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AirMan PDS185S-6C1 Service Manual

Screw compressor, ve pump type, in line pump type
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  • 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. In this book the fundamental matters and other things already mentioned in the “Instruction Manual” and the “Parts Catalogue” are omitted to avoid duplication. Therefore, for the operation and handling of this unit, we request you to refer to the instruction manual and caution plates, and further for the structure and components of the unit, please refer to the “Parts Catalogue”...

  • Page 4: Table Of Contents

    Table of Contents 1. Specification -------------------------------------------------------------------------------------------- 1-1 1.1 Specifications ----------------------------------------------------------------------------------------------------------------- 1-1 1.2 Set Value ----------------------------------------------------------------------------------------------------------------------- 1-3 1.3 Outline drawing -------------------------------------------------------------------------------------------------------------- 1-4 1.4 Internal Components and Part Names ------------------------------------------------------------------------------ 1-7 1.5 Instrument panel ------------------------------------------------------------------------------------------------------------- 1-9 1.6 Capacity Control Device ----------------------------------------------------------------------------------------------------- 1-12 1.7 Piping Diagram ----------------------------------------------------------------------------------------------------------------- 1-15 1.8 Fuel piping ----------------------------------------------------------------------------------------------------------------------- 1-16 2.

  • Page 5: Specification

    1. Specification 1.1 Specifications PDS185S-6C1R PDS185S-6C1 (VE PUMP Type) Item unit (IN LINE PUMP Type) for 55HP USA for 49HP USA for Asian countries ●Weight・Mass Overall length in.(mm) 121 (3,070) 117 (2,960) ← Overall length in.(mm) 73 (1,860) ← ←...
  • Page 6 1. Specification   PDS185S-6C1R PDS185S-6C1 (VE PUMP Type) Item  unit  (IN LINE PUMP Type) for 55HP USA for 49HP USA for Asian countries ●Emergency stop devices Actuating pressure of oil psi (MPa) 8.7 (0.06) ← ← pressure switch Actuating temperature of more than °F (℃)

  • Page 7: Set Value

    1. Specification    1.2  Set Value PDS185S-6C1R PDS185S-6C1 (VE PUMP Type) Item unit (IN LINE PUMP Type) for 55HP USA for 49HP USA for Asian countries ●Safety devices Discharge air temperature °F (℃) 248 (120) ← ← Engine oil pressure psi (MPa) 8.7 (0.06)

  • Page 8: Outline Drawing

    1. Specification 1.3 Outline drawing PDS185S-6C1 (VE PUMP Type) Unit：in.
  • Page 9 1. Specification PDS185S-6C1 (VE PUMP Type) Unit：mm...
  • Page 10 1. Specification PDS185S-6C1R (IN LINE PUMP Type) Unit：mm...

  • Page 11: Internal Components And Part Names

    1.4 Internal Components and Part Names 8 9 10 11 12 21 20 19 18 15 14 A070302 PDS185S-6C1 (VE PUMP Type) Description Function Separator receiver tank For separating compressor oil from compressed air sent into the tank. Pressure regulator For regulating intake air volume.
  • Page 12 1. Specification A070303 Description Function For draining condensate and water accumulated at the bottom of Fuel tank drain valve the fuel tank. Engine oil drain valve For draining engine oil for replacement of it and for maintenance. Compressor oil drain For draining compressor oil from separator receiver tank.

  • Page 13: Instrument Panel

    1. Specification 1.5 Instrument panel 12 11 A070178 1. Digital monitor indicator (temperature/pressure) ＜Indicator lamp＞ 2. Selector switch for digital monitor indication 8. Glow 3. Auto idle switch (Purge control) 9. Auto idle (Purge control) 4. Discharge air pressure ＜Warning lamp＞ 5.
  • Page 14 1. Specification 1.5.1 Digital monitor indicator ●Place starter switch “ON” and then digital monitor indicator goes on. ●Press monitor selector switch for selection of digital monitor display. Digital monitor selector switch Even during operation it is These items indicate possible to display the item the item which is which is required to be displayed on digital...
  • Page 15 1. Specification 1.5.2 Indicator lamp Indicator lamp Turn the starter switch to “ON” position. Then the lamp will go on. Item Contents Measures Monitor Press starter switch “ON” and the ― lamp goes on and after preheating GLOW is finished, the lamp will be off. AUTO IDLE Switch (Purge control) ―...

