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AirMan PDS400S-6B1 Instructional Manual

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INSTRUCTIONAL MANUAL
AIR COMPRESSOR
PDS400S-6B1
www.discount-equipment.com

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Summary of Contents for AirMan PDS400S-6B1

  • Page 1 INSTRUCTIONAL MANUAL AIR COMPRESSOR PDS400S-6B1 www.discount-equipment.com...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak,...
  • Page 3 ◆  This manual explains and illustrates proper handling of the unit, method of daily inspection and maintenance to enhance the performance of AIRMAN’s compressors. ◆  In order to use a machine safely, people with sufficient knowledge and sufficient technology need to deal with it.

  • Page 4: Table Of Contents

    Table of Contents   Safety ...............................  1-1 Caution before Operation ........................  1-2 Caution during Operation ........................  1-5 Caution during Inspection and Maintenance ...................  1-7 Safety Warning Labels ........................  1-10 Part Names ..............................  2-1 Unit Appearance and Part Names ....................  2-1 Internal Components and Part Names .................... ...

  • Page 5: Safety

    1.Safety This manual explains and illustrates general requirements for safety. Read all safety requirements carefully and fully understand the contents before starting the machine. For your better recognition, according to the degree of potential danger, safety messages are classified into three hierarchical categories, namely, , and with a caution symbol...

  • Page 6: Caution Before Operation

    1.Safety 1.1 Caution before Operation Air pressurized construction method prohibited Never use the unit directly or indirectly for the following purposes: Never use the unit for respirator equipment by which compressed air is supplied for human consumption. The compressed air contains carbon monoxide and other contaminants, and such air may cause serious injury or even death if used by a person for respiration.
  • Page 7 1.Safety Handling battery Keep flames away from battery. Battery may generate hydrogen gas and may explode. Battery electrolyte is dilute sulfuric acid. In case of mishandling, it could cause skin burning. When you deal with a battery, please be sure to wear protection implements, such as protection glasses D004 and a glove.
  • Page 8 1.Safety Maintain both physicl and mental health Do not operate the machine when you are tired or drunk or under the influence of drugs. Otherwise, a hasty conclusion or careless handling may cause unexpected injury or accident. Manage your physical and mental health and be cautious in handling the machine. Protection equipments Please wear protection implements, such as a helmet, protection glasses, earplugs, safety shoes, a glove, and a...

  • Page 9: Caution During Operation

    1.Safety Caution during Operation Do not replenish compressor oil during operation Do not, under any circumstance, open the oil filler cap of separator receiver tank while running or immediately after stopping operation. It is very dangerous because the oil filler cap could be blown off and high temperature compressed air and oil could jet out from the filler port, and cause serious injury.
  • Page 10 1.Safety Operation with compressed air supply port opened is prohibited Do not operate the machine with service valves and relief valve open unless air hoses and/or pipes are connected. High-pressurized air blows out and its air pressure could cause injury to the people nearby. When the machine has to be unavoidably temporarily operated with its port open, be sure to mount a silencer to reduce noise and wear protective materials such as earplugs to prevent...

  • Page 11: Caution During Inspection And Maintenance

    1.Safety Caution during Inspection and Maintenance Hang a “Now Checking and under Maintenance” tag Remove the starter key from the starter switch before starting inspection, and hang up a “Now Checking and under Maintenance” tag where it can be easily seen. The checker must keep the key during checking and maintenance.
  • Page 12 1.Safety Adjusting tension of fan belt Be sure to stop the engine and remove the starter key whenever the tension of the fan belt is to be adjusted. Remove the negative (–) side cable from the battery. If the machine is running, it might catch the operator’s hand into the fan belts, and this could cause a serious injury.
  • Page 13 1.Safety Opening coolant water drain valve cap Be sure to stop the engine, and let the coolant water sufficiently cool down before draining it. If the drain valve is opened before the coolant water is cooled enough, hot water could jet out, and it could cause scalding. H990432 Refilling or draining of engine oil After stopping the engine, wait for 10 to 20 minutes until the...
  • Page 15 1.Safety The pasting position of safe warning label is as follows. Separator receiver tank Engine part attachment position Part attachment position A040036 1-11...

  • Page 16: Part Names

    2. Part Names Unit Appearance and Part Names A040037 1. Lifting bail 5. Handle 2. Exhaust outlet 6. Service valve 3. Drawbar 7. Instrument panel 4. Door...

  • Page 17: Internal Components And Part Names

    2. Part Names Internal Components and Part Names 11 12 13 15 16 17 24 23 21 20 19 A040038 1. Auto-relief valve 17. Oil cooler 2. Pressure regulator 18. Exhaust muffler 19. Oil cooler drain valve 3. Pressure control valve 4.

