) shall be at 45℃ or below.
Deterioration on 10
incompatible of lube. oil blend No use of specific bland We cannot ensure without our recommendable lubricating oil.
lube oil capability
Short of oil
Non-conforming of 11 Pistonring is installed in wrong If piston ring is installed upside down, the L.O. consumption will be excessive.
maintenance direction. ※　Check the direction of distinguish mark up and down.
Note: Concerning to cooling water temperature described in number 5 ・ 6, necessary to measure each cases
such like compressor operates alone and both compressor and the other machines operate together.
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1 / 2
SERVICE NEWS Document No: 11.2.13006
Precautions for H-70 Series 2nd Stage Valve Assembly Published： 20th August 2013
For H-series marine starting compressors, please be sure to follow these items below after completed
2nd stage valve (VP-3100B) disassembly.
1. Damaged Condition of the 2nd Stage Valve

The damage of 2nd stage valve plate occurred at when operating the compressor with installing the
2nd stage valve after completed overhaul and reassembly.
Fig.1 Damaged Valve Plate Fig.2 Valve Holder Fig.3 Valve Guard
2. Cause of the Damage

Since there seems to have been contact marks on both of the tip of knock pin and the valve guard,
we consider the valve tightening nuts were tightened under a condition the knock pins were not
placed properly in the pin hole of valve guard. Accordingly, the amount of valve lift became bigger
than the normal. Therefore, impulse force applied to the valve plate was increased, and then led
this damage caused.
contact marks
pin hole
Increase of valve lift
Fig.4 knock pin Fig.5 valve guard
Fig.6 normal assembly Fig.7 abnormal assembly

(A condition knock pins are not
placed properly to pin hole.)
Contact information：Tanabe Pneumatic Machinery Co., LTD Nagoya Factory

1,1-chome Kawanishi, Komaki city, Aichi, JAPAN Postal Code: 485-0045
TEL：+81-(0)568-76-4191 FAX：+81-(0)568-75-2627 e-mail:info@tanacomp.co.jp
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2 / 2
SERVICE NEWS Document No: 11.2.13006
Precautions for H-70 Series 2nd Stage Valve Assembly Published： 20th August 2013
3. Main Points for Checking the Condition of Installation
There are main points are shown as follows in order to check whether each components of 2nd stage valve
are properly installed or not.
(1) Knock Pin and Pin Hole
① Turn of Valve Guard

Tighten the valve tightening nut as much as possible to it can be
valve guard
tighten by hand with holding the valve seat to turn the valve guard.
If installation has been properly performed, the valve guard will
never be turned even if there is still a quantity of idle, the knock
pin prevents the valve guard turns.
In case of the valve guard turns, check the piston of the knock pin
Hold the valve seat. and the pin hole.
Fig.8 Turn of valve guard
② Thickness of Valve
The dimension of the thickness of valve “T” is depended on the
dimension of the valve guard, lift washer, and valve seat. When the
knock pin is not properly placed on the pin hole, the dimension “T”
will be bigger than the normal dimension.
The gauge of “T”
T
Suction side： 21.6 mm Delivery side： 22.9 mm

When measured dimension was bigger than 0.5 mm of the above mentioned
Fig.9 Dimension of Valve gauge, it means the knock pin is probably not placed in the pin hole.
(2) The Quantity of Valve Spring

suc. valve del. valve
The valve spring for VP-3100B suction and delivery valves are
identical.
There are valve springs installed 1 pc for suction side and 3 pcs
for delivery side.
If the quantity of the valve spring is reduced, the amount of the
valve lift becomes increased to lead the damage of valve plate.
Make sure the quantity of the valve spring.
1 pc
3 pcs
Fig.10 Quantity of Valve Spring

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1 / 2
SERVICE NEWS Document No.： 11.2.13002
Installation Procedure of
Published： 14 July, 2013
H-70-type cylinder head gasket & valve seat gasket
Please follow this procedure on how to handle H-70 type cylinder head gasket & valve seat gasket.
1. Cylinder head gasket

