Confidential

HITACHI
OIL-FREE SCREW COMPRESSOR
NEXT series

Mechanical SERVICE MANUAL

Air-Cooled

DSP-45AT6N
DSP-55AT6N
DSP-75AT6N
DSP-55VATN
DSP-75VATN
Water-Cooled

DSP-45WT6N
DSP-55WT6N
DSP-75WT6N
DSP-55VWTN
DSP-75VWTN

“Instructions for the use of this manual”

Use this Service Manual in conjunction with Instruction Manual.
DSP–017
Contents
1. GENERAL DESCRIPTION
1.1 Appearance [Air-Cooled] …………………………………………………………………………………… 1
1.2 Components [Air-Cooled] ………………………………………………………………………………… 2
1.3 Appearance [Water-Cooled] ……………………………………………………………………………… 3
1.4 Components [Water-Cooled] ……………………………………………………………………………… 4

2. FLOW DIAGRAM
2.1 Flow Diagram [Air-Cooled] ………………………………………………………………………… 5
2.2 Flow Diagram [Water-Cooled] …………………………………………………………………… 7
2.3 Capacity Control System Standard …………………………………………………………………10

3. MAINTENANCE
3.1 Standard Maintenance Schedule ……………………………………………………………………… 13
3.2 Maintenance Schedule for Oil Mist Remover………………………………………………………… 17

4. HOW TO SERVICE THE AIR COMPRESSOR

4.1 Replacement of Air Intake Filter (Bi-Annually) ……………………………………………………… 18
4.2 Condensate drain port (Intercooler/Aftercooler) (Daily check)
Clean the strainer elements (Bi-Annually) & Orifices (Annually) ………………………………… 19
4.3 Lubricating oil Replacement (Annually) ……………………………………………………………… 23
4.4 Cleaning of Oil Strainer (Primary Side) (Bi-Annually) ……………………………………………… 24
4.5 Replacement of Oil Filter (Secondary Side) (Annually) …………………………………………… 24
4.6 Operation Check of Air Relief Valve (Bi-Annually) …………………………………………………… 25
4.7 Cleaning of Control Line Filter (Bi-Annually) [Fixed speed type] ………………………………… 25
4.8 Clean Cooler (Annually) ………………………………………………………………………………… 26
4.9 Replacement of Check Valve (2-Yearly) ……………………………………………………………… 27
4.10 Main Motor Greasing …………………………………………………………………………………… 28
4.11 Maintenance of Main Motor …………………………………………………………………………… 29
4.12 Maintenance of Oil Mist Remover……………………………………………………………………… 30
4.13 Maintenance of Cooling fan and cooling fan motor ……………………………………………… 31
4.14 The procedure to attach the motor cover [Water-Cooled] ………………………………………… 32
4.15 Maintenance of Oil Pump ……………………………………………………………………………… 34
4.16 Maintenance of Suction Throttle Valve ………………………………………………………………… 37
4.17 Oil Pump motor and Airend removal ………………………………………………………………… 43
4.18 Oil casing and Gear casing removal …………………………………………………………………… 45
4.19 Main motor removal ……………………………………………………………………………………… 46
4.20 Replace the Bushing ……………………………………………………………………………………… 48
4.21 Pinion Gear Replacement Procedure ………………………………………………………………… 52
4.22 Battery Replacement (6-Yearly) ………………………………………………………………………… 54
4.23 Inspection of Thermistor and Pressure Sensor ……………………………………………………… 55

5. PARTS LIST …………………………………………………………………………………………… 57

1. GENERAL DESCRIPTION
1.1 Appearance Air-Cooled

[Front View]
Enclosure
Enclosure panels
lower the sound level
Air Exhaust Air Exhaust of the air compressor
(Air Compressor Package) package.
This panel discharges
the hot air generated
in the air compressor.

Instrument Panel

Air Intake
(Inlet to the Air End)

Left Door Plate of Operating/

Open the left door only
Servicing Instructions
when servicing the R e a d c a re f u l l y t h e
DSP air compressor. plate before operating
Keep it closed when and servicing the DSP.
operating the DSP air
compressor.
Air Intake

Oil Level Gauge Oil Filling Port

This indicates the Use the port to fill the
quantity of the oil in gear case with oil.
the gear case. Check
the oil level before
starting the DSP and Air Intake
when operating it. Air Exhaust

[Rear View]

OMR

Compressed Air Discharge

Sling Fitting
Use the sling fitting
when moving and
installing the DSP air
Power Supply Port
compressor.
Check the
specifications, power
supply and voltage
Air Intake
before connecting the Air Intake
power supply. (Air Compressor Package)

1
1.2 Components Air-Cooled

[Front View]
Discharge pipe
(Compressed air discharge)

Oil cooler
Aftercooler

Enclosure

Intercooler

Instrument panel

Control panel

Check valve
2nd-stage
Airend

Common base
1st-stage
Airend

Oil filter Air intake filter

Oil level gauge

[Rear View]

Air relief valve

Cooling fan

Oil mist remover

(OMR)

Main motor

2
1.3 Appearance Water-Cooled

[Front View]
Enclosure
Air Exhaust Enclosure panels
Air Exhaust
(Air Compressor Package) lower the sound level
of the air compressor
This panel discharges
package.
the hot air generated in
the air compressor.

Instrument Panel

Air Intake
(Inlet to the Air End)

Plate of Operating /
Left Door Servicing Instructions
Open the left door only R e a d c a re f u l l y t h e
when servicing the plate before operating
DSP air compressor. and servicing the DSP.
Keep it closed when
operating the DSP air
compressor.
Air Intake
Oil Filling Port
Use the port to fill the
Oil Level Gauge gear case with oil.
This indicates the
quantity of the oil in
the gear case. Check
the oil level before
starting the DSP and
when operating it.
Air Exhaust
Air Intake

[Rear View]

OMR

Compressed Air Discharge

Power Supply Port

Check the Sling Fitting
specifications, supply
voltage and frequency Use the sling fitting
before connecting the when moving and
power. installing the DSP air
compressor.

Air Intake
(Air for Package)
(Vtype only) Air Intake
Air Intake (Air Compressor Package)

3
1.4 Components Water-Cooled

[Front View]
Discharge pipe
(Compressed air discharge) Cooling fan

Aftercooler Enclosure

Instrument panel

Intercooler

Control panel

2nd-stage
Airend
Check valve

1st-stage
Airend Common Base

Air intake filter

Oil filter
Oil level gauge

[Rear View]

Air relief valve

Oil mist remover

(OMR)

Oil cooler

Main motor

4
2. FLOW DIAGRAM
2.1 Flow Diagram Air-Cooled
2.1.1 Fix speed type
Compressed Air Flow and Oil Flow

Air exhaust Air exhaust Air exhaust

7 51 8 34

6
PS2 18
19 9 M 10
52 Compressed
air discharge

54 36

35
2
TH3 3
4
20 TH2 MOHR
14 17
13 15 5
Intercooler 32
condensate PS1
11 TH5 Air intake for
drain
1 39 main motor
TH4

24 23 PS4
63SV Control air for OMR
33
53
Air intake for 22
compressed air
31
21 15
Oil drain 14
Oil drain
38 13
Aftercooler condensate drain

Cooling air flow Compressed air flow Lubricating oil flow

Legend of the Diagram Legend of Sensors and Switches

Compressor Air Flow Capacity Control & Blowoff Air Flow Symbol Part name
1 1st-Stage Airend 21 Air Intake Filter PS2 Pressure Sensor (discharge air pressure)
2 2nd-Stage Airend 22 Suction Throttle Valve PS4 Pressure Sensor (oil pressure)
3 Gear Case 23 Blowoff Valve PS1 Pressure Sensor (interstage pressure)
4 Step-up Gear 24 Blowoff Silencer TH2 Temperature Sensor (2nd-stage in)
5 Main Motor TH4 Temperature Sensor (1st-stage out)
6 Intercooler Oil Flow TH3 Temperature Sensor (2nd-stage out)
7 Check Valve 31 Oil Strainer TH5 Temperature Sensor (oil)
8 Aftercooler 32 Oil Pump Thermostat (for main motor
MOHR
9 Air Relief Valve 33 Oil Relief Valve bearing temperature)
10 Discharge Port 34 Oil Cooler Pressure Differential Sensor (For
63SV
suction filter clogging detection)
11 Check Valve 35 Oil Filter
13 Orifice 36 Temperature Control Valve
14 Drain Solenoid 38 Oil Drain Valve
15 Y strainer 39 Oil Mist Remover
16 Drain trap
17 Demister Air Flow and Other
18 Motorized Isolation Valve 51 Fan Motor
19 Hi-Precooler (only for 125 psi (0.86 MPa type)) 52 Enclosure
20 Drain separator 53 Air Intake Duct
54 Cooling fan

5
2.1.2 Air-Cooled

Compressed Air Flow and Oil Flow

Air exhaust Air exhaust Air exhaust

7 51 8 34

6 18
PS2
19 10
24 23
9 M
52 Compressed
22 air discharge

54 36
22

23
35
2
3
TH3
20 TH2 4 THM
14
Intercooler
13 15 17 5
32
condensate PS1
TH5 Air intake for
drain
11 1 39 main motor
TH4

PS4
63SV Control air for OMR
33
53
Air intake for
compressed air
31 15
21
Oil drain 14
Oil drain
38 13
Aftercooler condensate drain

Cooling air flow Compressed air flow Lubricating oil flow

Legend of the Diagram Legend of Sensors and Switches

Compressor Air Flow Capacity Control & Blowoff Air Flow Symbol Part name
1 1st-Stage Airend 21 Air Intake Filter PS2 Pressure Sensor (discharge air pressure)
2 2nd-Stage Airend 22 Blowoff Solenoid Valve (1) PS4 Pressure Sensor (oil pressure)
3 Gear Case 23 Blowoff Solenoid Valve (2) PS1 Pressure Sensor (interstage pressure)
4 Step-up Gear 24 Blowoff Silencer TH2 Temperature Sensor (2nd-stage in)
5 Main Motor TH4 Temperature Sensor (1st-stage out)
6 Intercooler Oil Flow TH3 Temperature Sensor (2nd-stage out)
7 Check Valve 31 Oil Strainer TH5 Temperature Sensor (oil)
8 Aftercooler 32 Oil Pump Temperature Sensor (for main
THM
9 Air Relief Valve 33 Oil Relief Valve motor surface temperature)
10 Discharge Port 34 Oil Cooler Pressure Differential Sensor (For
63SV
suction filter clogging detection)
11 Check Valve 35 Oil Filter
13 Orifice 36 Temperature Control Valve
14 Drain Solenoid 38 Oil Drain Valve
15 Y-type Strainer 39 Oil Mist Remover
16 Drain trap
17 Demister Air Flow and Other
18 Motorized isolation valve 51 Fan Motor
19 Hi-Precooler (only for 125 psi (0.86 MPa type)) 52 Enclosure
20 Drain separator 53 Air Intake Duct
54 Cooling fan

6
2.2 Flow Diagram Water-Cooled
2.2.1 Fix speed type
Compressed Air Flow and Oil Flow

51
Air exhaust Air exhaust

18
25 9 M 10
Compressed
52 air discharge

PS2
6

7 8
2
3
TH3
TH2 4
20 MOHR
14
Intercooler
13 15 17 5
32
PS1
condensate Air intake for
TH5
drain 24 11
23 1 39 main motor
TH4
35
PS4
63SV Control air for OMR
33
53
Air intake for 22
compressed air
21 31 36 15
Oil drain 14
Oil drain 34
38 13
Aftercooler condensate drain

Cooling air flow Compressed air flow Lubricating oil flow

Legend of the Diagram Legend of Sensors and Switches

Compressor Air Flow Capacity Control & Blowoff Air Flow Symbol Part name
1 1st-Stage Airend 21 Air Intake Filter PS2 Pressure Sensor (discharge air pressure)
2 2nd-Stage Airend 22 Suction Throttle Valve PS4 Pressure Sensor (oil pressure)
3 Gear Case 23 Blowoff Valve PS1 Pressure Sensor (interstage pressure)
4 Step-up Gear 24 Blowoff Silencer TH2 Temperature Sensor (2nd-stage in)
5 Main Motor 25 Blowoff Cooler TH4 Temperature Sensor (1st-stage out)
6 Intercooler TH3 Temperature Sensor (2nd-stage out)
7 Check Valve Oil Flow TH5 Temperature Sensor (oil)
8 Aftercooler 31 Oil Strainer Themostat (for main motor
MOHR
9 Air Relief Valve 32 Oil Pump bearing temperature)
10 Discharge Port 33 Oil Relief Valve Pressure Differential Sensor (For
63SV
11 Check Valve suction filter clogging detection)
34 Oil Cooler
13 Orifice 35 Oil Filter
14 Drain Solenoid 36 Temperature Control Valve
15 Y-type Strainer 38 Oil Drain Valve
16 Drain trap 39 Oil Mist Remover
17 Demister
18 Motorized isolation valve Air Flow and Other
20 Drain separator 51 Fan
52 Enclosure
53 Air Intake Duct

7
2.2.2 Water-Cooled

Compressed Air Flow and Oil Flow

51
Air exhaust Air exhaust Air exhaust

18
23 22 24 10
9 M
52 Compressed
23 22 air discharge

PS2
6

7 2 8
3
TH3
20 TH2 4 THM
14
13 15 17 5
Intercooler 32
PS1
condensate Air intake for
drain TH5
11 1 main motor
TH4
39
35
PS4
63SV Control air for OMR
33
53
Air intake for
compressed air
31 36
21 15
Oil drain 14
Oil drain 34
38 13
Drain discharge
Cooling air flow Compressed air flow Lubricating oil flow

Legend of the Diagram Legend of Sensors and Switches

Compressor Air Flow Capacity Control & Blowoff Air Flow Symbol Part name
1 1st-Stage Airend 21 Air Intake Filter PS2 Pressure Sensor (discharge air pressure)
2 2nd-Stage Airend 22 Blowoff Solenoid Valve (1) PS4 Pressure Sensor (oil pressure)
3 Gear Case 23 Blowoff Solenoid Valve (2) PS1 Pressure Sensor (interstage pressure)
4 Step-up Gear 24 Blowoff Silencer TH2 Temperature Sensor (2nd-stage in)
5 Main Motor TH4 Temperature Sensor (1st-stage out)
6 Intercooler Oil Flow TH3 Temperature Sensor (2nd-stage out)
7 Check Valve 31 Oil Strainer TH5 Temperature Sensor (oil)
8 Aftercooler 32 Oil Pump Temperature Sensor (for main
THM
9 Air Relief Valve 33 Oil Relief Valve motor surface temperature)
10 Discharge Port 34 Oil Cooler Pressure Differential Sensor (For
63SV
suction filter clogging detection)
11 Check Valve 35 Oil Filter
13 Orifice 36 Temperature Control Valve
14 Drain Solenoid 38 Oil Drain Valve
15 Y-type Strainer 39 Oil Mist Remover
16 Drain trap
17 Demister Air Flow and Other
18 Motorized isolation valve 51 Fan
20 Drain separator 52 Enclosure
53 Air Intake Duct

8
Cooling Water Flow

Intercooler

Aftercooler
2nd-stage
airend

Oil cooler

1st-stage
airend

Motorized
water isolation
M

valve (WIVM) Water relief pet cock

Cooling
Cooling water
water outlet
inlet
Cooling water
outlet
Compressed air flow Cooling water flow

9
2.3 Capacity Control System Standard
2.3.1 Fix speed type (Load-Unload Operation) Air-Cooled Water-Cooled
The unloading process occurs when the compressed opens and exhausts the internal compressed air to
air demand decreases and the discharge pressure rises atmosphere.
as high as cut-out pressure. The pressure sensor (PS) The loading process occurs when the compressed air
detects the high pressure and energizes the 3-way demand increases and the discharge pressure dropped
solenoid valve (20Ux), changing its por t to por t as low as cut-in pressure. When the pressure sensor
connection. The control air is now flowing to and (PS) detects the low pressure, 3-way solenoid valve
pressurizing chamber (A) of the suction throttle valve (20Ux), suction throttle valve (STV), and blowoff valve
(STV), consequently closing the suction throttle valve work in reverse action and the airend reloads.
(STV) and unloading the airend while the blowoff valve

STARTING UNLOADING RELOADING STOPPING

Suction throttle valve (STV) closed Air demand decreases Air demand increases STOP button ON

START button ON Discharge pipe pressure rises Discharge pipe pressure drops 3-way solenoid valve (20Ux)
switched over to pressurize
Airend starts rotation to Pressure sensor (PS) operates Pressure sensor (PS) operates Chamber (A)
compress minor amounts of air
3-way solenoid valve (20Ux) 3-way solenoid valve (20Ux) Suction throttle valve
Starts in no load switched over to pressurize switched over to pressurize (STV) closes
Chamber (A) Chamber (B)
Changes to full voltage delta connection Blowoff valve opens
Suction throttle valve Suction throttle valve
3-way solenoid valve (20Ux) (STV) closes (STV) opens
switched over to connect Internal air in discharge pipe
Chamber (A) & Chamber (C) Blowoff valve opens Blowoff valve closes is exhausted to atmosphere

Suction throttle valve (STV) opens Internal air in discharge pipe Loading Compressor stops
is exhausted to atmosphere
Loading
3-Way Solenoid
3-Way Solenoid Valve (4) Valve (1) 20U1
20U4
To Chamber (B) Control air flow
COM
Vacuum valve
NO Starting/Stopping
To Chamber (A)
3-Way Solenoid Valve (20US) NC
Loading
Blowoff
valve 20US Unloading
NO
COM
NC COM

To the NO NC
Chamber (B) Chamber (A) Atmosphere For 20 seconds
Chamber COM
(C) COM
after starting with
a star-delta starter.
NC NC
NO NO
Suction Throttle Valve
20U2
3-Way Solenoid Valve (3) 3-Way Solenoid
20U3 Valve (2)
NC-COM connected for
5 seconds after reactor
is changed over to a
fullvoltage connection.
1st-stage
airend
Control Line Filter

Intercooler

Check valve Pressure sensor

Check valve Aftercooler PS

2nd-stage
airend
Compressed Air Discharge

10
2.3.2 Fix speed type (AUTO Operation) Air-Cooled Water-Cooled
AUTO operation is the Auto start - stop function in When the load ratio is less than 30%, CPU stop the main
addition to a standard on-off line, 0% or 100% capacity motor. And automatically restar t when the line
2-step control. The CPU on the PC board is continually pressure is dropped to cut-in pressure.
calculating a load ratio.

