AirMan PDS185S-6E1 Service Manual
  1. Manuals
  2. Brands
  3. AirMan Manuals
  4. Air Compressor
  5. PDS185S-6E1
  6. Service manual

AirMan PDS185S-6E1 Service Manual

Engine compressors, pc
Hide thumbs
Table of Contents

Advertisement

Quick Links

www.discount-equipment.com

Advertisement

Table of Contents
loading

Related Manuals for AirMan PDS185S-6E1

Summary of Contents for AirMan PDS185S-6E1

  • Page 1 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 Preface This service manual explains about the cautions for maintenance jobs and is to serve a guide for the electric system, and troubleshooting for service personnel. Fundamental matters and other things already mentioned in the “Instruction Manual” and the “Parts Catalogue”...

  • Page 4: Table Of Contents

    Table of Contents 1. Specification -------------------------------------------------------------------------------------- 1-1 1.1 Specifications ----------------------------------------------------------------------------------------------------------- 1-1 1.2 Set Value ----------------------------------------------------------------------------------------------------------------- 1-2 1.3 Outline Drawing -------------------------------------------------------------------------------------------------------- 1-3 1.4 Internal Components and Part Names ---------------------------------------------------------------------------- 1-5 1.5 Instrument Panel ------------------------------------------------------------------------------------------------------- 1-7 1.5.1 Indicator lamp ------------------------------------------------------------------------------------------------------- 1-8 1.6 Capacity Control Device ---------------------------------------------------------------------------------------------- 1-9 1.6.1 Auto idle control (purge control) -------------------------------------------------------------------------------- 1-10 1.6.2 Adjustment of auto idle control (purge control) and correction of engine speed -------------------- 1-11 1.7 Piping Diagram --------------------------------------------------------------------------------------------------------- 1-12...
  • Page 5 Table of Contents 3.12 Pressure Sensor (for intake negative pressure / service pressure and regulator secondary pressure) --------------------------------------------------------- 3-31 3.13 Fuel Meter (Display) --------------------------------------------------------------------------------------------------- 3-31 3.14 Sending Unit ------------------------------------------------------------------------------------------------------------- 3-32 3.15 Air filter Differential Pressure Switch ------------------------------------------------------------------------------ 3-32 3.16 Electronic Control Engine Component ---------------------------------------------------------------------------- 3-33 3.16.1 Supply pump ------------------------------------------------------------------------------------------------------- 3-34 3.16.2 Rail ------------------------------------------------------------------------------------------------------------------- 3-34 3.16.3 Rail pressure sensor --------------------------------------------------------------------------------------------- 3-34...
  • Page 6 Table of Contents 4.3 Operation of Emergency Switch ------------------------------------------------------------------------------------ 4-11 4.3.1 Discharge temperature indication lamp glows and engine stops --------------------------------------- 4-11 4.3.2 Engine oil pressure indication lamp glows and engine stops ------------------------------------------- 4-12 4.3.3 Engine water temperature indication lamp glows and engine stops ----------------------------------- 4-13 4.4 Others --------------------------------------------------------------------------------------------------------------------- 4-14 4.4.1 Residual pressure lamp lights on and engine will not be able to start -------------------------------- 4-14 4.4.2 Indicator lamps will not glow, but engine stops ------------------------------------------------------------- 4-14...

  • Page 7: Specification

    1. Specification 1.1 Specifications Item unit ●Weight・Mass Overall length in.(mm) 128.7(3,270) Overall length (Bonnet only) in.(mm) 75.2(1,910) Overall width in.(mm) 66.3(1,685) Overall height in.(mm) 61.0(1,550) Net dry mass lb(kg) 2,050( 930) Operating mass lb(kg) 2,271(1,030) ●Compressor Free air delivery cfm(m /min) 185(5.2) Working pressure...

  • Page 8: Set Value

    1. Specification 1.2 Set Value Item unit ●Emergency stop devices Actuating temperature of discharge °F(℃) 248(120) temperature switch Actuating temperature of water °F(℃) 230(110) temperature switch Actuating pressure of oil pressure psi(MPa)[bar] 7.1(0.049)[0.49] switch ●Warning devices Actuating temperature of discharge °F(℃) 239(115) temperature switch...

  • Page 9: Outline Drawing

    1. Specification 1.3 Outline Drawing...
  • Page 10 1. Specification...

  • Page 11: Internal Components And Part Names

    1. Specification 1.4 Internal Components and Part Names 4 5 6 11 12 13 14 15 16 17 PC13114 Description Description Instrument panel By-pass valve Service pressure sensor Oil cooler Regulator secondary pressure Oil cooler drain valve Pressure control valve Engine oil drain valve Oil separator Fuel cap...
  • Page 12 1. Specification 37 38 PC13113 Description Description Exhaust pipe Separator receiver tank Radiator Safety valve Reserve tank Discharge pipe Cooling fan Air-end Alternator Coupling Engine Starter Air filter differential pressure indicator Battery (For compressor air-end) Solenoid valve for starting unloader Radiator drain valve (purge) Compressor oil filter...

