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AirMan PDS185S-6C1 Instruction Manual

Screw compressor
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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. 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...

  • 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 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 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 The pasting position of safe warning label is as follows. 1-11...

  • Page 15: Part Names

    2.Part Names Internal Components and Part Names 10 11 12 20 19 18 A070302-1 Description Function Separator receiver tank For separating compressor oil from compressed air sent into the tank. Pressure control valve For keeping the receiver tank pressure higher than 0.4MPa in the tank. Pressure regulator For regulating intake air volume.
  • Page 16 2.Part Names A070303-1 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 valve For draining compressor oil from separator receiver tank.

  • 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 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 18: Towing The Unit

    3. Installation Towing the Unit Before towing the unit, check the following points and be sure to repair failures, if any: Air-pressure in the tires. Loose wheel bolts or nuts. Abnormal wear or damage to the tires. Damage of drawbar. Be sure to use a vehicle with enough capacity to tow the unit in operating weight.
  • Page 19 3. Installation 3.3.2 Service valve Discharge port : 20A(Rc3/4B)×2 [Taper male screw] A090556...

  • Page 20: Operation

    4. Operation Instrument panel 12 11 A070178 1. Digital ｍonitor indicator (temperature/pressure) ＜Indicator lamp＞ 2. Selector switch fordigital monitor indication 8. Glow 3. Auto idle switch 9.Auto idle 4. Discharge air pressure ＜Warning lamp＞ 5. Fuel level gauge 10. Charge 6.
  • Page 21 4. Operation 4.1.1 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 22 4. Operation Indicator lamp 4.1.2 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 pre- GLOW heating is finished, the lamp will be off.

  • Page 23: Lubricating Oil・Coolant・Fuel

    4. Operation Lubricating oil・Coolant・Fuel 4.2.1 Engine oil Oil should use the recommendation oil Viscosity of engine oil greatly affects startability, performance, oil consumption of the engine, as well as wear of the moving parts. Choose appropriate oil based upon the table below according to the outside air temperature. Relation between viscosity (SAE) and temperature SAE Viscosity number Temperature...
  • Page 24 4. Operation 4.2.3 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 25: 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 noticing its abnormality, such operation could cause seizure of components or may even cause fire.

  • Page 26: Operation

    4. Operation 4.3.2 Check Coolant Level 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.

  • Page 27: Drain Separator Receiver Tank

    4. Operation 4.3.4 Drain separator receiver tank Draining of Separator receiver tank After stopping the engine, confirm that the pressure gauge indicates 0MPa and there is no residual pressure in it, then open the drain valve gradually to drain the compressor oil. Note residual pressure in the receiver tank could force both extremely hot compressed air and oil to jet out and you may be scalded or seriously injured.
  • Page 28 4. Operation 4.3.6 Drain fuel tank Opening the drain valve“2”fitted under the fuel tank“1”, drain the condensate from the tank. When completely drained, firmly close the drain valve“2”. Drain the condensate in container“3”,and then dispose of condensate according to the designated regulations.
  • Page 29 4. Operation 4.3.8 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. <Procedure>...
  • Page 30 4. Operation 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 31 4. Operation 4.4.1 Procedure to start the unit Be sure to warm-up Be sure to let unit warm-up after starting for smooth operation of the engine and the compressor. Do not operate the engine at full load immediately after it starts up. This will shorten the equipment life. During the warm-up operation, examine the different parts of the equipment for any looseness, leakage of water, oil, fuel, and other irregularities.
  • Page 32 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 startup procedures ① do not ③ 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 33 4. Operation 4.4.4 Gauge Indication while Operating Minimum discharge air pressure is 0.39MPa during load 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 34: Stopping

    4. Operation Stopping <Procedure> ① Close the air valve completely and operate the machine about 5 minutes, until it cools down. ② Turn the starter switch to “STOP” position to stop the engine. (Starting unloader valve should stop with “operation” position.) ③...

  • Page 35: Capacity Control Device

    4. Operation Capacity Control Device A070217E Step Response When starting operation, purge solenoid valve SV1 opens. And compressed air is sent to unloader chamber A and speed regulator chamber B . The pressure in chamber A rises soon, and unloader Start valve fully closes due to low pressure.
  • Page 36 4. Operation When the certain set time ( it can be changed.) has passed at lower pres- sure than the set negative pressure, detecting the negative pressure in- side the compressor air end with a pressure sensor PRS1, solenoid valve SV1 opens and it closes unloader valve.
  • Page 37 4. Operation [ FUNCTION OF AUTO IDLE CONTROL ] Function Conditions of AUTO IDLE lamp First engine speed drops to the minimum speed by pressure regulator , owing to reduction of air con- sumption. Later the air consumption is reduced fur- ther, the unloader valve gradually closes and intake Lamp flickers at short in- negative pressure increases.
  • Page 38 4. Operation Purging mode operation is already arranged prior to delivery from factory. Therefore, it is not necessary to perform any adjustment in usual case. For adjustment of VR1, VR2 and VR3, follow the under-mentioned procedures. For adjusting set value with knob, turning the knob to left lowers the set value, while turning the knob to right raises the value.

  • Page 39: 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 extremely harsh conditions. Hang a “Now Checking and under Maintenance”...

  • Page 40: Daily Inspection And Operation Log

    5. Periodic Inspection/Maintenance Directions: Prohibition of any other jobs or works than directed herein 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.