STARTING UNLOADING RELOADING STOPPING

Suction throttle valve (STV) closed Air demand decreases Air demand increases STOP button ON

START button ON Discharge pipe pressure rises Discharge pipe pressure drops 3-way solenoid valve (20Ux)
switched over to pressurize Load-Unload Operation
Chamber (A)
Airend starts rotation to Pressure sensor (PS) operates Pressure sensor (PS) operates
compress minor amounts of air
Suction throttle valve
3-way solenoid valve (20Ux) 3-way solenoid valve (20Ux) (STV) closes
Starts in no load switched over to pressurize switched over to pressurize
Chamber (A) Chamber (B)
Changes to full voltage Blowoff valve opens
delta connection Suction throttle valve Suction throttle valve
(STV) closes (STV) opens Internal air in discharge
3-way solenoid valve (20Ux) pipe is exhausted to
switched over to connect atmosphere
Chamber (A) & Chamber (C) Blowoffvalve opens Blowoff valve closes

Suction throttle valve (STV) opens Compressor stops

Internal air in discharge Loading
pipe is exhausted to
Loading atmosphere

How long has Less than 10 minutes

motor been
running ?
10 minutes or more

30% or more
Load rate ?

Less than 30%

Has motor stopped and YES

restarted 3 times or more for
90 minutes ? If the third stop is done after 70
minutes or more has passed
NO after the first stop, the motor
continues to operate for 20
minutes after restart of the air
compressor, and then return to
the initial cycle.

Motor stops automatically

AUTO Operation

What is the plant How long has

compressed air piping motor been
Less pressure ? 15 sec or stopped ?
than more
specified Less than
15 seconds

More than specified STV: Suction Throttle Valve

20Ux: 3-Way Solenoid Valve

11
2.3.3 Capacity Control System Air-Cooled Water-Cooled

Air intake
Purging Air Flow and Action of Blowoff Solenoid Valve
Blowoff solenoid Blowoff solenoid
Air Intake filter 1st-stage blowoff solenoid valve (2) Operation phase
valve (1) valve (2)
Starting Fully opened Fully closed
Loading Fully closed Fully closed
1st-stage blowoff solenoid valve (1) Purging Fully opened Fully closed
Stop Fully opened Fully opened
Power Interruption Fully closed Fully opened
1st-stage 2nd-stage blowoff solenoid valve (1)
airend

Blowoff
2nd-stage blowoff solenoid valve (2) silencer

Intercooler

Pressure sensor

PS2
2nd-stage
airend Aftercooler
Air
discharge
Check valve

■ Relationship between Air Consumption Rate and Capacity Control System

※ The value in ( ) is indicated for water-cooled type.
Pressure setting
Rated Air Operating psi [MPa] Capacity
Model pressure consumption Capacity control system control type
(%) frequency (Hz) Example
psi [MPa] Initial of Lower

55 kW 100 - 75 (65) 134 (136) - 108 (108) AUTO ON

① CPCS motor Control VSDA
125 [0.86] 125 [0.86] 120 [0.83] or
speed control pressure AUTO OFF
75 kW 100 - 60 (50) 133 (137) - 80 (72) VSDB

Cut-out
55 kW 75 (65) - 5 82 138 [0.95] 125 [0.86] AUTO ON
pressure VSDA
② Two-step purge
125 [0.86] or
control Cut-in AUTO OFF
75 kW 60 (50) - 5 66 (60) 131 [0.90] 120 [0.83] VSDB
pressure

③ Motor stop/ Cut-in

All 125 [0.86] 5-0 Main motor stop 131 [0.90] 120 [0.83] AUTO ON
model restart control pressure VSDA

The air compressor supports the three (3) capacity control systems as shown above.
Depending on the varying air consumption, an appropriate system is automatically selected. For more information, see
the following page. Operation frequency is shown by Digital monitor. LCD monitor displays up to first figure after
decimal place.

12
3. MAINTENANCE
3.1 Standard Maintenance Schedule
Maintenance Schedule A (for 8,000 hours/year or less operation)
Follow this schedule (A) if the MAINT.SCHEDULE : A appears on the LCD monitor.
○●… Replace △○… Complete service in house
△▲… Clean or check ▲●… Ask your distributor to service

1 Daily and 3-month Schedule (for 8,000 hours/year or less operation)

Category
Part or Item Action Every Type Remarks
Dally
3 months
LCD indications Check △ Fixed / V Record data in the OPERATION RECORD LOGBOOK.
Oil level Check △ Fixed / V Add as required
Aftercooler/ Intercooler - Condensate Drain △ Fixed / V
Control line filter - Condensate Check △ Fixed
Main motor greasing – △ Fixed / V Fixed speed type: both DE / NDE side, Vtype: DE side

2 Bi-Annual Schedule (for 8,000 hours/year or less operation)

Part or Item Action Category Type Remarks
Air intake fitter Replace ○ Fixed / V
Oil filter (secondary) – Pressure Check △ Fixed / V Replace as required.
Control line filter – Condensate Clean △ Fixed
Strainer – Aftercooler/ Intercooler condensate drain Clean △ Fixed / V
Oil strainer (primary) Clean ▲ Fixed / V Clean as required.
Aftercooler/ Intercooler/ Oil cooler (air side) Check / Clean ▲ Fixed / V Clean as required.
Hi-Precooler Check / Clean ▲ Fixed / V Clean as required. (Air-cooled 125psi (0.86)MPa type)
Blowoff solenoid valve - Operation Check ▲ Fixed / V
Check valve - Leakage Check ▲ Fixed / V
Air relief valve - Operation Check ▲ Fixed / V

3 Annual and 3-Year Schedule (for 8,000 hours/year or less operation)

Category
Part or Item Action Type Remarks
1-year 3-year
Lubricating oil Replace ○ Fixed / V
Joints, Bolts, Nuts Tighten / Check △ Fixed / V
Air intake filter Replace ○ Fixed / V
Gasket - Inter/aftercooler condensate strainer Replace ○ Fixed / V
O ring - Inter/aftercooler condensate strainer Replace ○ Fixed / V
Oil strainer (primary) Clean ▲ Fixed / V
Oil filter (secondary) Replace ● Fixed / V
Consumable parts - Suction throttle valve Replace ● Fixed
Seal washer - Suction throttle valve Replace ● Fixed
Seal gasket - Suction throttle valve Replace ● Fixed
Thermistor, Pressure sensor, PCB other Electric parts Check ▲ Fixed / V Change any operating parts in need replacement.
Check for crack
Cooling fan ▲ Fixed / V
/ Clean
Check for crack
Contoller fan (1), DCBL controller ▲ V Clean the fin and duct
/ Clean
Check for crack
Cooling fan for fan inverter ▲ Fixed Clean the fin (Air-cooled type)
/ Clean

13
 Category
Part or Item Action Type Remarks
1-year 3-year
Orifice- Aftercooler condensate Check / Clean ▲ Fixed / V Clean as required.
Orifice and check valve- Intercooler condensate Check / Clean ▲ Fixed / V Clean as required.
Aftercooler/ Intercooler/ Oil cooler Check / Clean ▲ Fixed / V
Hi-Precooler Check / Clean ▲ Fixed / V Clean as required. (Air-cooled 125psi (0.86)MPa type)
Demister - Drain separator Check / Clean ▲ Fixed / V
3-Way solenoid valve & capacity control system Check ▲ Fixed Replace as required.
Blowoff solenoid Valve Check ▲ V
Air relief valve Check / Clean ▲ Fixed / V
Protection, Safety device Check ▲ Fixed / V Change any operating parts in need of replacement.
Motors Check / Clean ▲ Fixed / V Clean and measure the insulation for any resistance.
Relay (Drain solenoid valve) Replace ● Fixed / V

4 2-Year Schedule (for 8,000 hours/year or less operation)

Part or Item Action Category Type Remarks
Control line filter element Replace ○ Fixed
Blowoff solenoid valve (1) (2) Replace ● V
Consumable parts - Oil Pump Replace ● Fixed / V
Check valve Replace ● Fixed / V
Solenoid valve - Intercooler/ Aftercooler condensate Replace ● Fixed / V Replace the strainer together
Check valve & strainer- Intercooler condensate Replace ● Fixed / V
Check valve - Control line Replace ● Fixed
DCBL Controller Check / Clean ▲ V Clean the fin and duct.
Controller fan (1), DCBL controller Replace ● V
Cooling fan for control panel Replace ● Fixed Clean the fin (Air-cooled type)
Cooling fan for control panel Replace ● Fixed / V Except 45/55kW fixed speed type

5 6-Year Schedule: Overhauling (for 8,000 hours/year or less operation)

Part or Item Action Category Type Remarks
Airend (1st-stage, 2nd-stage) Replace ● Fixed / V A whole airend is replaced with a new
Main motor bearing Replace ● Fixed / V
Fan motor bearing Replace ● Fixed / V Air-cooled type
Demister - Drain separator Replace ● Fixed / V
3-Way solenoid valve Replace ● Fixed
Oil strainer (primary) Replace ● Fixed / V
Control line filter - Condensate Replace ● Fixed
Oil level gauge Replace ● Fixed / V
Shaft seal - Main motor Check / Clean ● Fixed / V
Temperature control valve Replace ● Fixed / V
Smoothing condenser - Controller Replace ● V
Check / Clean
PC board assembly (Including LCD) ● Fixed / V
/ Replace
Check for contamination and discoloration.
Check / Clean
Power PCB - Controller ● V Replace as required.
/ Replace
Can be used further if appropriate.
Check / Clean
Communication board ● Fixed / V
/ Replace
Electromagnetic contactor Check ▲ Fixed / V Replace as required.
Lithium battery Replace ● Fixed / V
Fan inverter Replace ● Fixed / V Air-cooled type

14
Maintenance Schedule B (for 4,000 hours/year or less operation)
Follow this schedule (B) if the MAINT.SCHEDULE : B appears on the LCD monitor.
○●… Replace △○… Complete service in house
△▲… Clean or check ▲●… Ask your distributor to service

1 Daily Schedule (for 4,000 hours/year or less operation)

Part or Item Action Category Type Remarks
LCD indications Check △ Fixed / V Record data in the OPERATION RECORD LOGBOOK.
Oil level Check △ Fixed / V Add as required
Aftercooler/ Intercooler - Condensate Drain △ Fixed / V
Control line filter - Condensate Check △ Fixed

2 Bi-Annual Schedule (for 4,000 hours/year or less operation)

Part or Item Action Category Type Remarks
Air intake fitter Replace ○ Fixed / V
Main motor greasing – △ Fixed / V Fixed speed type: both DE / NDE side, Vtype: DE side
Oil filter (secondary) – Pressure Check △ Fixed / V Replace as required.
Control line filter – Condensate Clean △ Fixed
Strainer – Aftercooler/ Intercooler condensate drain Clean △ Fixed / V
Oil strainer (primary) Check / Clean ▲ Fixed / V Clean as required.
Aftercooler/ Intercooler/ Oil cooler (air side) Check / Clean ▲ Fixed / V Clean as required.
Hi-Precooler Check / Clean ▲ Fixed / V Clean as required. (Air-cooled 125psi (0.86)MPa type)
Blowoff solenoid valve - Operation Check ▲ Fixed / V
Check valve - Air leak Check ▲ Fixed / V
Air relief valve - Operation Check ▲ Fixed / V

3 Annual Schedule (for 4,000 hours/year or less operation)

Part or Item Action Category Type Remarks
Lubrication oil Replace ○ Fixed / V Replace every 8,000h operating hour or 2 year, whichever comes earlier
Joints, Bolts, Nuts Tighten / Check △ Fixed / V
Air intake filter Replace ○ Fixed / V
Gasket - Inter/Aftercooler condensate strainer Replace ○ Fixed / V
O ring - Inter/Aftercooler condensate strainer Replace ○ Fixed / V
Oil strainer (primary) Clean ▲ Fixed / V
Thermistor, Pressure sensor, PCB other Electric parts Check ▲ Fixed / V Change any operating parts in need replacement.
Check for crack
Cooling fan ▲ Fixed / V
/ Clean
Check for crack
Contoller fan (1), DCBL controller ▲ V Clean the fin and duct
/ Clean
Check for crack
Cooling fan for fan inverter ▲ Fixed / V Clean the fin (Air-cooled type)
/ Clean
Orifice- Aftercooler condensate Check / Clean ▲ Fixed / V Clean as required.
Orifice and check valve- Intercooler condensate Check / Clean ▲ Fixed / V Clean as required.
Aftercooler/ Intercooler/ Oil cooler (air side) Check / Clean ▲ Fixed / V

15
 Part or Item Action Category Type Remarks
Hi-Precooler Check / Clean ▲ Fixed / V Clean as required. (Air-cooled 125psi (0.86)MPa type)
Demister - Drain separator Check / Clean ▲ Fixed / V
3-Way solenoid valve & capacity control system Check ▲ Fixed Replace as required.
Blowoff solenoid Valve Check ▲ V
Air relief valve Check / Clean ▲ Fixed / V
Protection, Safety device Check ▲ Fixed / V Change any operating parts in need of replacement.
Motors Check / Clean ▲ Fixed / V Clean and measure the insulation for any resistance.

4 3-Year Schedule (for 4,000 hours/year or less operation)

Part or Item Action Category Type Remarks
Control line filter element Replace ○ Fixed
Oil filter (secondary) Replace ● Fixed / V
Consumable parts - Suction throttle valve Replace ● Fixed ※
Seal washer - Suction thorottle valve Replace ● Fixed ※
Seal gasket - Suction thorottle valve Replace ● Fixed ※
Blowoff solenoid valve (1) (2) Replace ● V
Consumable parts - Oil Pump Replace ● Fixed / V
Check valve Replace ● Fixed / V
Solenoid valve - Intercooler/ Aftercooler condensate Replace ● Fixed / V
Check valve & strainer- Intercooler condensate Replace ● Fixed / V
Check valve - Control line Replace ● Fixed
DCBL Controller Check ▲ V Clean the fin and duct.
Controller fan (1), DCBL controller Replace ● V
Cooling fan for fan inverter Replace ● Fixed Clean the fin (Air-cooled type)
Cooling fan for control panel Replace ● Fixed / V Except 45/55kW fixed speed type
Relay (Drain solenoid valve) Replace ● Fixed / V
※When the power-saving operation is used, the parts need to be replaced every 2 years.

