AirMan PDS185S-5C2 User manual

Preface
A130375
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.
◆ Before operating the machine, read the manual carefully, fully understand its operation and
maintenance requirement. Maintain “SAFETY OPERATION AND PROPER MAINTENANCE OF THE
MACHINE”.
Be sure to follow safety warnings and cautions given in the manual.
Unsafe operation could cause serious injury or death.
◆For details of handling, maintenance and safety of the engine, see the Engine Operation Manual.
◆Keep the manual available at all times for the operator or safety supervisor.
◆ When this manual is missing or damaged, order it from our office nearby or distributor.
◆ Be sure that the manual is included with the machine when it is handed over to another user.
◆ There may be some inconsistency in detail between the manual and the actual machine due to
improvements of the machine. When you have anything unclear or you want to advise us, contact
our office nearby or distributor.
◆ If you have any questions about the machine, please inform us the model and serial number.
A plate stamped with the model and serial number is attached to side of the machine.
◆ Each illustrated figure (Fig.) has a number
(for instance, A130375) at the right bottom. This
number is not a part number, but it is used only
for our reference number.

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. Installation -------------------------------------------------------------------------------------------------- 3-1
3.1 Transportation ------------------------------------------------------------------------------------------------------------------ 3-1
3.2 Installation -----------------------------------------------------------------------------------------------------------------------
3-2
4. Operation ---------------------------------------------------------------------------------------------------- 4-1
4.1 Instrument panel --------------------------------------------------------------------------------------------------------------- 4-1
4.2
Lubricating oil・Coolant・Fuel ---------------------------------------------------------------------------------------- 4-4
4.3 Check before Starting Unit --------------------------------------------------------------------------------------------------
4-6
4.4 Operation -----------------------------------------------------------------------------------------------------------------------
4-10
4.5 Stopping ------------------------------------------------------------------------------------------------------------------------
4-14
4.6
Air Bleeding ------------------------------------------------------------------------------------------------------------------ 4-14
4.7
Capacity Control Device ------------------------------------------------------------------------------------------------ 4-15
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 Maintenance Items ------------------------------------------------------------------------------------------------------------
5-6
6. Maintenance ---------------------------------------------------------------------------------------------- 6-1
6.1 Maintenance of Battery ------------------------------------------------------------------------------------------------------- 6-1
6.2 Troubleshooting ----------------------------------------------------------------------------------------------------------------
6-3
7. Storage of the Unit -------------------------------------------------------------------------------------- 7-1
7.1 Preparation for Long-term Storage ---------------------------------------------------------------------------------------- 7-1
8. Specifications -------------------------------------------------------------------------------------------- 8-1
8.1 Specifications ------------------------------------------------------------------------------------------------------------------- 8-1
8.2 Outline drawing ----------------------------------------------------------------------------------------------------------------- 8-2
9. Wiring Diagram ------------------------------------------------------------------------------------------ 9-1
10. Piping Diagram -------------------------------------------------------------------------------------------10-1

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.

1.Safety
1-2
TR0201-1
A080001
TR0086
PC002
1.1 Caution before Operation
 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
wells and tunnels such as pneumatic engineering
method and pneumatic caisson method. Should this
unit stop operation due to trouble, it can cause death
and serous injury to the working persons. Refrain
from using the compressed air for such pneumatic
engineering method or pneumatic caisson method.
 Read each instruction plate which is displayed in the
manual or on the unit carefully, understand its content
and follow the indications thereof.
 Keep the Safety Warning labels clean. When they are
damaged or missing, apply new ones.
 Do not modify the machine without prior approval. The
safety 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. Otherwise,
serious accidents may occur.
 Exhaust gas from the engine is poisonous, and could
cause death when inhaled.
Avoid using the machine in an insufficiently ventilated
building or tunnel.
Compressed air is prohibited to be used for human respiration
Follow the safet
y
instr
u
c
tions
Ventilation

1.Safety
1-3
 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.
 Dispose of battery, observing local regulations.
 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.
 When handling 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, and this could cause a serious
injury.
Handlin
g
batter
y
D004
TR0093
Cautions of hose attachment and remova
l
TR0088
TR0303A
Safety outfit
TR0084

1.Safety
1-4
 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.
 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.
 Have first-aid boxes and fire extinguishers near the unit ready
for emergency situations such as injuries and a fire.
 It is advisable to have a list of phone numbers of doctors,
ambulance and the fire department available in case of
emergency.
 Such things as unnecessary equipment and tools, cables, hoods, covers and pieces of wood which
are a hindrance to the job, have to be cleaned and removed. This is because operators and/or
personnel nearby may stumble on them and may be injured.
 Place safety enclosures at the entrance of and around working site to prevent children or outside
people from entering the site.
Maintain both physicl and mental health
Protection equipments
TR0085
Safety fittings
TR0096
Safety around the machine

