AirMan PDS390S-4B1 User manual

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 Unit Appearance and Part Names ................................................................................................... 2-1
2.2 Internal Components and Part Names ............................................................................................
2-2
3. Installation ............................................................................................................................................... 3-1
3.1 Transportation .............................................................................................................................. 3-1
3.2 Towing the Unit ...............................................................................................................................
3-2
3.3 Location and Installation ...................................................................................................................
3-3
4. Operation ................................................................................................................................................. 4-1
4.1 Instrument panel ............................................................................................................................ 4-1
4.2
Door ................................................................................................................................................. 4-2
4.3
Check before Starting the Unit .................................................................................................... 4-2
4.4
Unit Operation ................................................................................................................................ 4-7
4.5
Stopping Procedures ..................................................................................................................... 4-11
4.6
Operation of after-cooler type and dry air type ......................................................................... 4-12
5. Periodic Inspection/Maintenance .......................................................................................................... 5-1
5.1 Important items as Periodic and Maintenance or after Maintenance .............................................. 5-1
5.2 Daily Inspection and keeping Operation Log ...................................................................................
5-2
5.3 Inspection on Separator Receiver Tank............................................................................................
5-2
5.4 Periodic Inspection List ...................................................................................................................
5-3
5.5 Periodic Replacement of Parts .........................................................................................................
5-5
5.6 Maintenance .....................................................................................................................................
5-6
6. Maintenance/Adjustment ....................................................................................................................... 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 ....................................................................................................................................... 1 9-1
10. Piping Diagram .......................................................................................................................................
1 10-1
10.1 Compressor air・Compressor oil piping .................................................................................... 10-1
10.2 Fuel piping ...................................................................................................................................... 10-2

1.Safety
1-2
TR0201-1
A080001
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.
Ventilation
 Exhaust gas from the engine is poisonous, and could cause
death when inhaled.
Avoid using the machine in an insufficiently ventilated building
or tunnel.
PC002
Follow the safety instructions
 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 dam-
aged or missing, apply new ones.
 Do not modify the machine without prior approval. The safety
may be compromised, functions may be deteriorated, or ma-
chine 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 acci-
dents may occur.
TR0086
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.
Compressed air is prohibited to be used for human respiration

1.Safety
1-3
Safety outfit
 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.
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.tools often used.
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.
 Dispose of battery, observing local regulations.
D004
TR0088
TR0088
TR0303A
TR0093

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 its abnormality, such operation could cause seizure of components or may even cause fire.
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 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.
TR0096
Safety around the machine
 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.

1.Safety
1-6
Do not touch hot parts
Never work nearby hot portions of the machine while it is run-
ning.
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.
W005
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 earplugs to prevent
damage to hearing. D003
Fire prevention
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 level. 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
the 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.
D004
W004

1.Safety
1-8
Adjusting tension of belt
Be sure to stop the engine and remove the starter key when-
ever 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 in-
to the 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 when-
ever 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
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 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. TR0206

1.Safety
1-9
Opening coolant water drain valve cap
Be sure to stop the engine, and let the coolant water sufficient-
ly 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.
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.
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.
Fear of fire
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.
Treatment of organic wastes
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 ma-
chine.
Be sure to follow the designated regulations when disposing of
oil, fuel, coolant (antifreeze), filter, battery or other harmful mate-
rials.
W005
W005
W004
A100285

2. Part Names
2-1
2.1 Unit Appearance and Part Names
A030267
1. Lifting bail
2. Exhaust outlet
3. Drawbar
4. Door
5. Handle
6. Service valve
7. Instrument panel
4
7
5 4 3
2
1
4
5 4
6
PDS390S-4B1