5 6-Year Schedule: Overhauling (for 4,000 hours/year or less operation)

Part or Item Action Category Type Remarks

Airend (1st-stage, 2nd-stage) Replace ● Fixed / V A whole airend is replaced with a new
Main motor bearing Replace ● Fixed / V
Fan motor bearing Replace ● Fixed / V Air-cooled type
Demister - Drain separator Replace ● Fixed / V
3-Way solenoid valve & capacity control system Replace ● Fixed
Oil strainer (primary) Replace ● Fixed / V
Control line filter - Condensate Replace ● Fixed
Oil level gauge Replace ● Fixed / V
Shaft seal - Main motor Check / Clean ● Fixed / V
Temperature control valve Replace ● Fixed / V
Smoothing condenser - Controller Replace ● V
Check / Clean
PC board assembly (Including LCD) ● Fixed / V
/ Replace
Check for contamination and discoloration.
Check / Clean
Power PCB - Controller ● V Replace as required.
/ Replace
Can be used further if appropriate.
Check / Clean
Communication board ● Fixed / V
/ Replace
Electromagnetic contactor Check ▲ Fixed / V Replace as required.
Lithium battery Replace ● Fixed / V
Fan inverter Replace ● Fixed / V Air-cooled type

16
3.2 Maintenance Schedule for Oil Mist Remover
① To ensure long and successful operation of the Oil ③ These maintenance inter vals are not considered
Mist Remover, follow the standard maintenance warranty.
schedule attached below.
④ If an inspected par t is worn, faulty or damaged,
② The standard maintenance schedule service intervals replace it as soon as possible.
stated below are based on normal environmental and
⑤ ○●: Replace △▲: Clean or check
operating conditions. If the Oil Mist Remover is in
○△: Complete service in house
severe environmental and operating conditions, use
●▲: Ask your distributor to service
more frequent service intervals.

Item Daily Bi-annually Annually 6-yearly Remarks

Regulator settings △
Vacuum indicator △
Relief valve △
Regulator performance △
Float trap nozzle △ Disassemble and clean.
Vacuum indicator △ Disassemble and clean.
Filter element △ Disassemble and clean.
Remover element ●
Filter element ●
Relief valve sheet/spring ●
Vacuum indicator ●
Disassemble and clean.
Filter regulator ●
Replace diaphragm and valve stem.
Disassemble and clean.
Ejector ▲
Replace if it is too dirty.
Disassemble and clean. Replace as
Solenoid valve ▲
required.
Solenoid valve coil assembly ●

CAUTION
The oil mist remover reduces oil consumption to almost zero. However, the oil should still be replaced
annually.

17
4. HOW TO SERVICE THE AIR COMPRESSOR
Before servicing the air compressor, stop it, disconnect the power (turn off the earth leakage (ground) circuit
breaker) and verify that the compressor’s internal pressure has dropped to atmospheric pressure.
The maintenance intervals shown refer to the standard Maintenance Schedule (A).

4.1 Replacement of Air Intake Filter (Bi-Annually)

A pressure sensor is provided on the suction throttle
valve to detect the pressure differential across the air
intake filter. When the sensor detects a pressure
Differential pressure sensor dif ferential as large as 0.72 psi (4.98 kPa) during
operation, AIR FILTER appears on the LCD display
with E0.21 on digital monitor. If this occurs, clean or
replace the air intake filter in accordance with
Maintenance Schedule (A) or (B). The procedure for
Air Intake filter cleaning the air intake filter is as follows.

Wing nut ① Stop the air compressor, disconnect the power and
verify no internal pressure.
② Remove the front door (1).
③ Remove the cover and wipe away the dirt inside of
the duct before removing the air intake filter.
④ Loosen the wing nut and remove the air intake filter.
Make sure the contamination and/or dust doesn’t
Cover enter the airend side.
Duct ⑤ Tap the air intake filter to remove large particles.
Then blow air to clean the surface of filter.
⑥ In the case of oily or carbon dust, dip the element
into neutral detergent and water solution for about 30
minutes. Rinse the element several times with clean
water (water pressure is less than 39 psi (0.27MPa))
and air-dr y it. Confirm the element is dried
completely.
⑦ Reinstall and tighten the wing nut.

CAUTION
If the air intake filter is clogged with dust/dirt particles; Differential pressure (resistance of flow) across
the air intake filter increases, which results in decreased air intake to the airend and a rise in discharge
air temperature. To avoid a problem, service the air intake filter regularly. If the compressor room
environment is dusty or dirty, service the air intake filter more frequently than instructed on the
Maintenance Schedule.

■ Filter Specifications

12.7mm 254mm Effective filtration area: 40.8 ft² (3.79 m2)

(0.50inch) (10.0inch)
Filtration efficiency: 98% or higher (full life)
(φ9.50inch)
φ241.2mm

18
4.2 Condensate drain port (Intercooler/Aftercooler) (Daily check)
Clean the strainer elements (Bi-Annually) & Orifices (Annually)
■ Check the condensate drain
Moisture in the intake air, especially in hot and humid environments, is condensed inside the air compressor during
compression. Daily inspect intercooler/aftercooler condensate drain to verify that there is a discharge of
compressed air (with condensate) when the air compressor is loaded. Bi-annually, clean the strainer element and
annually clean the orifice for both intercooler/aftercooler.

■ Operation of drain solenoid valve

Detailed open/close operations of the drain solenoid valve for the intercooler and aftercooler are as follows:

① During starting
 ・After operation startup (Y1 ON) and start unload, the valve opens 1 second.

② During loading
 ・The valve opens 2 seconds in every 45 seconds for 45/55 kW model.
 ・The valve opens 2 seconds in every 30 seconds for 75 kW model.

2S

45S for 45/55 kW

30S for 75 kW

③ During unloading (For V type, during blowoff)

 ・After 1 second has passed since unloading, the valve opens 1 second. If unload is continued, the valve will open
1 second in every 600 seconds.

④ During operation stop (including automatic stop)

 ・After 1 second has passed since operation stop, the valve opens 1 second.
(If the valve is open at the time of operation stop, the valve will be closed once.)

⑤ After operation stop

 ・The valve opens 1 second in every 30 minutes

1S

30min

19
 ■ Depressurizing the System
Aftercooler side Before cleaning the drain pipe, intercooler,
Ball valve (2)
aftercooler, control line filter, or replacing the check
Three-way change valve
valve, reduce the internal pressure to 0 (zero) by
Ⓔ Ⓕ opening the condensate drain. Stop the air
Ⓓ
compressor and disconnect the main power. Close
Ball valve
(1) Ⓒ Ⓐ Ⓑ the stop valve of the compressed air discharge.
Remove rear panel (1) [Ref No. 911] and rear panel
(3) [Ref No. 913].

(1) Intercooler side

Intercooler side
Turn the three-way change valve from Ⓐ to Ⓑ.

(2) Aftercooler side

Turn the ball valve (1) from Ⓒ to Ⓓ. And Turn the
ball valve (2) from Ⓔ to Ⓕ.

Verify that the interstage pressure (INTSTG.P) and

discharge pressure (DIS PRESS) is 0(zero) on the LCD
monitor. In addition, remove the parts slowly because
the pressure is still remained in air pipings due to the
wrong operation or piping works.

20
◆ Cleaning of strainer ■ Cleaning of strainer element
The strainers for both the intercooler and
aftercooler shall be cleaned.
① Discharge the compressed air in the procedure in
page 20.

Element ② Loosen the plug of strainer slowly with release the

Strainer internal pressure.
Gasket
③ Remove the cover of the strainer.
Plug
④ Remove the element, wash with water and blow air.
Tighten
⑤ Remove the element from inside the strainer and
Loosen wash with water.

⑥ Replace the cleaned element in its original position

and set the O-ring or gasket, and plug properly.

◆ Cleaning of orifice ■ Cleaning of orifice

Inspect and clean the orifices annually. Be sure to
stop the air compressor before inspecting and/or
cleaning the orifices.

■ Replacement of the strainer and solenoid

Orifice valve
Replace the solenoid valve and the strainer every 2
years (if operating 8000 hours/year) or 3 years (if
operating 4000 hours/ year) to new whole
assembled parts.

CAUTION
● Verify that there is discharged air with
condensate is discharged through the drain
Orifice ports of intercooler and aftercooler every
45seconds for 45/55 kW model and every 30
seconds for 75 kW model during loading.
● If compressed air is not discharged, clean
and unclog the drain port (filter & orifice).
● Operating the air compressor without
draining the condensate from the
intercooler/afterooler, may rust the airend
internally and cause a major failure.

21
◆ Disassembly of strainer element during operation ■ Cleaning the strainer element during
operation
If the strainer needs to be cleaned while the air
Aftercooler side compressor is running, contact the local HITACHI
Ball valve (2) distributor/master dealer or representative office.
Three-way change valve
While the air compressor is running, strainer is
Ⓔ Ⓕ
Ⓓ always pressurized. Be careful extremely to the
high pressure when the strainer is removed.
Ⓒ
Ball valve Ⓑ (1) Intercooler side
(1) Ⓐ
① Turn three-way change valve on the intercooler
side from Ⓐ to Ⓑ.
② Element is still pressurized depending on the
Intercooler side solenoid valve action, so be careful extremely
when opening the strainer plug. Remove the
strainer element.
③ Wash the element with water and blow air, and
reassemble it.
④ Turn three-way change valve from Ⓑ to Ⓐ.

(2) Aftercooler side

① Turn ball valve (1) on the aftercooler side from
◆ Valve conditions during normal operation Ⓒ to Ⓓ.
② Check that ball valve (2) is completely closed (Ⓔ
side). In this state, strainer pressure in the
Aftercooler side
Ball valve (2) solenoid valve is released by solenoid valve
Three-way change valve action.
③ After verifying the compressed air is discharged,
remove the strainer element. If solenoid valve
(1) or (2) is opened even slightly, strainer is still
Ball valve
pressurized.
(1)
④ If solenoid valve (2) is opened to the Ⓕ side in
this state, condensate can be drained while
Intercooler side
cleaning the strainer element.
⑤ Wash the element with water and blow air, and
reassemble it.
⑥ Turn the ball valve (1) on the aftercooler side
from Ⓓ to Ⓒ. Also check that ball valve (2) is
completely closed (Ⓔ side).

22
4.3 Lubricating oil Replacement (Annually)
■ Oil drain
① Stop the air compressor and disconnect the power.
Remove the front door (1) and left door.
② Place oil pans under the oil drain ports ①②③. The
dimension of oil pan is approximately 3 × 10 × 14
inches (75 × 250 × 300 mm). Prepare the oil jug of
6.6 gal (25 liters) or more for air-cooled type, and 3.9
gal (15 liters) or more for water-cooled type.
③ Remove the plugs of oil drain ports ① and ②. Then
connect copper pipes to the ports. The dimensions
of the copper pipes is 1/2B × 2 to 4 inches (1/2B ×
50 to 100 mm). After that, open the oil drain valves
Left door Front door (1) ① and ② to drain lubricating oil.
④ After opening oil drain valves ① and ②, remove the
Plug
Water-Cooled (for oil/air vent) Oil case plug (for oil/air vent). (Note that the oil/air vent
Air-Cooled
location of air-cooled type and water-cooled type are
Plug
(for oil/air vent) different.)
⑤ Remove the plug from oil drain port ③ to drain
Oil filling port plug
lubricating oil.
Oil cover
⑥ Replace all lubricating oil annually. Also once a year,
Oil drain valve ①
(for oil case draining) remove the oil port cover and wipe the sludge off of
the bottom of the gear case with a sponge and clean.
Oil drain valve ② ⑦ Close oil drain valves ① and ②. Tighten removed
(for oil case draining)
plugs with seal tape to oil drain ports ①, ②, ③ and
oil/air vent.
Oil filter
Yellow line ■ Oil filling
⑧ Remove the oil filling port plug, and fill the oil until
Oil drain port ① Oil drain port ②
Pan (with plug) (with plug) the oil reaches the upper red line of the oil level
gauge.

■ Check/refilling
Water-Cooled only
⑨ Turn on the power, press the START button and
press the STOP button after 5 – 6 seconds running.
⑩ Check the oil level on the oil level gauge. The oil
level drops because lubricating oil flows to the
piping, oil cooler and so on.
Oil drain port ③
(with plug) ⑪ Disconnect the power and add the oil until upper red
line.
WARNING ⑫ After refilling is complete, plug tightly.
● Change the oil regularly, as instructed in the ⑬ Turn the power on, press the START button and
standard maintenance schedule ( page make sure the oil level is between the upper and
13 to 16). Neglecting to change the oil lower red lines of the oil level gauge.
causes oil deterioration that could result in ⑭ Make sure no oil leaks from the oil drain valve and
clogging of the oil strainer and a fire. plugs.
● Be sure to use genuine Hitachi GL-68 DSP
compressor. Absolutely DO NOT mix
different types of lubricating oil.
● Overfilling with lubricating oil may increase
shaft power and result in rise in oil temperature.

23
4.4 Cleaning of Oil Strainer (Primary Side) (Bi-Annually)
① Drain the lubricating oil in the procedure described
in page 23.
② Remove the front door (1) [Ref. No. 904] and left
door [Ref. No. 991].
③ Remove the strainer cover. Then remove the oil
strainer and clean it.
④ Replace the oil strainer when overhauling the air
compressor.

IMPORTANT
Clogging of the oil strainer drops the oil pressure of the air
Oil Strainer compressor.
● Vtype
If the oil pressure sensor detects an oil pressure as low
as 12 psi (0.08MPa) or lower for operation frequency
Strainer cover
110 Hz or higher, or 6 psi (0.04MPa) for operation
frequency less than 110Hz, the air compressor
automatically shutdowns.
● Fixed-speed type
If oil pressure sensor detects an oil pressure as low as
12 psi (0.08MPa) or lower, the air compressor
automatically shutdowns.

4.5 Replacement of Oil Filter (Secondary Side) (Annually)

① Drain the lubricating oil in the procedure described
in page 23.
② Remove the left door [Ref. No. 991] and left panel
[Ref. No. 910].
③ Place an oil pan under the oil filter.
④ Use a filter wrench to loosen and remove the oil
filter from the oil support on the gear case. Remove
and replace the oil filter element.
⑤ Apply clean oil onto the filter O-ring. Tighten the oil
filter until the O-ring surface comes in contact with
the oil filter seating surface.
⑥ Seat the oil filter O-ring by tightening the filter with
Pan both hands. Immediately after the air compressor
(Prepare a pan with a size of restart verify that there is no leaks on the oil filter.
approx. 20 x 100 x 250 mm)

IMPORTANT

Clogging of the oil filter drops the oil pressure of the air
compressor.
● Vtype
If oil pressure sensor detects an oil pressure as low as
12 psi (0.08MPa) or lower for operation frequency 110
Hz or higher, or 6 psi (0.04MPa) for operation
frequency less than 110Hz, the air compressor
automatically shutdowns.
● Fixed speed type
If oil pressure sensor detects oil pressure as low as 12
psi (0.08MPa) or lower, the air compressor automatica
lly shutdowns.

24
4.6 Operation Check of Air Relief Valve (Bi-Annually)
① Maintain the rated maximum discharge pressure
(ex. 100psi(0.70MPa)).
[Rear view] Relief valve ring
② Pull the ring connected to air relief valve.

③ Verify that the air relief valve operates properly and

Relief valve get a hand off of the ring.

WARNING
During inspection of the operation of the air
relief valve, use the appropriate facial
protection. High pressure air containing dust
particles can cause severe injury.

Rear cover (3)

Rear cover (2) Rear cover (1)

4.7 Cleaning of Control Line Filter (Bi-Annually) [Fixed speed type]

① Discharge the compressed air in the procedure in
page 20.

② Remove the front door (1).

③ Remove the control line filter element, and then use

an air nozzle to blow out the inside surface (reverse
flow action) of the control line filter element in order
to remove any dust particles.

④ Replace the element at least every 2 years.

25
4.8 Clean Cooler (Annually)

Air-Cooled 1 For light and non-greasy dust particle

① Remove the front door and panel and rear panel
[Ref.No. 904, 905, 906, 944, 953, 911, 912, 913].

Maintenance ② Remove the maintenance cover (1)(2)(3)(4).

cover (2)
③ Use an air nozzle to blow the cooler surfaces.
Instrument
panel

For heavy and greasy dust particles

2
(detaching the cooler)
① Remove the enclosure panels.

② Drain the oil from the system.

Front panel ③ Disconnect all the sensor wires from the cooler.
Front door (2)
Front door (1)
Front frame ④ Disconnect all air / oil pipes at the joints.

