No. F68442 00004C INSTRUCTION MANUAL DENYO ENGINE COMPRESSOR DIS—-275S8SS2 (SB2) 390SS (SB) 685SS (SB) 775SS 980SS DIS—310HS (HB) 500US 550HS (HB) 765US Before using, be sure to read this manual for the sake of safety. Be sure to observe the items under symbol marks " 4\ WARNING" and" A\ CAUTION" for the sake of safety. Always keep this manual at your machine for the sake of safety. 4-2-2, Kamitakada, Nakano~ku, Tokyo, 164, JapanFOREWORD * Your machine is a portable type engine compressor. (Specifications: See p.62) * Do not install, operate or repair this machine without reading this operating manual. * This engine compressor (machine) must be operated by a person having sufficient knowledge and skill for the sake of safety. Notes on instruction manual “This instruction manual explains correct operation and maintenance of the machine to ensure its performance. Incorrect handling of the machine may lead to a serious injury or decease. Before using, be sure to read this manual carefully. Particularly, the items under " Safety precautions" (See p.1 to p.9) "+ WARNING" and" + CAUTION" must be read thoroughly. * Keep this manual in the case behind the rear door for future reference. * Read the contents of the warranty card attached to the machine. + If this manual becomes illegible by spot or damage, contact distributor or our office to get new manual.— Contents — 1.Safety Precautions 2.Construction 2-1. Outline and part names —— 2-2 Instrumental panel and part names 23. Meters 2-4. Use of switches and controllers 3.Operation 3-1 Checking prior to operation 3-2 Starting 3-3 Starting under cold weather 3-4. Precautions during operation 3-5 Stopping ~ 3-6 Emergency stop and monitor display 4Protection device ~ S.Lubrication oil, cooling water and fuel etc, S-1 Engine oil 5-2. Cooling water 5-3 Fuel -- 5-4 Safety valve 5-5 Regulator — 5-6 Compressor lube oil 6 Handling of battery 6-1 Caution on battery charge ~~ 6-2 Connection of booster cable, and installation ~ 7 Periodical checking and maintenance 7-1 Maintenance schedule — 7-2 Checking/every 100 hours 7-3 Checking/every 250 hours 7-4 Checking/every 500 hours 7-5. Checking/every 1000 hours 7-6 Checking/every 2000 hours 7-7 Table of periodical maintenance and checking 8.Trouble shooting and Countermeasures 9.Long - term storage 10.Service data 10-1 Specifications 10-2 Outline drawing 10-3. Combined Piping Diagram 10-4 Engine wiring diagram ~ 39 40 54 551.Safety Precautions In order to ensure safe operation, the following symbols are used for explanation of the machine operation. ‘The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. AS WARNING: This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. ZX CAUTION: This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. [Note] : This symbols show handling precautions for effective operation and many years of satisfactory operation. Some of the items shown by " A\ CAUTION" may also cause death or serious i Be sure to observe all the items, as they are important for safe operation. If the machine is used by an outsider, you are requested to explain him correct handling jury. and advise him to read this instruction manual carefully. * Do not modify the machine at your discretion, as it affects the safety, performance or the life of the machine. * If the machine is modified or it is used incorrectly against this manual or unauthorized parts are used, the warranty of manufacturer will become invalid.Safety label Safety labels are attached to the following positions of the machine. * Keep these safety labels clean at all times. * When safety labels are spoiled or lost, contact distributor or our office specifying the nameplate No. shown below and ask for new ones. (DIS-685SB) 1.Warning : exhaust gas (B9042 0000) 2. Safety Instructions (E9111 0050) 3. Warning : air delivery (E9411 0080) 4.Caution : Residual pressure (9411 0070) 5.Warning : hot coolant (B9041 0010) 6.Warning : diesel fuel (B9045 0000) 7.Caution : Run away (E9111 0060) 8.Caution : hot surfaces (B9040 0030) 9 Safety Instructions on trailer (£9111 0040)(DIS-390SS) 10.Caution : High pressure (E9411 0060) 11.Warning : moving parts (89040 0040) 12.Caution : hot surfaces (89040 0030) 11 (DIS-685SB) A-view 12Z\ WARNING ENGINE EXHAUST can kill. @ Insufficient ventilation may lead to death due to Jack of oxygen or poisoning by exhaust gases. * Do not use the machine in a place of poor ventilation or in a place where exhaust gases stays. * Do not use the machine indoors or in storehouse, tunnel, ship hold, tank, etc. of poor ventilation. * If it becomes necessary to use the machine in the above places, the exhaust pipe should be extended to a well ventilated place. In this case, use a ventilator to ensure proper ventilation. * Do not direct the exhaust outlet to nearby pedestrians and houses. Z\ WARNING ‘THE AIR DELIVERED can kill. HM Do not allow to breathe the air delivered by compressor . Otherwise, it may result in death accident. the compressor must not be used for raising air pressure in a room or for supplying air for diver's breathing. A\ WARNING MOVING PARTS can cause severe injury. BH Rotary unit which runs at a high speed is located in the machine. (Note that it is very dangerous if you touch it.) * Be sure to close the door and lock it during operation, * When the door needs to be opened during operation, do not get your hands and head in the machine to prevent them from being caught in the machine which may lead to injury. * When making check or maintenance of the machine, be sure to stop the machine in advance.A\ CAUTION DIESEL FUEL can cause fire or explosion. & i, Mi Feel and oil are flammable. Incorrect handling results in danger of ignition or fire. = When fuel needs to be supplied to the machine, be sure to stop the engine. Refrain from smoking Keep the machine away from fire, * Do not leave flammable objects (paper, wood chips, ; & etc.) and hazardous objects (oil, powder, etc.) near the machine. * Wipe off spilt fuel and oil. Z\ CAUTION Stacking I Improper stacking of machines may cause falling or dropping accidents. When stacking other machines on this machine, be sure to observe the following points. * Check that the bonnet of the machine is free from = = damage and that the fixing bolts are not loosened & Sis and missing. * Put the machine horizontally on a solid foundation which withstands the weight of stacked machines. * Machines can be stacked up to 2 stages. ‘The weight and size of stacked machines should be less than those of this machine. “ Using square timbers as shown right, put each machine making sure that the weight is even. fail I Do not operate the machines in the state of stacking to prevent falling or dropping accidents.Z\ CAUTION HOT PARTS can burn skin. High temperature units are located in the machine. (Note that these units are very dangerous if they are used incorrectly.) * Be sure to close the door and lock it during operation. * If the door needs to be opened during operation, do not get your hands and head in the machine to prevent unexpected burns. * When making check or maintenance of the machine, be sure to stop the machine. * The bonnet is still hot even after the machine is stopped. Be careful until the engine is completely cooled. A\ CAUTION HOT COOLANT can cause severe scalds. Mi If the radiator cap is opened while the water temperature is high, steam or hot water will spout out. * During operation or immediately after stopping the machine, do not open the radiator cap while the ‘water temperature is high. * When cooling water needs to be checked or supplied, ‘wait until the engine is cooled (50 ‘C or less as measured with the water temperature gauge). A\ CAUTION Noise I This machine generates large noise, if the door is open. Surrounding to large noise may cause hearing trouble. * Close and lock the door during operation * If opening the door is necessary during operation, be sure to put on the ear protector.Z\ CAUTION High pressure MI Dangerous High Pressure. Never open the oil filler ¢ port, while high pressure remains inside. Otherwise, ( A serious injury can result. Be sure to stop engine and release the inside pressure before filling oil A\ CAUTION High pressure remains MH Dangerous Residual Pressure. Never take off D the pipings keeping residual pressure, for it can cause a serious injury, Be sure to release the residual pressure before taking off. A\ CAUTION BATTERY Mi Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * Battery should be charged in a well ventilated location. Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and —). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. For maintenance of the machine, disconnect the ground cable on the ground side. I The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. * When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. — In the worst case, it will put out your eyes. MM For checking or handling of the battery, be sure to stop the engine and turn OFF the battery switch in advance.A\ CAUTION ‘Transportation HI Do not lift the machine at the support hook or the ladder because it is not strong enough for lifting and may cause a falling accident. * When lifting the machine, use the hanger located at the roof center. * Keep out under the lifted machine. Hl Do not lift or do not transport the machine during operation, as it may cause damage to the fan or serious trouble. * When loading the machine on the truck or the like, fix the machine firmly by support hooks on the both side. The detail as machine size is referred to ‘10-1. Specifications See p.62) A\ CAUTION Operator Do not operate the machine, if operator is tired too much or drinks some alcohol or take some drugs. * Otherwise, it may cause unexpected accidents or injury. WH During checking or maintenance, be sure to put on suitable clothes and protectors. * Do not put on baggy clothes, necklace, etc., because they are easily caught by projections which may cause injuries.Z\ CAUTION Run away Mi Be sure to set the wheel stoppers expect for moving. Otherwise, the unit may move or run away and can cause a serious accident. A\ CAUTION Safety instructions on Trailer Improper operating of the trailer can result in the accident to severe injury or death. For moving or parking, be sure to keep the following instructions: 1. Place the unit on a level and hard ground. Placing on an inclined location may cause free moving or tumbling down to injury. 2. Except for moving, securely pull the parking brake, if t is fitted, and always put the wheel stoppers. For the 2— wheeled trailer, set up the standing bar or caster to fix the unit securely. 8, For moving, remove the stoppers and release the parking brake if it is fitted. ‘Use the parking brake only for parking, and never use it for braking the unit when transporting. 4, For moving, securely connect the unit to the towing system of the towing vehicle which should have an enough towing capability and should be driven by a qualified driver. 5, Never move the unit at the towing speed of over 25km/h. 6, Put the unit on a truck for transporting the unit from a workshop.2.Construction 2-1 Outline and part names Following is DIS~275SB2 ~ 685SB. (Except trailer type. ) 1. Instrumental panel 8, Exhaust gas outlet port 2. Air outlet valves, 9. Compressor lube oil drain port 3. Fuel level gauge 10. Engine lube oil drain port 4, Fuel inlet port 11, Coolant drain port 5, Fuel tank 12, Fuel drain port 6. Lifting hook 13, Rope hook 7. Coolant inlet port - 10Following is DIS— 275882 ~ 980SS. (In the case of trailer type.) 1. Instrumental panel 8. Exhaust gas outlet port 2. Air outlet valves 9. Fuel drain port 3, Fuel level gauge 10, Engine lube oil drain port 4, Fuel inlet port 11. Coolant drain port 5. Lifting hook 12. Fuel tank 6. Rope hook 13. Compressor lube oil drain port 7. Coolant inlet port -u-2-2 Instrumental panel and part names ‘The instruments panel contains all the meters, instruments and switches necessary for ‘operating the machine: bo °° : = ae 7 SC) ° EZ Qe =e eae aaa wen Sea ‘Eygnvecournesson Denyo 1.Warning lamp unit ‘Delivery air pressure gauge 3.Discharge air temperature gauge 4.Unloader valve SStarter switch 6 Preheat lamp ‘7.Tachometer 8.Water temperature gauge 9Engine lube oil pressure gauge 10.Charging voltmeter 11.0il separator indicator 12.Battery switch 13.Compressor air filter warning lamp 14.Engine air filter warning lamp 15.Engine low speed warning lamp 16 Residual tank pressure warning lamp 17 Fuel level gauge2-3 Meters Engine indicators (1) Tachometer ‘This meter indicates the number of revolutions of the engine. (2) Hour meter ‘This meter indicates the total running time of the engine. This meter is built in the tachometer. (3) Water temperature gauge normal ‘This is normal when it indicates 75 to 95 ‘C during operation. (5-850) (Note] If it indicates higher values, close air outlet valves. ‘The speed regulator will reduce engine speed to the idle cycle, and wait until the temperature lowers. (4) Engine lube oil pressure gauge normal ‘This is normal when it indicates 200 ~ 600kPa during (200~600kPa) operation. [Note] If the engine is cool, it may indicate higher values at the time of start up. Put the engine in warming up operation and wait OY, until oil pressure becomes normal. en(6) Charging voltmeter ‘This meter indicates the voltage supplied by the alternator to batteries. It is normal when it indicates 25 to 29 V during operation. © (6) Fuel level gauge This meter indicates the quantity of fuel in fuel tank. (3) Compressor indicators (1) Delivery air pressure gauge ‘This meter indicates pressure of delivered air by compressor. (2) Discharge air temperature gauge ‘This meter indicates temperature of discharge air. ee i ‘This is normal when it indicates 60 to 105 ‘C during operation. (Note] Ifit indicates higher values, close air outlet valves. ‘The speed regulator will reduce engine speed to the idle cycle, and wait until the temperature lowers. Cy =eIndicator / warning lamps (1) Oil separator indicator When the Oil Separator Element is blinded, this indicator ALTER COT draws near the red range. 7 ‘While working, the green range shows its normality, the red range shows it shoudl be replaced. (2) Engine air filter warning lamp When the engine air filter element is blinded, this lamp lit on. O Indicating that the element should be immediately cleaned or replaced. (3) Compressor air filter warning lamp ‘When the compressor air filter element is blinded, this lamp O lit on. Indicating that the element should be immediately cleaned or replaced. (A) Residual tank pressure warning lamp When there is residual pressure in the oil chamber and O the engine is starting, this lamp lit on, At this time, the engine can not start. Restart the engine after confirming that the pressure gauge reads zero. (8) Preheat lamp When the starter switch is turned to the "PREHEAT" position, O this lamp lit on. When the preheat lamp lit off, it indicates that preheating is completed, except DIS-980SS and DIS—765US. In the case of DIS--980SS and DIS~765US,when the starter switch is turned to the "PREHEAT" position,this lamp becomes red heated in about 60seconds. At this time, preheating completed. -15-(6) Engine low speed warning lamp ‘This lamp lit on, if engine revolution failed abnormally. O If this lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. (7) Warning lamp unit 7 S i ‘This monitor indicates the following failures, if any one of iad them occurs. @® Engine lube Oil pressure failure If the machine is in normally operation,this lamp lit off. When the starter switch is tumed to "RUN" position to start the engine, the lamp lit on, and when the engine oil pressure rises after start up, it lit off. If this lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. Low ® Water temperature rises abnormally This lamp lit on when the water temperature rises abnormally. If the lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. WATER @ Battery charging failure If the machine is abnormaly operation,this lamp lit on. If the lamp lit on during operation, the emergency stop device = immediately operates to shut down the engine automatically. cHG ~ 16 -@ Discharge air temperature rises abnormally: This lamp lit on when the discharge air temperature rises, abnormally. If the lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. ® Compressor Oil filter blinding When the compressor oil filter element is blinded, this lamp are, 7 lit on. Indicating that the element should be immediately replaced. OIL FILT. © Failure of Fuel quantity When fuel quantity failed, this lamp lit on. If the lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. After stop the engine, fuel should be supplied at the tank. FUEL | eT2-4 Use of switches and controllers (Battery switch ON OFF (2)Starter switch ate Bae "Ns s ‘ he ake NG @ ‘This switch should be set to the "ON" position during operation. And after stop the engine, this switch should be set to the "OFF" position. (Note] Do not tum this switch to the "OFF" position during operation. Otherwise, the engine may not be able to be stopped by normal operation, it may cause damage to the electric ‘equipment. Functions: @ STOP This switch should be set in this position unless the machine is in operation. The key can be inserted or pulled out in this position. @ RUN ‘This switch should be set in this position when the machine is in operation. @ START ‘This is the position to start the engine. When your hand is released from the key after starting, it is automatically set to the "RUN" position. @ PREHEAT ‘This is the position to start the engine when the ambient temperature is low. Set the switch to this position until the preheat lamp becomes red heated, and then set it to the "START" position.