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AirMan PDS185S-5C2 Instruction Manual

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Summary of Contents for AirMan PDS185S-5C2

  • 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 the 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 starting the machine. For your better recognition, according to the degree of potential danger, safety messages are classified into three hierarchical categories, namely, 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 protection 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, protection glasses, earplugs, safety shoes, a glove, and a...

  • 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 15: Part Names

    2.Part Names Internal Components and Part Names...
  • Page 16 2.Part Names Description Function Speed regulator For adjusting engine speed in the system. Engine For driving the compressor. For keeping compressor oil at proper temperature. By-pass valve Exhaust muffler Equipment which muffles an engine exhaust sound. Radiator For cooling the coolant for engine because it is water-cooled. Oil cooler For cooling compressor oil circulating in the system.

  • 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.

  • Page 18: Installation

    3. Installation 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. PC002 The machine should be operated in following conditions: Ambient temperature...

  • Page 19: Operation

    4. Operation Instrument panel A090575-1 1. Discharge pressure gauge ＜Indicator lamp＞ (For pressure in separator receiver tank) 8. Glow 2. Fuel level gauge 9.Auto idle(Purge control) 3. Hour meter ＜Warning lamp＞ 4. Digital ｍonitor indicator 10. Charge (temperature/pressure/rate of suction press.) 11.
  • Page 20 4. Operation 4.1.1 Digital monitor indicator  Place starter switch “RUN” 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...
  • Page 21 4. Operation 4.1.2 Indicator lamp Indicator lamp Turn the starter switch to “RUN” position. Then the lamp goes on. Item Contents Measures Monitor Turn the starter switch “GLOW” and the lamp goes on and after ― GLOW preheating is finished, the lamp will be off.

  • Page 22: 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”.
  • Page 23 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 24: 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. 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 25 4. Operation 4.3.2 Check Coolant Level Taking off the radiator cap  B e 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 26: Operation

    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 27 4. Operation 4.3.6 Drain fuel tank Opening the drain valve “1” fitted under the fuel tank, drain the condensate from the tank. When completely drained, firmly close the drain valve“1”. Drain the condensate in container “2” , and then dispose condensate according designated regulations.
  • Page 28 4. Operation 4.3.10 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.  Follow the procedure below to adjust tension of belt for fan and alternator. ...
  • Page 29 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. ...
  • Page 30 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 31 4. Operation 4.4.4 Gauge Indication while Operating Minimum discharge air pressure is approx.58psi (4bar) 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 32: Stopping

    4. Operation Stopping  The unit is equipped with a built-in check valve. Therefore, some pressure will be left in pipes after the unit stops. Be sure to release such residual pressure from the pipes by opening the air valve gradually after the unit stops.

  • Page 33: Capacity Control Device

    4. Operation Capacity Control Device A100111E 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 34 4. Operation During unloaded operation, when the certain set time(it can be changed.) has passed at lower pressure than the set negative pressure, detecting the negative pressure inside the compressor air end with a pressure sensor PRS1, solenoid valve SV1 opens and it closes unloader valve. At AUTO IDLE the same time, it functions to relieve the compressed air from separator (Purge control)
  • Page 35 4. Operation [Function of AUTO IDLE (Purge control)] Function Conditions of “AUTO IDLE” lamp ① First engine speed drops to the minimum speed by speed regulator, owing to reduction of air consumption. Later the air consumption is reduced further, the unloader valve gradually closes and intake negative pressure increases.
  • Page 36 4. Operation 4.7.2 How to adjust setting values of AUTO IDLE(Purge control) AUTO IDLE(Purge control) 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 37: Periodic Inspection/Maintenance

    5. Periodic Inspection/Maintenance Important Items at Periodic Inspection and Maintenance or after Maintenance The following table shows the inspection and maintenance intervals under normal operation conditions. When used or operated under hard environmental conditions, it is impossible to warrant the unit even if the above conditions are performed according to the intervals listed in the above table.

  • Page 38: 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 LLC(antifreeze). Do not disassemble or adjust engine, compressor or part(s) for which inspection or maintenance is not referred to in this manual.
  • Page 40 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 ○ Check sedimenter for condensate ○ Check fuel ○ Check engine oil level.

  • Page 42: 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 44 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 46 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 47 5. Periodic Inspection/Maintenance 5.5.10 Change fuel filter [Every 500 hours] <Procedure> ① Take out the cartridge“1”by using a filter wrench. ② After coating fuel on the new cartridge “ 1” packing “2” , screw it in. (See 5.4) ③ After the packing“2”touches the sealing face, tighten it by approximately two-thirds turn using the filter wrench.
  • Page 48 5. Periodic Inspection/Maintenance 5.5.14 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 49 5. Periodic Inspection/Maintenance 5.5.15 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, replace the oil separator whenever the oil consumption increases and also oil is found mixed in the discharge air.
  • Page 50 5. Periodic Inspection/Maintenance 5.5.18 Change Fuel rubber hose [2,000 hours or every 2 years]  In case various rubber hoses for fuel system and engine lubrication system are hardened or deteriorated, replace them even before the specified replacement time.  Replacement of the fuel rubber hoses requires expert technical knowledge.
  • Page 52 5. Periodic Inspection/Maintenance 5.5.24 Check Pressure Control Valve O-Ring and Piston [3,000 hours or every 3 years ]  Disassemble and clean the component, and check O-ring “1”, “ 2”and the piston“4”shown in 5.5.23 Then, replace O-ring“1”,“2”and rubber on the piston“4”, if they are hardened. （See 5.4）...

  • Page 53: 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 54 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 55: 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 56 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 Check/Fasten wiring or connector. (1) Radiator clogging.

  • Page 57: 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 58: Specifications

    8. Specifications Specifications Model PDS185S-5C2 Single-stage oil cooled, screw type compressor Type Free air delivery /min) (5.0) Working pressure (bar) (6.9) Forced Lubrication by compressed pressure Lubricating system Direct driving with gear coupling Driving system 1,221 cu in. Receiver tank capacity (0.020)

  • Page 59: Outline Drawing

    8. Specifications Outline drawing...
  • Page 60 8. Specifications...

  • Page 62: Piping Diagram

    10.Piping Diagram 10-1...
  • Page 63 ° ° °...

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