⑤ Disconnect the discharge pipe.

⑥ Loosen and remove the cooler bolts.

Maintenance cover (4)
Maintenance cover (3)
Maintenance cover (1)
Magnet rubber
For heavy and greasy dust particles
3
(cleaning the detached cooler):
① Use an air nozzle to blow the cooler surfaces.

② Soak the cooler in a detergent bath or spray

detergent onto the cooler. Use an air nozzle to blow
the cooler surfaces.

③ Generally, there are 3 kinds of dust and dirt particles.

・Light dust particles
・Heavy dust particles
・Greasy dust particles
Contact the local HITACHI distributor/master
Rear panel (3) Rear panel (2) Rear panel (1)
dealer or representative office for the detail.

● Oil cooler
Water-Cooled
Scale removal
Remove the oil cooler water chamber cover. Flush
with scale remover and use a brass wire brush to
remove the scale from the inner surfaces of the oil
Wire brush
cooler tube nest.

● Intercooler/Aftercooler
Oil cooler If scale build up occurs often, contact the local
HITACHI distributor/master dealer or
representative office for scale removal.

26
4.9 Replacement of Check Valve (2-Yearly)

Air-Cooled 1 Depressurizing the System

Gasket (1) ① Discharge the compressed air in the procedure in

page 20.

Gasket (2)
Check valve cover
2 Removing the Enclosure Panels
(upper)
Remove the enclosure panels, such as front door (1)
Gasket
[Ref. No. 904], front panel [Ref. No. 906].
Check valve

Gasket
3 Disassembly
Check valve cover ① Loosen and remove the bolts tightened to the check
(lower)
valve cover (upper) for air-cooled.
(Check valve cover for water-cooled)

Flow direction (arrow direction) ② Remove the check valve cover, check valve, and
gasket.

③ Be careful for installing direction of the check valve.

Check
valve cover
Water-Cooled
Gasket
4 Cleaning and Inspection
Check valve
Suf ficiently clean the check valve and check valve
Gasket cover and so on. Make sure that no rust particles and/
or fragmented gaskets are left on the valve and/or
gasket contacting surfaces.
Aftercooler
header

Flow direction (arrow direction)

27
4.10 Main Motor Greasing
The main motor bearings must be greased as following ① Open the front door. Inject a specified amount of
table. grease through the grease inlet using a grease gun.
Grease following amount of RMS grease (Ref. No. 455)
② If used grease is discharged in the grease pan under
(Raremax Super by Kodo Yushi) .
the grease inlet, clean the pan as necessary.

③ Close the front door.

IMPORTANT

● Contact the local HITACHI distributor/master dealer or

representative office for the grease detail.
● Greasing must be done while the main motor The bearing on the opposite side is shield type; filling
operating.
of grease is not necessary on the opposite side.
● Cleaning of grease pan must be done while the air
compressor stops.

● Example of grease gun

Lever-type grease gun CH-400 Micro-Hose (pin type
SPK-1C) by Yamada Corporation
Grease filling amount
Filling Filling amount
Operation condition
frequency Fixed-speed Variable-speed
For 8,000 hours or less Every 3 Fill 2.3 oz
operating hours per year months (65 g) each Fill 2.6 oz
on the load (75 g) on the
For 4,000 hours or less Every 6 and opposite load side.
operating hours per year months sides.

[Fixed speed type]

Load-side bearing Anti-Load-Side bearing Load-side bearing
Grease port Grease port Grease port

Grease pan Grease pan Grease pan

CAUTION
Be cautious of replenishing grease more than the spcified amont. It may cause leaking of grease and/or
malfunction of the protective device due to overheat of the bearing. Grease at once during start-up
commissioning. Periodically replace the main motor bearing in accordance with “3. Maintenance”
Maintenance Schedule A Maintenance Schedule B in pages 13 to 16

28
4.11 Maintenance of Main Motor
① Checking the operating temperature ③ Disassembling
If the LCD monitor indicates main motor overload In a severe environment (dirty, corrosive, high dust
[OVERLOAD: MAIN] (fixed speed type) or temperature or high powder), disassemble and service the motor
increase of main motor fin [FIN-T] (Vtype), investigate every two years. In a normal environment, disassemble
the cause of the excessive heat and utilizing the Motor and service the motor every six years. For the most
Diagnostics and Troubleshooting chart below. common motor problems, see the Motor Diagnostic
② Cleaning and Troubleshooting chart below. If the problem
Clean the motor periodically to prevent dust cannot be solved with the chart, contact the local
particles from accumulating inside and outside of HITACHI distributor/master dealer or representative
the motor. When servicing the air compressor, office.
measure the insulation resistance of the motor
coil with a 500V megohmmeter and verify that
the insulation resistance is 1MΩ or more.

Motor Diagnosis and Troubleshooting

Phenomenon
Low Insulation Resistance
Overload Indication
Excessive Vibration
Excessive Rotation

Heated
Excessive Sound

Breaker Tripped
Electric Leak

Corrective Action
Bearing
Frame

Cause
Installation

Loose bolts ○ ◎ ○ Retighten the bolts.

Poor grounding ◎ Ground properly.

Note 3
Inadequate breaker capacity Replace with properly specified capacity breaker.
Wiring

○ ◎
Broken wires ○ Install new wires.
Note 3
Failed breaker, controller or contactor ○ ○ Check the contacts and replace if necessary.
Dust accumulation reduced cooling
○ Properly clean motor.
Environment

performance
Excessive ambient operating Improve the room ventilation or contact the local
◎ ○ ◎
temperature Hitachi distributor.
High humidity ◎ Contact the local Hitachi distributor.
Large external vibration/shock ◎ Take vibration and shock measurements.
Load Power Supply

Phase-lacking operation ◎ ◎ ○ ◎ ◎ ○ Check the brealer, contactor and motor wirings.

Check the wire thickness and length and contact the
Widely dropped voltage ○ ○ ◎ ◎
local power utilities company.
Fluctuating voltage ○ ○ ○ ○ Contact the local power utilities company.
Overload ○ ◎ ◎ ○ Check the capacity control system.
Thrust force by the machine ○ ○ ◎ Check the contact condition of bull gear and pinion gear.
Excessive bearing noise NOTE 2 ◎ ◎ ◎ ○ Contact the local Hitachi distributor.
Burnt motor coil NOTE 2 ○ ○ ○ ◎ ◎ ◎ ○ Contact the local Hitachi distributor.
NOTES)
1. ◎ : Close relationship between the cause and type of problem. 〇 : Relationship between the cause and type of problem.
2. Detect the fundamental cause of the problem and take corrective action.
3. Breaker, controller or contactors are hot.

29
4.12 Maintenance of Oil Mist Remover
1. Replacement of remover element 3. Maintenance of Relief Valve (See Fig. A.)
① Remove the pipe provided at the top of the remover ① Turn the nut at the top of the relief valve and remove
if required. Then remove 4 set screws (A) from the the plate. Replace the sheet and the spring with new
oil mist remover housing. components.
Pull up the upper part of the housing.
② Ensure that the spring is positioned at the center
② Loosen nut (B) and remove the cover. Now you can before assembly.
remove the remover element.

③ Install a new element. Carefully seat the upper and

4. Maintenance of Vacuum Indicator (See Fig. B.)
lower r ubber gaskets on the element without ① Contamination of the vacuum indicator may cause
allowing any gaps. malfunction of indicator.
Remove and clean the indicator at least every six
④ After replacement
months. In addition, replace the indicator once a year.
of element, grease (B)

the O-ring, replace Cover ② Pull down the indicator while pushing up the locked
the housing, and Rubber packing pipe joint at the top.
Remover
tighten set screws element Nut Spring
(A) diagonally and Plate Valve seat
O-ring
evenly.
Rubber packing

Locked joint
3/8 φ12

Pull
(A)
Fig. A Fig. B

2. Maintenance of Filter Regulator

5. Maintenance of Ejector
① Turn the cover to remove. Remove the baffle and
① If the ejector is dirty, performance may decrease.
replace the filter element with a new one.
Disassemble and clean at least once a year.
② Remove the upper 4 set screws and remove the
② The maintenance procedure is as follows:
upper part of the regulator. Replace the diaphragm
(1) Disconnect the control air tube at its detachable
and the valve stem with new components. Be careful
connection.
not to install the new diaphragm upside down.
(2) Loosen nut A (the nut can be tur ned
independently from the ejector body) and
disconnect the ejector from the manifold.
Diaphragm Screw (4 pcs)
(3) Remove the plastic case.
(4) Clean the ejector body with a neutral detergent
Stem
and dry it with an air nozzle. Assemble all of the
OUT IN
parts.
Regulator
O-ring
Valve
Filter element

Cover

Baffle

Nut A

30
 Confidential to Customer
4.13 Maintenance of Cooling fan and cooling fan motor
A picture and a drawing below indicate the structure of the cooling fan, fan motor and their fastening.
Cooling fan and fan motor is fastened by the left hand screw (L-bolt). Take care so that cooling fan is not damaged
when it is removed from the air compressor.

Fan motor Fasten part detailed Fan motor shaft

Keep the key direction.

F motor
mount Rounded edge is for the shaft end
and flat edge is for motor direction.

Cooling fan
(Turbo Fun)
Fan boss
Fan fixed plate
Spring washer
L-bolt

Fan Motor weight

45/55kW : approx. 80lbs(35kg),
75kW : approx. 90lbs(40kg)
Bell Mouth
Turbo Fun weight
45/55/75kW : approx. 35lbs(15kg)

F motor mount weight

45/55kW : approx. 18lbs(8kg),
75kW : approx. 20lbs(9kg)

55 kW 75 kW
Part name Model
460V
Fan Motor Output HP(kW) 2.0 (1.5) 2.9 (2.2)
Turbo fan Part number – 59042170 59042180
inch φ 0.866h6 (0-0.000512)
Shaft diameter
(mm) ( φ 22h6 (0-0.013))
φ 23.6
Fan diameter mm
( φ 600)
No. of impeller pcs. 7
inch 7.48
Impeller width
(mm) (190)
Part number – 59005050
Boss internal inch φ 0.866H8 (0 ＋ 0.000130)
diameter (mm) ( φ 22H8 (0 ＋ 0.033))
inch
L-bolt Bolt size M8 × 1.18 (30) (Left-hand thread)
(mm)

Fan motor bearing (ENS grease shielded)

Model 55 kW 75 kW
DE/ODE DE ODE DE ODE
Bearing type 6206ZZCM/L369 6206ZZCM/L369 6306ZZCMENSS 6306ZZCMENSS
Part number 5265B150 5265B150 52531140 52531140

31
 Confidential to Customer

4.14 The procedure to attach the motor cover Water-Cooled

(1) Fixed the thermostat on the DE side of end bracket.
Treat the cable with particular caution.

Be sufficiently careful not to The temperature sensing

portion is brazed into the
damage the temperature sensor.
portion circled in red. Be
careful not to damage this
Temperature Sensor brazed portion when
Fixing Bolt (M8×16) fixing.

(2) Assemble the motor with gear casing by spigot joint and tighten the M16 bolt with motor cover fixing bracket.
Attach the grease supply pipe on the motor DE side.

55kW (Figure viewed from motor anti-load side)

Grease
Supply Pipe

Motor Cover
Fixing bracket

Motor Cover
Fixing bracket

Air End side Motor side

Motor Connection Bolts (M16)

75kW (Figure viewed from motor anti-load side)

Grease Supply Pipe

Motor Cover
Fixing bracket

Air End side Motor side

Motor Cover Motor Connection Bolts (M16)

Fixing bracket

32
 Confidential to Customer

(3) Fix the motor cover 1 and 2 to the motor cover fixing bracket by M6 bolt and motor eyebolt.

55kW
Motor Cover 2

Notch
Motor Cover 1

Pull out the

temperature sensor
Motor eyebolt

Temperature
Rubber Bush Sensor

5×M6-25
Be sufficiently careful not to
damage the temperature sensor.

75kW
Motor Cover 2

Notch

Motor Cover 1
Pull out the
temperature sensor Motor eyebolt
Temperature
Rubber Bush Sensor

Be sufficiently careful not to

5×M6-25
damage the temperature sensor.

33
 Confidential to Customer
4.15 Maintenance of Oil Pump
4.15.1 Removal from the Gear Case Outer Rotor
Remove the oil piping from the oil pump. Then, detach Inner Rotor
the oil pump from the gear case. (When detaching the Inner Key
oil pump, be careful not to damage the gear.) Snap Ring

Bolt

Oil Pump Housing

Oil Piping Oil Pump body O-Ring

⑥ Hit the rotor-side end of shaft with a plastic or

Gear Case wooden hammer; do not use a steel hammer. Thus,
the assembly of shaft, bearings and oil seal can be
removed.

Driving-side
4.15.2 Disassembling
① Before disassembly, mark the matching positions on Shaft
the oil pump body and the bearing housing.
② Remove the gear support attached to the oil pump
Oil Seal
gear. Rotor-side
③ Pull out the oil pump gear using the gear removing
tool shown in Fig. 3, and then remove the key.
⑦ Place the removed assembly in a vice vertically; its
Oil Pump body rotor-side end must be downwards. Hit the shaft
Housing
with a plastic or wooden hammer to remove the
bearings.
Gear Support

Oil Pump Gear Ball Bearing

(Removing procedure)
Support Bolt, gear
Fix the oil pump gear and
the gear removing tool with ⑧ Remove the bush bearing from the bearing housing.
M6 bolts, and remove the
gear using the axial force Bush Bearing
of M10 bolt. M10 Bolt
M6 Bolt (2 places)

④ Loosen the bolts, and remove the bearing housing,

O-ring, outer rotor, inner rotor, and inner key in this
order. (Removing procedure)
Slide the hammer body to hit it strongly against the grip so
⑤ Remove the snap ring. that the bearing will be removed by the impact.

Bearing Puller Set

Bush Bearing
Hammer Body Grip

34
 Confidential to Customer
4.15.3 Cleaning and Checking
① Clean the oil pump body, inner rotor, outer rotor, ③ Attach the inner key to the pump side of the shaft.
and bearing housing. Then check the sliding Then fit the inner rotor and the outer rotor in this
sur faces of the components. If any damage is order.
detected, hand finish the component using an ④ Attach a bush bearing to the baring housing.
oilstone of #400 to #1000. ⑤ Attach an O-ring to the bearing housing. Then fit the
② Clean the shaft. Then, check the ball bearing, bush bearing housing to the oil pump body in accordance
bearing, oil seal insertion section, and key groove. If with the matching mark. After that, tighten the bolts.
any damage is detected, hand finish the component ⑥ Fit the oil seal to the driving side of the shaft and
using an oilstone of #400 to #1000. attach the snap ring.
Pay attention to the direction of the oil seal when
③ Clean the O-ring, shaft key, inner key, and bolts.
attaching it. Also note that the tool must be lightly
After that, check the components for damage.
tapped when fitting the oil seal. If the tool is hit
hard, the shaft may dislocate, and will not rotate
4.15.4 Assembling smoothly. Manually rotate the shaft to check the
rotating condition. If the shaft does not rotate
If the shaft does not rotate smoothly, make an smoothly, lightly tap the pump-side end of the
adjustment by lightly tapping the pump-side end of shaft to adjust it.
the shaft.

① Press-fit the ball bearing from the driving side of the

shaft. Driving Tool
Driving-side
② Attach the shaft assembly in [1] to the oil pump
body using the tool shown in Fig.4. Then, confirm Oil Seal
that the shaft rotates smoothly.

Rotor-side

Driving-side ⑦ Fix the gear support to the oil pump gear using bolts
(M5, at four places). Then, heat it to approximately
Driving Tool 210℉(100℃).
⑧ Attach the shaft key, and shrink-fit the oil pump gear
Oil Pump body
assembly in ⑦. Before attaching the assembly, push
Rotor-side the oil pump gear assembly until the gear support
comes in contact with the end of the oil pump gear
shaft.
⑨ Insert a bolt (M8) in the center hole of the gear
Before pushing the bearing in, fit the driving-side support and securely tighten it at the end of the oil
end of the shaft to a wooden block or a similar pump gear shaft.
material to prevent any damage. During the press-
Housing
fit of the bearing, ensure that the upper end of the Oil Pump body
bearing and the shaft end are parallel to each Gear Support
other. If the end surfaces are not parallel, the shaft
M6 Bolt
is displaced to the driving side. In such a case, (4 places)
push the bearing in again using the same tool and
M8 Bolt
when the bearing is fitted in a manner that the
bearing and the shaft end are parallel, check Oil Pump Gear
whether the shaft rotates smoothly. If the shaft Oil Pump Gear Assembly
does not rotate smoothly, lightly tap both the ends
After the components are assembled completely,
of the shaft to adjust it.
manually rotate the shaft again to check the
rotating condition.

