AirMan PDS185S-6E1 User manual

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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. 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” separately to be supplied with the unit.
If you should find any description which does not coincide with the instruction manual
and parts catalog, we request you to make sure to start the job after clarifying it.
Service personnel is required to safely take quick and proper countermeasures as well
as to use correct technology of maintenance in case of field services and periodical
maintenance. It is important that service personnel should have proper and sufficient
knowledge about the structure and function of the unit and should be well familiar with
such technique mentioned in them.
Regarding the part numbers mentioned in this manual, we request you to refer to the
Parts catalogue separately supplied together with the unit, because the parts numbers
in this manual are sometimes changed.
Copies of this service manual are intended to be distributed to limited numbers
of our customers. The unauthorized reproduction or distribution of this service
manual is prohibited.
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Table of Contents
1. Specification -------------------------------------------------------------------------------------- 1-1
1.1 Specifications ----------------------------------------------------------------------------------------------------------- 1-1
1.2 Set Value ----------------------------------------------------------------------------------------------------------------- 1-2
1.3 Outline Drawing -------------------------------------------------------------------------------------------------------- 1-3
1.4 Internal Components and Part Names ---------------------------------------------------------------------------- 1-5
1.5 Instrument Panel ------------------------------------------------------------------------------------------------------- 1-7
1.5.1 Indicator lamp ------------------------------------------------------------------------------------------------------- 1-8
1.6 Capacity Control Device ---------------------------------------------------------------------------------------------- 1-9
1.6.1 Auto idle control (purge control) -------------------------------------------------------------------------------- 1-10
1.6.2 Adjustment of auto idle control (purge control) and correction of engine speed -------------------- 1-11
1.7 Piping Diagram --------------------------------------------------------------------------------------------------------- 1-12
1.8 Fuel Piping --------------------------------------------------------------------------------------------------------------- 1-13
2. Maintenance --------------------------------------------------------------------------------------- 2-1
2.1 Cautions for Overhauling --------------------------------------------------------------------------------------------- 2-1
2.1.1 Precautions before starting work ------------------------------------------------------------------------------- 2-1
2.1.2 Disassembly and reassembly ----------------------------------------------------------------------------------- 2-1
2.2 Tightening Torque ----------------------------------------------------------------------------------------------------- 2-2
2.2.1 General bolts and nuts tightening torque --------------------------------------------------------------------- 2-2
2.2.2 Tightening torque of such important quality parts as bolts and nuts ----------------------------------- 2-3
2.3 How to Adjust Regulator --------------------------------------------------------------------------------------------- 2-6
2.4 Change of Element in Fuel Pre-filter ------------------------------------------------------------------------------ 2-7
2.5 Change Oil Separator ------------------------------------------------------------------------------------------------- 2-8
2.6 Change O-ring of Unloader ------------------------------------------------------------------------------------------ 2-9
2.7 Change O-ring of Auto-relief Valve and Vacuum Relief Valve ---------------------------------------------- 2-11
2.8 Maintenance and Adjustment of Pressure Control Valve ---------------------------------------------------- 2-12
2.9 Change of Pellet assembly of By-pass Valve ------------------------------------------------------------------- 2-13
2.10 Air Bleeding in Fuel Line --------------------------------------------------------------------------------------------- 2-14
2.11 Clean Inside of Fuel Tank -------------------------------------------------------------------------------------------- 2-14
2.12 Clean Drain Separator (Option: With aftercooler only) -------------------------------------------------------- 2-15
2.13 Values of Various Adjustments of Engine ------------------------------------------------------------------------ 2-15
3. Electric System ----------------------------------------------------------------------------------- 3-1
3.1 Electronic Control System of Engine ------------------------------------------------------------------------------ 3-1
3.1.1 Electronic control system ---------------------------------------------------------------------------------------- 3-1
3.1.2 Acceleration control ----------------------------------------------------------------------------------------------- 3-2
3.1.3 Diesel particulate filter (DPF) ----------------------------------------------------------------------------------- 3-3
3.1.4 DPF regeneration control ---------------------------------------------------------------------------------------- 3-4
3.1.5 Preheating control ------------------------------------------------------------------------------------------------- 3-7
