AirMan PDS400S-6E1 User manual

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Preface / Table of Contents
Thank you for having selected our “AIRMAN” product.
Keep this manual at hand to refer to it always when necessary.
When this manual is missing or damaged, order it from our office nearby or distributor.
Make sure that the manual is included with the machine when it is handed over to another user.
The contents of this manual sometimes may be different from this machine because it has been
improved. When you have anything unclear or you want to advise us, contact our office nearby or
distributor.
For details of handling, maintenance and safety of the engine, see the Engine Operation Manual.
―
Table of Contents
－
1. Part Names ------------------------------------------------------------------------------------------- 1-1
1.1 Internal Components and Part Names----------------------------------------------------------------------------1-1
2. Installation---------------------------------------------------------------------------------------------2-1
2.1 Transportation -------------------------------------------------------------------------------------------------------- 2-1
2.2 Towing the Machine ------------------------------------------------------------------------------------------------ 2-2
2.3 Installation conditions------------------------------------------------------------------------------------------------- 2-3
3. Operation ----------------------------------------------------------------------------------------------3-1
3.1 Instrument Panel ------------------------------------------------------------------------------------------------------ 3-1
3.2 Lubricating oil・Coolant・Fuel・DEF -------------------------------------------------------------------------------- 3-2
3.3 Check before starting unit ----------------------------------------------------------------------------------------- 3-5
3.4 Operating Procedure ------------------------------------------------------------------------------------------------- 3-12
3.5 Operation of after cooler type -------------------------------------------------------------------------------------- 3-19
3.6 SETTING screen ------------------------------------------------------------------------------------------------------ 3-21
3.7 DPF regeneration ----------------------------------------------------------------------------------------------------- 3-26
3.8 Emergency Stop -------------------------------------------------------------------------------------------------------3-28
4. Failure cause and measures ------------------------------------------------------------------- 4-1
4.1 Warning / Emergency display -------------------------------------------------------------------------------------- 4-1
4.2 Troubleshooting ------------------------------------------------------------------------------------------------------- 4-5
5. Periodic Inspection/Maintenance -------------------------------------------------------------5-1
5.1 Important Items as Periodic Inspection and Maintenance or after Maintenance ---------------------- 5-1
5.2 Inspection on Separator Receiver Tank ------------------------------------------------------------------------- 5-2
5.3 Periodic Inspection List --------------------------------------------------------------------------------------------- 5-3
5.4 Periodic Replacement of Parts ------------------------------------------------------------------------------------ 5-5
5.5 Maintenance Items --------------------------------------------------------------------------------------------------- 5-6
6. Storage and Disposal -----------------------------------------------------------------------------6-1
6.1 Preparation for Long-term Stoppage ----------------------------------------------------------------------------- 6-1
6.2 Disposal of Product -------------------------------------------------------------------------------------------------- 6-1
7. Specifications --------------------------------------------------------------------------------------- 7-1
7.1 Specifications --------------------------------------------------------------------------------------------------------- 7-1
7.2 Outline drawing -------------------------------------------------------------------------------------------------------- 7-3
7.3 Wiring Diagram -------------------------------------------------------------------------------------------------------- 7-5
7.4 Piping Diagram -------------------------------------------------------------------------------------------------------- 7-7
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Safety
S-1
This section explains safety cautions for safety work for operation, inspection, maintenance,
installation, movement and transportation. Read these safety requirements carefully and fully
understand the contents before starting the machine.
For your better understanding of the precautions in this manual and on this machine, safety
precautions are classified into “DANGER”, “WARNING” and “CAUTION” message with a warning symbol
marked, according to the degree of hazards.
When one of these messages is found, please take preventative safety measures and carry out “SAFETY
OPERATION AND PROPER MAINTENANCE OF THE MACHINE”.
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
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 machine, which has no concern to injury or accident of or to a
human body.
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.
PROPOSITION 65 WARNING
Breathing engine exhaust exposes you to chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust system.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary
For more information, go to www.P65warnings.ca.gov/diesel
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Safety
S-2
Please tell us a MODEL /SER.No. on the plate of the machine when you make an inquiry.
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.
