Tanabe LSHC-20B/30A/40A
Two-stage air-cooled reciprocating air compressor (emergency / service air)
Tanabe LSHC is a compact vertical, air-cooled, two-stage reciprocating compressor with tandem pistons: the low-pressure stage below and the high-pressure stage above, a TANABE UNION valve (combined suction and delivery valve) on the H.P. head and plate valves on the L.P. stage. It is V-belt driven, splash lubricated, and is used on ships as the emergency (first-start) air compressor or for service air. The manual covers installation, lubricating oil and running-in, V-belt tension, test run and daily operation, construction, dismantling and reassembly of valves, pistons, bearings and crankshaft, fault finding, the periodic check table, clearance tables and sectional drawings with parts lists.
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保养规程
Test run (first start or after long lay-up)
- Check foundation bolts, V-belt tension and that all bolts and nuts are tight. 第 12 页
- Fill oil to the H line on the oil gauge (0.7 l on LSHC-20B, 2.0 l on LSHC-30A/40A). 第 12 页
- Remove the crankcase side cover and spray oil on the main bearings, crank pin and lower cylinder wall. 第 12 页
- Turn the compressor by hand to check it rotates lightly, fully open the tank valve and confirm the direction of rotation. 第 12 页The flywheel is the cooling fan: wrong rotation means no cooling
- Open the air valve handle on the L.P. safety valve post to start unloaded. 第 13 页
- After start-up close the air valve and run unloaded for 30 minutes, checking bearings, cylinder and ammeter for heat and noise. 第 13 页
- If all is normal, close the tank stop valve and raise pressure slowly, checking again; then run on full load and check the unloader. 第 13 页
Daily operation and stopping
- Before start: check crankcase oil level (H) and direction of rotation. 第 13 页
- Open the air valve handle on the L.P. safety valve post, start, then close it to load the compressor. 第 13 页
- In service watch the pressure gauges, ammeter and temperature of bearings, cylinder head and delivery air; a leaking valve raises head and delivery temperature. 第 14 页
- Lift the safety valve by hand from time to time and drain the air tank and stage separators. 第 14 页
- To stop: unload, press the stop button, open each stage drain cock, close the air tank valve and isolate the power. 第 14 页
H.P. union valve: dismantle and clean
- Isolate power and release all pressure from the receiver. 第 17 页
- Loosen the guide plug in the centre of the cylinder head, remove the 4 head bolts and lift off the head. 第 19 页
- Pull the delivery valve cap up, press the spring retainer down and take out the split retainer lock with tweezers. 第 19 页
- Remove the valves with the spring; the suction valve comes out downward with its spindle. 第 20 页
- Clean in light oil with a soft brush; lap the seat with fine compound if rough; replace worn or cracked plates and springs. 第 20 页
- Oil all parts, reassemble and check lift: suction 0.8 mm, delivery 1.0 mm (VU-1100). 第 20 页Suction lift depends on head gasket thickness (1.0 mm)
Fitting piston rings and piston pin
- Fit rings with the R stamp upward, ends staggered 120° apart; use a ring tool to avoid damage. 第 22 页
- Do not twist or over-expand the thin stepped rings and never clamp the piston in a vice. 第 23 页
- Fit the floating piston pin and seat both snap rings fully in their grooves. 第 23 页A loose snap ring is dangerous
Reassembling connecting rod and head
- Assemble rod, cap, shims and bolts by match marks; adjust bearing clearance only with shims, never by bolt tightness. 第 24 页