(2)Unloader valve Functions: @ START start © > & ‘This is the position to start the engine. When engine start, ‘warming up the engine for 5 to 10 minutes at the this position. RUN @ RUN After warming up the engine ,set the unloader valve to the "RUN" position. You can use delivered air by compressor. eige3.Operation Be sure to check the mac! . Checking prior to operation . Starting egyeep From pre-start check to shut down — prior to starting. Starting under cold weather Precautions during operation . Stopping Emergency stop and monitor display 3-1 Checking prior to operation Z\ WARNING MOVING PARTS can cause severe injury. Rotary unit which runs at a high speed is located in the machine. (Note that it is very dangerous if you touch it.) * Be sure to close the door and lock it during operation. © When making check or maintenance of the machine, be sure to stop the machine in advance. @ @) (3) @ © © @O ® ® To prevent unexpected trouble, be sure to check the following points. Check on engine lube oil Check on compressor lube oil Drain condensed water from oil chamber drain Check on radiator coolant Checking on fan belt Checking on fuel Checking on battery fluid Checking for loose parts Removal of foreign objects in machine aneInspection: (1) Checking on engine lube oil (Read the instruction manual for the engine furnished separately.) @® Checking the level of engine lube oil by the dipstick. Make sure the oil level is always between H and L, ® When it is below the low limit, supply oil immediately. | | @® At the same time, check condition of oil a a by the dipstick. L [Note] O° x x Oil is consumed gradually during operation, When the machine is to be used continuously for a long tithe, be careful with lack of oil. (2) Checking on compressor lube oil Check whether or not the oil level is within the scope of the level gauge while the engine is off. (8) Drain condensed water from oil chamber drain Open the drain valve slightly and extract drainage. Close it immediately after oil flows out. -u-(Check on radiator coolant (Read the instruction manual for the engine furnished separately.) Z\ WARNING HOT COOLANT can cause severe scalds. If the radiator cap is opened while the water temperature is high, steam or hot water will spout out. * During operation or immediately after stopping. the machine, do not open the radiator cap while the water temperature is high. * When radiator coolant needs to be checked or supplied, wait until the engine is cooled (50 °C or less as measured with the water temperature gauge). ® Check (to see) that cooling water in the reserve tank is within the range of FULL—LOW. ® When it is below the low limit, supply (additional) water immediately. ® Normally, only the water level of the reserve tank needs to be checked. But, the radiator cap should be opened once a week to check that water is full in the radiator. [Note] When closing the radiator cap after water level is checked or water is supplied, turn the cap fully clockwise so that it can be firmly tightened. Otherwise, cooling water is evaporated which results in serious damage to the engine. -2-(5) Check on fan belt (Read the instruction manual for the engine furnished separately.) ® Check the belt for tension and elongation. Also, check it for damage. Replace if necessary. ® For adjustment or replacement of the belt, refer to the instruction manual for the engine. Press {about 100N(10kg)}) the position shown by arrow mark (middle of belt) with your thumb. ‘The bend should be within the range of 10mm. (©) Check on fuel @ Be sure to check the quantity of fuel prior to operation to prevent lack of fuel during operation. @ Loosen the drain plug of the fuel tank from A time to time, and remove sediments and water at the bottom of the tank. -m-(7) Check on battery fluid A\ CAUTION ‘The battery fluid is dilute sulfuric acid. Improper handling will cause unexpected bums. * When the batter fluidy gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. — In the worst case, it will put out your eyes. . Remove the battery fluid plug(cap) and check oO the liquid level (L0- 12mm above the electrodes). Tr sini Supply distilled water if necessary. (8) Checking for loose parts Check for loose bolts and nuts. Loose parts should be tightened firmly, Particularly, make check on (Nylon pipe union, Rubber house joint, the fitting of air cleaner, muffler, etc.) disconnection of electric wiring, short-circuit and loose terminals. (9) Removal of foreign objects in machine + Check that tools and cleaning cloth are not left in the machine. Remove if necessary. + Check the surroundings of the muffler and engine for presence of dust and flammable objects. Remove if necessary. + Check that the cooling air inlet and the cooling air outlet of the machine are not clogged with dust or other objects. Remove if necessary. - ume3-2 Starting (1) Fully close air outlet valves and start-run valve. (2) Turn the unloader valve to the "START" position. START RUN [Caution] Starting the engine with the unloader valve set to the "RUN" position will shorten the life of the machine and may cause hazards to an operator and neighboring persons. Be sure to start it after confirming start the unloader valve is set to the "START" position. (3) Turn the battery switch to "ON" position. [Note] Do not turn this switch to the "OFF" position during operation. Otherwise, the engine may not be able to be stopped by normal operation, or it may cause damage to the electric equipment. (4) When the starter switch is tuned to the "PREHEAT" position, preheat lamp lit on. When the preheat lamp lit off, it indicates that preheating is completed. (except DIS—980SS and DIS~765US. } In the case of DIS~980SS and DIS~765US, when the starter switch is turned to the "PREHEAT" position, this lamp becomes red heated in about 60seconds. (5) Turn the starter switch key to the "START" position to start the engine. (© Release the starter switch key if the engine is started. The key is automatically reset to the "RUN" position. =(7) After warming up the engine for 5 to 10 minutes, set the unloader valve to the "RUN" position. START RUN (8) Open the air outlet valves to delivery compressed ait, while confirming that the engine evenly increases speed by opening the valve and smoothly decreases it by closing the valve.3-3 Starting under cold weather ‘The engine may not be started smoothly under cold weather. Start it in the following ‘manner under the cold weather: (1) Fully open the start-ran valve. (2) Set the unloader valve to the "START" position and then start the engine. @) After warming up the engine for a few minutes, slowly close the start-run valve while observing the rotation of the engine, (4) After confirming that the engine has been fully warmed up, set the unloader valve to the "RUN" position. 