Valve side (up) Cylinder side (under)
narrow wide
caution
Give attention to the direction of cylinder head gasket.
Since the position of cylinder head gasket is depended on the knock pin, confirm the cylinder head gasket
which is one the metal part is narrow faces on the side (for a cylinder the top) contacts with valve.
2. Valve seat gasket
narrow wide
caution
Give attention to the direction of valve seat gasket.
Install the valve seat gasket which is one the metal part is narrow faces on the side contacts valve.
Metal part
Valve seat gasket
Valve (outer ring)
Cylinder head gasket

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2 / 2
Installation Procedure of
Published： 14 July, 2013
H-70-type cylinder head gasket & valve seat gasket
3． Attention at the time of maintenance
Cylinder head
Valve seat
Gasket (1st)
Valve (1st)
Outer ring
Cylinder head
gasket (1st)
Cylinder
caution
＊There are some cases, outer ring may adhere to cylinder head at the time of disassembling.
For the cases, pull out the outer ring after insert the bolts into each jack bolt holes.
After take out outer ring Take out outer ring
by using jack bolt

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Technical Bulletin on Pressure Switch Published： 2nd August, 2013

(K. K. Saginomiya Mfg. / SNS-C130PGQ)
For H-series marine starting air compressor, we would like to inform you about this pressure switch
(K. K. Saginomiya Mfg. / SNS-C130PGQ) used for functions; automatic start-stop operation and automatic
stop control in order to prevent a breakage which causes an air leak problem.
1. Damaged Condition of Pressure Switch

The bellows part of this pressure switch had damaged, and this damage caused an air leak from its
fracture portion.
Bellows
Pressure
receiving element Fracture Portion
Fig.1 Schematic drawing of pressure switch Fig.2 Pressure receiving element Fig.3 Fracture portion of bellows
2. Cause of Damage
The pressure switch manufacturer has reported us the result of their observation after they
investigated the damaged pressure switch as follows:
(1) Found wear tracks, changes in color, and etc. on mechanical part of the switch.
(2) Recognized specific striations of fatigue breaking on the fractured surface.
(3) There were no corrosive elements detected from the result of elemental analysis of fractured
surface.
From the above mentioned items 1, 2, and 3; this damage is presumed, the pressure receiving portion
had been subject to repeated loading by pulsation, pressure pulsation, and etc., and led to the
bellows caused this fatigue breaking.
Contact Portions
Contact Portions
Fig.4 Micro Switch Contact Portions Fig.5 Bellows Contact Portions

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2 / 3

Fig.6 Fractrographic Study of the Fractured Portion
3. Confirmation Method of Pulsation
It is possible to confirm the vibration of activation plate depending on whether the pressure switch
is influenced by pulsation or not.
Remove the switch cover to confirm the vibration shown in Fig.7 by directory touching the plate
whether the actuation plate is vibrating or not.
During the confirmation, be careful not to get any electric shock, due to an electrical current
might be flowing in the terminal portion.
Terminal
（Caution to electric shock）
Actuation Plate
Fig.7 Checkpoints for Pulsation
4. Cause and Remedy for Pulsation

A damage case has been reported, which caused by pulsation in the piping directly influenced the
pressure switch because of the pressure output port of the pressure switch was located on the midway
of the piping between the compressor and tank.
Pressure shall be pulled into the pressure switch from a lower pulsation portion where has a distance
from the pressure tank and compressor being a pulsation source.
When it is difficult to take in pressure from the lower portion, a dampener or pulsation preventive
joint shall be used in order to reduce pulsation rate on the pressure switch

10/29
3 / 3

Pressure Pressure
Switch Switch
Com- Com-
pressor TANK pressor TANK
Fig.8 Inappropriate Example Fig.9 Appropriate Example①

(Due to this example is utilizing pressure inside of the (Utilize pressure in tank.)
piping, directly influenced by the pulsation in the piping.)
Pressure
Dampener Switch
Com-
pressor TANK
Fig.10 Appropriate Example ②

(Install dampener or pulsation preventive joint on
the piping of pressure switch.)
Fig. 11 Pulsation Preventive Joint

11/29
1 / 1
文書番号：
MAINTENANCE NEWS Document No.：
12.2.13007
LP バルブのバルブプレート、スプリングの位置発行日：
2013 年 09 月 12 日
Position of valve plate and spring on LP valve Published：
船舶用エンジン起動用圧縮機 H シリーズにおいて、LP バルブの再組立の際にはバルブプレートの位置にご注