A130375
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Safety
S-3
[Safety Warning Labels]
Following labels are attached to the machine.
When they are found damaged or peeled off, order them from our office nearby or distributor and
attach them again.
1 2 3 4
  
5 6 8 9
  
10 11 12 13 14
   
15 1 6

7
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Safety
S-4
The pasting position of safety warning labels is as follows.
A180276E
7
6
5
2 3 4
12 13 14 15
8 9
1
16
Receiver tank portion sticking position
Shroud portion sticking position
11
10
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Safety
S-5
Compressed air from this machine contains poisonous
materials. Absorption of the compressed air can cause
serious injury. Never provide this compressed air for
human respiration.
This machine 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 machine 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 machine carefully, understand its
content and follow the indications thereof.
Do not modify the machine without prior approval. The
safety may be compromised, functions may be
deteriorated, or the machine life may be shortened.
Never use the machine for the purpose of compression of
gases other than air, or as a vacuum pump. Otherwise,
serious accidents may occur.
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.
As compressed air contains toxic gas etc., compressed air
should not be used to be blown or sprayed against food
etc.
Keep hands off from the rotating portion or belts while
running. It could cause serious injuries if hands should be
caught in.
As part of pre-start safety checks, always confirm that
there is no residual pressure in the tank by carefully
opening the service valve, even if the pressure gauge on
the screen indicates 0PSI.
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.
TR0201-1
A080001
TR0086
TR0092
TR0304
W011
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Safety
S-6
When cleaning dust accumulated in such devices as the
air-filter, by blowing compressed air, wear safety glasses,
etc. to protect your eyes.
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.
Be sure to perform the periodic checks 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.
The engine of this machine and electrical parts many electronic devices have been
installed. If you perform welding work, remove the connector of the electronic control
equipment. Application of excessive current to electronic controls can cause
equipment malfunction.
M003
H990432
W004-1
A100285
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1.Part Names
1-1
1.1 Internal Components and Part Names
A180429
PDS400S-6E1
No. Description Function
1 Safety valve For releasing compressed air to the atmosphere when the pressure
rises higher than the rated pressure in the system.
2 Air filter (For compressor air-end) Filtering device for filtering dust floating in intake air.
3 Air filter (For engine) Filtering device for filtering dust floating in intake air.
4 Sedimenter For separating coolant from fuel in the system.
5 Fuel pre-filter For removing dust and water mixed in fuel.
6 Fuel filter For filtering foreign matter and dust mixed in fuel.
7 Fuel air-bleeding electromagnetic pump For automatically bleeding air from fuel pipes in the system.
8 Reserve tank For checking coolant level and supplying it.
9 Compressor oil filter For filtering compressor oil in the system.
10 By-pass valve For keeping compressor oil at optimum temperature in the system.
11 Oil cooler For cooling compressor oil in the system.
12 Fuel tank drain valve For draining condensates from fuel tank.
13 Fuel tank For storing fuel.
14 Engine oil filler port For supplying and replenishing engine oil to engine.
15 Engine oil filter For filtering engine oil in the system.
16 Engine oil level gauge For checking engine oil level.
17 Separator receiver tank For separating air and oil from compressed air in the system.
18 Separator receiver tank drain valve For draining condensed water from separator receiver tank.
19 Compressor oil filler port For supplying or adding compressor oil.
20 Compressor oil level gauge For checking compressor oil level.
1 2 3 4 5 6 7 8 9 10 11
20
19 18 17 16 15 14 13 12
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1.Part Names
1-2
A180430
PDS400S-6E1
No. Description Function
21 SCR (Selective Catalytic Reduction) Selective reduction-type catalyst that uses DEF as a reducing
agent.
22 Radiator For cooling the coolant for engine in the system.
23 Engine For driving the compressor air-end in the system.
24 Solenoid valve for unloader spring
chamber For reducing loads during start-up.
25 Pressure regulator For controlling full load and unload operation.
26 Solenoid valve for starting unload For reducing load at start-up.
27 Pressure control valve For keeping the pressure in receiver tank constantly higher than a
certain level in the system.