  • Page 16: Capacity Control Device

    1. Specification 1.6 Capacity Control Device PC08054E Step Response When starting operation, purge/starting unloader solenoid valve (SV1) opens. And compressed air is sent to unloader chamber and speed regulator Start chamber . The pressure in chamber rises soon, and unloader valve fully closes due to low pressure.
  • Page 17 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 18 1. Specification 1.6.2 Setting of “AUTO IDLE” control (purge control) pressure/timer [Standard set values prior to delivery ex-works] Set prior to delivery Item Setting range ex-works Purge releasing pressure VR3 80psi (0.55MPa) 50-95psi (0.35-0.66MPa) Purge starting intake negative pressure VR2 30％...

  • Page 19: Piping Diagram

    1. Specification 1.7 Piping Diagram 1-15...

  • Page 20: Fuel Piping

    1. Specification 1.8 Fuel piping PDS185S-6C1 (VE PUMP Type) 1-16...
  • Page 21 1. Specification PDS185S-6C1R (IN LINE PUMP Type) 1-17...

  • Page 22: Maintenance

    2. Maintenance 2.1 Cautions for Overhauling 2.1.1 Precautions before starting work 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 23: Tightening Torque

    2. Maintenance 2.2 Tightening torque General bolts and nuts tightening torque Fasten all the bolts and nuts with the specified tightening torque when assembling. Low or Middle carbon steel bolt High tensile strength bolt Kind (SS400B etc…) (SCM435 etc…) Strength 4.6～6.8（4T～6T）...

  • Page 24: How To Adjust Regulator And How To Replace Diaphragm

    If it is necessary to re-adjust the speed regulator due to overhauling or any trouble, adjust it in accordance with the following procedures. PDS185S-6C1 (VE PUMP Type) Pressure adjusting screw Pressure regulator...
  • Page 25 2. Maintenance      PDS185S-6C1R (IN LINE PUMP Type)        Pressure adjusting screw    Pressure regulator      Speed regulator High speed side stopper   Engine   governor lever   PC08021     speed     High speed  ...
  • Page 26 2. Maintenance 2.3.2 Change Diaphragm Speed Regulator (Bellophragm type) ＜Procedure＞ ① Remove the speed regulator from the bracket and disassemble it. ② Replace diaphragms with new ones. ③ Check A to D shown in figure for any burrs. ④ Diaphragm is delivered in different state from the Diaphragm state in which it should be installed.

  • Page 27: Clean The Strainer Provided Inside The Engine Feed Pump

    2. Maintenance ⑥Install diaphragm to shaft and piston and fasten it with a locking nut. Tightening torque：69.4 lbf･in. (80 kgf･cm) Important：Be careful not to tighten the locking nut excessively. Excessive tightening can cause washer to turn together and twisting diaphragm. The diaphragm will be damaged in shorter period.

  • Page 28: Clean The Strainer Provided Inside The Sedimenter

    ④ After finishing cleaning, install all the disassembled parts in reverse order. 2.6 Change fuel filter (sedimenter built-in type) (PDS185S-6C1 VE PUMP Type only) ＜Procedure＞ ① Separate the sensor connector“1”(provided at the lower part of fuel filter) from the main wiring portion.

  • Page 29: Change Oil Separator

    2. Maintenance 2.7 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, Separator replace the oil separator whenever the oil consumption casing increases and also oil is found mixed in the discharge air.

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

    2. Maintenance 2.9 Check O-ring and Needle valve of Auto-relief valve and Vacuum relief valve ●Disassemble and clean the component, and check O-ring“1”, “ 2”, “ 3”and needle valve“4”. Then, replace O-ring“1”,“2”,“3”and rubber on the Auto-relief valve needle valve“4”, if hardened. Vacuum relief valve PC08057 2.10 Performance check of Pressure control valve...

  • Page 31: Clean Inside Of Fuel Tank

    2. Maintenance 2.12 Clean inside of Fuel Tank ●Condensate is caused and accumulated at the bottom of fuel tank, owing to churning of dust or dirt mixed when fuel oil is fed and water drop caused while fuel oil tank is used for a long time. When any condensate is found afloat and fuel filter gets clogged too fast, fuel oil tank should be cleaned after condensate is removed from fuel oil tank even before the specified cleaning interval time.