3.2 Emergency Controller ------------------------------------------------------------------------------------------------- 3-8
3.2.1 Emergency controller --------------------------------------------------------------------------------------------- 3-13
3.3 Engine Controller (ECU) --------------------------------------------------------------------------------------------- 3-17
3.4 Alternator ----------------------------------------------------------------------------------------------------------------- 3-24
3.5 Starter --------------------------------------------------------------------------------------------------------------------- 3-26
3.6 Starter / Glow Plug Relay -------------------------------------------------------------------------------------------- 3-27
3.7 EGR Valve Relay ------------------------------------------------------------------------------------------------------ 3-28
3.8 Solenoid Valve (SV1) for Starting Unloader and Purge /
Solenoid Valve (SV2) for Aftercooler Drain: Option ----------------------------------------------------------- 3-29
3.9 Engine Oil Pressure Switch (for emergency stops) ------------------------------------------------------------ 3-29
3.10 Fuel Air-bleeding Electromagnetic Pump ------------------------------------------------------------------------ 3-30
3.11 Discharge Temperature Sensor / Water temperature Sensor ----------------------------------------------- 3-30
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Table of Contents
3.12 Pressure Sensor (for intake negative pressure /
service pressure and regulator secondary pressure) --------------------------------------------------------- 3-31
3.13 Fuel Meter (Display) --------------------------------------------------------------------------------------------------- 3-31
3.14 Sending Unit ------------------------------------------------------------------------------------------------------------- 3-32
3.15 Air filter Differential Pressure Switch ------------------------------------------------------------------------------ 3-32
3.16 Electronic Control Engine Component ---------------------------------------------------------------------------- 3-33
3.16.1 Supply pump ------------------------------------------------------------------------------------------------------- 3-34
3.16.2 Rail ------------------------------------------------------------------------------------------------------------------- 3-34
3.16.3 Rail pressure sensor --------------------------------------------------------------------------------------------- 3-34
3.16.4 Injector -------------------------------------------------------------------------------------------------------------- 3-35
3.16.5 Water temperature sensor (ECU) ---------------------------------------------------------------------------- 3-35
3.16.6 Water temperature sensor (Gauge) -------------------------------------------------------------------------- 3-35
3.16.7 Engine oil pressure switch ------------------------------------------------------------------------------------- 3-35
3.16.8 Crank speed sensor --------------------------------------------------------------------------------------------- 3-36
3.16.9 Cam speed sensor ----------------------------------------------------------------------------------------------- 3-36
3.16.10 New air temperature sensor ----------------------------------------------------------------------------------- 3-36
3.16.11 Intake air temperature sensor -------------------------------------------------------------------------------- 3-36
3.16.12 Intake air throttles ------------------------------------------------------------------------------------------------ 3-37
3.16.13 EGR valve --------------------------------------------------------------------------------------------------------- 3-38
3.16.14 EGR (Intake/Exhaust) pressure sensor -------------------------------------------------------------------- 3-38
3.16.15 EGR gas temperature sensor --------------------------------------------------------------------------------- 3-38
3.16.16 Exhaust manifold temperature sensor ---------------------------------------------------------------------- 3-39
3.16.17 Diesel particulate filter (DPF) differential pressure sensor --------------------------------------------- 3-39
3.16.18 Diesel particulate filter (DPF) intermediate/inlet temperature sensor ------------------------------- 3-40
3.16.19 Fuel temperature sensor --------------------------------------------------------------------------------------- 3-40
4. Troubleshooting --------------------------------------------------------------------------------- 4-1
4.1 Repairing Procedures ------------------------------------------------------------------------------------------------- 4-1
4.1.1 Safety caution ------------------------------------------------------------------------------------------------------- 4-1
4.1.2 Caution during failure diagnosis -------------------------------------------------------------------------------- 4-1
4.1.3 How to use the failure diagnosis ----------------------------------------------------------------------------- 4-2
4.2 Failures of Compressor and Engine ------------------------------------------------------------------------------- 4-3
4.2.1 At start-up, starter rotates slowly ------------------------------------------------------------------------------- 4-3
4.2.2 Starter turns, but engine will not start ------------------------------------------------------------------------- 4-3
4.2.3 Engine revolutions will drop before rises up to rated pressure ----------------------------------------- 4-4
4.2.4 Engine will not turn to meet rated revolutions --------------------------------------------------------------- 4-5
