AirMan PDS100S-6B4 User manual

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Table of Contents
1. Safety ....................................................................................................................................................... 1-1
1.1 Caution before Operation ................................................................................................................ 1-2
1.2 Caution during Operation ................................................................................................................
1-6
1.3 Caution during Inspection and Maintenance ...................................................................................
1-8
1.4 Safety Warning Labels ....................................................................................................................
1-12
2. Operation ................................................................................................................................................. 2-1
2.1 Unit Appearance and Part Names ................................................................................................... 2-1
2.2 Internal Components and Part Names ............................................................................................
2-2
2.3 Instrument Panel .............................................................................................................................
2-3
2.4 Compressed Air Service Valve .......................................................................................................
2-5
2.5 Door ................................................................................................................................................
2-5
2.6 Check before Starting Unit ..............................................................................................................
2-5
2.7 Unit Operation .................................................................................................................................
2-12
2.8 Stopping Procedures .......................................................................................................................
2-15
3. Transportation and Towing the Unit ..................................................................................................... 3-1
3.1 Transportation ................................................................................................................................. 3-1
3.2 Towing the Unit ...............................................................................................................................
3-2
4. Installation ............................................................................................................................................... 4-1
4.1 Location and Installation ................................................................................................................. 4-1
5. Periodic Inspection/Maintenance .......................................................................................................... 5-1
5.1 Important Items as Periodic Inspection and Maintenance or after Maintenance ............................. 5-1
5.2 Daily Inspection and Operation Log ................................................................................................
5-2
5.3 Periodic Inspection List ...................................................................................................................
5-3
5.4 Periodic Replacement of Parts ........................................................................................................
5-5
5.5 Items and Places of Inspection.........................................................................................................
5-6
5.6 Maintenance Items ..........................................................................................................................
5-7
6. Maintenance/Adjustment ....................................................................................................................... 6-1
6.1 Adjustment of Regulator .................................................................................................................. 6-1
6.2 Maintenance of Battery ...................................................................................................................
6-2
6.3 Troubleshooting ..............................................................................................................................
6-4
7. Storage of the Unit ................................................................................................................................. 7-1
7.1 Preparation for Long-term Storage ................................................................................................. 7-1
8. Specifications ......................................................................................................................................... 8-1
8.1 Compressor Specifications ............................................................................................................. 8-1
9. Wiring Diagram ....................................................................................................................................... 9-1
10. Piping Diagram ....................................................................................................................................... 10-1
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1. Safety
1-1
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, , , and with a caution
symbol −attached to each message.
When one of these messages is shown, please take preventive measures and carry out “SAFETY
OPERATION AND PROPER MAINTENANCE OF THE UNIT”.
DANGER indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. This signal word is to be limited to the
most extreme situations.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices.
IMPORTANT indicates important caution messages for the performance or
durability of the unit.
Follow warnings mentioned in this manual. This manual does not describe all safety items. We,
therefore, advise you to pay special attention to all items (even though they may not be described
in the manual) for your safety.
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1. Safety
1-2
1.1 Caution before Operation
Ventilation
 Exhaust gas from the engine is poisonous, and could cause
serious injury or death when inhaled.
Avoid using the machine in an insufficiently ventilated building
or tunnel.
PC002
Follow all safety instructions
 Read each instruction plate which is displayed in the manual or
on the unit carefully, understand its content and follow the
directions.
 Keep the Safety Warning labels clean. If they are damaged or
missing, apply new ones.
 Do not modify the machine without prior approval. Safety of the
unit may be compromised, functions may be deteriorated, or
machine life may be shortened.
 Never use the unit for the purpose of compression of gases
other than air, or as a vacuum pump. Serious accidents may
occur.
TR0086
Maintain both physical and mental health
 Do not operate the machine you are tired, intoxicated or under the influence of drugs. Operation under
these circumstances may cause unexpected injury or accident.
Maintain your physical and mental health and be cautious in handling the machine.
Air pressurized construction method prohibited
 Never use the unit directly or indirectly for the following
purposes:
 Never use the unit for respirator equipment by which
compressed air is supplied for human consumption. The
compressed air contains carbon monoxide and other
contaminants. Such air may cause serious injury or death if
used by a person for respiration.
 This compressor is not designed for air pressurized
construction methods and underwater diving jobs.
Never use compressed air for human consumption such as
pressurizing diving air tanks. Consumption of compressed air
can cause death while diving.
TR0201
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1. Safety
1-3
Safety outfit
 When handling the machine, do not wear;
 loose clothes
 clothes with unbuttoned sleeves
 hanging tie or scarf
 accessories such as dangling jewelry
Such outfit could be caught in the machine or dragged in the
rotating portion of the machine which could cause a serious
injury.