  • Page 13: Instrument Panel

    1. Specification 1.5 Instrument Panel ELLOR CODE switch When this switch is pushed on while lamp is blinking, it shows error code. When starter switch is placed to “STOP”, displayed screen is reset. Indication selector switch A130957 AUTO IDLE switch This switch is used when fuel consumption is minimized at no load operation.

  • Page 14: Indicator Lamp

    1. Specification 1.5.1 Indicator lamp Turn the starter switch to “RUN” position. Then the lamp goes on. [Indicator lamp] Item Contents Measures Monitor When starter switch is placed to “RUN”, ― GLOW the lamp goes on and after preheating is finished, the lamp will be off.

  • Page 15: Capacity Control Device

    1. Specification 1.6 Capacity Control Device A131023E Step Response Compressed air flows into unloader chamber (A) because solenoid valve for purge control SV1 is opened at start-up. The pressure in chamber (A) rises Start soon to close unloader valve fully and accordingly it can reduce the load at start-up.

  • Page 16: Auto Idle Control (Purge Control)

    1. Specification 1.6.1 Auto idle control (purge control) This model is equipped with auto idle control operation mode. This operation mode is recommendable for such use: not so much air consumption is required and it is used continuously and also power consumption under unloaded operation is required to be saved.

  • Page 17: Adjustment Of Auto Idle Control (Purge Control) And Correction Of Engine Speed

    1. Specification 1.6.2 Adjustment of auto idle control (purge control) and correction of engine speed Item Indication Unit Primary set value Range of set values Purge releasing pressure 70 to 100 Waiting time for transfer to 5 to 60 purge mode operation Load factor for transfer to 5 to 30 ％...

  • Page 18: Piping Diagram

    1. Specification 1.7 Piping Diagram PC14063E 1-12...

  • Page 19: Fuel Piping

    1. Specification 1.8 Fuel Piping PC14001 1-13...

  • Page 20: Maintenance

    2. Maintenance 2.1 Cautions for Overhauling 2.1.1 Precautions before starting work (1) Work to be performed It is very important to always plan in advance what facilities, tools, instruments, materials, oil, etc. you will need to use; the exact locations and methods of performing inspection, adjustment, or disassembly;...

  • Page 21: Tightening Torque

    2. Maintenance 2.2 Tightening Torque 2.2.1 General bolts and nuts tightening torque Fasten all the bolts and nuts with the specified tightening torque when assembling. Kind Low or Middle carbon steel bolt High tensile strength bolt (SS400B etc…) (SCM435 etc…) Strength and 8.8－12.9（7T－12T）...

  • Page 22: Tightening Torque Of Such Important Quality Parts As Bolts And Nuts

    2. Maintenance 2.2.2 Tightening torque of such important quality parts as bolts and nuts [Excerpted from HIS C-40940 (company standard)] Strength Tightening torque lbf ･ in.(N ･ m)[kgf ･ cm] classification Application parts & portions Coarse thread / fine thread Remarks Torque Bolt...
  • Page 23 2. Maintenance 1 Air-end ① 2 Mounting ③ ④ ④ 3 Coupling portion between comp. air-end and engine ⑥ ⑦ ENG.SIDE COMP.SIDE ⑤ PC14002...
  • Page 24 2. Maintenance 4 Lifting portion ⑧ ⑧ PC14003 5 Pressure vessel and pipes ⑩ ⑨ ⑨ PC14004...

  • Page 25: How To Adjust Regulator

    2. Maintenance 2.3 How to Adjust Regulator  When adjusting regulator system, install a silencer to the air delivery port and wear earplugs for protection of hearing damage. Operation with compressed air supply port opened is prohibited. D003 The speed regulator is already adjusted prior to delivery ex. works. Never change the setting of ●...

  • Page 26: Change Of Element In Fuel Pre-Filter

    2. Maintenance 2.4 Change of Element in Fuel Pre-filter <Procedure> ① Turn fuel selector valve“1”to“OFF”position. ② Loosen the drain valve“2”and drain out condensed water inside. ③ Turn the cup “3”to the left and remove it. Be careful to remove the cup“3”because it is filled with fuel. Wipe out split fuel completely.

  • Page 27: Change Oil Separator

    2. Maintenance 2.5 Change Oil Separator  When changing the oil separator, both cover and element must be replaced with new ones. Even before the periodic interval time of replacement, replace the oil separator whenever the oil ● consumption increases and also oil is found mixed in the discharge air. When consumption of the oil is still unusual even after cleaning strainer in the scavenging orifice, ●...