意をお願い致します。
For H-series marine starting compressors, please be sure to follow position of valve plate when
reassemble.
良(Good) 不良(No Good)
バルブプレート、スプリングを図の位置に組付けてください。
Fix the valve plate and spring like above pictures.
お問合せ先：株式会社田邊空気機械製作所名古屋工場/Tanabe Pneumatic Machinery Co., Ltd. Nagoya Factory

〒485-0045 愛知県小牧市川西 1 丁目 1 番地/1,1-chome, Kawanishi, Komaki-City, Aichi, JAPAN Postal Code: 485-0045
12/29
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MAINTENANCE NEWS Document No.： 12.2.13009
Caution for assembling valves Published： 12nd Sep, 2013
Use Tanabe original nuts only for assembling valves.

Serial damage and/or accidents may occur by a loose valve seat bolt.
Valve set bolt

Tightening torque:
25N・m
Valve clamping bolt
Tanabe original nuts

Tightening torque:
25N・m
The thickness of generally available nuts is different from Tanabe original nut. Use of non-original
Tanabe nuts results in the valve set bolt becoming loose from the valve clamping bolt.
Check the followings whenever doing maintenance:
Gap
Check that the gap exists as pictured above!

In case that non-original nuts are being used no gap will exist -> serious damage will be the consequence.
Check that the Tanabe original nuts are firmly fixed!
Caution!
Following this notice whenever doing maintenance! Non original nuts will cause serious damage because
the valve set bolt will become loose. Use Tanabe original parts only and consult the instruction book
before starting maintenance work! Take note of caution tags!

13/29
1 / 2
“H” Series Compressors Procedure for Published： 12nd Sep, 2013

Replacement of “Lubricator”
1. Disconnect each pipe joint, undo fixing screws and remove lubricator from gear case.
2. Fix replacement lubricator, ensuring to use new gasket. Tighten only the lower joints on the
lubricator.
3. Disconnect joint (B) on lubricator line.
4. Fill the interconnecting pipe with oil at “Joint [B]” position (using hand-held oil-filler can).
When the pipe is filled oil should be overflowing at “Joint [A]” position
Note: It is essential that only Tanabe recommended lube oil is used.
Oiler
5. 5. When confident that interconnecting pipe is filled with oil, reconnect the pipe to the lubricator
at “Joint [A]” position only, leaving “Joint (B)” still loose.
6. To minimise possible wear it is necessary to ensure that all moving parts are lubricated and that
the compressor is initially run only in unloaded condition.
To do this take the following actions:

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“H” Series Compressors Procedure for Published： 12nd Sep, 2013

Replacement of “Lubricator”
a. Disconnect copper pipe at “Joint[C]” on the magnetic unloader valve.
b. Remove top cover and air filter element from inlet air housing.
Pour about 20 drops of oil into upper cylinder via air inlet valve port, to ensure that cylinder
walls are not dry.
7. Start the compressor (in the unloaded condition) and continue to add a few drops oil every few seconds.
8. It is essential to purge any air locks from within the copper tubes.
With the compressor running, oil should flow freely from “Joint [B]”within a short time. Only
then should you tighten that joint.
9. Stop the compressor. Reconnect “Joint [C]”.

Replace the suction air filter element and reconnect the cover.

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Procedure for measuring flow rate Published： 12nd Sep, 2013

lubricating oil from lubricator
Oil check valve assy. Universal elbow
1. Remove the bolt and gaskets that secure universal elbow.

Be careful about losing the bolt and gaskets.
Aluminum gaskets Bolt
2. The lubricating oil is supplied from the lubricator when

the compressor is in operation. Receive the dripping oil by
graduated cylinder 5 minutes from the start of operation.
Restore their original state after timing 5 minutes. And

measure the other side same procedure.
CAUTION! The lubricating oil is not supplied to the cylinder while

universal elbow is removed.
While measuring the supplied amount of lubricating oil,
supply the lubricating oil directly to cylinder from the
Oiler short pipe after removed the suction filter assembly.
We recommend that use an oiler when you supply the lubricating
oil to cylinder.
3. Appropriate lubrication amount for 5 minutes is 1.3 ~ 1.6

cc per 1 line.
It is 15.6 ~ 19.2 cc in terms of per hour.
* In this regard, the values are valid only in the

specification 1800rpm.