35
 Confidential to Customer

■ Oil Pump Model ■ Tool

Air-Cooled
㸯㸴㹫㹫 㸯㸴㹫㹫
Fix speed type 50Hz : TOP-N340FAM 㸦㸮㸬㸴㸱㸮㹧㹬㹡㹦㸧 㸦㸮㸬㸴㸱㸮㹧㹬㹡㹦㸧
Fix speed type 60Hz/ Vtype : TOP-N330FAM

㸦㸮㸬㸱㸳㸲㹧㹬㹡㹦㸧

㸦㸯㸬㸯㸶㹧㹬㹡㹦㸧
㸱㸮㹫㹫
Water-Cooled

㸷㹫㹫
ALL : TOP-N320FA

㹋㸯㸮 㸯㸰㹫㹫
■ Replacement Parts 㸦㸮㸬㸲㸵㸰㹧㹬㹡㹦㸧

When re-assembling, the parts shown in Table 㸴㸮㹫㹫㸦㸰㸬㸱㸴㹧㹬㹡㹦㸧 㸶㹫㹫

㸦㸮㸬㸱㸯㸳㹧㹬㹡㹦㸧
1 must be replaced with new ones.
ࠉࠉࠉࠉࠉ㹎㹟㹰㹲ࠉ㹡㹭㹢㹣ࠉࠉ㹌㹭㸸㸳㸷㸮㸯㸱㸮㸮㸮

Fig. 1 Oil pump gear removing tool

Table 1 Oil pump replacement parts list

ȭ㸳㸯㹫㹫㸦ȭ㸰㸬㸮㸮㸶㹧㹬㹡㹦㸧
Oil seal
31506931

㸦ȭ㸯㸬㸳㸵㸳㹧㹬㹡㹦㸧
㸦ȭ㸯㸬㸮㸰㸱㹧㹬㹡㹦㸧
ȭ㸰㸴㹫㹫

ȭ㸲㸮㹫㹫
A : 2.05inch(52mm)
B : 0.31inch(8mm)

㸶㸮㹫㹫㸦㸱㸬㸯㸳㸮㹧㹬㹡㹦㸧
O-Ring
33211090 㸯㸮㸮㹫㹫㸦㸱㸬㸷㸱㸵㹧㹬㹡㹦㸧
A : 3.79inch(96.2mm)
B : 0.12inch(3.1mm) ࠉࠉࠉࠉࠉࠉ㹎㹟㹰㹲ࠉ㹡㹭㹢㹣ࠉࠉ㹌㹭㸸㸳㸷㸮㸯㸱㸮㸯㸮

Fig. 2 Bearing/oil seal driving tool

Ball bearing
28015931 × 2
A : 2.05inch(52mm)
B : 0.59inch(15mm)

Needle bearing
28015980
A : 0.91inch(23mm)
B : 0.98inch(25mm)

36
 Confidential to Customer
4.16 Maintenance of Suction
Throttle Valve
Unloader Body Air Intake Duct
4.16.1 Removing the Suction Throttle
Blowoff
Valve Assembly Silencer
Air Cylinder

① Remove the air intake filter. See the air intake filter Assembly
maintenance manual for details.
② Remove the filter box, filter box gasket (513) and U
cover (1) (554).

③ Remove the pipes of air cylinder operating

components and the air exhaust valve.

④ Remove the bolt that attaches the air intake duct to Air Intake Filter
the 1st-stage air end block. After that, raise the suction
throttle valve assembly using a hoist to remove it.
Fig. 1 Suction throttle valve structure (1)
After removing the suction throttle valve assembly,
take necessary measures to prevent foreign matter
from entering the air intake of the 1st-stage air end,
such as covering the opening with a cloth.

① Remove the air cylinder from the STV body.

② Remove the blowoff silencer assembly from the air

cylinder.
532 508
506
550 540
（※1）
510
（※1）539
505
521
534 522
507 519 520
535 503
518
536 518
517
525 520
537
541
540 F27
509
F44
522 542
516 512
515
504 558
F28 559
515
526
514
574
529 513
512
530
569
（※2）
511 554
501
513
502

551
（※2）

500

Fig. 2 Suction throttle valve structure (2)

37
 Confidential to Customer
4.16.2 Disassembling the Air Cylinder
③ Mark the matching position along the circumference ⑨ Remove the backup ring (F28), and pull out air
of the air cylinder. cylinder cover 1 (504), cover 2 (505) from both sides
④ Remove blowoff valve body (532) placed at the end of air cylinder tube (503). Then remove air cylinder
of the air cylinder. O-ring (520).
⑤ Remove the inner bolt. After that, remove seal washer (520) (503)
(534), plate (508), valve sheet of blowoff valve piston (520)

(507), and blowoff valve piston (506) in this order. (F28)

(504)

(505)
(532)

⑩ Remove the snapring (F27), key (541), and pull out

spindle (509) from air cylinder tube (503). Then,
(506) remove seal packing (3) (518) attached to piston (517).
(507)
(508) ⑪ Remove air cylinder piston gasket (537) from
(534)
spindle (509).

⑥ Mark the matching position and direction of the

valve and remove nut (530). Then remove spring (537)
(F27)
washer (529), unloader valve (574), spacer (542), (518)
and unloader valve (514).
(517)
(509) (541)

(514)

(542)
(529) (574) ⑫ Remove seal packing (1) and (2) (515 and 516,
respectively), from the inner diameter of air cylinder
(530)
cover (504). After that, remove seal packing (4) and
(5) (519 and 521, respectively), rod metal (510),
O-ring (2) (540), and O-ring (1) (550) from the inner
diameter of air cylinder cover (504).
⑦ Remove nut (535), wave spring (536), and tie rod
(515) (516) (504)
(525). After that, remove air cylinder cover (526).
(540)
⑧ Remove seal packing (1) (515), air cylinder O-ring
(510)
(540) attached to the inner diameter of air cylinder
cover (526).
(519)
(526) (504) (521)
(550)

When removing the seal packing, be very careful

(525) (536)
(515) not to damage the piston or air cylinder cover.
(535)
(540)

38
 Confidential to Customer
4.16.3 Cleaning and Checking
① Clean the STV body. In particular, sand the valve ② Fit seal packing (3) (518) to piston (517). Then
seat surface with sandpaper until the machining attach air cylinder piston gasket (537) to spindle
surface is visible. (509). (Fig .5)
② Check the sliding surface in the air cylinder tube, ③ Attach a key (541) to the spindle, and then mount
and if there is r ust, finish the sur face with a the piston (517) and snapring (537).
sandpaper of #1000 or equivalent. (517)
③ If the sliding surface on the outer diameter of the (509) (518) (537) (541)
spindle is rusted, finish it with a sandpaper of #150
or equivalent.
④ Finish the outer surface of the STV valve plates with
sandpaper until the machining surface is visible. (F27)

⑤ Clean the groove for the seal packing, etc. with a wire
brush.
After cleaning, wipe off the oil from all the parts.
Fig.5 Air cylinder piston (517)

4.16.4 Assembling ④ Attach air cylinder cover 1 (504), cover 2 (505) on both
sides of air cylinder tube (503). When attaching, check
① Attach seal packing (1) and (2) (515 and 516,
the matching mark so that the direction is correct.
respectively), to the inner surface of the air cylinder
cover (504). (Fig. 3) Attach air cylinder O-ring (520) ⑤ Attach a backup ring (F28).
to the outer sur face of the cover (504). (Fig. 4) (503)
Attach seal packing (4) and (5) (519 and 521, (F28)
(505)
respectively), to the inner surface of the air cylinder
cover 1 (504). Attach air cylinder O-ring (540) and (504)
valve gasket (550) to the outer surface the cover 2
(505). Attach rod metal (510). Apply specified
grease to the seal packing grooves in advance.
Specified grease: Daphne Coronex No.1 (approx. 0.1oz(3 g))
⑥ Attach air cylinder cover (526) to the seal packing
(515) (516) (522) (504) (520) (515) and O-ring (spacer) (540). After that, attach
into cover 1 (504), tying rod (525), wave spring (536)
and nut (535).

(515) (540)

Fig.3 Cover (1) (504)

Fig.6 Air cylinder piston (526)
(520) (522) (540) (504) (519) (550) (521)
(526)

(510) (504)
(536)
(525)
(535)

Fig.4 Cover (2) (505)

39
 Confidential to Customer

⑦ Attach valve plate (C) (515), spacer (542), and valve ⑩ Attach air cylinder packing (511) to the STV body,
plate (A) (514) in this order to the STV body of the and then mount the air cylinder assembly. Check the
air cylinder. Then, fix them using spring washer matching mark around the air cylinder in advance.
(529) and nut (530).
⑪ Mount the blowoff silencer assembly and attach the
suction throttle valve assembly to the suction port of
the 1st-stage air end. After that, connect the pipes
(514) and ducts to put them back to their original state.

(529) (574) (542)

(530)

When attaching the valve, make sure that the

direction of the valve is correct.

⑧ Attach blowoff valve piston (506), valve sheet of

blowof f valve piston (507) plate (508), and seal
washer (534) in this order to the end of air cylinder.
Attach that, fix them with bolts.

⑨ Fix blowoff valve body (532) with bolts.

(532)

(506)
(507)
(508)
(534)

40
 Confidential to Customer

(45kW-100psi(0.69MPa)/125psi(0.86MPa), 55kW-125psi(0.86MPa))

(515) (538) (503) (510)

(530) (529) (574) (521) (F28) (516) (520) (518) (517) (505) (550) (540)

(519) (521)

(542) (509) (514)

(522) (526) (504) (537) (541) (F27) (525) (536) (535) (522)

(55kW-100psi(0.69MPa), 75kW-100psi(0.69MPa)/125psi(0.86MPa))

(574) (F28) (516) (503) (505)

(530) (529) (542) (509) (514) (521) (515) (538) (520) (518) (517) (522) (540) (550)

(519) (521)
(522) (526) (504) (F27) (537) (541) (525) (536) (535)

Fig. 7 Air cylinder inner structure

41
 Confidential to Customer
■ Replacement Parts
When re-assembling, the parts shown in Table 1
must be replaced with new ones.

Table 1 Air cylinder replacement parts list

Valve sheet of blowoff valve piston O-ring (2)
40615070 × 1 40615490 × 2
Fluorine-containing rubber Fluorine-containing rubber
A : 1.97inch(50mm) A : 2.03inch(51.5mm)
B : 0.59inch(15mm) B : 1.87inch(47.5mm)
C : 0.20inch(5.0mm) C : 0.08inch(2.0mm)

O-ring (1)
Seal gasket (1) (5)
24215150 × 3 45kW-100/125psi(7k/9k),
Fluorine-containing rubber 55kW-125psi(9k)
A : 1.50inch(38mm) 45915620 × 1
B : 1.18inch(30mm) Fluorine-containing rubber
C : 0.26inch(6.5mm) A : 2.62inch(66.5mm)
B : 2.46inch(62.5mm)
C : 0.08inch(2.0mm)
Seal gasket (2) (4)
45kW-100psi(7k),
24215160 × 2
75kW-100/125psi(7k/9k)
Fluorine-containing rubber
40615500 × 1
A : 1.57inch(40mm)
A : 2.58inch(65.6mm)
B : 1.18inch(30mm)
B : 2.34inch(59.4mm)
C : 0.26inch(6.5mm)
C : 0.12inch(3.1mm)

Seal gasket (3) Backup ring

24215180 × 2 5372F280 × 1
Fluorine-containing rubber PTFE
A : 3.94inch(100mm) A : 1.30inch(33mm)
B : 3.35inch(85mm) B : 0.98inch(25mm)
C : 0.37inch(9.5mm) C : 0.04inch(1.0mm)

O-ring C-shaped snap ring

Retaining ring
45915201 × 2
5372F270 × 1
Fluorine-containing rubber
SUS304
A : 3.88inch(98.53mm)
A : 1.29inch(32.8mm)
B : 3.74inch(94.97mm)
B : 1.10inch(27.9mm)
C : 0.070inch(1.78mm) C : 0.06inch(1.6mm)

Seal washer C STV cover gasket

24215340 × 1 59007890 × 1
‒ φA φB Non-asbestos rubber
A : 0.55inch(14mm) A : 10.04inch(255mm)
B : 0.23inch(5.8mm) B : 7.48inch(190mm)
C : 0.05inch(1.3mm) C : 0.04inch(1.0mm)

O-ring C Air end air intake gasket (1)

24215371 × 1 54005120 × 1
Fluorine-containing rubber Non-asbestos rubber
A : 1.20inch(30.6mm) B A : 7.87inch(200mm)
B : 0.96inch(24.4mm) B : 5.51inch(140mm)
A
C : 0.12inch(3.1mm) C : 0.04inch(1.0mm)

O-ring Air cylinder gasket

C
24215390 × 2 40615110 × 1
Fluorine-containing rubber φA φB Non-asbestos rubber
A : 0.26inch(6.6mm) A : 6.30inch(160mm)
B : 0.11inch(2.8mm) B : 4.76inch(121mm)
C : 0.07inch(1.9mm) C: 0.03inch(0.8mm)

42
 Confidential to Customer
4.17 Oil Pump motor and Airend removal
4.17.1 Oil Pump motor removal
Drain the lubricating oil from the gear case. After that,
disconnect the oil piping and remove the oil pump from
the gear case.
(When removing the oil pump, be careful not to
damage the gear.)

Oil Pump

4.17.2 Airend removal After removing the pipings and suction throttle valve, cover the openings.

313 (2) 312(2)

313 (1)
301
311 (2) 312 (1)
334
321 (2)
371 311 (1)

320 (1)

334 334

322

334
㹋㸶㸫㸲㸳
388
389
326

ȭ㸯㸶㹫㹫
㸦ȭ㸮㸬㸵㸮㸷㹧㹬㹡㹦㸧
ȭ㸯㸲㹫㹫 㹩㹬㹭㹡㹩ࠉ㹮㹧㹬
307 㸦ȭ㸮㸬㸳㸳㸯㹧㹬㹡㹦㸧
㸱㸳㹫㹫㸦㸯㸬㸱㸶㹧㹬㹡㹦㸧

㸲㸮㹫㹫㸦㸯㸬㸳㸵㹧㹬㹡㹦㸧

Fig. 4.17.2 (1) 㹈㹧㹥ࠉ㹤㹭㹰ࠉ㹩㹬㹭㹡㹩ࠉ㹮㹧㹬

㸯㸰㸬㸳㹫㹫
㸦㸮㸬㸲㸷㸰㹧㹬㹡㹦㸧

Fig. 4.17.2 (2)

43
 Confidential to Customer

① Be sure to remove the Cap nut (313), O-ring (311),

Fitting (312) and Oil nozzle (320) from gear casing
(301) before removing the airends.; Fig. 4.17.2 (1).

WARNING
Complete removal of the Oil nozzle (320) and
associated components is necessary to
prevent damage during the airends removal.

② Remove the knock pin (334) using the jig for knock
pin.; Fig 4.17.2 (2). Fig. 4.17.2 (3)
③ Screw eyebolts into 2 of the bolt holes on either side
of the upper flange.; Fig. 4.17.2 (3).
Eyebolt: M12 for 1st stage airend, M16 for 2nd stage
airend
④ Screw the jig (two guide bolts) into the bolt holes at
the top on the airend.; Fig. 4.17.2 (3). Remove bolts
on the airend flange.; Fig. 4.17.2 (4).
Guide bolt: M16 for 1st stage airend, M12 for 2nd
stage airend
⑤ Using the jig (two stud bolts), remove the airend as
follows. Put the stud bolts in the removal holes of
airend flange. Tighten the stud bolts slowly and
evenly.; Fig. 4.17.2 (5) and (6).
Stud bolt: M16 for 1st stage airend, M12 for 2nd
stage airend.; Fig. 4.17.2 (7).
Fig. 4.17.2 (4)

WARNING
Remove the airends horizontally and as gently
as possible. Rough action may cause damage
to driving gears.