TR0084
Cautions of hose attachment and removal
 Piping or the hose from this machine service valve should use
what can be borne enough for the discharge pressure of this
machine.
 Please connect piping or a hose to this machine service valve
firmly before operation and during operation. If the connection
part is loosening, there is a possibility of piping or a hose
separating and getting seriously injured.
 Please remove after closing a service valve and extracting
pressure remained, in case piping or a hose is removed. If
pressure remained should remain, a near thing blows away or
there is a possibility of a hose whipping, causing a
phenomenon and getting seriously injured.
 In order to use it safely, please read the handling of the work
tools often used.
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, it is very dangerous.
 When unit is transferred or moved from a working site, be sure to place it on truck bed, and tie it down
firmly. Also be sure to put a set of chocks to fix its wheels firmly in position.
 Never lift unit which is still in operation. It could cause critical damage to each component or lead to
serious accident.
Installation
 The machine should be parked horizontally on a level place.
 In case the machine has to be parked on a slope, place it
across grade so that the machine does not tend to roll
downhill.
 Grade on a slope shall be within 15 degrees
 Be sure to put one set of chocks1to the wheels.
A000054
TR0088
TR0088
TR0303A
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1. Safety
1-4
Check before starting the 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 any abnormality, operation could cause damage of components or may even cause fire.
Handling battery
 Keep flames away from battery.
 Battery generates hydrogen gas and may explode.
 Therefore, recharging should be done at a well-ventilated
place.
 Do not allow sparks or flame near the battery.
 Do not check the battery by short-circuiting the positive and
negative terminals.
 Never operate the machine nor charge the batteries with the
battery liquid level being kept lower than the "LOWER" level.
Continuing operation at this lower level will cause deterioration
of such parts as pole plates etc., and also it may cause
explosion as well as reduction of battery life. Add distilled water
so that the liquid level may reach the middle level between the
"UPPER" and "LOWER" level without any delay.
 Do not charge a frozen battery. Otherwise it may explode. If
the battery is frozen, warm it up until the battery temperature
becomes 61°F to 86°F (16°C to 30°C).
 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.
 When such battery electrolyte contacts your clothes or skin,
wash it away with large amount of water immediately.
 If the battery electrolyte gets into your eyes, wash it away
immediately with plenty of water and seek medical attention.
 Dispose of battery, observing local regulations.
D004
W010
TR0093
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1. Safety
1-5
Protection equipments
 Please wear protection implements, such as a helmet,
protection glasses, earplugs, safety shoes, a glove, and a
protection-against-dust mask, according to the contents of
work for safety.
TR0085
Safety fittings
 Have first-aid kits and fire-extinguishers near the unit ready for
emergency situations.
 It is advisable to have a list of phone numbers of doctors,
ambulance and the fire department available in case of
emergency.
TR0096
Safety around the machine
 Unnecessary equipment and tools, cables, hoods, covers which are a hindrance to the job, have to
be removed.
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1. Safety
1-6
1.2 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 and cause serious injury.
 Relieve all pressure before performing any maintenance.
W010
Draining during operation prohibited
 Do not, under any circumstance, open the items listed below
during operation:
 Separator receiver tank drain valve
 Coolant drain valve and plug
 Engine oil drain plug
 Oil cooler drain plug
PK0028
Beware of cooling fan
 Never put your hand near the engine cooling fan during
operation.
W009
Hands off from rotating parts and belts
 Keep hands off from the rotating portion or belts while running.
TR0304
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1. Safety
1-7
Never direct the compressed air to people and foods
 Never blow compressed air directly at people.
Scattered dust, or foreign objects in the compressed air may
cause serious injuries.
 Blowing compressed air on food is prohibited.
TR0092
Do not remove radiator cap during operation
 Do not, under any circumstance, open the radiator cap while
running or immediately after stopping operation. Otherwise
high temperature steam releases out and this could cause
scalding.
H990432
Do not touch hot parts
 Never work near hot portions of the machine while it is running.
 Such parts as engine, exhaust manifold, exhaust pipe, muffler,
radiator, oil cooler, compressor, piping, separator receiver tank,
and discharging pipe are especially hot, so never touch those
parts, because it could cause serious burns.
 Compressor oil, coolant water, and engine oil are also very hot
and dangerous to touch.
 Avoid checking or refilling them while the unit is running.
H990432
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.
 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 earplugs to prevent
damage to hearing. For testing service only.
