AirMan PDSE900S-4B1 Instruction Manual
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AirMan PDSE900S-4B1 Instruction Manual

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  • Page 2 Preface Thank you for having selected our “AIRMAN” product. ◆ This manual explains about the proper operation and daily inspection and maintenance of this machine. ◆ In order to use a machine safely, people with sufficient knowledge and sufficient technology need to deal with it.

  • Page 3: Table Of Contents

    Table of Contents 1. Safety -------------------------------------------------------------------------------------------------------- 1-1 1.1 Caution before Operation ---------------------------------------------------------------------------------------------------- 1-2 1.2 Caution during Operation ---------------------------------------------------------------------------------------------------- 1-5 1.3 Caution during Inspection and Maintenance ---------------------------------------------------------------------------- 1-7 1.4 Safety Warning Labels ------------------------------------------------------------------------------------------------------- 1-10 2. Part Names ------------------------------------------------------------------------------------------------ 2-1 2.1 Internal Components and Part Names ----------------------------------------------------------------------------------- 2-1 3.

  • Page 4: Safety

    1.Safety This manual explains and illustrates general requirements for safety. Read all safety requirements carefully and fully understand the contents before start- ing the machine. For your better recognition, according to the degree of potential danger, safety mes- sages are classified into three hierarchical categories, namely, , and with a caution symbol −attached to each message.

  • Page 5: Caution Before Operation

    1.Safety Caution before Operation Compressed air is prohibited to be used for human respiration Compressed air by this unit contains poisonous materials. Absorption of the compressed air can cause serious injury. Never provide this compressed air for human respiration. This unit is not designed to be used for working chambers pressurized by compressed air such as respiratory air provided to persons working inside TR0201-1...
  • Page 6 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 protec- tion implements, such as protection glasses and a glove.
  • Page 7 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, protec- tion glasses, earplugs, safety shoes, a glove, and a protec-...

  • Page 8: 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 9 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. ...

  • Page 10: 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 11 1.Safety Adjusting tension of belt  Be sure to stop the engine and remove the starter key whenever the tension of the 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 belts, and this could cause a serious injury.
  • Page 12 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.

  • Page 13: Safety Warning Labels

    1.Safety Safety Warning Labels Following labels are attached to the machine. Keep them clean at all times. If they are damaged or missing, immediately place an order with your nearest dealer for replacement. Part numbers are indicated on the lower right corner of the label. Adhere a new one to the original location.
  • Page 14 1.Safety ●  T he pasting position of safe warning label is as follows. A070196E 1-11...

  • Page 15: Part Names

    2.Part Names Internal Components and Part Names 5 6 7 8 19 18 16 15 14 13 12 PDSE900S,PDSF830S-4B1 A070206 Description Function Oil cooler For cooling compressor oil circulating in the system. Engine For driving the compressor. For filtering dust and foreign matter mixed or to be mixed in the Fuel filter fuel oil.
  • Page 16 2.Part Names A070207 Description Function Air filter(For compressor) For filtering the dust floating in the intake air. Air-end For compressing intake air. Air filter(For engine) For filtering the dust floating in the intake air. Coolant drain plug For draining condensate from engine. Engine oil filler port For supplying and replenishing engine oil to engine.

  • Page 17: 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 suspended, 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 and rear hooks.

  • Page 18: Handling The Drawbar

    3. Installation Handling the Drawbar Precautions on handling drawbar When the drawbar 1 is raised up for transportation, be sure to secure it by engaging the drawbar hook 3 with the holder 2 without fail. If the drawbar hook comes off the drawbar falls down, Lock position causing serious injury.

  • Page 19: Towing The Unit

    3. Installation 3.2.2 How to release the drawbar ① Push the fixed drawbar“1”against the machine in the direction of arrow mark. ② Turn the stopper“4”a little to make larger the clearance between stopper“4”and holder“2”than the diameter of the hook“3”. ③ Release the hook from the holder“2”through the clearance. ④...