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How to assemble anti-emulsification kit Published： 12th Sep, 2013
The picture of parts
Extension pipe for

Modified side cover Tapped hole: Rc1/8 Side cover gasket
breather foot
Flareless pipe joint
for copper tube
Size: R1/4 x φ6mm
Nipple
joint
Cross joint
Size: R1/4
O-ring Special nipple joint Ball Valve Flareless pipe joint
(Orifice joint) Size: for copper tube
Size: R1/4 Size: R1/8 x φ6mm

17/29
2 / 11
Assembly Procedure
①Tape flareless pipe joint, nipple joint, and the special nipple joint with seal tape.
②Replace side cover with modified one, intercooler side. (See picture 1)
The tapped hole should be positioned

upper right toward the crankcase
Parts in the picture are unpainted.
Picture 1

18/29
3 / 11
③Attach the flareless pipe joint to side cover. (See picture 2)
Caution: There is the sleeve inside of flareless pipe joint. Make sure not to lose.

Size: R1/8 x φ6mm
Picture 2

19/29
4 / 11
④Loosen and separate the pipes from the joint at the top of intercooler cover. (See picture 3)
⑤Remove joint at the top of intercooler cover. (See picture 3)
④Loosen and separate these pipes ⑤Remove this joint
Picture 3

20/29
5 / 11
⑥Assemble these parts at the top of intercooler cover.(See picture 4)

Size: R1/4 x φ6mm
Cross joint
Size: R1/4
Nipple joint
Size: R1/4
Picture 4
⑦Assemble these parts at the right of cross joint. (See picture 5)
Special nipple joint

(Orifice joint)

Size: R1/4 x φ6mm
Ball valve
Picture 5

21/29
6 / 11
◆The direction of special nipple joint and ball valve.

φ3mm φ1mm
Inlet Outlet
Inlet Special nipple joint Outlet
Notch
Allow: Flow direction

Inlet Ball Valve Outlet
⑧Bend copper pipe like following picture. And cut off copper pipe, if it is too long.
Cut off
Copper pipe
Size: φ6mm
A View A

22/29
7 / 11
⑨Remove burr on cut end of the pipe. And clean carefully cutting chips left in the pipe.
◆Working example
Cut by saw Remove inner burr by drill Remove outer burr by file
⑩Insert copper pipe into flareless pipe joint all the way inside like following picture.
(See picture 6). And tighten the nut by hand.
Sleeve Nut
Tightening by hand
Picture 6

23/29
8 / 11
⑪Tighten this nut 1 and 1/4 revolution using spanner, then made the sleeve bites into the pipe.
(See picture 7） Loosen nut once and check the sleeve.（See picture 8）
Tightening 1 and 1/4 revolution by spanner
Picture 7
The sleeve bites the pipe
Picture 8

24/29
9 / 11
⑫Take the same process on the end of pipe, side-cover side. If you put a mark on the nut and joint,
easy to check rotated angle measure. (See picture 9)
Marking
1 and 1/4 revolution
Picture 9
⑬Install O-ring in extension pipe for breather foot.
Extension pipe for breather foot
O-ring

25/29
10 / 11
⑭Remove breather cap, and install extension pipe by pipe wrench in breather foot.
Extension pipe
Breather foot
⑮Install breather cap in extension pipe.
Breather cap

26/29
11 / 11
⑯Connect the piping removed at the process ④ to cross joint at the top of intercooler cover.
Ball valve shall be operated under “Open” all the times.
Paint them if needed.

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1 / 2
Procedure for checking crank shaft for Published： 12nd Sep, 2013
“bending” condition
How to check the crank shaft for bending condition;

a. Remove the fly wheel cover.
b. Peer the paint off on the fly wheel.
c. Measure with dial gauge and compare results with acceptable tolerance figure.
d. Reassemble
Details for each work

a. Removal of the fly wheel cover.
 Stop the compressor. Remove the fly wheel cover
Fly Wheel Cover
Peer the paint carefully.