Screw Thrend.
(Metric)

Fig. 4.17.2 (5)

Nut

Fig. 4.17.2 (7)

Fig. 4.17.2 (6)

44
 Confidential to Customer
4.18 Oil casing and Gear casing removal
4.18.1 Oil casing removal
① Attach a eyebolt (M12), and hoist the oil casing.
② Remove the bolt, and detach the oil casing.

Oil casing weight ; 73 lbs (33 kg)

4× M12-50

Eyebolt (M12) Oil casing

4.18.2 Gear casing removal

① Hoist the gear casing using a suspension tool, as

shown in the left.

② Remove the bolt, and detach the gear casing.

Gear casing weight ; 112 lbs (51 kg)

8×M16-45
Gear casing
2nd-stage side 1st-stage side

Eyebolt shall be fixed by the nut

45
 Confidential to Customer
4.19 Main motor removal
Prepare the additional 2×M16 eyebolts for this procedure.
55kW Motor Weight : 864 lbs (392 kg),
4.19.1 Main motor removing for the fixed speed type. 75kW Motor Weight : 1186 lbs (538 kg)
① With hanging the motor by using a motor eyebolt, remove the 8×M16-45 bolt for the gear casing and shaft seal
cover, and remove the 2×M16-80 for the motor and base plate
② Screw the 2×M16 stud bolt into the removal holes, and remove the shaft seal cover from the gear casing using the
2×M16-80 bolt. 2×M16-80 bolt shall be tightened slowly and evenly.
③ When the shaft seal cover is removed from the gear casing, change the 2×M16-80 bolt to 2×M16 eyebolts. Hang the
motor by three eyebolts so that motor can keep the horizontal situation.
④ Move the motor for ODE side until bull gear can be seen.
⑤ Remove the motor. If you want to remove the motor for horizontal direction, lift the motor by crane so that shaft seal
cover does not hit the motor base.

① 8×M16-45 bolt ② Gear casing

Eyebolt 2×M16 stud bolt

2×M16-80 bolt

2×M16-80 bolt
Gear Casing Shaft Seal Cover

③ 2×M16-80 bolt ④
(Hang the motor by three eyebolts)

Gear casing
Gear casing 2×M16 eyebolts Bull gear

⑤ Shaft seal cover

Motor base

46
 Confidential to Customer

55kW Motor Waight 441lbs (200 kg),

4.19.2 Main motor removal for the Vtype. 75kW Motor Waight 507 lbs (230 kg)
① With hanging the motor by using a two motor eyebolts, remove the 8×M16-45 bolt for the gear casing and shaft seal
cover, and remove the 2×M16-60 for the motor and base plate

② Screw the 2×M16 stud bolt into the removal holes, and remove the shaft seal cover from the gear casing by using the
2×M16-80 bolt. 2×M16-80 bolt shall be tightened alternately.

③ When the shaft seal cover is removed from the gear casing, change the 2×M16-80 bolt to 2×M16 eyebolts. Hang the
motor by four motor eyebolts so that motor can keep the horizontal situation.

④ Move the motor for ODE side until bull gear can be seen.

⑤ Remove the motor. If you want to remove the motor for horizontal direction, lift the motor by crane so that shaft seal
cover does not hit the motor base.

① Eyebolts 8×M16-45 bolt ② Gear Casing

2×M16 stud bolt

2×M16-80 bolt

Gear Casing
2×M16-60 Shaft Seal Cover

③ 2×M16-80 bolt ④
(Hang the motor by four motor eyebolts)

Gear casing

Bull gear Gear casing

2×M16 eyebolts

⑤ Shaft seal cover

Motor base

47
 Confidential to Customer
4.20 Replace the Bushing
4.20.1 Main motor removal (Ref. 4.19 Main motor removal)

4.20.2 Oil pump motor removing (Ref 4.17 Oil Pump motor and Airend removal)

4.20.3 Oil pump gear shaft removal

Oil Pump Gear Shaft

① Remove the 6×M10 bolts.
② Screw the M10 bolt into the removal holes on the oil
pump gear shaft.
Tighten the bolt to remove the oil pump gear shaft.

It is not necessary to remove the oil pump gear

from the oil pump gear shaft.

Removal hole (M10)

Oil Pump Gear M10 bolt

4.20.4 Bull gear removal

① Remove the gear retaining plate. Keep in mind that M20 bolt is the left hand screw.

② Put the jig for bull gear removal (1) and (2) indicated in the next page on the bull gear.

③ Tighten the jig (2) bolt to remove the bull gear.

④ Remove the key.

Hold the bull gear without drop.

Bull gear M20 bolt (left hand screw) Pull-out tool

Gear retaining plate

48
 Confidential to Customer
ࠉ㸱㸵㸬㸳㹫㹫
㸦㸯㸬㸲㸵㸴㹧㹬㹡㹦㸧
ࠉࠉ㸱㸮㹫㹫 ࠉ㸵㸬㸳㹫㹫
㸦㸯㸬㸯㸶㸯㹧㹬㹡㹦㸧 㸦㸮㸬㸰㸷㸳㹧㹬㹡㹦㸧
ࠉࠉ㸰㸳㹫㹫
㸦㸮㸬㸷㸶㸲㹧㹬㹡㹦㸧 ࠉࠉࠉࠉࠉࠉ㸴™㹋㸯㸮
㸯㸳㹫㹫㸦㸮㸬㸳㸷㹧㹬㹡㹦㸧㹢㹣㹣㹮

㸧 Fixed speed type

㹫 㹡㹦
㸮㹫 㹧㹬
(A) External diameter : φ13.8654∼φ15.3250inch

r
㸯㸲 㸬㸳㸯

㸴㸮
ȭ
㸦ȭ㸴㸬㸳㸮㹧㹬㹡㹦㸧

ࠉ ȭ㸳
㸦ȭ㸱㸬㸱㸳㹧㹬㹡㹦㸧

(φ352.181∼φ389.257mm)
㸦
ࠉࠉȭ㸯㸴㸳㹫㹫
ࠉࠉࠉȭ㸶㸳㹫㹫

㸦㹀㸧 㸦㸿㸧 (B) Internal : φ2.36inch (φ60mm)

Weight : 42.11∼50.93 [lbs] (19.1∼23.1 [kg])
㸴㸮
r
Vtype
(A) External diameter : φ15.0637∼φ15.7013inch
(φ382.620∼φ398.813mm)
(B) Internal : φ2.16inch (φ55mm)
Fig. 1 Bull gear detailed dimension Weight : 49.4/53.8 [lbs] (22.4/24.4 [kg])

㸰㸰㸳㹫㹫㸦㸶㸬㸶㸳㸶㹧㹬㹡㹦㸧
㸯㸮㹫㹫 㸶㸮㹫㹫 㸲㸳㹫㹫 㸶㸮㹫㹫
㸦㸮㸬㸱㸷㸱㹧㹬㹡㹦㸧 㸦㸱㸬㸯㸳㸮㹧㹬㹡㹦㸧 㸦㸯㸬㸵㸵㸰㹧㹬㹡㹦㸧 㸦㸱㸬㸯㸳㸮㹧㹬㹡㹦㸧
㸦㸯㸬㸷㸴㸷㹧㹬㹡㹦㸧

$ $ Caution
㸳㸮㹫㹫

1. Light chamfer the corners which are not

indicated C size.
㸦㸮㸬㸴㸴㸷㹧㹬㹡㹦㸧

㸦㸮㸬㸴㸴㸷㹧㹬㹡㹦㸧
㸯㸵㹫㹫
㸯㸵㹫㹫

㹋㸯㸶™㸯㸳
2. Electro galvanizing is required.
㸦㸮㸬㸯㸷㸵㹧㹬㹡㹦㸧

ࠉ
ࠉ

3. Material: S25C
ࠉ㸳㹫㹫

ȭ㸰㸳㹫㹫
ࠉ
㸦ȭ㸮㸬㸷㸶㸲㹧㹬㹡㹦㸧
㸦㸯㸬㸳㸵㸳㹧㹬㹡㹦㸧
㸲㸮㹫㹫

Fig. 2 Jig for bull gear removal (1) dimension Part code No : 59031260

㸰㸵㹫㹫 㸱㸮r
㸦㸯㸬㸮㸴㸱㹧㹬㹡㹦㸧 㹋㸯㸶™㸯㸳
㸦㸯㸬㸰㸰㸶㹧㹬㹡㹦㸧
㸱㸯㸬㸰㹫㹫

㸯㸰㹫㹫 㸰㸮㸳㹫㹫 㸯㸴㸳㹫㹫 㸰㸳㹫㹫

㸦㸮㸬㸲㸵㸰㹧㹬㹡㹦㸧 㸦㸮㸬㸶㸮㸵㹧㹬㹡㹦㸧 㸦㸴㸬㸲㸷㸴㹧㹬㹡㹦㸧 㸦㸮㸬㸮㸷㸶㸲㹧㹬㹡㹦㸧
㸰㸮㸮㹫㹫
㸦㸵㸬㸶㸵㸲㹧㹬㹡㹦㸧

Fig. 3 Jig for bull gear removal (2) dimension Part code No : 59031270

49
 Confidential to Customer
4.20.5 Bushing replacement
■ Removal procedure
① Loosen the 10×M16 bolts and remove the shaft seal cover from
the main motor.
② Remove the 4×M8 flat head bolt. For the Vtype, remove the M6
set screw.
③ Remove the bushing, O-ring (inside) and collar together by using
the general pulley remover.

■ Assembling procedure
①-A (Fixed speed type)
Attach the collar onto the main motor shaft by shrink fitting. The
collar shall be contact the motor slinger. The temperature for the
10×M16 bolts shrink fitting shall be c①-B (Vtype)
Shaft seal cover Adjust the position of the M6 set screw for the collar and for the
motor shaft. Tighten the M6 set screw with applying the adhesive
(ThreeBond TB1324N (red)).
② Attach the O-ring and bushing. Tighten the 4×M8 flat head bolt.
③ Attach the shaft seal cover and tighten the 10×M16 bolts.

4×M8 flat head bolt M8 flat head bolt Collar M6 set screw
Bushing

O-ring
Slinger

Fixed speed type Vtype

General pulley remover Sample of general pulley remover

50
 Confidential to Customer
4.20.6 Attach the bull gear
① Attach the key.
Bull gear Gear retaining plate
② Apply the anti seizing paste between the motor shaft
and the bull gear.
Anti seizing paste shall be the molybdenum disulfide
basis.
③ Attach the bull gear onto the main motor shaft by
shrink fitting. The bull gear shall be contact the
motor shaft end face. The temperature for the shrink
fitting shall be 300℉ (150℃).
④ Attach the gear retaining plate. Keep in mind that
M20 bolt is the left hand screw.

Key

4.20.7 Attach the oil pump gear shaft

① Attach the oil pump gear shaft on the bull gear.
M10 bolt
Tighten the 6×M10 bolts.

Oil pump gear Oil pump gear shaft

Oil pump gear shaft assy.

Part code No : 59010830 (Fixed speed type)

: 59010840 (Vtype)

4.20.8 Attach the gear case and the oil case.

4.20.9 Attach the air end.

Bushing replacement shall be done after removing the oil pump. And when the main motor is attached, carefully
intermesh the gears teeth without excessive force.

51
 Confidential to Customer
4.21 Pinion Gear Replacement Procedure
4.21.1 Removing the Air End
Remove the air end.
( see p. 43 “4.17 Oil Pump motor and Airend
removal” 4.17.2 Airend removal)

4.21.2 Pulling Out the Pinion Gear

Attach the pinion gear pull-out tool. When attaching
the tool, ensuring that the O-ring is not stuck. Then Max Oil Pressure
Air End Shaft Dia.
Required
increase the oil pressure slowly and gradually using a φ 1.17 inch 21750 psi
1st-stage
high-pressure pump to check for oil leak. ( φ 29.8mm) (150MPa)
φ 0.976 inch 20300 psi
2nd-stage
( φ 24.8mm) (140MPa)

(1) O-Ring (2) O-Ring

To Pump
Shaft Pinion Gear Pump connecting port
Pull-Out Tool
(PS1/4)

Recommended equipment : SKF Oil injector 226400 series

4.21.3 Shrink-Fitting the Pinion Gear

Shrink-fit the pinion gear. Be sure to fully insert the
component until it comes in contact with the stepped
section of the motor. The temperature of shrink fitting
must be approximately 392℉ (200℃).

52
 Confidential to Customer

■ Tool
(1) Dimensions of the removing tool dimension

• 1st-stage side Part code No : 59031290

1. Thermal refining required (quenching at 850°C to 950°C(1562℉ to 1742℉),

Material : SCM415H (mm)
tempering at 550°C to 650°C(1022℉ to 1202℉)) Hardness: HRC 32 to 40

PS1/4, 15 deep 2. M16 screws must be machined with a cutting tool.

Drill through, Pilot hole, 11.5 dia.,
2 dia. 18 deep 3. Applicable model: DSP-45/55/75N 1st-stage side

Drilled hole, 4 dia.,

90 deep
Drilled hole, 6 dia.,
Drill through, 1.6 dia. 98 deep

• 2nd-stage side Part code No : 59031300

1. Thermal refining required (quenching at 850°C to 950°C(1562℉ to 1742℉),

Material : SCM415H (mm)
tempering at 550°C to 650°C(1022℉ to 1202℉)) Hardness: HRC 32 to 40

PS1/4, 13 deep 2. M12 screws must be machined with a cutting tool.

Pilot hole, 11.5 dia., 15 deep 3. Applicable model: DSP-45/55/75N 2nd-stage side
Drill through,
2 dia.

Drilled hole, 6 dia.,

110 deep

Detail B (4 : 1)

(2) O-Ring

Cross Section A-A

Notes

1. This item must be standardized by JIS or SEA AS568.

2. Hardness: Hs 70 ± 5

3. Material: NBR

Model Part Name Nominal No. d1 d2 Part Code No.

1.296inch 0.1390inch
O-ring (1) AS568B-219 59013040
(32.92mm) (3.53mm)
1st-stage
0.9870inch 0.1031inch
O-ring (2) AS568B-120 59013050
(25.07mm) (2.62mm)
1.109inch 0.1390inch
O-ring (1) AS568B-216 59013060
(28.17mm) (3.53mm)
2nd-stage
0.7988inch 0.1031inch
O-ring (2) AS568B-117 59013070
(20.29mm) (2.62mm))

53
4.22 Battery Replacement (6-Yearly)
(2) Battery replacement method
When “BATTERY OUT” is displayed for “PROBLEM”
on the LCD monitor, replace the batter y. When
replacing, disconnect the power and complete the
replacement work within 15 minutes.
③
① Remove the screw on the right of the LCD display.

② Insert the special tool attached with the battery to

③ Tab the slots shown as figure provided and lift up the
LCD unit from the instrument panel.
④
③ To remove the LCD unit, pull it to right side so
① Screw ② Special tool slot that the tabs are not damaged.

Battery
④ The battery is mounted on the back of the LCD
⑤ unit. Unplug the battery connector. The battery
is held by double-sided adhesive tape.

⑤ Replace with new battery.

④ LCD unit

CN11 BT (3) Cautions for disposal of old batteries

The used battery shall be returned to your
distributor or disposed of properly in accordance
(1) Battery life and specifications
with your local government disposal regulations.
Item Specs Used battery is furthermore shorted if the positive
Battery Coin-type manganese dioxide lithium battery and negative terminals come in contact with each
Voltage 3V other or come in contact other metal objects, and
Capacity 220 mAh
could cause the battery to produce heart, rupture or
Battery model CR2032
catch fire. Do not expose the battery to fire. Used
Special specs Lead wire connector connection
batteries cannot be recharged.
Replacement
Battery replacement display on LCD monitor
criteria
Approx. 1 year with power off
Life
Approx. 6 years under ordinary service conditions

● The batteries is an exclusive part. Contact the local

HITACHI distributor/master dealer or representative
office.