  • Page 28: Change O-Ring Of Unloader

    2. Maintenance 2.6 Change O-ring of Unloader <Caution during O-ring replacement> When changing O-ring“1”,“2”,“3”, and“4”, coat ● slightly the sliding surface with grease. PC14005 <Replacement of O-ring “4”> O-ring“4”is composed of O-ring and resin ring ● O-ring Resin ring (generally called Teflon ring). When attaching it, the resin is likely to expand and change itself.
  • Page 29 2. Maintenance ③ Slightly coat inner circumference portion of the correction tool with grease and insert it into the piston“5”and then correct the resin ring. IMPORTANT Insert the ring gradually to the piston, correcting it and paying attention not to get caught.

  • Page 30: Change O-Ring Of Auto-Relief Valve And Vacuum Relief Valve

    2. Maintenance 2.7 Change O-ring of Auto-relief Valve and Vacuum Relief Valve After disassembling and cleaning the component, ● check the O rings “1” , “ 2” and “3” . When the rubber of these rings is found hardened, replace any one of Auto-relief valve them.

  • Page 31: Maintenance And Adjustment Of Pressure Control Valve

    2. Maintenance 2.8 Maintenance and Adjustment of Pressure Control Valve <Procedure> ① If the discharge pressure drops lower than 51psi(0.35MPa)[3.5bar] during operation, replace the spring“3”of pressure control valve. After confirming that the compressed air in the pipes is completely relieved, disassemble the valve. ②...

  • Page 32: Change Of Pellet Assembly Of By-Pass Valve

    2. Maintenance 2.9 Change of Pellet assembly of By-pass Valve By-pass valve fitted on this unit is of full bore type. While the unit is used for normal operation, it ● is not to perform periodical replacement of the inner pellet assembly, but when such trouble as excessive rise of compressor oil temperature, it becomes necessary to replace it, in accordance with the following procedures.

  • Page 33: Air Bleeding In Fuel Line

    2. Maintenance 2.10 Air Bleeding in Fuel Line Should the machine stop due to fuel shortage, perform air bleeding according to the following ● steps. <Procedure> ① Replenish fuel. ② When starter switch is turned to “RUN” position, electromagnet pump starts to automatically bleed air in fuel line.

  • Page 34: Clean Drain Separator (Option: With Aftercooler Only)

    2. Maintenance 2.12 Clean Drain Separator (Option: With aftercooler only) When the condensate cannot be drained out, being clogged with dirt, dust, and sludge, sludge ● accumulated at drain port during long operation and depending on environment conditions, clean drain separator. <Procedure>...

  • Page 35: Electric System

    3. Electric System 3.1 Electronic Control System of Engine 【Excerpted from YANMAR SERVICE MANUAL】 3.1.1 Electronic control system Model TNV engines come with the Common Rail System and the Exhaust Gas Recirculation (EGR) system to conform to the engine emission regulations (EPA 2012 rules). The electronic engine control system regulates the exhaust gas recirculation flow rate and the fuel injection volume depending on the engine load and speed signals from the engine controller (ECU), so that the exhaust gas is kept clean according to the emission control regulations.

  • Page 36: Acceleration Control

    3. Electric System 3.1.2 Acceleration control Emergency controller (control of output and engine speed) receives electric signal outputted from pressure sensor, and it controls electronic fuel injection system by outputting to engine controller. Pressure regulator The pressures at 2nd stage is converted into voltage and Pressure sensor outputted.

  • Page 37: Diesel Particulate Filter (Dpf)

    3. Electric System 3.1.3 Diesel particulate filter (DPF) The DPF consists of the diesel oxidation catalyst (DOC) and the SF, held by a case that sends the exhaust gas to the DOV and the SF. The role of the DPF is to prevent the discharge of PM by breaking down the hazardous constituents with the DOC and collecting the PM with the SF.

  • Page 38: Dpf Regeneration Control

    3. Electric System 3.1.4 DPF regeneration control DPF differential pressure sensor and temperature sensor are installed in the DPF. If the DPF cannot perform continuous regeneration due to low load operation, the ECU uses these electrical components to control assisted DPF regeneration (DPF regeneration control) automatically to prevent PM from over-accumulating.
  • Page 39 3. Electric System ・The dilution of the lubricating oil with fuel caused by the post-injection is kept to a minimum, but some dilution is possible for low-load operation (low temperature exhaust gas). Make sure that you do a daily check of oil level. ※Active regeneration-1 and active regeneration-2 are collectively explained as “active regeneration”...
  • Page 40 3. Electric System <Manual regeneration procedure> ① Regeneration required lamp“1”and error lamp “4”go on. At the same time, regeneration lamp “5”flashes. And also engine speed automatically changes to 1,350 min Regeneration required ② Close service valve. ③ Keep pressing regeneration switch“3”longer than 3 seconds.