  • Page 41: Periodic Inspection List

    5. Periodic Inspection/Maintenance Periodic Inspection List (Unit:Hour) Every Every Every Every Every Every Page Maintenance Daily 1,000 2,000 3,000 Check compressor oil level. ○ Drain separator receiver tank. ○ Check looseness in pipe connecting part, and wear 4-10 ○ and tear of pipe. Check oil, water, fuel and air leak.
  • Page 42 5. Periodic Inspection/Maintenance ◎Refer to engine operation manual for inspection and maintenance of an engine. (Unit:Hour) Every Every Every Every Every Every Page Maintenance Daily 1,000 2,000 3,000 Drain fuel tank ○ (Including sedimenter). Check fuel ○ Check engine oil level. ○...

  • Page 43: Periodic Replacement Of Parts

    5. Periodic Inspection/Maintenance Periodic Replacement of Parts Part number changes upon modification. For replacement of parts, make sure whether the part number is correct or applicable. Part Name Part Number Quantity Engine oil filter NISSAN 15208 43G0A Compressor side 32143 11800 Air filter element Engine side...

  • Page 44: Maintenance Items

    5. Periodic Inspection/Maintenance 5.5 Maintenance Items 5.5.1 Change engine oil [At 50 hours for the first change and at every 250 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 45 5. Periodic Inspection/Maintenance 5.5.3 Check battery electrolyte [Every 250 hours] If there seems to be a problem in starting an engine due to a flat battery, carry out the checks by following the procedures below: 1. Ordinary type battery: Check battery electrolyte level and if the level is not within the specified level, add distilled water.

  • Page 46: Change Compressor Oil. ※1

    5. Periodic Inspection/Maintenance 5.5.5 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 indicates 0MPa and there is no residual pressure in it, and then gradually loosen the oil filler cap for refilling oil.

  • Page 47: Change Compressor Oil Filter. ※1

    5. Periodic Inspection/Maintenance 5.5.6 Change compressor oil filter [At 300 hours for the first change and every 1,000 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＞...
  • Page 48 5. Periodic Inspection/Maintenance 5.5.8 Change air filter element [Every 500 hours] Use our genuine part Air filter is an important part which is crucial to machine's performance and life. Be sure to use genuine parts. ＜Procedure＞ ① After removing the cap“1”by loosening its latch“2”, clean its interior properly.

  • Page 49: Change Diaphragm Of Speed Regulator

    5. Periodic Inspection/Maintenance 5.5.10 Change diaphragm of speed regulator [Every 1,000 hours] <Caution during diaphragm replacement> When installing diaphragm“1”, be sure to use the special jig to prevent it from twisting. Before installing diaphragm “1” , be sure to apply molybdenum disulfide (paste spray) to inside of the diaphragm“1”.
  • Page 50 5. Periodic Inspection/Maintenance 5.5.13 Change Coolant [1,000 hours or every 2 years] Caution in filling or discharging engine oil 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.

  • Page 51: Change Oil Separator

    5. Periodic Inspection/Maintenance 5.5.14 Change Oil Separator [Every 2,000 hours] 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 52: Change O-Ring Of Unloader

    5. Periodic Inspection/Maintenance 5.5.17 Change Fuel rubber hose [2,000 hours or every 3 years] In case various rubber hoses for fuel system and engine lubrication system are hardened or dete- riorated, replace them even before the specified replacement time. Replacement of the hoses requires expert technical knowledge. So contact directly us or distributor. 5.5.18 Change Pressure Regulator [Every 3,000 hours]...
  • Page 53 5. Periodic Inspection/Maintenance 5.5.21 Check O-ring and Needle Valve of Auto-relief Valve and Vaccume relief valve [3,000 hours or every 3 years ] 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 needle valve“4”, if hardened.
  • Page 54 5. Periodic Inspection/Maintenance 5.5.23 Check Pressure Control Valve O-Ring and Piston Disassemble and clean the component, and check O-ring“1”,“2” and the piston“4” shown in 5.5.22 Then, replace O-ring“1”,“2” and rubber on the piston“4”, if they are hardened. （See 5.4） Ask your nearest dealer for its replacement. After replacement, run the machine to check its function (See 5.5.22), air-leak or any disorder.

  • Page 55: Maintenance

    6. Maintenance 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 56 6. Maintenance 6.1.1 Charge Battery Be sure to read the operation manual of the battery charger 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 57: Troubleshooting

    6. Maintenance 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 58 6. Maintenance Symptom Cause Countermeasures (1) Engine oil shortage. Replenish oil (2) Engine oil filter clogging. Change Engine oil pressure lamp (3) Faulty oil pressure switch. Change goes on. and engine stops. (4) Loosened or disconnected wir- Check/Fasten ing or connector. (1) Radiator clogging.

  • Page 59: Storage Of The Unit

    7. Storage of the Unit Preparation for Long-term Storage When the unit is left unused or not operated longer than half a year (6 months), store it at the dry place where no dust exists after the following treatments have been done to it. Put the unit in a temporary cabin if it is stored outside.

  • Page 60: Specifications

    8. Specifications Specifications ＞ Shows 49HP specifications ＜ Model PDS185S-6C1 Single-stage oil cooled, screw type compressor Type 185 ＜166＞ Free air delivery /min) (5.2) ＜(4.7)＞ Working pressure (bar) (6.9) Forced Lubrication by compressed pressure Lubricating system Direct driving with gear coupling...

  • Page 61: Outline Drawing

    8. Specifications Outline drawing...
  • Page 62 8. Specifications...

  • Page 63: Wiring Diagram

    9. Wiring Diagram...

  • Page 64: Piping Diagram

    10.Piping Diagram 10-1...
  • Page 66 発行 本社工場 新潟県燕市下粟生津3074 TEL ０２５６－９３－５５７１ FAX ０２５６－９４－７５６７ (無断複写・転載を禁ず) 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)2009 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved　 39600 05630 PRINTED IN JAPAN 2010. 4...

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