4.2.5 Minimum speed not available even upon no-load operation ---------------------------------------- 4-6
4.2.6 Safety valve bursts out during unloaded operation -------------------------------------------------------- 4-6
4.2.7 Oil mixed found in delivery air ----------------------------------------------------------------------------------- 4-7
4.2.8 Water found mixed in discharge air (Aftercooler type) ------------------------------------------------ 4-7
4.2.9 Discharge air is insufficient -------------------------------------------------------------------------------------- 4-8
4.2.10 Purge control operation will not start even if AUTO IDLE (purge control) switch is pressed -- 4-9
4.2.11 Even when the pressure at consumer’s side drops, it will not recover from
purge control operation -------------- 4-10
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Table of Contents
4.3 Operation of Emergency Switch ------------------------------------------------------------------------------------ 4-11
4.3.1 Discharge temperature indication lamp glows and engine stops --------------------------------------- 4-11
4.3.2 Engine oil pressure indication lamp glows and engine stops ------------------------------------------- 4-12
4.3.3 Engine water temperature indication lamp glows and engine stops ----------------------------------- 4-13
4.4 Others --------------------------------------------------------------------------------------------------------------------- 4-14
4.4.1 Residual pressure lamp lights on and engine will not be able to start -------------------------------- 4-14
4.4.2 Indicator lamps will not glow, but engine stops ------------------------------------------------------------- 4-14
4.5 Explanation of Trouble Diagnosis ---------------------------------------------------------------------------------- 4-15
4.6 Engine Trouble Diagnosis Function ------------------------------------------------------------------------------- 4-17
4.6.1 Engine trouble diagnosis ----------------------------------------------------------------------------------------- 4-17
4.6.2 List of diagnostic trouble codes (DTC) ------------------------------------------------------------------------ 4-21
4.6.3 Trouble diagnosis tool (SMARTASSIST-Direct) ------------------------------------------------------------ 4-23
5. References ----------------------------------------------------------------------------------------- 5-1
5.1 Consumable Parts and Electrical Appliances ------------------------------------------------------------------- 5-1
5.2 Engine Wiring Diagram ----------------------------------------------------------------------------------------------- 5-3
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1. Specification
1-1
1.1 Specifications
Item unit
●Weight・Mass
Overall length in.(mm) 128.7(3,270)
Overall length (Bonnet only) in.(mm) 75.2(1,910)
Overall width in.(mm) 66.3(1,685)
Overall height in.(mm) 61.0(1,550)
Net dry mass lb(kg) 2,050( 930)
Operating mass lb(kg) 2,271(1,030)
●Compressor
Free air delivery cfm(m3/min) 185(5.2)
Working pressure psi(MPa)[bar] 100(0.69)[ 6.9]
Pressure of pressure control valve psi(MPa)[bar] 58(0.40)[ 4.0]
Burst pressure of safety valve psi(MPa)[bar] 150(1.03)[10.3]
Ambient conditions: temperature °F(℃) 5 to 104(-15 to +40)
Ambient conditions: altitude yd(ｍ) Less than 1,640(1,500)
●Engine
Type YANMAR 4TNV88C-DHKS
Rated output (Gross) hp/min-1
(kW/min-1) 47.6/3,000(35.5/3,000)
Rated output (Net) hp/min-1
(kW/min-1) 45.6/3,000(34.0/3,000)
Fuel consumption g/kW･h 248
Rated RPM min-1 3,000
RPM at unload conditions min-1 1,350
Net dry mass lb(kg) 441(200)
●Lubricating oils
Engine oil capacity (H/L level) gal.(L) 1.95/0.90(7.4/3.4)
Compressor oil capacity
(including receiver tank and oil cooler
etc.)
gal.(L) 3.59(13.6)
Compressor oil capacity to be filled
Ambient temperature ： 5°F to 104°F (-15 ℃ to +40 ℃ )
HULS : ANDEROL 3032
MOBIL : RARUS SHC 1024
TEXACO:SYN-STARDE32
Coolant capacity gal.(L) 1.80(6.8)
Fuel tank capacity gal.(L) 23.8(90)
●Fuel consumption ratio
(for reference only)
At purge operation gal./Hr(L/Hr) 0.40(1.5)
At no load gal./Hr(L/Hr) 0.74(2.8)
At 50% gal./Hr(L/Hr) 1.29(4.9)
At 70% gal./Hr(L/Hr) 1.64(6.2)
At full load gal./Hr(L/Hr) 2.38(9.0)
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1. Specification
1-2
1.2 Set Value
Item unit
●Emergency stop devices
Actuating temperature of discharge
temperature switch °F(℃) 248(120)
Actuating temperature of water
temperature switch °F(℃) 230(110)
Actuating pressure of oil pressure
switch psi(MPa)[bar] 7.1(0.049)[0.49]
●Warning devices
Actuating temperature of discharge
temperature switch °F(℃) 239(115)
Actuating temperature of water
temperature switch °F(℃) 221(105)
Battery failure When not charged
Actuating pressure of air filter
indicator psi(kPa)[bar] 0.9(6.23)[0.0623]
●Set value
Pressure control valve psi(MPa)[bar] 58(0.40)[ 4.0]
Actuating pressure of safety valve psi(MPa)[bar] 150(1.03)[10.3]
Unload starting pressure psi(MPa)[bar] 100(0.69)[ 6.9]
Time for starting purge mode
operation
(At AUTO IDLE operation mode)
sec 5 to 60
(Set at 10 sec. ex. works)
●Engine RPM
Rated RPM min-1 3,000
RPM at unload min-1 1,350
●Indications of gauges or instruments
during operation
Discharge pressure gauge
(at full load) psi(MPa)[bar] 58 to 100(0.40 to 0.69)[4.0 to 6.9]
Discharge pressure gauge
(at no load) psi(MPa)[bar] 104 to 131(0.72 to 0.90)[7.2 to 9.0]
Discharge pressure gauge
(at purge operation) psi(MPa)[bar] 39 to 73(0.27 to 0.50)[2.7 to 5.0]
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1. Specification
1-3
1.3 Outline Drawing
Unit：in.
A131026
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1. Specification
1-4
Unit：mm
A131025
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