  • Page 41: Preheating Control

    3. Electric System 3.1.5 Preheating control [ON glow control (Pre-heat)] When the starter switch is placed “RUN” position automatically the glow plug relay is electrified in accordance with the time applied to coolant temperature. Being electrified, the preheat lamp goes on at the same time.

  • Page 42: Emergency Controller

    3. Electric System 3.2 Emergency Controller Part number:46870 64001 PC14017E PC14018E...
  • Page 43 3. Electric System 1. Exterior connection drawing PC14019E ※1 As engine oil pressure switch contact is B, the contact is ON when engine shuts down. After engine starts, the contact becomes OFF due to rise of engine oil pressure. Oil pressure detecting circuit of controller functions at circuit of contact A.
  • Page 44 3. Electric System 2. Timing of each output relay PC14020E 3. Warning・emergency display and emergency stop functions Item Indicator Sensor Actuation Detecting timing Time lag Lamp goes on at Discharge temp. H Thermister Always 120 sec － 239°F(115℃) Lamp goes on at Water temp.
  • Page 45 3. Electric System 4. Functions of each output relay Mark Name Function Coolant temperature: Lower than 50°F(10℃)･･･ When coolant temp. is higher than 50°F(10℃), or Relay for starting It goes OFF when when 120 seconds pass, it becomes ON. unloader starter switch is ON.
  • Page 46 3. Electric System 6. Pressure sensor / Emergency controller Output – revolution speed list (for reference only) The voltage values in the following table are standard reference ones. They are different a little from actual ones during operation. Output voltage of pressure sensor Pressure sensor Regulator secondary pressure Output voltage (DCV)

  • Page 47: Emergency Controller

    3. Electric System 3.2.1 Emergency controller (1) List of CN1 terminal functions (12 pins) Line Pin No. Connection Function color CN1-1 － CN1-2 － When more residual pressure than 14.6psi Residual pressure start prohibition (0.1MPa)[1bar] is left in the receiver tank, Ry3 CN1-3 lamp relay of emergency controller becomes “ON”...

  • Page 48: Air Filter (For Engine)

    3. Electric System Line Pin No. Connection Function color When engine oil pressure drops to the set pressure of emergency stop, it makes emergency controller Ry4 relay ON and it sends abnormality CN2-3 Engine oil pressure switch signal to ECU to stop engine. Emergency stop set oil pressure : ●...
  • Page 49 3. Electric System (3) List of CN3 terminal functions (8 pins) Line Pin No. Connection Function color Regulator secondary pressure CN3-1 Grounding sensor Regulator secondary pressure CN3-2 Detection of regulator secondary pressure. sensor Vout terminal Engine controller (ECU) CN5-62 CN3-3 Grounding terminal CN3-4...
  • Page 50 3. Electric System DPF controller A130992 (4) List of CN19 terminal functions (8 pins) Line Pin No. Connection Function color When abnormality occurs to engine or excessive soot is accumulated, electricity is supplied to DPF controller from engine controller (ECU) to CN19-1 Error lamp make error lamp light on.

  • Page 51: Engine Controller (Ecu)

    3. Electric System 3.3 Engine Controller (ECU) Part number:46870 64400 PC14021E 3-17...
  • Page 52 3. Electric System (1) List of CN4 terminal functions (60 pins) Line Pin No. Connection Function color CN4-1 Injector 2 Injects fuel to injector 2. CN4-2 Injector 3 Injects fuel to injector 3. CN4-3 － When power stays on, fuel is sent to common rail CN4-4 Supply pump by pressure.
  • Page 53 3. Electric System Line Pin No. Connection Function color CN4-36 － ECU judges cylinder according to (CSS) signal, CN4-37 W/L Cam speed sensor OUT terminal and it decides engine speed and piston position. CN4-38 Crank speed sensor shield Noise prevention －...
  • Page 54 3. Electric System (2) List of CN5 terminal functions (96 pins) Line Pin No. Connection Function color CN5-1 20A fuse Power supply CN5-2 Grounding CN5-3 20A fuse Power supply CN5-4 Grounding CN5-5 20A fuse Power supply CN5-6 Grounding CN5-7 － CN5-8 －...
  • Page 55 3. Electric System Line Pin No. Connection Function color CN5-34 － Starter switch C terminal via CN5-35 Inputting start signal. emergency controller CN5-36 － CN5-37 － CN5-38 － EGR pressure sensor CN5-39 W/G EGR valve control. (Intake Vout terminal) CN5-40 －...
  • Page 56 3. Electric System Line Pin No. Connection Function color CN5-64 － SA-D “SMARTASSIST-Direct” CN5-65 Grounding No.4 terminal ･Emergency controller CN2-11 It detects deficiency of charging battery, and it CN5-66 terminal enables alarm lamp ON. ･Alternator L terminal CN5-67 － Power supply (DC12V) of EGR valve relay CN5-68 EGR valve relay exciting coil exciting coil...
  • Page 57 3. Electric System Line Pin No. Connection Function color SA-D “SMARTASSIST-Direct” CN5-90 Power supply (DC12V) No.1 terminal CN5-91 － When engine fails or too much soot is accumulated on DPF, DPF controller CN19-1 terminal is electrified to light the lamp ON. For CN5-92 Error lamp the details of error, trouble diagnosis tool (SA-D)