  • Page 20: Location And Installation

    3. Installation Location and Installation 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: Compressed Air Service Valve

    3. Installation Compressed Air Service Valve Do not fail to install a check at the outlet of compressed air Compressor and then start piping. If the piping is performed without a check valve “1” installed, it is feared that the liquid in the piping can be returned into the compressor air-end it can cause a damage to the compressor air-end.

  • Page 22: Operation

    4.Operation Instrument Panel A070176 1. Fuel level gauge ＜Emergency stop lamp＞ ＜Indicator lamp＞ 2. Coolant temperature gauge 15. Discharge air temperature 9. Preheating 3. Discharge air temperature 16. Coolant temperature gauge 17. Engine speed down ＜Warning lamp＞ 4. Discharge air pressure 10.
  • Page 23 4.Operation Indicator lamp Item Contents Monitor Place the starter switch to “Preheating”, and the lamp Preheating goes on. Warning lamp When the lamp goes on, take appropriate measures to recover the situation swiftly. Item Contents Measures Monitor Lamp goes on when separator gets clogged and differential pressure increases.

  • Page 24: 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 por- tions that are rotating or very hot. Careless touch may cause serious injury. PK0028 Pull the handle foward to open the door“1”.

  • Page 25: Lubricating Oil・Coolant・Fuel

    Be sure to change the oil completely at every scheduled interval.  Follow the designated regulations to dispose of compressor oil. ＊Unit is delivered ex. factory, filled with “AIRMAN OIL LONG LIFE HP”.
  • Page 26 4.Operation 4.3.3 Coolant Quality of coolant and antifreeze Use soft water of good quality such as tap water for coolant. When water with dirt, sand, and/or dust contained, or hard water such as well water (ground water) is used, this will cause deposits inside radiator or on cylinder head, and will cause engine overheat due to poor flow of coolant.

  • Page 27: Check Before Starting Unit

    4.Operation Check before Starting Unit Check before starting unit Be sure to check the unit before operation. When any abnormality is found, be sure to repair it before restarting the unit. Be sure to make daily checks before operation. If the unit is operated without prior check and without no- ticing its abnormality, such operation could cause seizure of components or may even cause fire.
  • Page 28 4.Operation 4.4.2 Check Coolant Level Taking off the radiator cap Taking off the 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 29: Check Compressor Oil Level

    4.Operation 4.4.3 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 30 4.Operation 4.4.5 Check Fuel  Check fuel level gauge before operation. Replenish enough fuel to prevent fuel shortage during operation, if the level is low.  Be sure to fasten the fuel tank cap firmly after replenishment. If fuel is spilt, wipe it up completely.
  • Page 31 4.Operation 4.4.8 Check 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. 1. Check the alternator belt of cooling fan (Procedure) ①...
  • Page 32 4.Operation 4.4.9 Check Wiring of Each Part Check each wiring for any loose connection, damage to insulating sheathed portion, disconnection, and short-circuit. 4.4.10 Check Piping of Each Part Check each piping for any loose connection and also check each hose and pipe for any tear and leaks. 4-11...

  • Page 33: Unit Operation

    4.Operation Unit Operation 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.
  • Page 34 4.Operation 4.5.2 Operating Procedures when Engine Fails to Start up on First Attempt When the engine fails to start up even after performing the startup procedures ① to ⑤ do not keep the starter running, but set the starter switch back to “STOP” and wait about 30 seconds. Then, repeat the startup procedure once again.
  • Page 35 4.Operation 4.5.4 Gauge Indication while Operating During operation, keep the discharge air pressure gauge indicating higher pressure. PDSE900S ------------------------------- than 0.64MPa PDSF830S,PDSG750S --------------- than 0.59MPa 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 36: Performance Check Of Safety Valve

    4.Operation Coolant tem- Discharge air Discharge air Model Tachometer perature temperature pressure gauge gauge gauge PDSE900S 0.86～1.03MPa 1,100min-1 Unload PDSF830S 1.03～1.27MPa 70～120℃ 50～95℃ 1,200min-1 PDSG750S 1.27～1.52MPa PDSE900S 0.64～0.86MPa Full load PDSF830S 0.59～1.03MPa 2,200min-1 70～120℃ 50～95℃ PDSG750S 0.59～1.27MPa 4.5.5 Performance Check of Safety Valve Keep face or hand away from the discharging outlet of safety valve.

