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York Turbomaster M Series User manual

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INSTALLATION, OPERATION AND
MAINTENANCE
SERIES M TURBOMASTER
COMPRESSORS
Supersedes: 220.11-NM1 (366)
Form 220.11-NM2 (602)
SERIES M TURBOMASTER COMPRESSORS
00617VIP
YORK INTERNATIONAL2
FORM 220.11-NM2 (602)
This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils, materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
in which it is situated, as well as severe personal injury
or death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this in-
dividual possesses independent training that will en-
able them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual shall have read and
understood this document and any referenced materi-
als. This individual shall also be familiar with and com-
ply with all applicable governmental standards and regu-
lations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION identifies a hazard which
could lead to damage to the machine,
damage to other equipment and/or en-
vironmental pollution. Usually an in-
struction will be given, together with
a brief explanation.
NOTE is used to highlight additional
information which may be helpful to
you.
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious
injury.
WARNING indicates a potentially haz-
ardous situation which, if not avoided,
could result in death or serious injury.
External wiring, unless specified as an optional connection in the manufacturer’s product
line, is NOT to be connected inside the panel cabinet. Devices such as relays, switches,
transducers and controls may NOT be installed inside the panel. NO external wiring is
allowed to be run through the panel. All wiring must be in accordance with YORK’s pub-
lished specifications and must be performed ONLY by qualified YORK personnel. YORK
will not be responsible for damages/problems resulting from improper connections to the
controls or application of improper control signals. Failure to follow this will void the
manufacturer’s warranty and cause serious damage to property or injury to persons.
FORM 220.11-NM2 (602)
3YORK INTERNATIONAL
NOMENCLATURE
CHANGEABILITY OF THIS DOCUMENT
In complying with YORK’s policy for continuous prod-
uct improvement, the information contained in this
document is subject to change without notice. While
YORK makes no commitment to update or provide
current information automatically to the manual owner,
that information, if applicable, can be obtained by con-
tacting the nearest YORK Engineered Systems Group
office.
It is the responsibility of operating/service personnel
as to the applicability of these documents to the equip-
ment in question. If there is any question in the mind
of operating/service personnel as to the applicability
of these documents, then, prior to working on the equip-
ment, they should verify with the owner whether the
equipment has been modified and if current literature
is available.
Diffuser
Enhancement
M238 A
–7
First Stage
Impeller
Width Designation
Nominal Casing I.D.
Impeller O.D.
Designation
No. of Stages
Multistage Compressor
D
––
Additional Stage
Information
REFERENCE INSTRUCTIONS
DESCRIPTION FORM NO.
CONCRETE BASES 160.71-N1.1
INSTALLATION – OM SYSTEMS 160.71-N1
EFFECTS OF MOISTURE IN REFRIGERANT SYSTEMS 55.60-NM10
VACUUM DEHYDRATION 55.60-NM12
CENTRIFUGAL COMPRESSOR COUPLING ALIGNMENT 160.71-N2
YORK INTERNATIONAL4
FORM 220.11-NM2 (602)
TABLE OF CONTENTS
SECTION 1Description of System and Fundamentals of Operation ................................. 7
SECTION 2Installation .................................................................................................... 11
SECTION 3Operation ...................................................................................................... 14
SECTION 4Service .......................................................................................................... 32
FORM 220.11-NM2 (602)
5YORK INTERNATIONAL
LIST OF TABLES
1 Casing Sizes ..................................................................................................................... 7
2 Approximate Housing Weights For Series M Compressors ........................................... 13
3 Approximate Component Weights For Series M Compressors ..................................... 13
4 Major Compressor Parts ................................................................................................ 19
5 AOP Differential Coltrol Settings ................................................................................... 29
6 COP Low Oil Differential Safety Settings ..................................................................... 29
7 Oil Pressure Switch Tubing Sizing.................................................................................. 30
8 Maintenance Requirements for YORK Multistage Centrifugal Compressors .............. 33
9 Compressor Tools ........................................................................................................... 37
10 Shaft Seal Parts ..............................................................................................................39
11 Typical Shaft Seal Installation “Height” Dimension ....................................................... 40
12 Clearances ..................................................................................................................... 46
13 Screw Sizes for Pulling Drive End Journal Bearing ....................................................... 46
14 General Bolt Torques ..................................................................................................... 47
TABLE PAGE
YORK INTERNATIONAL6
FORM 220.11-NM2 (602)