54
 Confidential to Customer
4.23 Inspection of Thermistor and Pressure Sensor
If the thermistor or pressure sensor shows any sign of failure during operation, replace the part in accordance with the
part name listed below.
Table 1 Thermistor/pressure sensor part name list
Code Sensor type Remarks
PS1 Pressure sensor For 1st-stage discharge pressure Main board side
PS2 Pressure sensor For 2nd-stage discharge pressure Main board side
PS4 Pressure sensor For oil pressure LCD side
TH2 Thermistor For 2nd-stage suction temperature Main board side
TH3 Thermistor For 2nd-stage discharge temperature Main board side
TH4 Thermistor For 1st-stage discharge temperature LCD side
TH5 Thermistor For oil temperature LCD side

■ Sensor position for water-cooled type

TH3

TH2 TH5 TH4

[Fixed speed type]

PS2
PS1 PS4

PS4 PS2 PS1

55
 Confidential to Customer

■ Sensor position for air-cooled type

TH3

TH2 TH5 TH4

[Fixed speed type]

PS1 PS2
PS4

PS4 PS2 PS1

■ Connection position on the PCB side

LCD PCB side CPU PCB side
(See the back side of instrument panel.) (control panel side)

CN10 CN16
(From TH2) (From PS2)

THM
CN11 CN13
CN4 (From PS1) (From TH3)
(From TH5)
[Fixed speed type]

CN13 CN1
CN2 CN3
(From TH3) (From PS1)
(From PS4) (From TH4)

CN2 CN16
(From TH10) (From PS2)

56
5. PARTS LIST
1 Air End Assembly
243
Ref.
235
234
No. Description
100 1st-Stage Air End (new)
233 235 132 1st-Stage Air End Discharge Cover
133 1st-Stage Air End Jacket Cover
238
134 Gasket, 1st-stage air end discharge cover
200 135 Gasket, 1st-stage air end jacket cover
143 138 Knock pin, 1st-stage air end
143 Pinion Gear, 1st-stage air end
134
232 233 200 2nd-stage Air End (new)
135
232 2nd-Stage Air End Discharge Cover
133 233 2nd-Stage Air End Jacket cover
234 Gasket, 2nd-stage air end discharge cover
138 235 Gasket, 2nd-stage air end jacket cover
238 Knock pin 2nd-stage air end
243 Pinion Gear, 1st-stage air end
100 299 1st stage and 2nd stage Air End Assembly (new)

299
133
132 135

2 Gear Case Assembly

824
823
301 824
Ref.
D53 No. Description
823
334 301 Gear Case
320
D53 307 Gear, oil pump
371
316 Gasket, oil filling port
321
317 Plug, oil filling port
318 Cover, oil filling port
319 O-Ring
320 Oil Nozzle (1)
321 Oil Nozzle (2)
322 Gasket, 1st-stage air end
334 334 323 O-Ring, cleaning cover
324 Closure Plate
322
326 O-Ring, oil pump
334 Parallel Pin (1)
336 Oil Level Gauge
338 Cover, inspection cover
334 339 O-Ring, cover
388 364 Bolt, oil level gauge
389 371 Gasket, 2nd-stage air end
326 383 Oil Relief Valve
388 M6 Flat Head Bolt
389 Gear Stopper
E83
307 398 O-Ring
399 Gasket, oil relief valve
823 Seat, oil pipe
324 824 Cap Nut
883 Oil Temperature Control Valve
338 884 O-Ring
339
883 B32 Float
D53 O-Ring
884 H78 E83 O-Ring
319
F39 Oil Casing
399 G64 O-Ring 25
383 F39 323 G65 O-Ring 30
317 H78 Closure Plate

B32 339
338
316

G64

318
G65
398

364
336

57
 3 Motor Assembly
[Fixed speed type] Ref.
Description
410 (※2) No.
436 (※2) 302 Bull Gear
306 Pinion Gear, oil pump
309 Bushing
387 438 (※2) 313 Cover, shaft seal
365
309 337 O-Ring (motor flange)
397 340 Key
394 401 437 365 O-Ring
392 453 (※2)
393 367 Cover,Gear
391 454
455 (※1) 387 Collar
395
313 J16 391 Shaft Seal
337 392 Cover, visco seal
340 438 393 O-Ring, shaft seal
302 (※2)
394 O-Ring, shaft seal
367 395 Wave Spring, visco seal
460 462 397 Snap Ring, 102
461 401 Motor
306 410 Rubber Bush
430
425 Vibration Isolation Rubber
430 Base, motor(1)
431 Base, motor(2)
432 Base, motor(3)
436 Motor Cover(1)
437 Motor Cover(2)
425 438 Fixing Bracket, Motor Cover
453 Bearing (Load-side)
454 Bearing (Anti-Load-side)
455 Grease
460 Pinion Gear and Gear Shaft Assembly
461 Gear Shaft, oil pump
F72
462 Bolt
F72 Grease Pan
J04 Bolt
J16 Thermostat
J17 DCBL Motor Thermistor
387
365 ※1 Does not come with the
309 product.
397 ※2 Only for Water-cooled type.
394 J17
392 340
393 401
391 453
395 454
313 ※455
337
302
J04
367 431
460 462 432
461
306

430

425

F72

58
4 Suction
[Fixed speed type] Ref.
Description
No.
532 508 500 Suction Throttle Valve Assembly
506 501 Air Cylinder Assembly
550 540
（※1） 502 Body, STV
510
（※1）539 503 Tube, air cylinder
505 504 Cover (1)
521 505 Cover (2)
534 522 506 Piston, blowoff valve
507 519 520
503 507 Valve Sheet, blowoff valve piston
535 508 Plate
518
536 518 509 Spindle, air cylinder
517 510 Rod Metal
525 520 511 Gasket, air cylinder
537 512 Gasket (1), air end air intake
541 513 Gasket, STV cover
540 F27
509
514 Valve Plate, STV
F44 515 Seal Gasket (1)
522 542 516 Seal Gasket (2)
516 512 517 Piston, air cylinder
515 518 Seal Gasket (3)
504 558
F28 519 Seal Gasket (4)
515 559
520 O-Ring, air cylinder
526
521 Seal Gasket (5)
514
574 522 Bush, air cylinder
529 513 525 Tying Rod, air cylinder
512
530 526 Cover, air cylinder
569
（※2） 529 Spring Washer (SUS)
511 554
501 530 Rod Nut
513 532 Body, blowoff valve
502
534 Seal Washer, air cylinder
535 Nut
536 Wave Spring
551
（※2） 537 O-Ring (piston)
538 O-Ring (spacer)
539 O-Ring (needle)
540 O-Ring (2), air cylinder
541 Holder, piston
542 Spacer
500
550 O-Ring (1), air cylinder
551 Set of Air Cylinder Consumable Parts
554 Unloader Cover (1)
558 Adjusting Bolt, suction bypass valve
559 Seal Washer, suction bypass valve
569 Grease, air cylinder
F44 574 Valve Plate, STV
F27 C-type Snap Ring
512 F28 Backup Ring
F44 Air Intake Duct
※1 Only for 55 kW-7K and 75 kW.
※2 Does not come with the
product.

502 Ref.
Description
No.
500 Suction Throttle Valve Assembly
502 Body, STV
512 512 Gasket, air end air intake
513 Gasket, STV cover
554 Unloader Cover
F44 Air Intake Duct

513

554

513

59
 5 Coolers & Ventilating Fan (1)
Ref.
Air-Cooled 696 697 No. Description
581 Partition (1)
582 Partition (2)
583 Partition (3)
698 696 584 Plate Washer
608 585 Maintenance Cover (3)
586 Maintenance Cover (4)
608 Aftercooler
H72 586 E51 695 623 Intercooler
628 Duct Panel (1)
639 Oil cooler
642 Duct Panel (2)
643 Duct Panel (3)
585 644
644 Duct Panel (4)
H71 639
646 H71 645 Duct Panel (5)
646 Duct Panel (6)
645
647 Duct Panel (7)
648 Duct Panel (8)
643 649 Duct Panel (9)
650 Duct Panel (10)
651 Duct Panel (11)
648
685 647 652 Duct Panel (12)
623 653 Cover (1), Intercooler
692 685 Cover (2), Intercooler
694 691 Cover (3), Intercooler
F61 692 Duct Panel (1), Intercooler
693 Duct Panel (2), Intercooler
694 Duct Panel (3), Intercooler
693 651 E52 695 Duct,Oil cooler
582 650 642 696 Duct Panel (1), Aftercooler
628
581 697 Duct Panel (2), Aftercooler
582 698 Duct Panel (3), Aftercooler

581 583 653 E51 Maintenance Cover (1)

584
584 E52 Maintenance Cover (2)
584
584 F61 Magnet Rubber (1)
649 H71 Magnet Rubber (2)
652
691 H72 Magnet Rubber (3)

5 Coolers & Ventilating Fan (2)

Ref.
Description
Air-Cooled 681 No.
681 Fan Motor
686 Support, cooling fan
J18 678 Bell Mouth
678 679 lmpeller
686
629 Fixing Bracket (1)
630 Fixing Bracket (2)
631 Support (1), base frame
632 Support (2), base frame
F47
633 Support (3), base frame
634 Support (4), base frame
※ 635 Support (5), base frame
679 636 Support (6), base frame
F47 Rubber Bush
J18 Fan Shaft Key
636
※ Only for 75 kW.
636
635
632 633

630 636

634 629
630 631
629
630

60
 5 Coolers & Ventilating Fan (1)
Ref.
No. Description
Water-Cooled 608 601 Shell, aftercooler
601
602 Tube Nest, aftercooler
605 Gasket, aftercooler tube nest
608 Aftercooler Assembly
610 Oil cooler Assembly
605
611 Tube Nest, oil cooler
602 612 Cover, oil cooler water chamber
613 Gasket, oil cooler water chamber cover
614 Cover, oil cooler
615 Gasket, oil cooler cover
623 Intercooler Assembly
624 624 Shell, intercooler
625 Tube Nest, intercooler
623 626 626 Gasket, intercooler tube nest
614 627 Support (1), oil cooler
632 625
610 615 632 Plug
E39 Vibration Isolation Rubber
611 E76 Support (2), oil cooler

613
612 E76

627 E39

E39

5 Coolers & Ventilating Fan (2)

678 Ref.
No. Description
Water-Cooled 628 Base, coolers
629 Duct, air exhaust
630 Support (1), base frame
679 631 Support (2), base frame
633 Support (3), base frame
681 634 Support (4), base frame
671 Duct (1), fan motor
678 Support (2), fan motor
686 679 Fan
681 Fan Motor
940 686 Support (1), fan motor
940 Rubber Bush
F47 Vibration Isolation Rubber
671

629

628

F47

634
631

630

633

61
6 Oil Pump
Ref.
No. Description
300 Consumable Parts Kit, oil pump
327 Oil Pump Assembly
328 Bearing
329 Oil Seal
345 342 Oil Pump body
356 343 Housing, oil pump bearing
345 Key
327 356 Key
362 Snap Ring
362
363 O-Ring
329 342 378 Bush Bearing
328

363

378
343

7 Instrument Panel
Ref.
No. Description
G57 719 Digital Panel
744 Lithium Battery
H79 746 Control PCB
719 748 Seat, instrument panel
744 755 PCB Cover
G57 E-Stop
Display unit assembly H39 UNLOAD STOP Button
(included in #745 Starter board H43 Switch Guard
PCB assembly)
H79 Rubber Bush
H80 OPE Code Pipe
H81 OPE Code (1)
H82 OPE Code (2)
H99 Unload Stop Nameplate

755
746
H81
748

H82

H99

H39
H80
H43

62
8 Control Panel
[Fixed speed type] 705
706
707 G14
45/55/75 kW 704
E09
(Air coold only) G18
745 G15 G13 (Water cooled only)
G16 G19
D73
※D12
D06
702

G17 D10
D75 D10
G04 G20
G06 G05 G04 G21
G07
G05 729

704 701
G20 709 708
B44 G04 J15
G05
Water
730 cooled Air
J14
G04 cooled
G05 G04
G05 (Water cooled only)
G06
G07

E47
E45

E48 (Air cooled only)

Ref.
No. Description
700 Control Panel
701 Electromagnetic Contactor (42)
702 Electromagnetic Contactor (6)
704 Electromagnetic Contactor, Fan Motor
705 Fuse (1A)
706 Fuse (1.25A)
707 Fuse (1.6A)
708 Current Transformer
709 Terminal Block (1)
729 Electromagnetic Contactor (52)
730 Condenser
745 PC Board
B44 Door, Control Box
D06 Terminal Block (2)
D10 Surge Absober
D12 Cooling Fan
D73 Reversed Phase Relay
D75 Transformer
E09 Line Noise Filter
E45 Rubber Bush
E47 Rubber Bush
E48 Rubber Bush
G04 Conduit nut
G05 Conduit
G06 Conduit nut
G07 Conduit
G13 Relay MY2N
G14 Relay MY4N
G15 AVR 60W
G16 AVR 10W
G17 AVR 90W
G18 Circuit Breaker
G19 Circuit Breaker
G20 Fuse (4A)
G21 Fuse (10A)
J14 Inverter, Cooling Fan
J15 Communication Board
※ 75 kW Water cooled only

63
8 Control Panel
E18

55 kW G04 E48 G04 G04

G06 G05 G05 G05 D12
G07 D75

E10
G04 G14
F73 G05
G13 E09 G16 (Air cooled only)
G06
745 G07 D10 705
706
Air-coold 707 G15
E06
G06 D06 Water-coold
G07 E46 704
E47 G19 G20
D73G15
G17
704 G18 G17
G20 706
730 G19 707
E45 (Water-coold only) E04 D73
E07
G04 E48 (Air cooled only) D06
G05 G04 J15 G21
J14
G05
(Water cooled only)
B44 708
753 E17
701
709

Ref.
No. Description
E04 Controller Fan (1), DCBL Controller
E06 Power Printed Circuit Board
E07 Smoothing Condenser
E09 Line Noise Filter
E10 DCBL Controller
E17 DC Reactor(2)
E18 Cover, Fin(1)
E45 Rubber Bush
Ref. E46 Rubber Bush
No. Description E47 Rubber Bush
700 Control Panel E48 Rubber Bush
701 Electromagnetic Contactor (52) F73 Cover, Fin(2)
704 Electromagnetic Contactor, Fan Motor G04 Conduit Nut
705 Fuse (1A) G05 Conduit
706 Fuse (1.25A) G06 Conduit Nut
707 Fuse (1.6A) G07 Conduit
708 Current Transformer G13 Relay MY2N
709 Terminal Block (1) G14 Relay MY4N
730 Condenser G15 AVR 60W
745 PC Board G16 AVR 10W
753 DC Reactor (1) G17 AVR 90W
B44 Door, Control Box G18 Circuit Breaker
D06 Terminal Block (2) G19 Circuit Breaker
D10 Surge Absober G20 FUSE (4A)
D12 Cooling Fan G21 FUSE (10A)
D73 Reversed Phase Relay J14 Inverter, Cooling Fan
D75 Transformer J15 Communication Board

64
8 Control Panel
E18
Air-Cooled

75 kW

G04 G04
G05 G05
G06 753
G07 G04 E10
G05 G09 745
G08 G17
G13
F73 G15 G14 D06 701
D12
B44

G06
G07
D10
G04 705 E09
G05 G16 E04
706
704
707 G19 D73
E06 G20

E47
E45
D75
E07 J15 G21 708
J14

Ref.
No. Description
700 Control Panel
701 Electromagnetic Contactor (52)
704 Electromagnetic Contactor, Fan Motor
705 Fuse (1A)
706 Fuse (1.25A)
707 Fuse (1.6A)
708 Current Transformer
745 PC Board
753 DC Reactor (1)
B44 Door, Control Box
D06 Terminal Block (2)
D10 Surge Absober
D12 Cooling Fan
D73 Reversed Phase Relay
D75 Transformer
E04 Controller Fan (1), DCBL Controller
E06 Power Printed Circuit Board
E07 Smoothing Condenser
E09 Line Noise Filter
E10 DCBL Controller
E18 Cover, Fin (1)
E45 Rubber Bush
E47 Rubber Bush
F73 Cover, Fin (2)
G04 Conduit Nut
G05 Conduit
G06 Conduit Nut
G07 Conduit
G08 Conduit Nut
G09 Conduit
G13 Relay MY2N
G14 Relay MY4N
G15 AVR 60W
G16 AVR 10W
G17 AVR 90W
G19 Circuit Breaker
G20 Fuse (4A)
G21 Fuse (10A)
J14 Inverter, Cooling Fan
J15 Communication Board