3+4 Precautions during operation Occasionally check all gauges and meters on the instrument panel to ensure that the compress or is operating under the standard conditions stated below: DIS-275 + 390 - 685 + 75 Delivery air pressure gauge(MPa) 0.69 (full load) —_| (0.74 ~ 0.78 (no load) ‘Monitor lamps Not lit on DIS-980 0.69 (full load) 0.74 ~ 0.78 (no-load) Delivery air pressure gauge(MPa) + | 0.83 cult toad) 0.88 ~ 0.91 (no-load) ‘Monitor lamps | Not lit on | DIS—310H + 550H [Delivery air pressure gauge(MPa) 1.03 (full load) | 1.08 ~ 1.12 (no load) /Monitor lamps Not lit on | DIS~500U + 765U Delivery air pressure gauge(MPa) 1.27 (full load) [1.32 ~ 1.36 (no-load) /Monitor lamps Not lit on3-5 Stopping (1) Close air outlet valves. The speed regulator will reduce engine speed to the idle cycle. ut the machine in cooling operation for about 5 minutes, (2) Turn the starter switch key to the "STOP" position, The engine stops and the compressed air remaining in the compressor will be automatically discharged. Do not attempt to quickly discharge it through the air outlet valves or the start-run valve. we Note # Never discharge the compressed air through the start-run valve in cold weather; oil may sometimes be mixed wit the discharged air. (3) The residual air will be discharged in about 90 to 210 seconds. Restart the engine after confirming that the delivery pressure gauge reads zero, (4) Turn the battery switch to "OFF" position. 3-6 Emergency stop and monitor display ‘The monitor indicates the following: [- jine lube | Water | Charging | Discharge air | Failure of || Engine | oipresure | tecperanre | | (anperdure | fuel quantity] low speed Engine lube O11 pressure failure oO o | Water temperature 0 ° Tises abnormally Batte | charging failure ° Discharge fr temperature ° ° fises abnormally Failure of } Fuck quantity — | ° ° Engine Tow speed ° ° - 2 -1, Engine low speed warning lamp ‘This lamp lit on, if engine revolution failed abnormally. If this lamp lit on during operation, the emergency stop device immediately operates to shutdown the engine automatically. 2, Warning lamp unit This monitor indicates the following failures, if any one of them occurs. @ Oil pressure failure If the display lamp is not lit, engine lube oil pressure is normal(150kPa or more). Should it come on during operation, the emergency stop device will immediately stop the engine. This lamp is kept lit on until the starter switch is turned off. ® Water temperature rises abnormally ‘This lamp lit on when the water temperature rises abnormally(more than 100 € ). Should it come on during operation, the emergency stop device will immediately stop the engine. @ Battery charging failure If the machine is abnormaily operation, this lamp lit off. If the lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. @® Discharge air temperature rises abnormally ‘This lamp lit on when the discharge air temperature rises abnormally (more than 110%). If the lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. © Failure of Fuel quantity When fuel quantity failed, this lamp lit on, and it should be supplied at the tank. If the lamp lit on during operation, the emergency stop device immediately operates to shut down the engine automatically. = 19 -4.Protection device Protection devices and emergency stop devices are provided for protection of the machine against trouble during operation. When the running caution lamp lights, stop the engine immediately. Check and remove the cause of trouble, Table of protection device Indicate by warning lamp action stop the engine indicate function warning lamp Engine lube oil ‘When the oil pressure falls abnormally, pressure ° ° the device act. Set point : 150kPa |When the cooling water temperature rises Water temperature ° ° abnormally, the device acts ‘Set point : 100°C ‘When the battery charging is failure, the Battery charging ° ° device acts. Discharge air ‘When the Discharge air temperature rises temperature ° ° abnormally,the device acs. ‘Set point : 110°C ‘When the engine revolution failed Engine low speed ° ° abnormally, the device act. Failure of When fuel quantity failed ,the device act. fuel quantity ° ° Replacing or cleaning of filter is necessary Engine air filter ° ‘because of blinds of filter, when this lamp Tit on ‘Compressor Replacing or cleaning of filter is necessary air filter ° ‘because of blinds of filter, when this lamp lit on. /Compressor Replacing of filter is necessary because of ube ol filter ° blinds of filter, when this lamp lit on, = 30 -5.Lubrication oil,cooling water and fuel etc. 5-1 Engine oil Use specified engine oil, otherwise, it greatly affects the starting operation and life of the engine. (Q) Kind of oil Use oil, CD class or higher, classified by API service. (2) Oil viscosity Recommended oil viscosity is SAE 10W-30, all- season type. Use oil according to ambient temperature referring to the table below. Ambient temperature (‘C) -30 -20 -10 0 10 20 30 « + SAE2Z0++ 00% + +SAES0++ ++ ee SAESWH20 505 o> eee ees SAELOW-30 settee wee eee) SABISW-40 terres tee [Note]: Do not mix with different kind of oil, or else, it deteriorates the oil quality. (3) Quantity of replacement oi Damme [pssom [peesnss | pares | osson 15.5L 15.5L 24, 24L | 65L DIS-310HB,HS | DIS-SSOHBHS | DIS-S00US | DIS-765US 155L 24L 24L om Value in parentheses is filter capacity. -a-5-2 Cooling water (1) Cooling water to be used Soft water likes with less impurities such as tap water can be used as cooling water. (2) Cooling water used in cold season When cooling water is likely to be frozen in a cold season, mix it with Long Life Coolant (1). Mixing rate of LLC should be selected within the range of 30-50%. Standard mixing rate of LLC and operating ambient temperature are as shown below. 30%: ~10T 40%: -20°C 50%: —30°C In general, LLC needs to be replaced after 2 years of use. (@) Total quantity of cooling water DIS-275SB2,SS2 | DIS-390SB,S | DIS-685SB,Ss_ | _DIS-775SS DIS-980SS 14.5L 33L, 4m. an. 50L, DIS-310HB,HS | DIS-SSOHBHS | DIS-sooUS | DIS-765US 33L, aL am. SOL, Value in parentheses is reserve tank capacity. - 2 -5-3 Fuel (1) Fuel to be used #2 Diesel Fuel [Note] If other kinds of fuel is used or fuel being used contains water or dust, it deteriorates the engine performance or leads to a serious trouble. 5-4 Safety valve The pressure safety valve is factory adjusted and sealed prior to shipment of the compressor. Do not remove the seal or try to adjust the valve. Adjustment value of safety valve [DIS-2758B2,882 | DIS-390SB,SS_| DIS-685SB,SS_| _DIS-775SS DIS-9808S 0.834 MPa 0.834 MPa, 0.834 MPa 0.834 MPa, 0.961 MPa DIS-310HB,HS | DIS-SSOHBHS | DIS-soous | _DIS-765US 1.177 MPa 1.177 MPa 1.491 MPa 1.491 MPa 33 -5-5 Regulator ‘The compressor has been correctly adjusted prior to shipment from the factory, and rarely requires further adjustment, if ever. Should it require any adjustment, however, as a result of overhauling or other cause, follow the following procedures: (1) Prior to starting the engine, check whether or not the engine governor lever is set to the high-speed stopper. Otherwise, the engine will not turn at the maximum speed during full-load operation. (2) Start the engine only after confirming that the unloader valve is set to the "START" position. Should the engine stop running immediately after starting, restart it only after confirming that the delivery air pressure gauge reads zero. (3) Engine start automatically follows for a few minutes. When the engine is sufficiently ‘warmed, set the unloader valve to the Run position. Then the engine runs at a no-load condition at an idle speed. (4) Gradually close the air outlet valve from the Full open position, Adjust the screw on the pressure regulating valve so that the govemor lever shifts to the low-speed side as soon as the air pressure exceeds operating pressure. (5) Repeat opening and closing the service valve and confirm that the regulators work smoothly, - ae5-6 Compressor lube oil Use lube oil exclusively for this series of rotary compressors. (1) Recommended compressor lube oil and its standard replacement interval Compressor lube oil : Denyo genuine compressor oil Corena Oil RA32 (Shell) Replacement interval : Every 1000 hours for normal operation (2) Precautions on oil replacement Never mix lobe oils of different brands or fresh lube oil with in the tank. Such mixing occasionally produces insoluble glue, lacquer, or shellacs, which may cause the oil filter to become clogged and break down or cause abnormal wear of the rotor or bearings, resulting in serious damage. Periodically check the lube for degradation, discoloration, ‘excessive viscosity, and impurities. When the machine is operated under the following conditions, the lube oil changing intervals may have to be shortened to about 100 hours 1) Operation in poorly ventilated locations where the ambient temperature rises excessively. 2) Operation for long duration of time, especially in a tunnel or high humidity. 