  • Page 58: Alternator

    3. Electric System 3.4 Alternator YANMAR part number:129423-77200 Internal wiring diagram PC10028-1 PC10057E Nominal capacity DC12V-40A (1) List of functions Line Pin No. Connection Function color Starter motor B terminal Power for charging voltage. It detects battery voltage, and it controls rotor coil Starter switch BR terminal electromagnetic current.
  • Page 59 3. Electric System (3) Check and confirm the following when faulty charging warning lamp lights on Abnormal Measure battery voltage when : Less than DC12V Recharge battery. stopping Normal: DC12V Abnormal : Battery voltage is same Measure voltage of alternator as when stopping Repair alternator because it is in trouble.

  • Page 60: Starter

    3. Electric System 3.5 Starter YANMAR part number:129242-77010 Internal wiring diagram PC10036E PC10030E Voltage DC12V Output 1.7kW (1) List of functions Line Pin No. Connection Function color For supplying power to starter which enables Battery + terminal starter pinion to turn. For supplying power to make starter pinion to spring out and also a little power to make pinion Starter relay No.3 terminal...

  • Page 61: Starter / Glow Plug Relay

    3. Electric System 3.6 Starter / Glow Plug Relay Part number:44346 16600 YANMAR part number:129927-77920 PC14024E (1) Specification Rated voltage DC12V Coil resistance (at 20℃) 103Ω±10％ 50A 14VDC Resistance load (at 85℃) Rated control capacity (2-1) Starter relay functions list Line Pin No.

  • Page 62: Egr Valve Relay

    3. Electric System 3.7 EGR Valve Relay Part number:44346 16500 YANMAR part number:198461-52950 PC14025E (1) Specification Rated voltage DC12V Coil resistance (at 20℃) 30Ω±10％ Motor load Contact rating Halogen lamp load (2) List of functions Line Pin No. Connection Function color Engine controller (ECU) Power supply circuit for EGR valve relay exciting...

  • Page 63: Solenoid Valve (Sv1) For Starting Unloader And Purge / Solenoid Valve (Sv2) For Aftercooler Drain: Option

    3. Electric System 3.8 Solenoid Valve (SV1) for Starting Unloader and Purge / Solenoid Valve (SV2) for Aftercooler Drain: Option Part number:46811 30000 (Rc1/4) (Rc1/4) ･Closed while electricity PC14027 is supplied (NO) Diameter of orifice φ3 (1) Specification Rated voltage DC12V (2) List of functions For details of functions, see“(1) List of CN1 terminal functions (CN1-7 terminal) of 3.2.1 Emergency...

  • Page 64: Fuel Air-Bleeding Electromagnetic Pump

    3. Electric System 3.10 Fuel Air-bleeding Electromagnetic Pump Part number:43650 02700 YANMAR part number:129612-52100 (1) Specification Rated voltage DC12V Operating current 1.5A (MAX) More than Delivery capacity 0.11 to 0.29gal/min (0.4 to 1.1 L/min) PC10014 3.10 Discharge Temperature Sensor / Water Temperature Sensor Part number:44364 08200 ※Water temperature sensor is used for temperature indication, warning/emergency indication lamp and emergency stop.

  • Page 65: Pressure Sensor (For Intake Negative Pressure / Service Pressure And Regulator Secondary Pressure)

    3. Electric System 3.12 Pressure Sensor (for intake negative pressure / service pressure and regulator secondary pressure) Part number:44328 20600 Trouble diagnosis of pressure sensor itself Check and confirm that output voltage between ②－③ is 0.5±0.1V when DC5V is applied between ①－③ terminals at an atmospheric pressure.

  • Page 66: Sending Unit

    3. Electric System 3.14 Sending Unit Part number:36159 04100 Warning switch is not used. PC08037E-1 Float position Resistance value (Ω) 110.0±7.0 32.5 3.0±2.0 3.15 Air filter Differential Pressure Switch Part number:32148 03000 ･Operating pressure : 6.2kPa ･A Contact SC10016 3-32...