65
8 Control Panel
E18
Water-Cooled

75 kW
G04 G04 G18
G06 G05 G05 G19
G20 D73 753
G07 704
D06
G04 E10
G05 701
730
745
G17
G14 D10
707 G15 G13
D12
706
B44

F73 E04
G06
G07

E09
708
D75
G08
G09 E06
E47

E07
E45

Ref.
No. Description
700 Control Panel
701 Electromagnetic Contactor (52)
704 Electromagnetic Contactor, Fan Motor
706 Fuse (1.25A)
707 Fuse (1.6A)
708 Current Transformer
730 Condenser
745 PC Board
753 DC Reactor (1)
B44 Door, Control Box
D06 Terminal Block (2)
D10 Surge Absober
D12 Cooling Fan
D73 Reversed Phase Relay
D75 Transformer
E04 Controller Fan (1), DCBL Controller
E06 Power Printed Circuit Board
E07 Smoothing Condenser
E09 Line Noise Filter
E10 DCBL Controller
E18 Cover, Fin (1)
E45 Rubber Bush
E47 Rubber Bush
F73 Cover, Fin (2)
G04 Conduit Nut
G05 Conduit
G06 Conduit Nut
G07 Conduit
G08 Conduit Nut
G09 Conduit
G13 Relay MY2N
G14 Relay MY4N
G15 AVR 60W
G17 AVR 90W
G18 Circuit Breaker
G19 Circuit Breaker
G20 Fuse (4A)

66
 9 Air Pipe

Air-Cooled C07

874
865

125 psi (0.86 MPa) type

061

058 F03

F01
875 033
670
060
057
059 040

E30

100 psi (0.69 MPa) type 041 865

029 056

869 Ref.
No. Description
004 O-Ring, condensate water separator seat
870
006 Cover, Condensate Separator
871 021 Demister
022 Air Piping (1)
865 870 023 Air Piping (2)
025 059 868 024 Air Piping (3)
060 025 Air Piping (4)
865
028 026 Air Piping (5)
027 Air Piping (6)
033 028 Air Piping (7)
029 Air Piping (8)
033 Gasket(1)
034 Gasket, 1st-stage air end discharge flange
039 035 035 Gasket, cooler
026 D72
037 Gasket, 2nd-stage suction
039 Gasket, 2nd-stage air end discharge flange
040 Piping, Aftercooler Condensate Water
037 041 Air Relief Valve seat
056 Air Piping (9)
033 034 024 057 Air Piping (10)
058 Support, discharge piping
059 Piping Support (1)
F02 D71 022 060 Piping Support (2)
033
061 Piping Support (3)
027 023
033 670 Hi-Precooler
004 E29 865 Gasket (2)
021 868 Lower Cover, check valve
006 869 Upper Cover, check valve
870 Gasket
※B99 033 871 Check Valve
B35 D70
874 Discharge Piping
875 Air Relief Valve
B78
B35 Fix Board, separator
B78 Vibration Isolation Rubber
C07 Motorized Isolation Valve
D70 Thermistor (TH4)
D71 Thermistor (TH2)
D72 Thermistor (TH3)
E29 Cover,piping (1)
E30 Cover,piping (2)
F01 Air Piping (11)
F02 Condensate Separator
F03 Air Piping (12)
※Does not come with the product.

67
 9 Air Pipe

C07
Water-Cooled

028

865 029

003

027 875
002 868
865
D72
001
024
038 870
871
039 870
033

869
025
036
010
Ref.
No. Description
033 037 001 Aftercooler Header (2)
002 O-Ring, aftercooler
044 003 Gasket (3)
004 O-Ring, Condensate Separator
D71 006 Cover, Condensate Separator
010 Gasket, cooler Header
F02 026 021 Demister
033 034 033 022 Air Piping (1)
004 023 Air Piping (2)
024 Intercooler Header (2)
025 Air Piping (3)
021
022 026 Air Piping (4)
006 027 Air Piping (5)
※B99 023 028 Air Piping (6)
B35
033 029 Air Piping (7)
033 Gasket (1)
B78 034 Gasket, 1st-stage air end discharge flange
036 O-Ring (intercooler)
D70 037 Gasket, 2nd-stage suction
038 Gasket, cooler header
039 Gasket, 2nd-stage air end discharge flange
044 Intercooler Header (1)
865 Gasket (2)
868 Cover, check valve
869 Aftercooler Header (1)
870 Gasket
871 Check Valve
875 Air Relief Valve
B35 Fix Board, separator
B78 Vibration Isolation Rubber
C07 Motorized Isolation Valve
D70 Thermistor (TH4)
D71 Thermistor (TH2)
D72 Thermistor (TH3)
F02 Condensate Separator
F05 Flange
※Does not come with the product.

68
10 Drain Pipe
Ref.
No. Description
006 Strainer Assy
007 Gasket, strainer
043 Check Valve
047 Strainer Element
052 Orifice, condensate piping (AC)
876 2 way Valve (1)
A B35 Support (3), condensate piping
B36 Support (4), condensate piping
F48 Vibration Isolation Rubber
H75 F67 3 way Switching Valve
Air-Cooled F68 Support (1), condensate piping
Water-Cooled F69 Support (2), condensate piping
876 H74 Condensate Solenoid Valve
B35 H75 2 way Valve (2)
B36

007
006
047
F74

052
B
H74
006

F69
F48 047 007
F48

F68 F67
043

11 Oil Piping (1)

Air-Cooled Ref.
Description
No.
768 Seat, oil piping
769 Support, greasing port
770 Oil Piping (1)
771 771 Oil Piping (2)
H53
789 773 Piping (1), oil drain
774 Piping (2), oil drain
770 785 Support, oil piping
786 Fixing Plate (1), oil piping
B06 789 Fixing Plate (2), oil piping
769 887 Oil Drain Valve
H91 890 Gear Case Breathing Piping
B06 Rubber Seat
D34 O-Ring (gear case bearing)
786 H73
H53 Float Cover
890 768 H73 O-Ring (cooler piping)
H91 Grease Nipple

D34

H73

H91

887 773 774

785

69
11 Oil Piping (2)
Ref.
Air-Cooled No. Description
775
772 369 O-Ring, strainer cover
E40 396 Strainer Cover
770 Oil Piping (OP suction)
771 Oil Piping (OP discharge)
772 Oil Piping (1)
773 Oil Drain Piping (1)
775 774 Oil Drain Piping (2)
775 Oil Piping (2)
776 Oil Piping (3)
828 828 Orifice
880 Oil Strainer
882 Oil Filter Element
888 Oil Temperature Sensor
996 Filter Wrench A
D35 O-Ring
D80 Seat, oil piping
D35 E40 Seat, oil air ventilation
D35
H73 O-Ring
※ Does not come with the product.
776

774
771

H73
888
D80
369
880
H73 396
 882
※996

D35
770 D35
773

11 Oil Piping (1)

Water-Cooled H53
768
771
H91

769
H73 H91

890

770

D34

H73 Ref.
No. Description
768 Seat, oil piping
769 Support, greasing port
770 Oil Piping (1)
887 773
771 Oil Piping (2)
774
773 Piping (1), oil drain
774 Piping (2), oil drain
785 Support, oil piping
887 Oil Drain Valve
890 Gear Case Breathing Piping
785 D34 O-Ring (gear case bearing)
H53 Float Cover
H73 O-Ring (cooler piping)
H91 Grease Nipple

70
11 Oil Piping (2)
Ref.
No. Description
Water-Cooled 828 369 O-Ring, strainer cover
396 Strainer Cover
770 Oil Piping (OP suction)
771 Oil Piping (OP discharge)
773 Oil Drain Piping (1)
774 Oil Drain Piping (2)
828 Orifice
880 Oil Strainer
D35 882 Oil Filter Element
888 Oil Temperature Sensor
D35
996 Filter Wrench A
D35 O-Ring
D80 Seat, oil piping
H73 O-Ring
※ Does not come with the product.

771 774
H73
888
770

369
880
H73 396  882
※996
D80

D35
D35

773

12 Water Piping
Ref.
C06 Description
No.
Water-Cooled 008 Piping (1)
009 Piping (2)
011 Pet Cock
012 Piping (3)
016 Piping (4)
017 Stop Valve, for a water flow control
018 Seat, cooling water piping
096 Stop Valve, drainage
009 096 C06 Motorized Water Isolation Valve
D33 Support, water piping
H58 Vibration Isolation Rubber
011

012
016
018
H58 017

008

009

D33

71
13 Blowoff Piping
Ref.
Air-Cooled No. Description
900 Blowoff Silencer
[Fixed speed type] 901 Seat, blowoff silencer
902 Cover, blowoff silencer
B38 Plate, blowoff piping
E33 E33 Support, blowoff piping (1)
E34 Support, blowoff piping (2)
E94
E94 Blowoff Air Piping

E34

B38

902

900

901

Ref.
No. Description
900 Blowoff Silencer
901 Seat, blowoff silencer
902 Cover, blowoff silencer
B38 Plate, blowoff piping
E21 Blowoff Solenoid Valve (1)
E22 Blowoff Solenoid Valve (2)
E23 Adapter
E33 Support, blowoff piping (1)
E34 Support, blowoff piping (2)
E96 E94 E80 Support, silencer cover
E94 Blowoff Air Piping (1)
E95 Blowoff Air Piping (2)
E33
E96 Blowoff Air Piping (3)

901 E34

E95
B38

E22
E23
E23 900

E21 902
E80

E22

72
13 Blowoff Piping
E93 Ref.
No. Description
Water-Cooled 900 Blowoff Silencer
901 Seat, blowoff silencer
[Fixed speed type] 902 Cover, blowoff silencer
A90 Tee Fitting
E93 Blowoff Cooler
E94 Blowoff Air Piping (1)
E95 Blowoff Air Piping (2)
E94

902
A90

900

E95

901

E22 Ref.
No. Description
900 Blowoff Silencer
901 Seat, blowoff silencer
902 Cover, blowoff silencer
A90 Tee Fitting
E21 Blowoff Solenoid Valve (1)
E23
E22 Blowoff Solenoid Valve (2)
E23 Adapter
E80 Support, silencer cover
E95 E94 Blowoff Air Piping (1)
E21 E95 Blowoff Air Piping (2)
E22 E23 E94 E96 Blowoff Air Piping (3)

901
900

902
E80 E96

A90

73
14 Control Air Pipe
Ref.
Air-Cooled [Fixed speed type] No. Description
019 Check Valve
085 O-ring, control line filter
799 Element, control line filter
849 Support, pressure sensor
892 Support plate, solenoid valve
896 3-Way Solenoid Valve
897 Control Line Filter
898 Pressure Differential Indicator
899 Solenoid Valve Manifold
A92 Seat, sensor
A95 Adapter, control air piping
A98 Nipple
D26 Pressure Sensor (discharge air)
D79 Filter Nipple
D99 Pressure Sensor (interstage)
H83 Pressure Sensor (oil)
898

D79

892

A92
019
899

896
849
D26
A95
A98 H83

A92
D99

897
085
799

74
14 Control Air Pipe
Ref.
Air-Cooled No. Description
849 Support, pressure sensor
898 Pressure Differential Indicator
A92 Seat, sensor
D26 Pressure Sensor (discharge air)
D79 Filter Nipple
D99 Pressure Sensor (interstage)
E40 E40 Seat (1), pressure detecting pipe
H63 Seat (2), pressure detecting pipe
H83 Pressure Sensor (oil)

H63
898

D79

849

D99

H83
D26

A92

75
14 Control Air Pipe
Ref.
No. Description
Water-Cooled [Fixed speed type] 019 Check Valve
085 O-ring, control line filter
799 Element, control line filter
849 Support, pressure sensor
892 Support plate, solenoid valve
896 3-Way Solenoid Valve
897 Control Line Filter
898 Pressure Differential Indicator
899 Solenoid Valve Manifold
A92 Seat, sensor
A95 Adapter, control air piping
A98 Nipple
D26 Pressure Sensor (discharge air)
D79 Filter Nipple
D99 Pressure Sensor (interstage)
H83 Pressure Sensor (oil)
898

D79

892
A92
019
899

896 849

D26
A95
A98 H83

A92
D99

897
085
799

76
14 Control Air Pipe
Ref.
Description
Water-Cooled No.
849 Support, pressure sensor
898 Pressure Differential Indicator
A92 Seat, sensor
D26 Pressure Sensor (discharge air)
D79 Filter Nipple
E40
D99 Pressure Sensor (interstage)
E40 Seat (1), pressure detecting pipe
H63
H63 Seat (2), pressure detecting pipe
H83 Pressure Sensor (oil)

898

D79

849

D99

H83
D26

A92

77
15 Enclosure (1)

Air-Cooled
915
911
H59 914 912 925 H71
910 913 926

H60

938 940
D14 966
943

944
991
945
D25

906

H70 929
908 990
D25 946
D14 953
976
H97 A71
939 977

H98 A71 942

904
905

Ref.
No. Description
904 Front Door (1)
905 Front Door (2)
906 Front Panel
908 Right Panel
910 Left Panel
911 Rear Panel (1)
912 Rear Panel (2)
913 Rear Panel (3)
914 Top Panel (1)
915 Top Panel (2)
925 cover(1), piping
926 cover(2), piping
929 Rubber Bush, control cable
938 Handle
939 Rubber Bush
940 Rubber Bush
942 Common Base
943 Left Frame
944 Front Frame
945 Right Frame
946 Rear Panel (4)
953 Instrument Panel
966 Top Panel (3)
976 Rear Duct (1)
977 Rear Duct (2)
990 Cover
991 Left Door
A71 Fork Slot Cover
D14 Magnet
D25 Chain
H59 Left-Corner Cap
H60 Right-Corner Cap
H70 M6 Exterior Screw
H71 Magnet Rubber
H97 Name plate for model
H98 Name plate for NEXT

78
15 Enclosure (2)
Ref.
Air-Cooled No. Description
917 917 Duct, air intake
921 Cover, air intake filter duct
922 Air Intake Filter
932 Wing Nut
933 Stud Bolt
937 Bolt with assistant
975 Duct, motor
933 982 Support, Frame (3)
922 H88 Protective Cover
H95 Support, Frame (1)
H96 Support, Frame (2)
921
975

H96

937 932
982

H95
H88

79
15 Enclosure (1)

Water-Cooled
925 926 H71

915
911 912 940
H59 914
910
913

H60

938 D14 966

951
944 D96
991

D25 969

906 D91
929
990
H70
908
D25 946
D14
953

939
H97 A71

A71
H98 942 Ref.
No. Description
904 Front Door (1)
905 Front Door (2)
904 906 Front Panel
905 908 Right Panel
910 Left Panel
911 Rear Panel (1)
912 Rear Panel (2)
913 Rear Panel (3)
914 Top Panel (1)
915 Top Panel (2)
925 cover(1), piping
926 cover(2), piping
929 Rubber Bush, control cable
938 Handle
939 Rubber Bush
940 Rubber Bush
942 Common Base
944 Front Frame
946 Rear Panel (4)
951 Left Frame
953 Instrument Panel
966 Top Panel (3)
969 Right Frame
990 Cover
991 Left Door
A71 Fork Slot Cover
D14 Magnet
D25 Chain
D91 Seal Cover (1)
D96 Seal Cover (2)
H59 Left-Corner Cap
H60 Right-Corner Cap
H70 M6 Exterior Screw
H71 Magnet Rubber
H97 Name plate for model
H98 Name plate for NEXT

80
15 Enclosure (2)
Ref.
No. Description
Water-Cooled 917 Duct, air intake
921 Cover, air intake filter duct
922 Air Intake Filter
932 Wing Nut
933 Stud Bolt
937 Bolt with assistant
975 Cover (1), motor duct
E59
976 Duct, motor (1)
977 Duct, motor (2)
E60 978 Cover (2), motor duct
E59 Duct (1), Starter Box
E60 Duct (2), Starter Box
H87 Protective Cover (1)
H88 Protective Cover (2)
H95 Support, Frame (1)
H96 Support, Frame (2)

917
Control panel

933 978
922 977 976

921

H96

937 932
975

H95
H88

H87

81
16 Oil Mist Remover
Ref.
No. Description
D37 Element
D38 O-Ring
D39 Solenoid Valve
D40 Pressure Gauge
D41 Ejector
D42 Vacuum Indicator
D44 D43 E96
D43 Valve Sheet
D44 Valve Spring
D41 D45 Air Filter/Air Pressure Regulator
D46 Diaphragm, air pressure regulator
D48 Element, air filter
D49 Float Trap
D78 Packing
E62 O-Ring, air pressure regulator
E63 OMR Consumable Parts Kit
D42 E96 OMR Relief Valve
H17 Valve
H76 H18 Stem
D37 ※E63
H76 Tube Fitting Assy (1)
H77 Tube Fitting Assy (2)
※ Does not come with the product.

D38

Details of A
D45

D46
D40

H18

OUT IN
H77
E62

D49

H17

D39
D48

D78
A

82
 DSP Service Manual A 2014.10

Hitachi Industrial Equipment Systems Co.,Ltd.

Printed in Japan