LIST OF FIGURES
1 Model Series M Turbomaster Compressor ........................................................................ 7
2 Typical Compressor Cross-Sectional View ....................................................................... 9
3 Typical Primary Compressor Gas Flow .......................................................................... 15
4A Balance Piston ................................................................................................................. 17
4B Cut-A-Way View - Model 255 Compressor .................................................................. 17a
5 External Sump Vent Equalizing Lines ............................................................................. 19
6 Exploded View of Atmospheric Shaft Seal ..................................................................... 20
7 Oil Piping Schematic, Applicable for Models Prior to 1970 ............................................ 22
8 Oil Piping Schematic, Applicable for Models After 1970 ................................................ 23
9 Compressor Tools ............................................................................................................ 37
10 Coupling Guard ................................................................................................................ 37
11 Coupling Wrench Application .......................................................................................... 37
12 Loosening the Drive Shaft with Special Wrenches ......................................................... 38
13 Loosening Drive Shaft with Wrenches ........................................................................... 38
14 Shaft Seal Parts ............................................................................................................... 39
15 Assembling Shaft Seal Collar .......................................................................................... 40
16 Seal Ring Assembly ......................................................................................................... 40
17 Removing Drive End Journal Bearing Assembly ............................................................ 42
18 Removing Drive End Oil Seal Assembly......................................................................... 42
19 Exploded View PRV and Oil Seal Assembly .................................................................. 43
20 Oil Reservoir ................................................................................................................... 47
21 Discharge End Bearing and Oil Pump Assembly, Exploded View ................................. 48
22 Checking Alignment of Oil Pump .................................................................................... 49
23 Removing the Oil Reservoir ............................................................................................ 50
24 Exploded View, Oil Reservoir and Oil Seal Assembly .................................................... 51
25 Exploded View, Balance Piston Seal Assembly .............................................................. 52
26 Removing the Pre-Rotation Vane Assembly ................................................................... 53
27 PRV Housing Assembly (Open and Closed Vanes) ....................................................... 53
28 Vane Clamping Fixture .................................................................................................... 54
29 Lifting Top Half of Compressor Casing .......................................................................... 56
30 After Lifting Top Half of Compressor Casing with Sump Housing Removed ............... 56
31 Removing Interstage Labyrinth Seals ............................................................................. 57
32 Diffusers Removed ......................................................................................................... 58
33 Exit Plate Removal .......................................................................................................... 58
34 Removing First Stage Impeller Labyrinth Seal................................................................ 59
35 Rotor ................................................................................................................................ 59
FIGURE PAGE
FORM 220.11-NM2 (602)
7YORK INTERNATIONAL
SECTION 1
DESCRIPTION OF SYSTEM AND FUNDAMENTALS OF OPERATION
GENERAL DESCRIPTION
YORK’s Series M Turbomaster Compressors are de-
signed for compressing various refrigerants, oil field
hydrocarbon gases, CO2, air and chemical vapors.
They are manufactured in three nominal sizes mea-
sured at the inside diameter of the casing. The sizes
are 26, 38, and 55 inches. In addition, a 26 inch cas-
ing with a small diameter high speed rotor is identi-
fied as a 25 inch compressor.
cludes the pressure containing parts and stationary seals.
These compressors can incorporate 1 to 8 stages of com-
pression within a single casing. Series M Turbomaster
compressors may be directly driven by a turbine, mo-
tor, engine, or through a speed increaser/reducer. Ro-
tation must always be driven counter clockwise facing
the shaft end.
FUNDAMENTALS OF OPERATION AND MACHINE
COMPOSITION
This family of compressors has great flexibility in ap-
plication and the materials of construction will vary
based upon the design operating requirements for which
it was selected. Casing material can be cast iron, nodu-
lar iron or cast steel depending upon the design opera-
tion requirements. See Figure 2 for a typical compres-
sor cross-sectional view. Impeller materials can be alu-
minum or stainless steel, or a combination of both to
meet the requirements.
