AIRMAN Pe INSTRUCTION MANUAL ENGINE COMPRESSOR PDSF1000DP-4€5 PDSFIOOODPC-4C5 Please be sure to read this manual before using this machine. HOKUETSU INDUSTRIES CO., LTD.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 cure 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 as 4.1 Internal Components and Part Names-————- 2. Installation 2.1 Transportation ——- 2.2 Handling the Drawbar — 2.3. Towing the Machine —————. 2.4 Installation conditions — 3. Operation —mmm-——aevenenennenenennenennnnnnnen 3.4. Instrument Panel 3.2. Lubricating oil « Coolant » Ful ~ 3.3. Check before starting unit 3.4 Operation —— 3.8 Operation of after cooler type 4. Failure cause and measures --—-- 4.1 Indicator lamp and Warning / Emergency display 4.2 Troubleshooting ———-—————-—- 5. Periodic Inspection/Maintenance —- 5.1. Important tems as Periodic Inspection and Maintenance or after Maintenance —— 5.2. Inspection on Separator Receiver Tank —~ 6.3. Periodic Inspection List 5.4 Periodic Replacement of Parts 5.5 Maintenance Items -- 6. Storage of the Machine and Disposal of Product -—--- 6.1 Preparation for Long-term Stoppage ---—- 6.2 Disposal of Product, 7. Specifications ——- 7.1 Specifications 7.2 Outline drawing 7.3 Wiring Diagram — 7.4 Piping DiagramSafety ‘This section explaine 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 A\ marked, according to the degree of hazards. ‘When one of these messages is found, please take preventive measures for safety to carry out “SAFETY OPERATION AND PROPER MAINTENANCE OF THE MACHINE”. 2 | DANGER indicates an imminently hazardous situation which, if not avoided by A DANG any user, will result in death or serious injury. This signal word is to be limited to the most extreme situations. WARNING indicates a potentially hazardous situation which, if not avoided, could Ax WARNING result in death or serious injury to a user. CAUTION indicates a potentially hazardous situation which, if not avoided, may AX CAUTION] | resuttin minor or moderate injury t may also be used to alert against unsafe practices, IMPORTANT indicates Important caution messages for the performance or IMPORTANT] | curabilty of the machine, which has no concem 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. ‘@ Please tell us a MODEL /SER.No. on the plate of the machine when you inquiry. Aplate stamped with the model and serial number is attached to side of the machine. PORTABLE COMPRESSOR woDEL SER. NO onWn, opeRaTi4g raeseune NET DRY MASS ka ‘OPERATING MASS ko WoKUETsU iNDUSTRIES co. LTD, MADEINIAPAN 37103 108110, 3 Each illustrated figure (Fig.) has a number (for instance, A180375) at the right bottom, ‘This number is not a part number, but itis used only for our reference number. ‘8130875 $1Safety [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 [4 WARNING) [A CAUTION] [4 WARNING] [4 CAUTION! ef = ‘say fuol other thin diese! fue. ah \Z arr ie Sv 2 S ENTANG.SVENT PRE ACN FEES on} [ERE coeur fearsome | [omcaaty oc, cup mewn| |g er cetera Wl rier rca ial antec tel Forte | eet Beers. | ene soon sso] seein sxnecxs 6 = 8 9 10 [A CAUTION (A WARNING] |ADANGER | | 4 WARNING 6 7 pa of A\| 3 ae we Sbatrie SeNOSes anu naa eases ST | eGR | |pResouRe Det on steer |p eereerertmee || eerie ie Pasar | |eperetigemetin,| |seeapcri | |Seaiecrigmest fRieterwasrmae| |ecicctee = seen eon seus sour) enn ura ll 12 13 14 A WARNING ESS rsnmeereenas AN jw) | BEGAREFULNOT So ‘ose cAUGHTIN é O Lock AWHEEL © Before lifting the machine up, make sure to check the lifting bail “I” for any crack or loosened bolts. ® Connect the hook “2” of the crano 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. © Use auxiliary ropes “3” to prevent the machine from swinging and/or twisting, giving signe and signals each other @ Select a truck or a crane with a capacity sufficient J | for the size and weight of the machine by referring to 1 3. miem i} the values shown in Chapter 7 “Specifications” of the manual. © Any crane operations must be performed by a qualified crane operator. ‘a160001-1 2.1.2 Mounting the machine on the truck bed Se © Be cure to fasten the machine with ropes “1” as shown in the figure left, and securoly 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. Transportation © Never get under the machine which is lifted up, because itis 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, g z s < 22.Installation 2.2 Handling the Drawbar 2.2.1 How to secure the drawbar © Place the drawbar “I” to the front of the machine so that the wheel tires can be aligned. © With the stopper “4” being at the lock position, raise the drawbar “1” up to the position at which the hook “3” can be engaged with the holder “2”. (See Fig. 1) If the stopper stays at the holder and co the drawbar “1” cannot be firmly fixed. (See Fig.2) @ Make sure that the hook is securely engaged with the holder, © Make sure that the stopper “4” stays at the lock position. (See Fig.1) Fiat 1 2 / ‘Lock position © —— 3 