- Tighten rod bolts with spring washers to 480 kgf·cm. 第 24 页
- Use the TANABE 1.0 mm head gasket only and tighten head bolts evenly to 480 kgf·cm. 第 26 页A thinner gasket reduces top clearance and causes knocking
保养周期
| 项目 | 周期 | 操作 | 说明书 |
|---|---|---|---|
| Crankcase oil | Daily | Check level between H and L marks; top up only when stopped | 第 13 页 |
| Crankcase oil (running-in) | 50 h, then 100 h | Drain warm, clean the oil pan with light oil, fill fresh oil | 第 8 页 |
| Crankcase oil | 500 h (about 1–3 months) | Change oil | 第 9 页 |
| Valves | 500–1000 h | Dismantle and clean, check valve plates and springs for wear | 第 29 页 |
| Pistons, rings, cylinder | 3000 h | Check wear, ring grooves and cylinder bore | 第 29 页 |
| Bearings and crankshaft | 5000–8000 h | Check rod and main bearings, crankshaft wear | 第 29 页 |
| Safety valve | Monthly | Check opening pressure by lifting / raising pressure | 第 29 页 |
| Pressure gauges | At least yearly | Check and calibrate | 第 29 页 |
| Whole compressor | Every 3 years | Overhaul | 第 29 页 |
故障及处理方法
Abnormal noise from the cylinderForeign matter in cylinder, worn cylinder/piston, too thin head gasket, broken valve plate or spring, worn piston pin bushAbnormal noise in the crankcaseWorn main or rod bearing, loose connecting rod boltHigh delivery air temperatureLeaking delivery valve, faulty valve seat gasket, carbon on valves, poor coolingHeavy carbon on valvesHigh oil consumption, wrong oil level or poor oilPressure does not risePipe leak, damaged valve or dirt on seat, worn piston ringsOil pressure does not increaseLow oil, worn bearing metal, reverse rotationHigh oil consumptionWorn piston/cylinder or rings, oil above H markExcessive vibrationLoose bolts or flywheel, weak foundationPiston seizureDust entering the cylinderV-belt slippingSeized piston or bearing, belt too slack
技术参数
| Type | Vertical, air-cooled, 2-stage compression | 第 3 页 |
|---|---|---|
| L.P. cylinder bore (LSHC-20B) | 69.85 mm | 第 3 页 |
| H.P. cylinder bore (LSHC-20B) | 34.92 mm | 第 3 页 |
| Stroke (LSHC-20B) | 50.8 mm | 第 3 页 |
| L.P. valve | TANABE plate valve VP-1100B-5 | 第 3 页 |
| H.P. valve | TANABE UNION valve VU-1100 | 第 3 页 |
| Lubrication | Splash lubrication | 第 3 页 |
| Drive | V-belt | 第 3 页 |
| Crankcase oil capacity | 0.7 l (LSHC-20B); 2.0 l (LSHC-30A/40A) | 第 12 页 |
| Weight (LSHC-20B) | approx. 42 kg | 第 3 页 |
| Compressor oil | SAE 30 (ISO VG 100); SAE 20 (ISO VG 56) below 10 °C room temperature | 第 8 页 |
| Cylinder head and rod bolt torque | 480 kgf·cm | 第 24 页 |
| Cylinder head gasket | 1.0 mm (H.P. top clearance 0.5–1.0 mm) | 第 26 页 |
| H.P. valve lift (VU-1100) | suction 0.8 mm, delivery 1.0 mm | 第 20 页 |
| L.P. valve lift (VP-1100B) | suction 1.2 mm, delivery 1.2 mm | 第 22 页 |
| H.P. pressure gauge range | 30 kg/cm² | 第 14 页 |
备件与目录号
| 零件 | 编号 | 数量 | 说明书 |
|---|---|---|---|
| H.P. safety valve assembly | VS-204004 | 1 | 第 32 页 |
| L.P. safety valve assembly | VS-104004 | 1 | 第 32 页 |
| Suction filter assembly | F-0100 | 1 | 第 32 页 |
| H.P. union valve (LSHC-20B) | VU-1100 | 1 | 第 32 页 |
| L.P. valve assembly (LSHC-20B) | VP-1100B | 2 | 第 22 页 |
| H.P. union valve (LSHC-30A/40A) | VU-2100 | 1 | 第 20 页 |
| L.P. valve assembly (LSHC-30A/40A) | VP-1200C | 2 | 第 22 页 |
| Cylinder head gasket 1.0 mm | 1 | 第 26 页 | |
| H.P. and L.P. piston rings | 1 set | 第 32 页 | |
| Connecting rod bearing (white metal) | 1 | 第 32 页 | |
| Piston pin bushing (phosphor bronze) | 1 | 第 32 页 | |
| Main bearing (taper roller) | 2 | 第 32 页 | |
| Crankshaft oil seal | 1 | 第 32 页 |
来源：制造商说明书《EM-20-4 INSTRUCTION MANUAL FOR TANABE AIR COMPRESSOR TYPE LSHC》，共 35 页。页码以原文为准。作业前请核对船上的说明书。
本页为自动翻译。零件号、代码和页码与原文一致。