3) Operation in dusty or sandy locations Be sure to change the initial lube oil after 500 hours of operation. Your compressor is provided with Corena Oil RA 32 (Shell) at the factory prior to shipment. If you replace it with an lube oil of a different brand, be sure to fully extract the old oil before feeding the fresh one. (3) Quantity of replacement oil Iis-2758B2,SS2 | DIS-390SB,SS | DIS-6858B,SS "| DIS-7758S DIS-9808S, 35L, 75L, TL | BL 140L, DISSIOHBAS | DIS.ssoHR,AS | DIs-sooUS | DIS-76sUS 75k 75L, | 75k 75L Value in parentheses is filter capacity. -% -(4) Lube oil changing procedures )) 2) 3) 4) dD 6) Operate the compressor for a while to warm the oil so that it may be drained easily. Shut down the compressor and confirm that the air pressure has reached zero. ‘Then, open the drain valve, Disconnect the oil cooler pipe joints and drain the oil remaining in each pipe and in the oil cooler. {in the case of DIS-980SS and DIS-765US, open the drain valve of oil cooler, drain the oil remainin in the oil cooler ) Close the drain valve and securely tighten the pipe joints. (in the case of DIS-980SS and DIS-765US, close the drain valve of oil cooler:) Fill the oil chamber with fresh oil until the oil level reaches the upper limit. Close the filler port completely. Operate the compressor and thoroughly check each part for any cil leakage. Stop the engine. After confirming that the air pressure gauge indicates zero, check the oil level. Add oil necessary. (5) Recommended compressor lube oils Brand ‘Manufacturer Corena Oil RA32 Shell Neurex RT32 Esso Mobil Rarus 424 Mobil Faircall RA32 Japan energy Kyoseki RS Comp Kyodo Sekiya Turbinol 32 General Sekiyw Cosmo Screw Cosmo Sekiya (6) Cold weather operation ‘The pour point of the Corena Oil RA32 (Shell) which is provided to the Compressor al the factory, is -20 °C. Use lube oil with the pour of -20 °C or lower for ambient temperature below -5'C. Eee6.Handling of battery A\ cauTION BATTERY WW Battery generates flammable gases. Improper handling may lead to explosion or serious injury. * Battery should be charged in a well ventilated location. Otherwise, flammable gases are accumulated which may be ignited and exploded. * When connecting a booster cable, do not jumper the terminals (+ and —). Otherwise, the flammable gases generated from the battery may be ignited and exploded by sparks. * For maintenance of the machine, disconnect the cable on the ground side. Wl The battery acid is dilute sulfuric acid. Improper handling will cause unexpected burns. * When the battery acid gets on your clothes or skin, wash it out with a large volume of water immediately. If it gets in your eyes, wash with a large volume of water immediately and consult your doctor. — In the worst case, it will put out your eyes. For checking or handling of the battery, be sure to stop the engine. ato6-1 Caution on battery charge Charging of loaded battery * Disconnect the wiring cable from the battery terminals before charging. (Otherwise, the alternator may be damaged due to unusual voltage applied to the alternator) * When disconnecting the wiring cables from the battery terminals, remove the ground cable first. (If a tool touches the space between the "+" terminal and the machine, electric spark will occur which is very dangerous) When connecting the wiring cables to the battery terminals, connect the ground cable last. * While the battery is being charged, open all the liquid plugs to discharge the gas. Keep the battery away from fire to prevent unexpected explosion. Handle the battery carefully to prevent electric sparks. * If the battery is overheated (liquid temperature above 45 ‘C ), stop charging for a while. * At the completion of charging, stop charging immediately. (The relation between battery charge condition and specific gravity See p.42) If the battery is still charged, the following trouble will occur. 1) Battery overheat 2) Decrease in battery acid 3) Deterioration of battery performance * Do not connect the battery polarity in reverse (connection of "+" and "—" or "-" and "+") to prevent damage to the alternator or the like. ae6-2 Connection of booster cable, and installation ‘When the engine is started using booster cables, connect the cables as follows. (1) Connection of booster cable @® Connect the clip of the booster cable "A" to the terminal "+" of the machine in trouble. ® Connect the other clip of the booster cable "A" to the terminal "+" of normal machine. ® Connect the clip of the booster cable "B" to the terminal "B" to the terminal "~" of normal machine, ® Connect the other clip of the booster cable "B" to the engine block of the machine in trouble. (2) Removal of booster cable @ Remove the clip of the booster cable "B" connected to the engine block of the machine in trouble. ® Remove the clip of the booster cable "B" connected to the terminal "~" of normal machine. ® Remove the clip of the booster cable "A" connected to the terminal "+" of normal machine, @® Remove the clip of the booster cable "A" connected to the terminal "+" of the machine in trouble, (3) Caution on handling of booster cable tater ofthe cin tle @ eng Unk he mace a Wet ater ofthe mle le @ o ogee Dek of ene a wale ® Use booster cables and clips of the size that matches the size of battery. @® The battery used for normal machine should be the same in capacity as the battery of the machine in trouble. @® After connection, check that clips are firmly connected. @® When connecting booster cables, make sure that the terminal "+" does not touch the terminal "—", @® The engine block should be connected at a place more than 30cm away from the battery. = 39 -Periodical checking and maintenance 7-1 Maintenance schedule 100 hours: Checking/every 100 hours * Lubricating speed regulator * Cleaning of air cleaner element 250 hours: Checkinglevery 250 hours * Replacement of engine oil (Only 275, 390, 310H) * Checking on battery specific gravity * Replacement of engine oil filter cartridge (Only 275, 390, 310H) 500 hours: Checking/every 500 hours * Checking and Cleaning Oil return filter orifice. * Replacement of air cleaner element * Checking operation of the safety valve * Replacement of engine oil (685, 775, 980, 550H, 500U) Replacement of engine oil filter element (685, 775, 980, 550H, 500U) * Replacement of engine fuel filter element (cartridge) (275, 390, 685, 775, 980, 310H, 550H, 500U, 765U) 1000 hours: Checking/every 1000 hours * Replacement of compressor oil * Replacement of compressor oil filter cartridge * Replacement of diaphragm in speed regulator * Checking on diaphragm in capacity regulator © Replacement of diaphragm in pressure regulator valve ® Replacement of O-ring in minimum pressure valve * Replacement of O-ring in compressor oil filler port * Replacement of O-ring on connecter * Cleaning of radiator and oil cooler Cleaning of inside fuel tank Replacement of engine fuel filter element (only 9808S) Checking on rubber suspension Checking on lining 2000 hours: Checking/every 2000 hours * Checking of oil separator element * Checking on nylon and rubber hose On the engine system, main checking items only are shown in this manual For details, refer to the instruction manwal for the engine furnished separately. Pe7-2 Checking/every 100 hours (1) Lubricating speed regulator (2) Cleaning of air cleaner element This element should be cleaned, regardless of operating time, when the air filter warning Se lamp lit on. \ ~ Dry dust clings on element - Remove the air cleaner element and clean the element with dry and clean compressed air. * While it is being cleaned, check the element /y el for any damage. Replace if necessary. * Before installing the air cleaner, wipe off dirt on the element cover. * When insert the element, insert the element bee completely pressing equal edge of clement. (p a) O +x +o -4l-7-3 Checking/every 250 hours (1) Replacement of engine oil Replace the engine oil every 250 hours. Only DIS-275SB2-SS2, 390SB-SS, 310HB-HS @ Remove the engine oil drain plug or open the engine oil drain valve, and discharge oil completely. It can be discharged easily when the engine is warm. @® After engine oil is discharged, tighten the plug or closed drain valve firmly. @® Charge new engine oil from the oil filler until it reaches the notched line of the "H" on the dipstick, For oil quantity, (See p.31) @® After engine oil is supplied, run the engine for a few minutes. After 10 to 20 minutes, check that oil is supplied to the level between H and L . (2) Checking on battery specific gravity. If battery is likely to be discharged due