D003
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1. Safety
1-8
Fire prevention
 Do not, under any circumstance, bring lit cigarettes or matches
near oils as engine oil and compressor oil, etc.
They are extremely flammable and dangerous.
 Refilling oils should be done in an outdoor well-ventilated
place.
 Refuel after stopping the engine, and never leave the fuel
nearby the machine. Do not spill. Clean environmental spills.
 Such parts as muffler and exhaust pipe can be extremely hot.
Remove twigs, dried leaves, dried grass and waste paper, etc.
from the exhaust outlet of the muffler.
 Keep a fire extinguisher available by the machine in case of a
fire.
D004
H990433
1.3 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.
 Remove the negative (–) side cable from the battery.
SY001
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 0 psi (0 bar) and there is no residual pressure in it,
and then gradually loosen the oil filler cap for refilling oil.
 Note residual pressure in the separator receiver tank could
force both extremely hot compressed air and oil to jet out and
you may be scalded or seriously injured. W010
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1. Safety
1-9
Draining separator receiver tank
 After stopping the engine, confirm that the pressure gauge
indicates 0 psi (0 bar) and there is no residual pressure in it,
then open the drain valve gradually to drain the compressor oil.
 Note residual pressure in the separator receiver tank could
force both extremely hot compressed air and oil to jet out and
you may be scalded or seriously injured.
H990432
Be careful of high-pressurized air blowout
 After stopping the engine, make sure that pressure gauge
indicates 0 psi (0 bar). Even when the gauge shows 0 psi (0
bar), open a service valve and further do not fail to make sure
that there is no residual pressure in the air piping. Then begin
repair and maintenance.
 Residual air under pressure can cause severe injury.
W010
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.
TR0304
Hands off from cooling fan
 Be sure to stop the engine and remove the starter key
whenever check or maintenance work is carried out near the
cooling fan.
 If the cooling fan is rotating, it may catch the operator or part of
his body into the fan, and it could cause a serious injury.
W009
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1. Safety
1-10
Cleaning by air-blow
 When cleaning dust accumulated in such devices as the
air-filter, by blowing compressed air, wear safety glasses, etc.
to protect your eyes.
M003
Lighting apparatus
 It is recommended to use a lamp with safety guard fitted in low
light conditions.
 Any lamps without safety guard are not recommended since
they can be broken and they could ignite flammables such as
fuel, etc.
TR0206
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.
If this procedure is neglected, the inner pressure can blow off
the cap. Steam jetting out of the radiator could result in
scalding. Follow this procedure under all circumstances.
H990432
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.
H990432
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1. Safety
1-11
Refilling or draining of engine oil
 After stopping the engine, wait for 10 to 20 minutes until the
engine oil cools off. Then check the level of the engine oil, or
refill or drain the oil.
 Engine oil is very hot and highly pressurized during or just after
the operation. Hot oil could blow out of the tank and can cause
scalding.
H990432
Fire warning
 Be sure to perform the periodical check of compressor oil and
oil separator.
 Neglecting checks could cause overheat of the oil, resulting in
a fire.
H990433
Disposal of waste liquid, etc.
 Waste liquid from the machine contains harmful material. Do not discharge it onto the ground or into
the river, lake or sea. Such material will contaminate the environment.
 Be sure to use a container to hold the waste liquid from the machine.
 Be sure to follow the designated regulations when disposing of oil, fuel, coolant (antifreeze), filter,
battery or other harmful materials.
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1.Safety
1-12
1.4 Safety Warning Labels
Following labels are attached to the machine.
Keep them clean all the time. If they are damaged or peeled off, immediately place an order with
your nearest dealer for replacement, with the number indicated on the lower right corner of the
label. Adhere a new one to the original place.
1. Caution, exhaust gases
(39176 73300)
2. Caution, radiator cap
(hot water)
(39176 69600)
3. Lifting bail
(39176 69300)
4. Caution, cooling fan
(39176 73500)
5. Caution, high temp.
(39176 69500)
6. Caution, fan belt
(39176 73800)
7. Caution, Fire
(39176 69700)
8. Caution, residual pressure
(39176 69800)
9. No fire
(39176 35600)
10.Caution, Do not inhale
(39176 73600)
11.Caution, hose whipping
(39176 73400)
6
4
9
7 8
10
3 2
1
4
5
11
5
A050230
A
A
-View
6
4
5
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2. Operation
2-1
2.1 Unit Appearance and Part Names
A030132
1. Exhaust outlet
2. Lifting bail
3. Door
4. Handle
5. Service valve
6. Drawbar
7. Instrument panel
PDS185S-6B4
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