  • Page 67: Electronic Control Engine Component

    3. Electric System 3.16 Electronic Control Engine Component 【Excerpted from YANMAR SERVICE MANUAL】 PC14030 Supply pump Top view PC14031 1. Supply pump 7. Engine oil pressure switch 14. EGR Intake/Exhaust) pressure sensor 2. Rail 8. Crank speed sensor 15. EGR gas temperature sensor 3.

  • Page 68: Supply Pump

    3. Electric System 3.16.1 Supply pump The fuel passes the pre-filter and is pressure-fed by a fuel feed pump to the main filter, then it arrives at the supply pump. The ECU controls the opening of the intake metering valve and adjusts the fuel intake volume so that the rail pressure is at the target value.

  • Page 69: Injector

    3. Electric System 3.16.4 Injector The ECU controls the injector to maintain optimum injection volume and injection timing and injects the high pressure fuel accumulated in the rail into the cylinder. Each piece of injector has its correction data for improvement injection volume...

  • Page 70: Crank Speed Sensor

    3. Electric System 3.16.8 Crank speed sensor The crank speed sensor is equipped on the flywheel side and the cam speed sensor is equipped on the gear side. Based on these 2 sensor outputs, the ECU recognizes the engine speed and each piston position. PC14036 YANMAR part number:129A00-21710 Installation...

  • Page 71: Intake Air Throttles

    3. Electric System 3.16.12 Intake air throttles YANMAR part number:129A00-12900 Installation ：79.7±15.9lbf･in. (9±1.8N･m) [92±18kgf･cm] Note: Be sure to read the precautions before handling the intake throttle. Motor Sensor terminal terminal PC14040 Characteristics of the intake throttle The intake throttle is a device that controls the amount of the engine air intake.

  • Page 72: Egr Valve

    3. Electric System 3.16.13 EGR valve Controls the exhaust gas recirculation flow rate depending on the engine speed / load signals from the ECU. It is installed on the top of the exhaust manifold. YANMAR part number:129A00-13901 PC14042 3.16.14 EGR (Intake/Exhaust) pressure sensor EGR control for reduction of exhaust gas is implemented by EGR (Intake/Exhaust) pressure sensor, intake air temperature sensor, EGR gas temperature sensor and exhaust manifold temperature sensor.

  • Page 73: Exhaust Manifold Temperature Sensor

    3. Electric System 3.16.16 Exhaust manifold temperature sensor YANMAR part number:129A00-13770 PC14045 3.16.17 Diesel particulate filter (DPF) differential pressure sensor DPF differential pressure sensor, DPF intermediate/inlet temperature sensor are equipped together with throttle valve for DPF regeneration control. For the details of DPF regeneration control, refer to 3.1.4 clause.

  • Page 74: Diesel Particulate Filter (Dpf) Intermediate/Inlet Temperature Sensor

    3. Electric System 3.16.18 Diesel particulate filter (DPF) intermediate/inlet temperature sensor PC14048 YANMAR part number: DPF intermediate temperature sensor 129C00-13950 DPF inlet temperature sensor 129C00-13940 Installation ：221.3－354.0lbf･in. (25－40N･m) [255－410kgf･cm] Note: Do not lift the DPF by holding the sensor part. 3.16.19 Fuel temperature sensor It is installed to the supply pump, and the thermistor changes the resistance according to the temperature.

  • Page 75: Troubleshooting

    4. Troubleshooting 4.1 Repairing Procedures When performing failure diagnosis, pay special attention to the followings, observing general cautions. 4.1.1 Safety caution (1) Removing such cap and/or plug for receiver tank, fuel tanks and pipes where pressure is loaded, stop the machine and relieve all the interior pressure. Install measuring instruments connected firmly.

  • Page 76: How To Use The Failure Diagnosis

    4. Troubleshooting (5) Procedures of diagnosis When you become well experienced, you can find out the cause easily during the process of confirmation (4). But easy understanding could cause unexpected failure. So check and judge it according to the following procedures. ①Check the easiest thing or portion first.

  • Page 77: Failures Of Compressor And Engine

    4. Troubleshooting 4.2 Failures of Compressor and Engine 4.2.1 At start-up, starter rotates slowly Check battery voltage and ※Faulty Battery specific gravity too Re-charge and or supply specific gravity low or electrolyte short water / replace Normal Volt: More than 12V Faulty electric Gravity: More than 1.26 conductance alternator B...