to failure in startup of the engine, measure the specific gravity of battery acid, The relation between battery charge condition (charging rate) and specific gravity is as shown below. Liquid Charging ‘temp. | 20 0 -10 rate (%) (ec) 100 128 | 129 | 130 90 126 | 127 | 1.28 80 124 | 125 | 1.26 5 123 | 14 | 125 -4-(3) Replacement of engine oil filter cartridge Replace the engine oil cartridge every 250 hours. Only DIS-275SB2-SS2, 390SB-SS, 310HB-HS Hi Cartridge type (Cartridge type is unit of filter case and element.) © Remove the cartridge type element (cartridge) using filter wrench. LJ @® Clean the filter base. Coat the packing of new cartridge with engine oil thin, Then, mount the cartridge. + When mounting, tighten the cartridge from 3/4 turn by using filter wrench after the packing is fitted SS to the seal of the filter base @® After the cartridge is replaced, run the engine for a while. After 10 to 20 minutes, check to see that oil is supplied to the level between H and L, Parts number of oil filter cartridge DIS-275SB2,SS2 | 06020 41191 (HINO 15607-1330 ) DIS-390SB,SS_| 06020 41191 (HINO 15607-1330) DIS-310HBHS | 0602041191 (HINO 15607-1330) 4g7-4 Checking/every 500 hours (1) Oil return filter orifice Remove the filter and orifice from the oil chamber cover. Check and clean it. Parts number of filter | 61432 16004 Parts number of orifice DIS-275SB2,SS2 61632 17004 | DIS-390SB,SS 61632 17004 DIS-685SB,SS (61632 17004 DIS-775SS 61632 17004 DIS-980SS 61832 17104 DIS-310HB,HS 64332 17004 DIS-550HB,HS 64332 17004 DIS-500US 64332 17004 DIS-76SUS | 64332 17004 (2) Replacement of air cleaner element ‘The element should be replaced referring to "Cleaning of air cleaner element"(See p.41) . Parts number of air cleaner element Engine | Compressor DIS-275SB2,SS2 06020 46365 06020 40192 DIS-390SB,SS 06020 40192 06020 40179 DIS-685SB,SS 06020 40179 06020 40178 | DIS-775SS 06020 46612 06020 46363 DIS-980SS 06020 46361 06020 46363 DIS-310HB,HS 06020 40192 06020 40179 DIS-550HB,HS 06020 40179 06020 40178 DIS-SOOUS 06020 40179 06020 40178 DIS-765US £69242 00344 (Inner) | £69242 00344 (Inner) 06020 46363 (Outer) | 06020 46363 (Outer) = at -(3) Checking operation of the safety valve Confirm daily that the safety valve operates correctly. If the safety valve releases air by pulling the lever in a no-load condition, it is normal. (4) Replacement of engine oil Replacement is refer to 1'7-3.(1) Replacement of engine oil See p.42 J Expect DIS-275SB2-SS2, 390SB-SS, 310HB-HS (5) Replacement of engine oil filter element In the case of DIS-685SB°SS, 7758S, 550HB-HS, 500US Parts number of oil filter cartridge DIS-685SB,SS (06020 41240 (HINO 15607-1731) DIS-7758S (06020 41240 (HINO 15607-1731) DIS-550HB,HS (06020 41240 (HINO 15607-1731) DIS-500US. (06020 41240 (HINO 15607-1731) = 45 -In the case of DIS-9808S, 765US @® Loosen the drain plug in the lower part of filter case and discharge the oil completely. @® Loosen the center bolt and remove the filter case, element and spring or the like. @® Wash each parts except the element by washing oil. ® Mount the element for replacement and (O-ring in reverse order. Tighten the center bolt in regulation torque certainly. @© After the element is replaced, run the engine for a while. After 10 to 20 minutes, check to see that oil supplied to the level between H and L (Gee p.21). Parts number of oil filter cartridge DIS-9808S 06020 41244 (HINO 15607-1580) 06020 41245 (HINO 15607-1561) DIS-765US 06020 41244 (HINO 15607-1580) 06020 41245 (HINO 15607-1561) = 46 = caster tenant(6) Replacement of fuel filter element (cartridge) In the case of DIS-275SB2-SS2, 390SB-SS, 310HB-HS I Cartridge type (Cartridge type is unit of filter case and element.) Fi ® Remove the cartridge type element (cartridge) using filter wrench. @® Clean the filter base. Coat the packing of new cartridge ‘with engine oil thin, Then, mount the cartridge. + When mounting, tighten the cartridge from 3/4 turn by using filter wrench after the packing is fited = to the seal of the filter base. @® After the cartridge is replaced, discharge air in the fuel piping. — For details, refer to the instruction manual for the engine. Parts number of fuel filter cartridge DIS-275SB2,82 | 06020 42167 (HINO 23401-1340 ) DIS-390SB,S8_| 06020 42164 _( HINO 23300-2010 ) DIS-310HB,HS | 06020 42164 (HINO 23300-2010 ) In the case of DIS-6858S-SB, 7758S, 550HS, 500US, 765US @ Loosen the drain plug "B",and loosen the plug "A" . And then, discharge the fuel . ® Loosen the center bolt "C" and remove the filter case, element and spring or the like, @® Mount the new element for replacement and O-ring in reverse order. Tighten the center bolt in regulation torque certainly. @ After the element is replaced, discharge air in the fuel piping. = For details, refer to the instruction manual for the engine. Parts number of oil filter cartridge DIS-685SB,SS_| 06020 42163 (HINO 23401-1290) _~2pes. DIS-7758S 06020 42163 (HINO 23401-1290) ~2pcs. DIS-5S0HB,HS | 06020 42163 (HINO 23401-1290) _~2pcs. | DIS-S0OUS —_| 06020 42163 (HINO 23401-1290) _~2pcs. DIS-765US __ | 06020 42168 (HINO 23401-1390) _~Ipc. -at-7-5 Checking/every 1000 hours (A) Replacing compressor oil Replacing procedures Refer to '5-6.(4) Lube oil changing procedures (See p.36).J (2) Replacing compressor oil filter Remove the cartridge type element (cartridge) using filter wrench. ® Clean the filter base. Coat the packing of new cartridge with engine oil thin. Then, mount the cartridge. + When mounting, tighten the cattridge from 2/3 turn by using filter wrench after the packing is fitted to the seal of the filter base. @ After the cartridge is replaced, run the engine for a while. ‘Then, check to see that oil is supplied to the level between Hand L, after confirming that the delivery air pressure gauge Ss ey reads zero. Parts number of oil filter DIS-275SB2,SS2 139240 00044 DIS-390SB,SS £49240 00084 Ss DIS-685SB,SS (06033 10171 DIS-7758S (06033 10171 DIS-9808S (06033 10171 DIS-310HB,HS £49240 00084 DIS-SSOHB,HS (06033 10171 DIS-S0OUS 06033 10171 DIS-765US (06033 10171 (3) Checking Speed regulator diaphragm Install the diaphragm by placing the cloth OQo surface against the cover. Parts number of diaphragm (06034 00004 -8-(4) Checking on diaphragm in capacity regulator Check the diaphragm in capacity regulator, and replace it ‘with a new one as required. Parts number of diaphragm [ Dis-275sB2,S82 06030 44208 | DIS-390SB,SS 06030 44208 | DIS-685SB,SS 06030 44208 DIS-7758S (06030 47212 DIS-9808S (06030 47212 DIS-310HB,HS (06030 44208, DIS-S50HB,HS (06030 44208 DIS-500US (06030 44208 DIS-765US (06030 47212 (5) Replacement of diaphragm in pressure regulator valve Replace a diaphragm assembly. Parts number of diaphragm DIS-275SB2,882 | (06034 00020 DIS-390SB,SS (06034 00020 DIS-685SB,SS (06034 00020 lu DIS-7758S (06034 00020 : DIS-9808S 06034 00020 DIS-310HB,HS 06034 00020 DIS-5S0HB,HS 06034 00020 | Dis-soous (06034 00020 [ DIs-76sUs 06034 00020 oe(6) Replacement of O-ring in minimum pressure valve Remove the minimum pressure valve cover , replace the O-ring. Parts number of O-ring DIS-275SB2,8S2 01500 00048, Parts number of O-ring DIS-390SB,SS (06030 45304 a DIS-685SB,SS (06030 46107 — DIS-775SS 06030 46107 I i DIS-9808S (06030 46107 DIS-310HB,HS 06030 45304 DIS-5S0HBHS | (06030 46107 DIS-SOOUS (06030 46107 DIS-765US (06030 46107 (7) Replacement of O-ring in compressor filler port Remove the compressor oil filler port from compressor ora oil chamber, replace the O-ring, Parts number of O-ring (01500 00048 = 50 -(8) Replacement of O-ring on connecter (9) Cleaning of radiator and oil cooler When the fin or tube is blinded, it should be cleaned with steam or high pressure water. [Note] ‘When a high pressure washer is used, spray water from a place about 1.5m away to prevent damage to the fin or tube. (10) Cleaning of inside fuel tank Drain the fuel in the fuel tank completely, and ‘wash out deposits and water collected inside the tank, (11) Checking of rubber suspension Check on the rubber suspension, whether it is damaged or deformed by the oil. Contact distributor or our office to replace the rubber suspension, if necessary.