  • Page 18: Installation

    3. Installation Transportation Transportation When loading and unloading unit, be sure to use the lifting bail provided on the center of the unit top. Never get under the unit which is lifted up, because it is very dangerous. When unit is transferred or moved from working site, be sure to place it on truck bed, and fasten it by ropes at the front eye and rear stand.

  • Page 19: Towing The Unit

    3. Installation 3.2 Towing the Unit Keep traction speed lower than 20 km/h. (High speed model is lower than 80 km/h) Select a tractor with capacity sufficient for weight and size of this unit. It is 60 psi (4.2 bar) what is standard air pressure of tire. Replace the defaced or damaged tire Don’t change the size and kind of this machine’s tire.

  • Page 20: Location And Installation

    3. Installation Location and Installation Ventilation Exhaust gas from the engine is poisonous, and could cause death when inhaled. Avoid using the machine in an insufficiently ventilated building or tunnel. Do not position the exhaust gas outlet in direction of a person or a house.

  • Page 21: Operation

    4. Operation Instrument Panel 1. Fuel level gauge ＜Indicator lamp＞ 2. Coolant temperature gauge 10.Preheating ＜Warning lamp＞    3. Discharge air temperature gauge 11.Charging 4. Differential pressure gauge 12.Engine air filter   of oil separator 13.Compressor air filter 5. Tachometer (with hourmeter) ＜Emergency stop lamp＞   ...

  • Page 22: Door

    4. Operation Door 4.2.1 Open/Close the Door Keep the door closed and locked while running the unit. When the door has to be opened, be careful not to touch portions that are rotating or very hot. Careless touch may cause serious injury. PK0028 Pull the handle forward to open the door.
  • Page 23 4. Operation 4.3.2 Check Coolant Level Taking off the Header tank radiator cap Be sure to stop the machine and allow time to cool. Then loosen the radiator cap one notch. After the coolant water is sufficiently cooled and the inner pressure is released, take the cap off. If this procedure is neglected, the inner pressure can blow off the cap.

  • Page 24: Check Compressor Oil Level

    4. Operation 4.3.3 Check Compressor Oil Level Refilling of compressor oil When you refill the separator receiver tank with compressor oil, stop the engine, and make sure that the pressure gauge indicates 0MPa and there is no residual pressure in it, and then gradually loosen the oil filler cap for refilling oil.
  • Page 25 4. Operation 4.3.5 Drain Water Sedimenter Check if the red float 1 in the water sedimenter rises up to the water drain level , then drain water if it is near the drain level. (Draining procedure) ① Loosen the drain plug 3 and drain out condensed water inside.
  • Page 26 4. Operation 4.3.7 Check V-Belt Tension Too tight belt tension could damage shaft and shorten bearing life. Too loose belt tension may result in damaging belt earlier and machine components due to overheat. Follow the procedure below to adjust tension of fan belt and V-belt for alternator.

  • Page 27: Unit Operation

    4. Operation Unit Operation Operation with compressed air supply port opened is prohibited Do not operate the machine with service valves open unless air hoses and/or pipes are connected. High-pressurized air blows out and its air pressure could cause injury to the people nearby. When the machine has to be unavoidably temporarily operated with its port open, be sure to mount a silencer to reduce noise and wear protective materials such as earplugs to prevent...
  • Page 29 4. Operation 4.4.2 Operating Procedures when Engine Fails to Start up on First Attempt When the engine fails to start up even after performing the start up procedures ① to ⑤ not keep the starter running, but set the starter switch back to ”STOP” and wait about 30 seconds.
  • Page 30 4. Operation 4.4.5 Gauge Indication while Operating Minimum discharge air pressure is 58psi ( 4.0 bar ) during operation Continuing equipment operation at a lower pressure than the above pressure may cause overheating, since it affects the separation of lubricating oil inside the oil separator and reduces the oil flow to the compressor air-end, resulting in temperature rise.

  • Page 31: Stopping Procedures

    4. Operation 4.4.6 Check Clogging in Oil Separator When the differential pressure gauge of oil separator shows Red (replacement required) red range, replace the oil separator.（See 5.6.15） H000477 Stopping Procedures ①  Close the service valve completely and operate the machine about 5 minutes, until it cools down.

  • Page 32: Periodic Inspection/Maintenance

    5. Periodic Inspection/Maintenance Important Items at Periodic Inspection and Maintenance or after Maintenance The manual shows proper interval for periodic inspection and maintenance under normally operating conditions. Inspection and maintenance should be performed more often under extremely harsh conditions. Hang a “Now Checking and under Maintenance” tag Remove the starter key from the starter switch before starting inspection, and hang up a “Now Checking and under Maintenance”...