  • Page 32: Values Of Various Adjustments Of Engine

    2. Maintenance 2.14 Values of Various Adjustments of Engine Item unit PDS185S/185S-6C1R Engine model NISSAN TD2714 lbf･in. First time 434-521 (500～600) Tightening torque of head bolts (kgf･cm) 868-955 (1000～1100) Second time Air intake in.(mm) 0.014 (0.35) (in warm season) Valve clearance Discharge in.(mm)

  • Page 33: Electric System

    3.1 Engine electric appliances 3.1.1 VE PUMP The engine mounted on PDS185S-6C1 is equipped with VE type injection pump. VE pump has been developed to be small, light-weighted, high speed injection pump. They are mainly mounted on diesel cars and small trucks.
  • Page 34 3. Electric System Unload Flyweight Control lever Full load Governor lever Full load Drive shaft adjusting screw Stop solenoid Feed pump Cam disk Plunger Timer Delivery valve Plunger spring PC08024 Structure of VE pump Governor spring Control lever Idol spring Governor sleeve Collector lever Flywheel holder...
  • Page 35 3. Electric System 3.1.2 Control Part number:46879 41400(PDS185S-6C1 : VE PUMP Type for USA) Part number:46879 45700(PDS185S-6C1R: IN LINE PUMP Type for Asia) PC08026E...
  • Page 36 3. Electric System 1.Exterior connection drawing (1)PDS185S-6C1(VE PUMP Type) PC08027E...
  • Page 37 3. Electric System (2)PDS185S-6C1R (IN LINE PUMP Type) PC08028E...
  • Page 38 3. Electric System 2.Function timing upon starting PC08029E...
  • Page 39 3. Electric System 3.Warning and emergency stop device (1)PDS185S-6C1(VE PUMP Type) Detecting Item Sensor Actuation Time lag timing Discharge air Flickering at Thermister Always 1.0 sec － temperature 239°F (115℃) Engine water Flickering at Thermister Always 1.0 sec － temperature 225°F (107℃)
  • Page 40 3. Electric System 4.Function of control output relay Mark Name Remark Stop signal relay It switches “OFF” when emergency stop device functions. After alternator generating signal is inputted, it switches “OFF”. Operation signal relay (It prevents overrun of starter motor and plunging of pinion gear.) It switches “ON”...
  • Page 41 3. Electric System 6.List of functions (1)Connector CN1 Line Pin No. Connection Remark color Earth － Earth When voltage is applied to CN1-8 terminal by switching “ON” starter switch, voltage is outputted from CN1-4 terminal, and it actuates stop solenoid Stop solenoid [stop motor relay].
  • Page 42 3. Electric System (2)Connector CN2 Line Pin No. Connection Remark color Detection of discharge air temperature. Discharge air temp. sensor It ignites controller surface warning: emergency stop No.1 terminal lamp at higher temperature than set one. Also when it is higher than the emergency stop actuating set temperature, interior contact (RY1) between CN1-4 and CN1-8 terminals will be turned “OFF”...
  • Page 43 ※1：Abnormal oil pressure detection circuit of controller starts to function in 10 seconds after it detects alternator generating signal with CN2-17 terminal. ※2：Emergency stop circuit detecting fuel filter condensate accumulation is installed on PDS185S-6C1 (VE pump type) only. 3-11...
  • Page 44 3. Electric System 3.1.3 Alternator Cable connection (1)List of functions Line Pin No. Connection Remark color Starter motor B terminal Power for charging voltage. 10A Fuse Detect output voltage from alternator and adjust the (Through joint connector) current flowing to rotor coil. Hour meter Signal output for hour meter.
  • Page 45 3. Electric System (3) Diagnosing when battery charging warning lamp lights Abnormal : less than 12V Measure battery voltage Re charging battery. when engine stops. Normal: 12V Abnormal : same voltage as battery voltage when stopping. Measure the voltage of Repairing alternator because it is alternator BAT terminal faulty.