(12) Checking on lining (13) Replacement of fuel filter element Only DIS-9808S @ Loosen the drain plug "B’,and loosen the plug " And then, discharge the fuel. ® Loosen the center bolt "C" and remove the filter case, element and spring or the like. ® Mount the new element for replacement and O-ring in reverse order. Tighten the center bolt in regulation torque certainly. @ After the clement is replaced, discharge air in the fuel piping. = For details, cefer to the instruction manual for the engine. Parts number of oil filter cartridge (06020 42163 (HINO 23401-1290) | 06020 42168 (HINO 23401-1390) -52- ~2pes.7-6 Checking/every 2000 hours (1) Checking of oil separate element @) When the oil in the discharge air seems to have increased, check and replace oil separator element . As with an air cleaner element, the service life of an oil separator clement differs substantially depending upon operating conditions. It is high time to replace the oil separator element, when oil contained in the discharge air comes out of the valve(s). Parts number of Oil separ wate element [pis-2758B2,882 39241 00064 DIS-390SB,SS (06032 10027 DIS-6855B,SS 96032 10025 DIS-77588 (06032 10025 DIS-980SS (06032 10026 DIS-310HB,HS (06032 10027 DIS-550HB,HS (06032 10025 DIS-500US (06032 10025 DIS-765US (06032 10025 Parts number of gasket DIS-275SB2,SS2 £39040 01704 ~-2pes, | DIS-390SB,SS £39040 01604 ~-2pcs. DIS-685SB,SS £39040 01704 ~-2pcs. DIS-7758S £39040 01604 ~-2pcs. DIS-980SS £39040 01704 DIS-310HB,HS £39040 01704 DIS-550HB,HS £39040 01704 ~~ DIS-500US 39040 01704 DIS-765US 39040 01704 Checking on nylon and rubber hose Check on the nylon and rubber hose, whether they are hardened or deteriorate. Contact distributor or our office to replace the nylon hose and rubber hose, if necessary. 83 -7-7 Table of periodical maintenance and checking ©:Check or Clean_©:Replacement List of maintenance and inspection daily [every 1008 every Jevery 25h | 500h every 1000h, every 2000 Engine (Check on engine lube oil [Check on compressor lube oil [Drain condensed water from oll chamber drain (Checking on radiator coolant [Checking on fan belt (Checking on fuel (Checking on battery Quid [Checking for loose parts [Remove of foreign objects in machine SJofo}ojolofojo}o| [Lubricating speed regulator lo] Cleaning air cleaner element (Checking on battery specific gravity Replacement of engine ol (Oy [Replacement of engine oil filter cartridge O}O}o} (Oy [Replacement of fuel fiter element Ores [Replacement of sir cleaner element (Checking on diaphragm in speed regulator (Cleaning inside fuel tank [Checking on lining [Checking on rubber suspension O|olo}9| exon EraemsmMszomr, (Cleaning air cleaner element (Checking & Cleaning Oil return filter orifice (Checking operation of the safety valve (Checking and cleaning oil return fiter orifice [Replacement air cleaner element Ofofo}o| (Checking on diaphragm in capacity rewulator [Replacement of diaphragm in pressure regulator valve Replacement of compressor oil Replacement of compressor oil filter cartridge Replacement of Oring in minimum pressure valve [Replacement of O-ring in compressor oi filler port Replacement of Oring on connecter ojo|ofojo|o}e! 3_Checking on oil separator element ofa} 3_Checking on nylon and rubber hose 2X: Contact distributor or our office. (©): In the case of DIS-685SB°SS, 7758S, 980SS, SS0HB-HS, SOUS, 765US = 54 -8.Trouble shooting and Countermeasures Should the machine be out of order during operation, check for causes and take appropriate measures: 8-1.ENGINE DOES NOT START Starter does not rotate or rotates only slowly. Battery has been discharged Check electrolyte level and specific gravity. Battery terminals are disconnected, loosened, and/or degraded + Clean and securely connec. Grounding is not sufficiently conducted ~ Securely connect the grounding wire ‘Starter switch, magnet switch, safety relay, and/or starter are defective Call service shop. Engine controller is defective “Call serviee shop. Starter rotates but the engine dose not start. No fuel ~ Replenish uel filter is clogged = Replace. Fuel used is deteriorated or improper ~ Use light oi. reheating system is defective Call service shop, ‘Stop solenoid does not work “Check fase. If Blown out, check for cause and replace it Check and replace solencis. Call service shop, Cold weather Fel is frozen “Use fuel fr col weather(such as ASTM No) ‘Water accurplated in fuel system ‘Warm the sytem to folly extract water is frozen contained in the fuel tank, filter, and pipes. Engine oil i excessively viscous ~ Replace with oll of appropriate viscosity. ‘Conmpresor oil is excessively viscous ‘Use oil with pour point lower than 30°C Battery i not lly charged ~ Charge a8-2 ENGINE STOPS DURING OPERATION (1) IF THERE IS SOMETHING WRONG WITH THE COMPRESSOR: Pressure setting is too high. Pressure regulator is not corectly adjusted Pressure regulator is defective ‘Ai leaks from pressure regulator pipes Pressure regulator is frozen Pressure regulator pipes are frozen Lower pressure setting of the regulator, Call service shop. ~~ Check and repair leaking portions. “Check and repair frozen parts. ‘Check and repair frozen par. Others. Problems in fuel system Compressor oil is excessively Replace with less viscous cil (2) IF THERE IS SOMETHING WRONG WITH THE ENGINE: Fuel tank is empty ~ Replenish ‘Air isnot fully extracted ~ Fully extract air from fuel Fuel filter is clogged ~ Replace. Fuel is deteriorated or different = Use light oil Fuel injection system is defective Engine oil level is higher than the upper limit Call service shop. ‘Reduce it to the upper limit Engine oil is excessively viscous Engine oil pressure is reduced ‘Overheating. Replace with less viscous oil. Reduce it co the upper limit. ‘Compressor sucks exhaust gas from ‘other compressors operated in parallel Others. ‘Warming is insufficient viscous Start the engine with the unloader valve set to the "START" position to fully warm the engine Governor rod is not correctly adjusted ~ Readjust. - 56(3) IF THERE IS SOMETHING WRONG WITH ELECTRIC INSTRUMENTATION: Emergency stop circuit is abnormal Discharge air temperature is abnormally high Switch or sensor is defective Cheek and repair Wiring to water temperature switeh, ~ Call service shop. hydraulic pressure switch, discharge air temperature sensor is disconnected. - Check and repair Call service shop. Engine control unit is defect 8-3 NO AIR IS DELIVERED Service valve is closed Open. Unloader valve is set to “START position ~ Reset to "RUN" position. ‘Minimum pressure valve is abnormal (Overhaul and clean Pressure regulator valve is abnormal Cheek and replace diaphragm. Nn nnn 8-4 UNLOADER ROTATION IS EXCESSIVE Governor rod is not correctly adjusted ~ Readjust Air leaks from contol pressure pipe ~ Check and repai. ‘Ar Jeaks from capacity regulator diaphragm “= Check and repair ‘Speed regulator diaphragm is defective Replace. 8-5 SAFETY VALVE OPERATES Pressure regulator valve is not correctly adjust > Readjust ‘Pressure regulator valve interior or pipe is frozen + Check and repair frozen parts ‘Air leaks from control pressure pipe “> Check and repair. Pressure regulator valve is abnormal ‘Check and repair. Safety valve is set to low valve Readjust ‘Air leaks from capacity regulator diaphragm = Check and repair. ‘Pressure regulator diaphragm is defective = Replace.8-6 ENGINE SPEEDS DOWN BEFORE AIR PRESSURE REACHES OPERATING PRESSURE. Unloader valve isnot set to "RUN" positon Reset. Pressure regulator valve is not corecly adjusted ~ Readjst. Fuel filter is clogged “Clean filter element, Fuel is deteriorated or different Use light oi. Engine air cleaner is clogged Engine fuel system is abnormal Engine is defective ~ Clean ait cleaner element. “Call service shop. Call service shop. 8~7 DELIVERY AIR PRESSURE IS EXCESSIVELY HIGH Pressure regulator valve is not correctly adjusted 8-8 DELIVERY AIR VOLUME Unloader valve is not set to "RUN" position Engine does not reach rated speed due to poor adjusted governor rod Engine does not reach selected speed ‘Compressor air cleaner is clogged ‘More air is consumed by load Readjust bn IS SMALL (pressure is insufficient) FuESEUEeUn IIIS ISIUIENIUININSED DSU SE SE NEN DE OEECE TUE Cnc erc noone eeceoceoes “ Readjus. = See 8-6 ~ Clean or replace, ‘Recheck air consumption by the load Air leaks in a load-side pipe Check the pipe. Pressure regulator valve is not corectly adjusted ~ Readjust. ‘Compressor oil filter is clogged ~ Replace filter. ‘Capacity regulator does not work correctly ‘Check and repair the regulator. = 58 -8-9 OIL IS MIXED IN DELIVERED AIR (oil not fully separated) ‘The machine is not installed oon level ground Delivered air pressure is low ‘Compressor oil level is higher than the upper limit Drainage is larger than usual Filter orifice of the oil return pipe are clogged Engine was started with the unloader valve set to "RUN" position ‘Service valve(s) or start run valve has been quickly opened after the engine stopped [fe of the oil separator has come to an end + Install it om level ground (allowable inclination is 5 forward/backward and JefUright directions). Set pressure retaining valve t0 0.49 to 0.54 MPa. “= Confirm than the level is within the specified range when the engine is stopped. “= Open the drain valve to extract drainage in the oil chamber. Check and clean the orifice. ‘Start the engine with the unloader valve set fo "START" position and operate it in a no-load condition. ‘Do not attempt to quickly discharge it through the sir outlet valve(s) after the engine stopped. ~ Replace. 