  • Page 78: Engine Revolutions Will Drop Before Rises Up To Rated Pressure

    4. Troubleshooting 4.2.3 Engine revolutions will drop before rises up to rated pressure Less than 100psi (0.69MPa)[6.9bar] Solenoid valve Check function of starting Check DCV between opens unloader / purge solenoid CN1-9 and CN1-7 terminal valve of emergency controller [at AUTO IDLE operation] (interior contact Ry2) DC 0V Less than 100psi...

  • Page 79: Engine Will Not Turn To Meet Rated Revolutions

    4. Troubleshooting 4.2.4 Engine will not turn to meet rated revolutions Check whether it is Adjustment possible to adjust it by Faulty adjustment Re-adjust correcting full load revolutions Faulty adjustment Adjustment Faulty adjustment of Check adjustment of Re-adjust pressure pressure pressure regulator Faulty adjustment Clogging is...

  • Page 80: Minimum Speed Not Available Even Upon No-Load Operation

    4. Troubleshooting 4.2.5 Minimum speed not available even upon no-load operation Check whether it is Adjustment possible to adjust it by Faulty adjustment Re-adjust correcting no load revolutions Faulty adjustment Approx. less than 1.1V Check pressure sensor Faulty pressure sensor Replace it output voltage (DCV) Normal...

  • Page 81: Oil Mixed Found In Delivery Air

    4. Troubleshooting No clogging Faulty Disassemble / clean or Check unloader valve Faulty unloader replace function (whether it closes) Normal Disassemble / check Faulty oil seal of Replace oil seal compressor air-end 4.2.7 Oil mixed found in delivery air Too much Arrange oil level to Check compressor oil level Oil level too high...

  • Page 82: Discharge Air Is Insufficient

    4. Troubleshooting 4.2.9 Discharge air is insufficient Clogging is large Air filter clogging Clean or replace Check air filter for clogging Normal Air leak Check purge solenoid valve Faulty seat Repair or replace it for any air leak Normal Faulty Disassemble / clean or Check function of unloader Faulty unloader valve...

  • Page 83: Purge Control Operation Will Not Start Even If Auto Idle (Purge Control) Switch Is Pressed

    4. Troubleshooting Differential pressure is Check the pressure large Faulty oil separator Replace it difference before and after 19.3－21.4psi oil separator equipped (98.1－147kPa) Normal [0.98－1.47bar] Abnormality compressor Disassemble / check air-end Repair ※For the detailed countermeasures, refer to “Service manual” published by engine manufacturer. 4.2.10 Purge control operation will not start even if AUTO IDLE (purge control) switch is pressed Air leak...

  • Page 84: Even When The Pressure At Consumer's Side Drops, It Will Not Recover From

    4. Troubleshooting 4.2.11 Even when the pressure at consumer’s side drops, it will not recover from purge control operation Purge releasing pressure too low Check setting of purge Faulty setting of purge Adjust (See 1.6.2) releasing pressure (L) releasing pressure (L) 86psi(0.6MPa)[6.0bar] Service pressure and output voltage...

  • Page 85: Operation Of Emergency Switch

    4. Troubleshooting 4.3 Operation of Emergency Switch 4.3.1 Discharge temperature indication lamp glows and engine stops More than 104°F(40℃) Check ambient Unsuitable place of Relocation temperature installation Less than 104°F(40℃) Shortage Check compressor oil level Shortage of oil Replenish or replace Proper Less than 248°F(120℃)

  • Page 86: Engine Oil Pressure Indication Lamp Glows And Engine Stops

    4. Troubleshooting 4.3.2 Engine oil pressure indication lamp glows and engine stops Shortage Shortage of oil Check engine oil level Replenish or replace Proper Faulty Replace it Check engine oil filter Filter clogging Normal Faulty Check engine oil pressure Faulty oil pressure switch Replace it switch Normal...

  • Page 87: Engine Water Temperature Indication Lamp Glows And Engine Stops

    4. Troubleshooting 4.3.3 Engine water temperature indication lamp glows and engine stops More than 104°F(40℃) Check ambient Unsuitable place of Relocation temperature installation Less than 104°F(40℃) Shortage Shortage of coolant and Check water quantity and Replenish or replace bad quality quality in radiator Normal Less than...

  • Page 88: Others

    4. Troubleshooting 4.4 Others 4.4.1 Residual pressure lamp lights on and engine will not be able to start More than It starts after discharge 0.1MPa Check the accuracy of Residual pressure pressure gauge drops at discharge pressure gauge start-lock functions 0MPa 0MPa DC 0V...