FIG. 1 – SERIES M TURBOMASTER COMPRESSOR
00618VIP 00619VIP
They consist of two major parts groups, the rotor and
the casing. The rotor assembly includes the main shaft,
impellers, and shaft driven oil pump. The casing in-
CASINGS SIZES I.D. 25" 26" 38" 55"
WHEEL B8.25 12.2 18.0 26.7
DIAMETERS
A10.0 14.8 21.9 31.5
(INCHES)
TABLE 1 – CASING SIZES
YORK INTERNATIONAL8
FORM 220.11-NM2 (602)
Description of System and Fundamentals of Operation
The internal stationary seals can be supplied in alumi-
num, bronze, or coated cast iron depending on the appli-
cation. The impeller diameter(s), blade width, and posi-
tion on the rotor can be varied to permit the introduction
of side load connection(s) if required. There can be side
load flows into several different stages and they can en-
ter into the bottom or top half of the compressor casing
as needed to accommodate the application.
Bearings
The compressor is equipped with aluminum sleeve
taper-bore or taper-land journal bearings, with the size
of the suction end bearing being varied as a function of
shaft horsepower. The thrust bearing system can incor-
porate hydrostatic bearings in the active (shaft move-
ment toward coupling) and reverse directions, tilting
pad in the active with hydrostatic in the reverse direc-
tion, or tilting pad in both active and reverse directions.
Temperature Sensors and Proximity Probes
The compressor may be equipped with bearing tem-
perature sensors and/or proximity probes for purposes
of monitoring compressor shaft vibration and/or axial
thrust position.
Seals
The compressor is equipped internally with gas/oil seals
over wind-back spirals on the shaft to control oil from
entering the compressor casing. There is also an atmo-
spheric shaft seal to minimize leakage of oil and pro-
cess gas to the outside where the shaft passes through
the housing. Some leakage from this seal is normal with
the rate being dependent on shaft speed, coupling di-
ameter, and pressure differential across the seal. There
is a provision for that fluid to be directed to an atmo-
spheric drain trap cast into the leg of the main casing.
Bolt Patterns
Due to the varied application of this compressor fam-
ily, there can be differences in the bolting and the pat-
terns of the bolting. There will be more bolts utilized
in the external patterns when the compressor is designed
for a higher design working pressure. There can be
variations on the internal bolting strength and sizing if
the application requires resistance to the effects of cer-
tain corrosion phenomenon. The application drawings
will indicate these special circumstances with special
bolt torque values or notes regarding special identify-
ing features such as “redrawn screws will have green
bolt heads.”
As Built Drawings
It is difficult to define the parameters of a standard mul-
tistage compressor although the typical two stage com-
pressor applied on a water chilling / air conditioning
duty is the most common type.
It is imperative to have the “as built”
drawings for the specific compressor
on hand before ordering spare parts
or attempting to work inside the com-
pressor. Failure to do so could result
in damage to the machine.
SAFETY
It is recommended that all maintenance and service re-
pair work be performed by experienced personnel.
There must be recognition of the potential hazards that
can exist. Those hazards may include (but are not lim-
ited to);
There can be electrical circuitry that
presents an electrocution hazard. Be
sure that the source of all power sup-
plies have been properly isolated and
secured before attempting any service
related activities.
The unit must have the coupling
guards in place and fully attached at
any time the shafts will be rotating. Be
sure that the shafts have stopped com-
pletely and the main power source has
been properly isolated before attempt-
ing any service related work activities
on the system.
FORM 220.11-NM2 (602)
9YORK INTERNATIONAL
FIG. 2 – TYPICAL COMPRESSOR CROSS-SECTIONAL VIEW
LD07317
1
YORK INTERNATIONAL10
FORM 220.11-NM2 (602)
There may be surfaces or fluids with
temperatures that are hot enough to
cause burns or ignite flammable ma-
terials. Care must be taken to protect
against burns or the ignition of flam-
mables.
The system may contain materials
that need to be disposed of in accor-
dance with governing regulations.
Please be sure to follow all pertinent
requirements when disposing of such
materials.
The system contains fluids under po-
tentially dangerous pressures, exer-
cise caution when preparing to service
or remove parts from the system. Be
sure to wear eye protection to avoid
any possible splash hazards.
The compressor contains many close
clearance areas and heavy parts which
can result in situations where fingers
or other extremities may be pinched,
crushed, or even severed. Care should
be taken when lifting or moving any
parts to be sure that any extremities are
free from those dangers.
Certain liquids that are expelled from
the system at atmospheric pressure
may be capable of producing a freeze
hazard to skin or eyes. Eye protection
and gloves should be worn to avoid
potential splash hazards.
Description of System and Fundamentals of Operation