  • Page 37: Stopping Procedures

    4.Operation 4.5.6 Check Clogging in Oil Separator When the differential pressure gauge of oil separator shows red range, replace the oil separator. （See 5.6.15） Pointer Green zone Red zone It is normal when It should be re- placed when the the pointer is pointer enters within this zone.

  • Page 38: 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 op- erating conditions. Inspection and maintenance should be performed more often under ex- tremely harsh conditions. Hang a “Now Checking and under Maintenance”...

  • Page 39: Daily Inspection And Operation Log

    5. Periodic Inspection/Maintenance Daily Inspection and Operation Log Be sure to carry out daily inspection every morning before operation. See Chapter 2 “Operation” of the manual for the details of inspection. Pay attention to and carefully observe the following points during daily operation or inspection and maintenance work.

  • Page 40: Periodic Inspection List

    5. Periodic Inspection/Maintenance Periodic Inspection List (Unit:Hour) Maintenance 1,000 2,000 3,000 6,000 12,000 Page Daily Check compressor oil level. ○ Drain separator receiver tank. ○ Check looseness in pipe connecting part, and 4-11 ○ wear and tear of pipe. Check oil, water, fuel and air leak. 4-14 ○...

  • Page 41: Periodic Replacement Of Parts

    5. Periodic Inspection/Maintenance ◎Refer to engine operation manual for inspection and maintenance of an engine. (Unit:Hour) Maintenance Daily 1,000 2,000 3,000 6,000 Page Check fuel ○ Drain fuel tank ○ Drain check in pre- filter ○ Check engine oil level. ○...

  • Page 42: 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 43 5. Periodic Inspection/Maintenance 5.6.2 Change Engine Oil Filter [At 50 hours for the first change and at every 500 hours thereafter] (Procedure) ① Drain condensate from the engine oil filter by loos- ening the drain plug “1”. ② Remove the center-bolts “2” and then take out ele- ment “3”...
  • Page 44 5. Periodic Inspection/Maintenance 5.6.4 Check and clean Air Filter Element [Every 250 hours] Cleaning of Air Filter Element should be perfectly performed Clogged or cracked or pitted element could allow entrance of dust into engine and compressor to cause earlier wear of moving parts. Periodical inspection and cleaning of element should be performed to maintain life of compressor and engine long.

  • Page 45: Change Compressor Oil

    5. Periodic Inspection/Maintenance 5.6.5 Change Compressor Oil [At 300 hours for the first change and at every 500 hours thereafter] Refilling of compressor oil When you refill the separator receiver tank with compressor oil, stop the engine, and make sure that the pressure gauge indi- cates 0MPa and there is no residual pressure in it, and then gradually loosen the oil filler cap for refilling oil.

  • Page 46: 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. (Procedure) ①...

  • Page 47: Clean Strainer In The Scavenging Orifice

    5. Periodic Inspection/Maintenance 5.6.7 Clean Strainer in the Scavenging Orifice [Every 500 hours] (Procedure) ① Remove the hose “1”if the oil recovery line provided on the top of Separator receiver tank. ② Remove the recovery orifice “2”first. ③ Pull out the strainer“3”out of the nipple. ④...
  • Page 48 5. Periodic Inspection/Maintenance 5.6.9 Change Fuel Filter [Every 500 hours] (Procedure) ① Remove the cartridge“1”, using a filter wrench. ② Spread thin film of oil on a packing“2”of a new cartridge“1”and screw it in. (For replacement parts, refer to 5.5) ③...
  • Page 49 5. Periodic Inspection/Maintenance 5.6.11 Clean outside of the Radiator･Oil Cooler [Every 1,000 hours] When the fin tubes of a radiator “ 1” , an oil cooler “ 2” are clogged with dust or other foreign materials, the heat exchange efficiency drops and this will raise coolant temperature and discharge air tem- perature.