  • Page 89: Explanation Of Trouble Diagnosis

    4. Troubleshooting 4.5 Explanation of Trouble Diagnosis Item Cause Remedy Faulty unloader. Unloader valve cannot be open. Remove unloader assembly from compressor air-end, and disassemble it for inspection and replace O-ring. Check pressure sensor Engine speed is controlled by the proper 3.2 clause: Emergency output voltage.
  • Page 90 4. Troubleshooting Item Cause Remedy Check engine oil When engine oil pressure becomes lower Check and confirm in pressure switch. than 7.1psi(0.049MPa)[0.49bar], contact accordance with the “4.6 becomes off to bring engine to emergency Engine Trouble Diagnosis stop. (Time lag 20 seconds) Function”.

  • Page 91: Engine Trouble Diagnosis Function

    4. Troubleshooting 4.6 Engine Trouble Diagnosis Function With regard to this electronic governor engine (Direct injection type with high-pressure common rail system), engine controller (ECU) is equipped with trouble diagnosis function. 4.6.1 Engine trouble diagnosis 1. Check and confirmation of trouble When engine fails, engine error lamp “1”...
  • Page 92 4. Troubleshooting ③ Connecting ECU, select“Diagnostics (Execution)”. and then communication speed : 250k selection ECU address 00 : engine selection PC14052E ④ Select Diagnostic codes –“Logged DTC”from Diagnostics (Execution) screen. PC14053E Logged DTC Active PC14054E ⑤ Clicking“Active failure“, Action and Probable causes will be displayed. ・Action ・Probable causes PC14055E...
  • Page 93 4. Troubleshooting ⑥ For the list of diagnostic trouble codes, refer to 4.6.2. For the detailed countermeasures, refer to “Service manual” published by engine manufacturer. ※How to clear Logged DTC after repairing troubles is to be performed by pressing “Clear Logged DTC”...
  • Page 94 4. Troubleshooting ② Implementing DPF Active Regeneration. Press RUN button to proceed regeneration. Stopping it, press STOP button. When regeneration is finished, Red lamp goes off. PC14058E 4-20...

  • Page 95: List Of Diagnostic Trouble Codes (Dtc)

    4. Troubleshooting 4.6.2 List of diagnostic trouble codes (DTC) This clause shows the list of the diagnostic trouble codes when engine is in trouble, which are explained in 4.6.1. DTC code Description DTC code Description P0008 No signal from both sensors P0471 EGR high-pressure side sensor abnormal learning value P000F...
  • Page 96 4. Troubleshooting DTC code Description DTC code Description P1435 DPF middle temperature sensor (insufficient sensor output) P1647 Dual accelerator sensor (open position) failure P1436 DPF inlet temperature sensor abnormally high temperature P1648 QA corrected injection amount for cylinder NO.1 error P1445 DPF recovery regeneration failure P1649...

  • Page 97: Trouble Diagnosis Tool (Smartassist-Direct)

    4. Troubleshooting 4.6.3 Trouble diagnosis tool (SMARTASSIST-Direct) Using SMARTASSIST-Direct (hereafter called SA-D), it is possible to diagnose electrical failure of engine control system and check the system, by reading diagnostic troubles codes (DTC) and referring to troubleshooting manual and renewal/replacement of parts change information, injection enforced driving and checking and confirming engine various control values.
  • Page 98 4. Troubleshooting 4. Renewal/replacement of parts change information ① When replacing ECU, software download/rewriting should be done. [Supplementary ECU does not contain software and data. And so it is necessary to download the data and ECU log which is not yet changed (injection correction value and etc.,) should be necessarily re-written and also it is necessary to change Ser.

  • Page 99: References

    5. References 5.1 Consumable Parts and Electrical Appliances Item Part Number ●Element / Filter / Belt Air filter ASS’Y (For compressor) 32100 44900 Air filter element (outer) 32143 11800 Air filter ASS'Y (For engine) 32100 44601 Air filter element (outer) 32143 11700 Oil separator 34220 16101...
  • Page 100 5. References Item Part Number ●Electrical appliances Emergency controller 46870 64001 Engine controller(ECU) 46870 64400 44346 16600 Starter/glow plug relay (YANMAR:129927-77920) 44346 16500 EGR valve relay (YANMAR:198461-52950) Starting unloader (for purge) solenoid 46811 30000 valve Fuse 10A 46934 03200 Fuse 20A (2 pieces) 46934 03300 Fuse 50A 44470 02900...

  • Page 101: Engine Wiring Diagram

    5.2 Engine Wiring Diagram Option ※ Parts name Emergency controller Residual pressure start prohibition lamp Engine controller (ECU) Fuse (20A) Fuse (20A) Fuse (10A) Fuse (80A) Glow plug relay Starter relay EGR valve relay PC14062E PC14061...
  • Page 102 ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. Copyright(C)2014 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved　 AIRMAN NPC-0096 PRINTED IN JAPAN 2014. 7 HOKUETSU INDUSTRIES CO., LTD.
  • Page 103 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,...

Table of Contents