  • Page 33: Daily Inspection And Keeping Operation Log

    5. Periodic Inspection/Maintenance Precautions for check and maintenance Be sure to use recommended fuel, oil, grease, and antifreeze. Do not disassemble or adjust engine, compressor or part(s) for which inspection or maintenance is not referred to in this manual. Use genuine parts for replacement. Any breakdown, caused by using unapproved parts or by wrong handling, will be out of the scope of “WARRANTY”.

  • Page 34: Periodic Inspection List

    5. Periodic Inspection/Maintenance Periodic Inspection List Such items marked shall be carried out by customers. ○ For the following items or clauses marked ●, contact us directly or our distributors because they require expert technical knowledge on them. The following table shows the inspection and maintenance intervals under normal operation conditions. In case the unit is operated under harsh environmental conditions and operation conditions, the intervals should be shortened.

  • Page 35: Periodic Replacement Of Parts

    5. Periodic Inspection/Maintenance (Unit:Hour) Maintenance Daily 1,000 2,000 3,000 6,000 Page Drain water sedimenter ○ Check fuel level ○ Check engine oil level. ○ Check coolant level. ○ Check looseness in pipe connectors, terminals ○ and tear in wiring. Check V-belt tension. ○...

  • Page 36: Maintenance

    5. Periodic Inspection/Maintenance Maintenance 5.6.1 Change Engine Oil At 50 hours for the first change and at every 500 hours thereafter Caution in filling or discharging engine oil After stopping the engine, wait for 10 to 20 minutes until the engine oil cools off.

  • Page 38: Change Compressor Oil

    5. Periodic Inspection/Maintenance 5.6.5 Change Compressor Oil Refilling of compressor oil When you refill the separator receiver tank with compressor oil, stop the engine, and make sure that the pressure gauge indicates 0psi ( 0bar ) and there is no residual pressure in it, and then gradually loosen the oil filler cap for refilling oil.

  • Page 39: Change Compressor Oil Filter

    5. Periodic Inspection/Maintenance 5.6.6 Change Compressor Oil Filter At 300 hours for the first change and every 500 hours thereafter Use our genuine oil filter Poor quality oil filters do not trap dust sufficiently and will cause damage to the bearings in a short period.
  • Page 41 5. Periodic Inspection/Maintenance 5.6.13 Change Coolant Taking off the radiator cap Be sure to stop the machine and allow time to cool. Then loosen the radiator cap one notch. After the coolant water is sufficiently cooled and the inner pressure is released, take the cap off. If this procedure is neglected, the inner pressure can blow off the cap.

  • Page 42: Supply Grease To Trailer Spring Pin

    5. Periodic Inspection/Maintenance (Procedure) ① To drain coolant, remove cap 2 of header tank on radiator top and open the drain valve drain it. ② Also be sure to drain engine by loosening the drain plug without fail. ③ After completing drainage, close the drain valve and drain plug and then supply coolant through the filler port of the header tank.

  • Page 44: Maintenance/Adjustment

    6. Maintenance/Adjustment Maintenance of Battery Handling battery Keep flames away from battery. Battery may generate hydrogen gas and may explode. Therefore, recharging should be done at a well-ventilated place. Do not spark near the battery nor light a match, nor bring lit cigarette and match close to the battery.

  • Page 46: Troubleshooting

    6. Maintenance/Adjustment Troubleshooting Should any trouble occur during operation, do not leave it. Investigate the cause and take appropriate measures. Read the manual carefully and fully understand what to do in case of trouble. The better you understand the construction and function of the unit, the faster you can find a problem and solution.
  • Page 47 6. Maintenance/Adjustment Symptom Cause Countermeasures (1) Engine oil shortage. Replenish oil (2) Engine oil filter clogging. Change Engine oil pressure (3) Malfunction of engine oil pump Change lamp goes on. (4) Faulty oil pressure switch. Change (5) Loosened or disconnected Check/Fasten wiring or connector.

  • Page 48: Storage Of The Unit

    7. Storage of the Unit Preparation for Long-term Storage When the unit is to be kept unused in storage for a long time, be sure to follow the preparations below and put the unit in a dry and less dusty place. Put the unit in a temporary cabin if it is stored outside.

  • Page 49: Specifications

    8. Specifications Specifications Length in.(mm) 142(3,600) Single-stage oil cooled, Type screw type compressor Length in.(mm) 95 (2,445) (draw-bar excluded) Free air delivery cfm(m /min) 400 (11.3) Width in.(mm) 78(1,975) Working pressure psi(bar) 100 (6.9) Maximum Height in.(mm) 68(1,720) psi(bar) 150 (10.3) pressure Dry weight lb(kg) 4,004 (1,820)

  • Page 51: Piping Diagram

    10. Piping Diagram   A040051     10-1  ...
  • Page 52 www.discount-equipment.com...

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