1.Safety
1-5
TR0092
PK0028
1.2 Caution 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.
 Do not, under any circumstance, open the portions below
during operation:
 Separator receiver tank drain valve
 Coolant drain valve and plug
 Engine oil drain valve
 Oil cooler drain valve
 Fuel tank drain vale and plug
 Never blow compressed air directly at people.
Scattered impurities, dust, or foreign objects in the compressed
air may cause skin and eyes to be seriously injured.
 Blowing compressed air on food is prohibited.
 Keep hands off from the rotating portion or belts while running.
It could cause serious injuries if hands should be caught in.
 Do not, under any circumstance, open the radiator cap while
running or immediately after stopping operation. Otherwise high
temperature steam jets out and this could cause scalding.
Hands off from rotatin
g
parts and belts
Do not remove radiator cap during operation
TR0304
H990432
Do not replenish compressor oil during operation
W010
Never direct the compressed air to people and foods
Draining during operation prohibited

1.Safety
1-6
H990432
D004
H990433
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
earplugs to prevent damage to hearing.
Never work nearby hot portions of the machine while it is
running.
Do not touch hot portions of the machine while inspecting the
machine when running.
Such parts as engine, exhaust manifold, exhaust pipe,
muffler, radiator, oil cooler, air-end, pipe, 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.
Do not, under any circumstance, bring lit cigarettes or
matches near such oils as engine oil and compressor oil, etc.
They are extremely flammable and dangerous, so be careful
when handling.
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. It may cause a fire. When it
is spilt, wipe it up completely.
Do not fill fuel oil up to the cap lever. When fuel tank is
filled up to the cap level, fuel oil will be overfilled due to
volume expansion caused by rise of ambient
temperature. Further, fuel will be possibly spilled from
fuel tank due to vibration caused during movement
and/or transportation of machine.
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.
Operation with compressed air supply port opened
is
p
rohibited
D003
Do not touch hot parts
Fire prevention

1.Safety
1-7
1.3 Caution during Inspection and Maintenance
 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.
If the above procedure is neglected, and another person
starts operating the machine during check or maintenance, it
could cause serious injury.
 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.
 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.
 After stopping the engine, make sure that pressure gauge
indicates 0MPa. Even when the gauge shows 0MPa, open a
service valve and further do not fail to make sure that there is
no residual pressure in the air piping. Then start such a job
as repair and maintenance.
 Residual air under pressure will blow off and severely injure
operator.
 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 separator receiver tank could
force both extremely hot compressed air and oil to jet out
and you may be scalded or seriously injured.
Hang a “Now Checking and under Maintenance” tag
SY001
Refillin
g
of compressor oi
l
Be careful of hi
g
h
-
pressurized air blowout
W010
W010
Draining separator receiver tank
H990432

1.Safety
1-8
TR0304
W009
M003
TR0206
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.
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.
When cleaning dust accumulated in such devices as the
air-filter, by blowing compressed air, wear safety glasses,
etc. to protect your eyes.
It is recommended to use a lamp with safety guard fitted
where the site is dark.
Operating the machine gropingly or by relying on one’s
intuition could cause unexpected accidents.
Any lamps without safety guard are not recommended since
they can be broken and they could ignite flammables such
as fuel, etc.
Ad
j
ustin
g
tension of belt
Hands off from coolin
g
fan
Cleanin
g
b
y
air-blo
w
Li
g
htin
g
apparatus

1.Safety
1-9
A100285
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.
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.
The engine oil is very hot during operation and just after it
stops. Be careful because the hot oil also pressurized
blows off and it can cause burning.
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.
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.
Openin
g
coolant water drain valve cap
H990432
Refillin
g
or drainin
g
of en
g
ine oi
l
H990432
Fear of fire
H990433
Treatment of organic wastes

2.Part Names
2-1
2.1 Internal Components and Part Names
4 5 6 7
10
A
100100
1 2 3
17 18 19 20 21 22 23
111213 14 15
29 2827 26 25 24
34 33 32 31 30
9
8
16