  • Page 46 3. Electric System 3.1.4 Glow controller (QGSⅡ) Part number:44327 04100 VIEW-A (1) Coolant temperature･glow instantaneous characteristic ( at the time of key-OFF-ON) Water temp.°F Lamp lights time t1 (sec) Voltage of No.6 terminal (V) Glow time t2 (sec) (℃) 5 (-15) 14.0 32 (0) 104 (40)
  • Page 47 3. Electric System 3.1.5 Solenoid valve Part number:46811 24100 ･Opened while electricity is supplied (NC) PC08032 Purge/starting unloader solenoid valve (NC) ●Function When voltage is applied to CN1-6 terminal (power supply) of controller with the starter switch “ON”, interior contact (RY3) controller CN1-9 and CN1-3 terminal turns “ON”, purge/starting unloader solenoid valve gets electrically connected to be opened.
  • Page 48 3. Electric System 3.1.6 Discharge air temperature sensor, Coolant temperature sensor Part number:44364 06500 Characteristic of temperature resistance Water Permissibl Resistance temp. (kΩ) °F (℃) Value (%) 176 (80) 1300 ±7 PC08033 203 (95) ±6 《Note》Take care not to tighten excessively. 230 (110) ±5 Less than 1.96N･m(20kgf･cm)
  • Page 49 3. Electric System 3.1.9 Fuel meter Part number:36158 00500 Lamp (12V 24W) 1(IG) 2(U) 3(IL) 4(E) PC08036 (1) Position of meter pointer Pointer position Resistance (Ω) Remaining fuel gal.(L) 5.3 (20) 32.5 14.5 (55) 21.1 (80) (2) List of functions Line Pin No.
  • Page 50 3. Electric System 3.1.10 Sending unit (With fuel level switch) Part number:36159 04100 PC08037E Pointer position Resistance (Ω) Remaining fuel gal.(L) 5.3 (20) 32.5 14.5 (55) 21.1 (80) 3-18...
  • Page 51 3. Electric System 3.1.11 Fuel filter VE PUMP Type only (PDS185S-6C1 Part number:43540 07400 PC08038E ●Functions During normal operation, it is not electrically supplied. When water level inside fuel filter rises and becomes more than 0.03-0.05gal.(120-170mL), the floating switch inside filter gets “ON” for electrical connection to controller CN2-15 terminal. After electrical connection to stop solenoid continues 10 seconds and it is cut, it causes engine emergency stop.
  • Page 52 3. Electric System 3.1.13 Stop solenoid (PDS185S-6C1 VE PUMP Type only) Fuel return connector Governor spring Orifice Strainer Full load adjusting screw Stop solenoid Cam disk Control sleeve Plunger PC08039 (1) Specification Rated voltage DC12V Power consumption Current 1.33A Pull･Holding 9.02Ω...
  • Page 53 3. Electric System 3.1.14 Stop motor (PDS185S-6C1R IN LINE PUMP Type only) Part number:44358 01200 PC08040 List of functions Pin No. Line color Connection Stop motor relay No.6 terminal (NC) Stop motor relay No.5 terminal (NO) Earth Stop motor relay No.3 terminal (COM) －...
  • Page 54 3. Electric System [Function of stop motor] 1. Before engine starts PC08041E-1 ① As the ACC contact is open before starting engine, the exciting current is not provided, but internal contact is as shown in fig a. ② When the contact plate inside the stop motor assembly is positioned as shown in fig a, there is a conduction between B terminal and P2 terminal.
  • Page 55 3. Electric System 3. Rotation of contact plate PC08043E-1 ① When motor begins to rotate, the worm fitted to the motor shaft rotates and at the same time worm wheel rotates. ② The worm wheel and contact plate are interconnected and so it continues to rotate as shown in Fig C.
  • Page 56 3. Electric System 5. Engine stops (normal stop) PC08045E-1 ① To stop engine, handle starter switch to open ACC contact (“Stop” position) so that excitation circuit of stop motor relay may be released to move the contact point as shown in Fig e. ②...