28 Compressor air-end For compressing air in the system.
29 Battery For electrically starting engine.
30 DEF tank Container for DEF
31 Engine oil drain valve For draining engine oil.
32 Oil cooler drain valve For draining compressor oil from oil cooler and oil line.
33 Radiator drain valve For draining engine coolant.
34 DPF (Diesel Particulate Filter) Apparatus for removing harmful components contained in the
exhaust gas.
21 22 23 242526 27 28
34
33 32 31 30 29
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1.Part Names
1-3
A180431
PDSF330DP-6E1
No. Description Function
21 SCR (Selective Catalytic Reduction) Selective reduction-type catalyst that uses DEF as a reducing
agent.
22 Radiator For cooling the coolant for engine in the system.
23 Engine For driving the compressor air-end in the system.
24 Solenoid valve for unloader spring
chamber For reducing loads during start-up.
25 High pressure regulator Pressure regulator used to control air pressure during high
pressure operation.
26 Pressure switching solenoid valve Equipment for switching the operating pressure between low
pressure and high pressure.
27 Low pressure regulator Pressure regulator used to control air pressure during low pressure
operation.
28 Solenoid valve for starting unload For reducing load at start-up.
29 Pressure control valve For keeping the pressure in receiver tank constantly higher than a
certain level in the system.
30 Compressor air-end For compressing air in the system.
31 Battery For electrically starting engine.
32 DEF tank Container for DEF
33 Engine oil drain valve For draining engine oil.
34 Oil cooler drain valve For draining compressor oil from oil cooler and oil line.
35 Radiator drain valve For draining engine coolant.
36 DPF (Diesel Particulate Filter) Apparatus for removing harmful components contained in the
exhaust gas.
21 22 23 24 25 26 27 28 29 30
36
35 34 33 32 31
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1.Part Names
1-4
[After cooler type]
Only the special devices 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 1-1,1-2.
No. Description Function
1 Drain separator For separating water from compressed air cooled through after cooler.
2 After cooler For cooling compressed air.
3 Drain port of air pipe For draining condensate from drain separator.
4 Drain warming valve For preventing freezing of water separated through drain separator
when exhausting it.
A180431
PDS400SC-6E1
4 3 2 1
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2.Installation
2-1
2.1 Transportation
When loading and unloading the machine, be sure to use the lifting bail provided on the center of the
machine top.
2.1.1 Lifting up <Procedure>
1. Before lifting the machine up, make sure to check the
lifting bail [A] for any crack or loosened bolts.
2. Connect the hook [B] of the crane or shackle with
lifting bail eye fitted at the top center of the machine,
and make sure that there is no person standing
around the machine. Then perform the hoisting
operation.
3. Select a truck or a crane with a capacity sufficient for
the size and weight of the machine by referring to the
values shown in Chapter 7 “Specifications” of the
manual.
4. Any crane operations must be performed by a
qualified crane operator.
2.1.2 Mounting the machine on the truck bed
Be sure to fasten the machine with ropes [1] as
shown in the figure right, and securely fix it on the
truck bed.
Be sure to put one set of chocks [2] to the wheels. Pull
the parking brake lever it firmly after the machine is
loaded on the truck bed.
Never get under the machine which is lifted up, because it is very dangerous.
Never lift the machine which is still in operation, or it could cause critical damage to
each component or lead to serious accident.
Transportation
A160749
A160750
1 2 1
B A
Lifting bail
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2.Installation
2-2
2.2 Towing the Machine
Before towing the machine, make sure to check and confirm that the following points
have no problem.
Tire air pressure is proper.
Tire fixing nuts are not loose.
Tires are not worn nor damaged.
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 machine
is being towed.
Make sure if there is no deform or damage on the drawing vehicle and the drawbar
of the machine.
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.
Caution for towing the machine
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2.Installation
2-3
2.3 Installation conditions
The machine has to be parked horizontally on a level place.
The machine has to be parked right-angled on a slope.
The machine has to be parked on a slope within an angle of 15°
The machine should be operated in following conditions:
Ambient temperature-------------- -5°F to 104°F (-15℃to +40℃)
Humidity------------------------------ Lesss than 80％
Altitude-------------------------------- Lower than1,500m above sea level
※If you use the machine not in the conditions stated above, it may causes serious breakdown.