2.Part Names
2-2
No. Description Function
1 Speed regulator For adjusting engine speed in the system.
2 Engine For driving the compressor.
3 By-pass valve For keeping compressor oil at proper temperature.
4 Exhaust muffler Equipment which muffles an engine exhaust sound.
5 Radiator For cooling the coolant for engine because it is water-cooled.
6 Oil cooler For cooling compressor oil circulating in the system.
7 Fuel tank For storing diesel fuel oil.
8 Engine oil level gauge For checking engine oil level.(Right side of engine)
9 Coolant drain valve For draining engine coolant.
10 Air-end For compressing intake air.
11 Air filter(For compressor) For filtering the dust floating in the intake air.
12 Fuel filter For filtering diesel fuel oil.
13 Solenoid valve for AUTO
IDLE mode For reduction of power under unloaded operation
14 Engine oil filter For filtering engine oil
15 Air filter(For engine) For filtering the dust floating in the intake air.
16 Pressure control valve For keeping the receiver tank pressure higher than 58PSI in the tank.
17 Safety valve
For releasing compressed air to the atmosphere when the pressure rises
higher than the rated pressure.
18 Engine oil filler port For supplying and replenishing engine oil to engine.
19 Pressure regulator For regulating intake air volume.
20 Oil separator For separating oil mist mixed in compressed air.
21 Separator receiver tank For separating compressor oil from compressed air sent into the tank.
22 Compressor oil filler port For supplying and replenishing compressor oil.
23 Compressor oil level gauge For checking compressor oil level.
24 Compressor oil drain valve For draining compressor oil from separator receiver tank.
25 Engine oil level gauge For checking engine oil level.(Operation side)
26 Engine oil drain valve For draining engine oil for replacement of it and for maintenance.
27 Fuel tank drain valve
For draining condensate and water accumulated at the bottom of
the fuel tank.
28 Radiator drain valve For draining engine coolant at the bottom of radiator.
29 Oil cooler drain valve For draining compressor oil at the bottom of oil cooler.
30 Battery For electrically starting engine.
31 Sedimenter For separating water mixed in fuel oil.
32 Reserve tank For feeding engine coolant.
33 Electromagnetic pump
For air bleeding in fuel pipe system and also for fuel feeding to
engine.
34 Compressor oil filter For filtering compressor oil circulating in the system.

3. Installation
3-1
3.1 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.
 Never lift unit which is still in operation, or it could cause critical damage to each component or lead to
serious accident.
 When lifting unit up, make sure that all the fixing bolts on the bonnet are surely tightened because it is
feared that the unit may fall.
3.1.1 Lifting up
① Before lifting the unit up, make sure to check
the lifting bail for any crack and loosened
bolts.
② Connect the hook“1”of the crane or shackle
with lifting bail“2”eye fitted at the top center
of the unit, and make sure that there is no
person standing around the unit. Then
perform hoisting operation.
③ Select a truck or a crane with capacity
sufficient for weight and size of the unit by
referring to the values shown in Chapter 8
“Specifications“ of the manual.
3.1.2 Movement with a forklift
 Protect the package from damage with
cushion material“3”
 Make sure to insert the fork“4”more
than half of the length of the unit for
security.
3.1.3 Mounting the unit on the truck bed
 Be sure to put chocks“5”at the front and rear
frames to the machine.
 Hook the rope“6”as shown in the figure. Thus
secure the unit on the truck bed.
Transportation
A
090572
1 2
A
090637
4 3
5 5
A
100101
6 6

3. Installation
3-2
PC002
3.2 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.
 The machine should be operated in following conditions:
Ambient temperature･･･････ 5°F to 104°F( -15℃～＋40℃)
Humidity ･････････････････ Less than 90%
Altitude ･･････････････････ Lower than 1,500 m above sea level
 Make sure to install the unit, keeping more space than 5 inches from any solid
object nearby, for prevention of cooling performance drop.
 If more than two machines are placed parallel in operation, keep enough distance so that exhaust
air from one machine does not effect the other one.
 Also, a machine has to be installed in the environment where fresh air is always available.
 Keep enough space around the unit for inspection and maintenance access.
3.2.1 Mounting the unit on the truck bed
 Make sure to fix the unit, using
anchor hole“1”of frame as shown
in the fig.
Tightening torque of the bolts ：
M12 : 43N・m
A
090631
1
Size of anchor bolt holes
A
090636-1
Unit:in.

4. Operation
4-1
4.1 Instrument panel
1. Discharge pressure gauge
(For pressure in separator receiver tank)
2. Fuel level gauge
3. Hour meter
4. Digital ｍonitor indicator
(temperature/pressure/rate of suction press.)
5. Selector switch for digital monitor indication
6. Starter switch
7. Auto idle switch(Purge control)
＜Indicator lamp＞
8. Glow
9.Auto idle(Purge control)
＜Warning lamp＞
10. Charge
11. Compressor air filter clogging
12. Engine air filter clogging
＜Emergency stop lamp＞
13. Discharge air temperature
14. Water temperature
15. Engine oil pressure
A
090575-1
1 2 3 4 5 8 9
15
14
13
7 6
12 11 10

4. Operation
4-2
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
possible to display the item
which is required to be
checked.
Digital monitor
A
fter start, d( discharge air temperature) is displayed. It is
possible to select such item by pressing the selector switch:
A
t each press, d (discharge air temperature)→E (Engine
water temp.) →P (discharge pressure) → C ( rate of suction
press.) are selected.
A
090576-1
These items indicate
the item which is
displayed on digital
monitor.
[Discharge air temperature] [Engine water temperature]
[Discharge pressure]
[Rate of suction presss.]
Push
Push
Push
Push