8-10 OVERHEATING Re-confirm surrounding conditions ‘Cooling water is emptied or short Fan belt is loosened Radiator and oil cooler cores are clogged Delivery pressure is high Engine thermostat is abnormal = Reduce suction of exhaust ges. “ Check and replenish cooling water Cheek and replace radiator cap. (Check and retghten. Clean. ‘Check and repair pressure regulator valve ~ Check and readjust - 59 -8-11 COMPRESSOR AIR TEMPERATURE IS HIGH Delivery pressure is high + Readjust the set pressure. ‘Re-confiem surrounding conditions ~ Reduce suction of exhaust gos. Cheek and clean. (Cheek and retighten Compressor oil filter is clogged Fan belt is loosened Oil cooler cores are clogged Clean, Compressor oil is short = Replenish, Oil cooler core interior is clogged Clean. By-pass valve does not work correctly “ Check and replace. = 60 -9.Long— term storage When the machine is to be stored for a long period of time, choose a cool place free from moisture and dust, and observe the following points. (2) Remove dirt clung the machine and clean it thoroughly. If painting is peeled off, it should be repaired. (2) Remove the battery from the machine. The battery should be charged completely before it is stored. — Battery is discharged of itself. Recharge it once a month. (8) If any defects are found, check and repair the machine so that it can be used for future operation. (4) For details of handling the engine, refer to the instruction manual for the engine provided separately. Z\ CAUTION Stacking I Improper stacking of machines may cause falling or dropping accidents. When stacking other machines on this machine, be sure to observe the following points. * Check that the bonnet of the machine is free from damage and that the fixing bolts are not loosened and missing. * Put the machine horizontally on a solid foundation which withstands the weight of stacked machines. * Machines can be stacked up to 2 stages. The weight and size of stacked machines should be less than those of this machine. * Using square timbers as shown below, put each machine making sure that the weight is even. 1 Do not operate the machines in the state of stacking to prevent falling or dropping accidents. -61-10.Service data 10-1 Specifications Model DIS2TSSE? | DIS 27SSS2 | DIS-2905B | DIS.29085 | DISSIOHB | DIS-310HS Compressor Type Single sage, ol-cooled, srew type rotary compressor Actual free air delivery 7.8 (275) 11.0 (390) 8.8 (310) m ‘/min(cfm) Operating pressure _ MPaipsi) 0.69 (100) 0:69 1100) 105 0150) Lube cilesacity La) | 3508) | 3503) | 75098] 75099 [75098 | 75098) il Chamber capaciyy m (gal) 0.085 @2.5) 0.19 02) 0:19 602) Engine Maker and model HINO WOAD-H HINO WOIC-TR nae Eeguseuarsaale tse | evclewatee cone donimbeteareed ype No.of ender 4 4 Bore * stoke an Toa 8 io 13 Displacement L 400 3839 Rated output EWES) @5 (85) 45 (115) Specdredtokad, | __2850/ 1300 26007 1250 260071250 Labonte oi apedty Lea) | 55a | ssa | say | ss) | assay | 1550.0 Cooling water capacity Ligal) | 1458) | 145@8) | 340872) | 33872) | 358.79 [3x87 Starting motor 24V- 45kW TAY - 45KW Charging generator 2aV- 20, 2AV = 208 Fuel Diese fuel (ASTM No? or equivalest Tbrcating ot [ADI service class (CD class or higher) Fuel tank L(gal) | 130(34.3) 110(29.1) 170(44.9) | 180(47.6) | 170(44.9) | 180(47.6) Battery [__95E4iR x2 SSEAIR x 2 OSEAIR x 2 Set Length overall mmm | 2535, 3545 36g | 3130 | 2680 3130 ‘Width overall mmm | 1200 1425 1300 | 1510 | 1300 1510 Height mm | 1280 1670 was | ios [1275 1805 Dry weight gts) [1420131 | 1510;9329) _| 172009792) | 198014366) | 1750858) _| 20204458) Total weight atlos) | 159003506) | 1660(3660) | 198014365) | 20404939) | 2o10eas1) | 2980(5027) ‘The above specifications and set dimensions are subject to change. Dry weight : This weight does not contain the cooling water, engine oil and fuel. ‘Total weight : This weight contains the cooling water, engine oil and fuel. -6-DIS-9805S, Model DIS-6858B | DIS-6858S | DIS-7755S Compressor Type Single stage, ol-cooled, screw type rotary compressor ‘Actual fee air delivery ] z 19.4 (685) | 219.075) | 27.8@8) | 27.6(973) sm */min(cti) Operating pressure MPa(psi) 0.69 (100) 0.69 (100)_| 0.690100) | 0.830121) Lube oil capacity __Ligal) | 75098) | 7509.8) | 8522.8) 1407.0) Oil Chamber capacity m * (gal) 0.26(68.7) | 0.29076.) (0.40(106) Engine Maker and model HINO _HO7C-TE HINO KISD-TA Type “ayele, water-cooled diesel engine, direct injectionturbocharged type No. of eylinders 6 6 Bore » stroke mun 10 x18 137 « 150, Displacement L 6728 13267 Rated output WES) 140 (190) 195 (265) Speedated/no-load 2500 / 1200 1900 / 1150 ‘nin ~* (opm) Labricate oil capacity Leal) | 24634 | 24634 | 24634) 650172) Cooling water capacity Liwal) | 47124) | 47024) [| 47024) 50(13.2) Starting motor 24V - 55IW DAV - 7eW (Charging generator 24 - 208 2aV = 200 Fuel Diesel fuel (ASTM No.2 or equivalent) Lubricating oil "APL service class (CD elass or higher) Fuel tank Legal) | 300079.) [ 2807740) | 3502.5) -400(106) Battery 145F51 x2 14SESIX2 145651 x 2 Set Length overall nm | 3400 3790 4030 4570 ‘Width overall mom | _ 1540 1600 1600 1900 Height mm | 1600 2085 2085 2290 Dry weight eg(bs) |_2770(6108) | 31807012) | 342007541) 4900(10800) Total weight keds) | 314006924) | 35300784) | 3840(8467) 5520(12170) ‘The above specifications and set dimensions are subject to change. Dry weight : This weight does not contain the cooling water, engine oil and fuel Total weight : This weight contains the cooling water, engine oil and fuel. eoModel DIS-550HB | DIS-SS0HS] DIS-500US | _DIS-765US Compressor Type Single stage, el-cooled, screw type rotary compressor ‘Actual fee air delivery 15.6(550) 1420600) | 21.7(765) 1m *hmin(efin) Operating pressure MPacpsi) 1.03(150) 127as6 | _1.27086) Lube oil capacity L(gal) | 7509.8) | 7509.8) | 7509.8) 7509.8) Oil Chamber capacity m* (eal) | 0.26(687) | 0260687 | 026687) | 0.26(68.7) Engine ‘Maker and model HINO HO7C-TE HINO KIBC-TI Type ‘ayleater gonad ise engi, det injection, No. of eylinders 6 6 Bore x stroke mm | 110 «118 135» 150 Displacement if 678 12.882 Rated output kWips) | 140 (190) 2206300) Speedrated/no-load 2500/1200 2000/1150 ‘in {gpm} Labricate oil capacity L(eal) | 240634) | 28634 | 24634 | 6707.7) Cooling water capacity L¢gal) | 47024) | 4724 | 47024) | 50032) Starting motor 24V - 5.SkW 2aV - TW Charging; generaior 24V - 208 24V = 208 Fuel Diesel fuel (ASTM No. or equivalent) Lubricating ofl "API service class (CD class or higher) Fuel tank Ligat) | 3000793) | 280740) | 2800740) | 400(106) Batiery 14SFSL x2, 145G51-2 Set Length overall mam | 3400 3790_| _3790 4300 Width overall mm | _ 1540 1600 | 1600 1855 Height mm, 1600 2035 | 2035 2125 Dry weight Kedibs) | 277066107) | 3180(7012) | 3200(7056) | _ 4460(9834) Total weight xkedbs) | 3140(6928) | 3530(7784) | 3550(7828) | 4980(10980) ‘The above specifications and set dimensions are subject to change. Dry weight : This weight does not contain the cooling water, engine oil and fuel. Total weight : This weight contains the cooling water, engine oil and fuel. ~ 64 -10-2 Outline drawing + DIS—275SB2 1000 | : a q — z If | a 3) erry + DIS—275SS2 - 65 -+ DIS-390SB , 310HB 1255 ball . = 2680 1300 + DIS—390SS , 310HS 10 = 66 -+ DIS—685SB , 550HB I I | “a _| — | ues] |, tees sae + DIS-7758S+ DIS-980SS ae dnvreestass =) geo i ul u + + DIS-765US agas ies tana [mae ara] ~~ |I_ 34 y = f | Gs ee {ed s| 2 = 68 -10-3 Combined Piping Diagram itt10-4 Engine wiring diagram + DIS-275SB2,275SS2,390SB,390SS,310HB,310HS -1-+ DIS—685SB,685SS,775SS,550HB,550HS,500US+ DIS-980SS,765US -n-