The surface should be
smoothly.
b. Peer the paint on the fly wheel
・ The outer side of fly wheel is painted.
Peer the paint carefully using sand paper to enable measurements.
・ It is necessary to remove minute bruises by polishing the surface.

28/29
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Procedure for checking crank shaft for Published： 12nd Sep, 2013
“bending” condition
a. Check measurements of dial gauge and compare to acceptable tolerance.
 Put a dial gauge on common bed

See photo.
Dial Gauge
 Turn the fly wheel (1 rotation).

Read the difference between
maximum and minimum figures.
If the difference figure is within
5/100mm, the crank shaft is not
bent. The compressor is operational.
After performing the above check return parts to former condition. Fasten fly wheel cover in place.
End

29/29

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TANABE PNEUMATIC MACHINERY Co., Ltd.

1-4. Fault Tree Diagram : Deposition of carbon ········································· 4

2-3. Technical Bulletin on Pressure Switch(K. K. Saginomiya Mfg. / SNS-C130PGQ) ········ 9

3-2. Caution for assembling valves ···················································· 13

3-3. “H” Series Compressors Procedure for Replacement of “Lubricator”············· 14

3-5. How to assemble anti-emulsification kit ·········································· 17

Fenomenon Factor analysis Explain Method of confirmation Result Eval

Ingress of foreign 1 Suction filter is broken by moisture, salt and

Ingress of foreign matter by 3

9 30 minutes operation shall be needed to fill the

11 If keep using the gasket continuously, it may lead

16 Clearance leakage occured from cylinder head

17 Clearance leakage occured from cylinder

Seize of valve plate by 18 If the assembling is upside down, lubricating oil

19 In case of using 7 inches of old type with grommet

22 Recompression may cause temperature rise inside of

23 Recompression may cause temperature rise inside of

24 Recompression may cause temperature rise inside of

25 Recompression may cause temperature rise inside of

No maintenance or maintenance 26 Maintenance and Inspection are needed by

28 Narrow side assembling for 1st stage valve's

Component(plate,spring etc.) 29 Component assembling is wrong or not correct

30 Insufficient of tightning torque is caused slack

31 Valve plate is not assembling correct

Tempreature at suction air is 35 Valve is high temperature by short of cooling

Case Factor Analysis Explaination Method of Confirmation Result Evaluation

2 Fragments generated at when piston & cylinder getting burn-out

7 If oil scraper ring & piston ring had installed in wrong

10 If work with taking a hold by vice bench or work without

If any additional modification such like a grinding work had

Since reaction force of valve set spring does not have

Since reaction force of valve set spring does not have

Since reaction force of valve set spring does not have

Non-conformance 24 The packing condition has not been kept

Situation Factor Analysis Explanation Method of Confirmation Result Evaluation

12 Measure suction air temperature (installation environment temperature).

Deterioration on the 35 Lubricating oil has not been replaced

Fault Tree Diagram：Deposition of carbon 2013/9/12 ：Inagaki

Situation Analysis of Factor Explanation Result Evaluation

Deposition of Run back of 1st stage delivery 1

6 10℃ temperature difference between Can be short of coolant

Rise of temperature occurred at 7

SERVICE NEWS Document No: 11.2.13006

1. Damaged Condition of the 2nd Stage Valve

2. Cause of the Damage

Fig.4 knock pin Fig.5 valve guard

Fig.6 normal assembly Fig.7 abnormal assembly

Contact information：Tanabe Pneumatic Machinery Co., LTD Nagoya Factory

SERVICE NEWS Document No: 11.2.13006

3. Main Points for Checking the Condition of Installation

(1) Knock Pin and Pin Hole

① Turn of Valve Guard

Suction side： 21.6 mm Delivery side： 22.9 mm

(2) The Quantity of Valve Spring

Fig.10 Quantity of Valve Spring

Contact information：Tanabe Pneumatic Machinery Co., LTD Nagoya Factory

SERVICE NEWS Document No.： 11.2.13002

お問合せ先：株式会社田邊空気機械製作所名古屋工場/Tanabe Pneumatic Machinery Co., Ltd. Nagoya Factory