  • Page 50: Supply Grease To Trailer Spring Pin

    5. Periodic Inspection/Maintenance 5.6.12 Clean the strainer provided inside the engine feed pump [Every 1,000 hours] Joint bolt Periodically remove the strainer“1”inside the feed pump, and clean it. Remove the strainer “1” by loosening the joint bolt and clean it with diesel fuel oil, and also using high air pressure blow.
  • Page 51 5. Periodic Inspection/Maintenance 5.6.14 Change Coolant [Every 1,000 hours or every 2 years] Caution of coolant change Be sure to stop the machine and loosen the radiator cap slowly, after the coolant water is sufficiently cooled and the inner pres- sure is released, then take the cap off.

  • Page 52: Change Oil Separator

    5. Periodic Inspection/Maintenance 5.6.15 Change Oil Separator [Every 2,000 hours] (Procedure) ① In order to pull out the separator, remove the bolts (14 pieces) fixing the top cover on the separator cover. ② Remove the nylon tubes fitted on the piping of separator cover, using a spanner etc. ③...
  • Page 53 5. Periodic Inspection/Maintenance 5.6.16 Check Fuel hose [Every 2,000 hours or every 2 years]  When any crack or wear is found on the hoses, change it even before the scheduled time.  Ask your nearest dealer for its replacement. 5-16...

  • Page 54: 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 55 6. Maintenance/Adjustment 6.1.1 Charge Battery Be sure to read the operation manual of the battery charger Battery to know if it is applicable, before using it. Disconnect the cable between battery and the unit, and charge the battery with a 12V battery charger. Do not charge two batteries at the same time.

  • Page 56: Troubleshooting

    6. Maintenance/Adjustment Troubleshooting Should any trouble occur during operation, do not leave it. Investigate the cause and take appro- priate 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 prob- lem and solution.
  • Page 57 6. Maintenance/Adjustment Symptom Cause Countermeasures (1) Engine oil shortage. Replenish oil (2) Engine oil filter clogging. Change Engine oil pressure lamp (3) Malfunction of engine oil pump Change goes on and engine stops. (4) Faulty oil pressure switch. Change (5) Loosened or disconnected Check/Fasten wiring or connector.

  • Page 58: 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 59: Specifications

    8.Specifications Specifications Model PDSE900S-4B1 PDSF830S-4B1 PDSG750S-4B1 Single-stage oil cooled, screw type compressor Type 25.0 23.5 21.2 Free air delivery /min 0.86 1.03 1.27 Working pressure Forced Lubrication by compressed pressure Lubricating system Direct driving with rubber coupling Driving system 0.248...

  • Page 60: Outline Drawing

    8.Specifications Outline drawing A040390-1...

  • Page 61: Wiring Diagram

    9. Wiring Diagram A090360E...

  • Page 62: Piping Diagram

    10. Piping Diagram 10.1 Compression air・Compressor oil PDSE900S,PDSF830S-4B1 10-1...
  • Page 63 10. Piping Diagram PDSG750S-4B1 10-2...

  • Page 64: Fuel

    10. Piping Diagram  10.2  Fuel     To engine Gauze filter       Injection pump Feed pump     Fuel filter             Fuel tank   Pre-filter     A070200         10-3  ...
  • Page 66 发行者 总公司 工厂 新泻县燕市下粟生津 3074 TEL 0256-93-5571 FAX 0256-94-7567 （禁止擅自复印以及转载） ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. 8TH FLOOR SHINJUKU SAN-EI BLDG, 22-2 NISHI-SHINJUKU 1-CHOME,SHINJUKU-KU TOKYO 160-0023 JAPAN TEL:81-3-3348-7281 FAX:81-3-3348-7289 URL:http//www.airman.co.jp Copyright(C)2012 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved. 39600 04330 Printed MAR.2013...

This manual is also suitable for:

Pdsf830s-4b1Pdsg750s-4b1

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