2. Part Names
2-2
2.2 Internal Components and Part Names
(Standard type)
1. Differential pressure gauge
2. Pressure control valve
3. Safety valve
4. Pressure regulator
5. Air filter element (compressor)
6. Speed regulator
7. Air filter element (engine)
8. Engine oil filter
9. Coolant drain plug (engine)
10. Engine
11. Sedimenter
12. Engine oil filler port
13. Fuel filter
14. Reserve tank
15. Fuel air bleeding electromagnetic pump
16. Radiator
17. Oil cooler
18. Exhaust muffler
19. Coolant drain plug (radiator)
20. Oil cooler drain plug
21. Fuel tank
22. Engine oil drain plug
23. Engine oil level gauge
24. Fuel tank drain valve
25. Air end
26. Drain valve for separator receiver tank
27. Compressor oil filler port
28. Battery
29. Compressor oil level gauge
30. Compressor oil filter
31. Service valve
A080344
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
27 26 25 24 23 22
21 20 19 18
31
30
29
28
PDS390S-4B1

2. Operation
2-3
(After-cooler type)
Only the special devise additionally or optionally attached to the standard unit are shown in the
following figure. For the details of the other standard devices, refer to page 2-2.
A080338
1
2
3
PDS390SC-5B1
4
5
6
1. After cooler 2. Discharge noise reducing valve 3. Drain port of air pipe
4. Drain Separetor 5. Drain level gauge 6.Drainvalve

2. Operation
2-4
(Dry air type)
Only the special devise additionally or optionally attached to the standard unit are shown in the
following figure. For the details of the other standard devices, refer to page 2-2.
A080339
4
5
6
PDS390SD-5B1
7
8
9
1. Temperature selection valve 2. After warmer 3. Duct of cooling air outlet
4. After cooler
5. Discharge noise reducing valve 6. Drain port of air pipe
7. Drain Separator
8. Drain level gauge 9. Drain valve
2
3
1

3. Installation
3-2
3.2 Towing the Unit
 When towing unit, make sure there is no person or obstacle at
both front and rear sides and under the unit.
Although the machine is designed to be drawn, drawing is
allowed only in construction site.
 Towing speed should be within 20 km/h.
 When drawing the compressor, make sure to retract the castor.
Drawing the compressor with the castor not retracted, and
drawing it using the castor can lead to serious accidents or
damaged to the castor.
Caution for towing unit
 Be sure to use a vehicle with enough capacity to tow the unit in operating weight.
 Standard pressure for a tire is at 540kPa.
 Be sure not to use wrong size or type of tire in changing.
 Make sure that the end of the drawbar is so surely and firmly connected to the coupler of the towing
vehicle that the disconnection may not occur while the unit is being towed.
 Make sure if there is no deform or damage on the drawing vehicle and the drawbar of the unit.
 Be sure to keep your hand or finger away from any part of the coupling device when coupling or
uncoupling a drawing device to a draw bar.
 Be sure to drive the drawing vehicle safely, avoiding dangerous place or ground, if any.
 If you do not follow the above instructions, it could cause serious injury or big damage.
 When drawing the compressor, make sure to retract the castor. Drawing the compressor with the castor
not retracted, and drawing it using the castor can lead to serious accidents or damaged to the castor.
H000045
A030295
Wrong drawing method Correct drawing method
How to retract the castor

3. Installation
3-3
3.3 Location and Installation
Ventilation
 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 ･･･････ －15°C to ＋40°C
 Humidity ･････････････････ Less than 90%
 Altitude ･･･････････････････ Lower than 1,500 m above sea level
 Install the machine in a place with good ventilation, lower temperature and with surroundings as
dry as possible.
 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.
3.3.1 Installation
 The machine has to 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.
 Following grades on a slope for the machine are recom-
mended :
Boxtype within10°degrees
Trailertype within15°degrees
 In case of trailer type, be sure to put one set of chocks“1”
to the wheels.
3.3.2 Service valve
A
030270
1
PC002
Discharge port : 20A(Rc3/4B)×4
[Taper male screw]
Discharge port : 50A(Rc2B)×1
[Taper female screw]
A
090555