  • Page 57: Troubleshooting

    4. Troubleshooting 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 58 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 59: Failures Of Compressor And Engine

    4. Troubleshooting Failures of compressor and engine 4.2.1 At start-up, starter rotates slowly ※1 Battery specific gravity Faulty Re-charge and or Check battery voltage and too low or electrolyte supply water/replace. specific gravity. short. Normal Volt: more than 12V Gravity: more than 1.26 Faulty Replace terminal or Check battery cable.
  • Page 60 4. Troubleshooting 4.2.3 Engine revolutions will drop before pressure rises up to rated one Check adjustment of Adjustment Faulty adjustment of Re-adjust pressure pressure regulator pressure Faulty adjustment Change pressure gauge for Adjustment Faulty pressure gauge replacement one, and Replace it. re-adjust pressure gauge.
  • Page 61 4. Troubleshooting 4.2.4 Engine will not turn to meet rated revolutions Long Check rod length of speed Faulty adjustment of Re-adjust rod regulator. Normal Check adjustment of Adjustment Faulty adjustment of Re-adjust pressure pressure regulator pressure Faulty adjustment Filter clogging Faulty air filter.
  • Page 62 4. Troubleshooting 4.2.5 Engine RPM will not drop to lowest RPM during unloaded operation Short Faulty adjustment of Check rod length of speed Re-adjust rod regulator. Normal Disassemble / clean Check function of speed Malfunction of speed Replace parts. regulator. regulator.
  • Page 63 4. Troubleshooting 4.2.7 Oil mixed found in delivery air Too much Arrange oil level to Oil level too high Check compressor oil level. specified lever. Proper level Lower than 49psi (0.34MPa) Faulty pressure Check discharge air Disassemble / adjust control valve. pressure.
  • Page 64 4. Troubleshooting 4.2.8 Discharge air is insufficient Filter clogging Check air filter for clogging. Clean or replace it. Faulty air filter. Normal Purge solenoid valve Check the purge solenoid Air leak found Repair or replace it. check valve seat valve check valve for any air defective.
  • Page 65 4. Troubleshooting 4.2.9 Purge control operation will not start even if auto idle switch is pressed Air leak found Service air piping Check service piping for any Repair air piping. leaking air leak. No air leak found Lower than Faulty setting of Check setting of purge purge starting intake 30％...
  • Page 66 4. Troubleshooting 4.2.10 Even when the pressure at consumer’s side drops, it will not recover from purge control operation. Purge releasing Faulty setting of purge pressure too low Check setting of purge releasing pressure Adjust (See 1.6.2) releasing pressure (RV3) (VR3) 80psi (0.55MPa) Service pressure...

  • Page 67: Operation Of Emergency Switch

    4. Troubleshooting 4.3 Operation of emergency switch 4.3.1 Discharge air temperature warning lamp glows and engine stops. More than 104°F (40℃) Unsuitable place of Check ambient temperature. Relocation installation. Lower than 104°F (40℃) Lower than 248°F (120℃) Check Abnormal Check resistance Replace it.
  • Page 68 4. Troubleshooting 4.3.2 Engine oil pressure warning lamp glows and engine stops Shortage Replenish or replace. Check engine oil level. Shortage of oil Proper Faulty Replace it. Filter clogging. Check oil filter. Normal Check engine oil pressure Faulty oil pressure Faulty Replace it.
  • Page 69 Faulty of engine Repair the trouble cooling system and get rid of the cause. 4.3.4 Residual fuel level warning lamp goes on and engine stops (PDS185S-6C1 VE PUMP Type only) Lower than 3.8gal.(14.5L) Check fuel residual level Shortage of fuel Supply fuel.

  • Page 70: Others

    4. Troubleshooting 4.3.5 Fuel filter drain warning lamp glows and engine stops (PDS185S-6C1 VE PUMP Type only) Condensate Drain condensate Condensate found Check for condensate inside and perform air accumulated inside fuel filter bleeding fuel filter No condensate found Detective portion of...

  • Page 71: Explanation Of Trouble Diagnosis

    4. Troubleshooting 4.5 Explanation of trouble diagnosis Item Cause Remedy Unloader valve cannot be open. Disassemble unloader valve, Faulty unloader. and check the function of valve and piston. Further check unloader orifice for any clogging. Check and locate pressure In case of malfunction of safety Check and confirm that maladjustment or defective valve, safety valve assembly...
  • Page 72 4. Troubleshooting Item Cause Remedy For actuation pressure of oil Check engine oil pressure pressure switch, See 1.2 “List of set switch. values”. Check and make sure that no Check for any defective disconnection has been found for connection. engine oil pressure switch (Switching “OFF”...

  • Page 73: References

    5. References 5.1 Comparison between consumable parts and electrical appliances PDS185S-6C1 PDS185S-6C1 PDS185S-6C1R VE PUMP Type VE PUMP Type IN LINE PUMP Type Item (for 55HP USA) (for 49HP USA) (for Asian countries) ●Element Air filter ASS’Y 32100 40900 ←...
  • Page 74 5. References PDS185S-6C1 PDS185S-6C1 PDS185S-6C1R VE PUMP Type VE PUMP Type IN LINE PUMP Type Item (for 55HP USA) (for 49HP USA) (for Asian countries) ●Electrical appliances Purge/starting unloader 46811 24100 ← ← solenoid controller 46879 41400 46879 45700 ←...

  • Page 75: Engine Wiring Diagram

    5.2 Engine Wiring Diagram PDS185S-6C1 VE PUMP Type PC08046E...
  • Page 76 PDS185S-6C1 VE PUMP Type PC08047E...
  • Page 77 PDS185S-6C1R IN LINE PUMP Type PC08048E...
  • Page 78 PDS185S-6C1R IN LINE PUMP Type PC08090E...

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