The machine has to be installed in the environment where fresh air is always available,
temperature is low and ambient air is dry as much as possible.
If more than two machines are placed parallel in operation, keep enough distance so that exhaust
air from one machine does not affect the other one.
Also, a machine has to be installed in the environment where fresh air is always available.
Keep enough space around the machine for inspection and maintenance access.
Exhaust gas from the engine is poisonous. It
could cause death or serious injury if 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.
When installing the machine in a tunnel or
the like, ensure a supply of fresh air and
provide adequate ventilation.
Be sure to place the exhaust pipe in an
outdoor location, so that no exhaust gas will
be leaked from any pipe seam.
Do not position the exhaust gas outlet in the
direction of a house.
Because the exhaust gas from the engine is
poisonous, avoid positioning it in the
direction of passers-by.
PC002
A150835
Exhaust pipe 
Use an air blower
for taking in air
○
Exhaust gas
×
A150836
○
×
Private house
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2.Installation
2-4
Be sure to stop the wheels on both wheels
[1] on the tire.
Be sure to place the safety fence around the
machine in order to prevent other people
than those involved in construction work from
entering the construction site or from
accessing the machine
2.3.1 Service valve
A160694
A160751
1
安全护拦
Installation notes
Placing safety fence in position
A120199
Safety fences
Bore of service valve: 20A(R3/4B)×2
[Taper male screw]
Bore of service valve: 50A(Rc2B)×1
[Taper female screw]
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2.Installation
2-5
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 is
loose, there is a possibility of piping or a hose
separating and getting seriously injured.
Please remove after closing the service valve
and relieving remaining pressure. If pressure
remains, there is a possibility of the hose
whipping, causing damage and possibly
injury.
In order to use it safely, please read the
handling of the work tools often used.
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.
Half-open of service valve could cause
cracks of valve seat and air leaks. Be sure to
use as full-close or full-open, not to use as
half-open.
A150841
○ ○
×
Half-open
Fully-close Fully-open
Cautions of service valve
TR0088
Cautions of hose attachment and removal
TR0303A
Operation with discharge port
(compressed air supply port) opened is prohibited
D003
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3.Operation
3-1
3.1 Instrument Panel
Each display of the operation panel is illustrated as follows.
Read and fully understand the explanations and be sure to operate safely:
A180427
[START] button
Start operation by holding
the button for 1 second.
[CONTROL POWER] switch
Switch to start and stop
the unit.
Switch to change high pressure
mode and low pressure mode.
Touch Screen
Display operation conditions
and set each parameter.
PRESSURE SELECTOR switch
(
PDSF330 onl
y)
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3.Operation
3-2
3.2 Lubricating oil・Coolant・Fuel・DEF
3.2.1 Engine oil
Use engine oil recommended by us.
Be sure to use CJ class or higher engine oil or superior class. (Using engine oil with poor quality may
shorten the life of the engine).
Classification API service classification CJ-4 class or higher
Viscosity SAE10W-30
Viscosity of engine oil greatly affects startability, performance, oil consumption of the
engine, as well as wear of the moving parts.
Ambient temperature range and oil viscosity (SAE)
A180160E
When two or more different brands of oil are mixed, its performance can be
deteriorated. Do not mix oils.
Follow the designated regulations to dispose of engine oil.
3.2.2 Compressor oil
Be sure to use recommended oil listed below.
Even continuous oil replenishment cannot improve its deteriorated condition. Be sure to change the oil
completely at every scheduled interval.
Maker Brand
MOBIL MOBIL RARUS SHC 1024
SHELL SHELL CORENA S4R (VG32)
Mixture of different brands compressor oil could cause an increase of viscosity and
make compressor oil sticky. In the worst case, it could cause sticking trouble of
compressor air-end “Compressor air-end will not turn”. Also repairing of such air-end
needs expensive cost. Therefore, be sure to avoid mixing different brands oil. In case
compressor oil brand in use has to be unavoidably changed, it is absolutely
necessary to completely clean up the interior of compressor air-end. In such a case,
contact “AIRMAN” dealer or us directly.
Follow the designated regulations to dispose of compressor oil.
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