Hooo46s ys70088 Precautions on handling drawbar (© When the drawbar “1” is raised up for transportation, be sure to secure it by engaging the hook "3" with the holder "2" without fail © If the hook comes off the drawbar falls down, ‘causing serious injury. © Therefore, make sure that the stopper “4” is locked at the lock position shown in the figure. © When the drawbar stays at the release position shown in the figure, the hook could come off the holder, causing the drawbar to fall down © Handle the hook holder and stopper so Carefully to prevent your fingers from being caught and injured, Hono46s g70092 22 — ,2.Installation 2.2.2 How to release the drawbar © Push the fixed drawbar “1” against the machine in the direction of arrow mark. © Turn the stopper a little to make larger the clearance between stopper “4” and holder “2” than the diameter of the hook “3”. ©Release the hook “3” from the holder “2” through the clearance. @ Lower the drawbar, ®Return the stopper to the lock position, 2.3 Towing the Machine Before towing the machine, check the following conditions and make sure that there is no problem to start towing it. © Ensure that there is nothing wrong with the air prescure in the tires. (See 5.5.38) © As certain that any of the nuts used to mount the tires in place are not loosened. (See 5.5.36) © When towing the machine, make sure there is no person or obstacle at both front and rear sides and under the machine. © The max. towing speed during transport is, less then 20km/h on travel straight AQ WARNING Ho00467 © Be sure to use a vehicle with enough capacity to tow the machine in operating weight. © 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. Ad CAUTION 232.Installation 2.4 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—---—--—- 15°C to +40°C © Humidity: Less than 80% @ Altitude— Lower than1,500m above sea level Ifyou 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, © Ifmore 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 E ventilated building or tunnel. © Do not position the exhaust gas outlet in direction of a person or a house, Exhaust pipe © When installing the machine in a tunnel or < the like, ensure a supply of fresh air and fos Use an airblower! provide adequate ventilation h [fortakngin a” | @ Bo cure to place the exhaust Pipe in an a i ) Outdoor location, so that no exhaust gas will LG be leaked from any pipe seam. Lia Ox. g z s < © 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 Girection of passers-by. Private house atso116 24AAWARNING 2.Installation Installation notes © Be sure to put one set of chocks "1" to the wheels. Pull the lever “1" of parking brake and brake securely. © This parking brake is a device exclusively used to hold the machine when itis parked. it is not for use as a stopping brake during its transportation. Ai7o116 Placing safety fence in position © Be sure to place the safety fence around the machine in order to prevent other people than those involved in construction work from centering the construction site or from ‘accessing the machine 30118 252.Installation 2.4.1 Service valve Bore of service valve: 504 (Rc2B) x 3 Bore of service valve: 20A (R3/4B) [Taper male screw] [Taper female screw) ‘A1S0885 Cautions of hose attachment and removal © Piping or the hose from this machine service valve should use what can be borne enough for the discharge pressure of this machine. © Please connect piping or a hose to this machine service valve firmly before operation and during operation. If the connection part is loosening, there is a possibilty of piping or a ‘trovss | _ hose separating and getting seriously injured © Please remove after closing a service vaive and extracting pressure remained, in case piping or a hose is removed. If pressure remained should remain, a near thing blows ‘way or there is @ possibility of a hose whipping, causing a phenomenon and getting seriously injured © In order to use it safely, please read the handling of the work tools often used, AXWARNING Operation with discharge port (compressed air supply port) opened is prohibited © Do not operate the machine with service valves and relief valve open unless air hoses and/or pipes are connected, High-pressurized air blows out and ts 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 00s | wear protective materials such as earplugs to prevent damage to hearing. 262.Installation Cautions of service valve Fully-close Fully-open _| © 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. Ad CAUTION Haltopen Atéo841 2.4.2 The compressed air outlets © When the machine is operated with compressors in parallel or when the machine is ‘operated in conjunction with high-pressure devices of other types, the compressed air ‘outlets must be secured with check valves before starting piping work. (You must use and install the check valves that can withstand the maximum working pressure of the machine.) Further, two machines should be adjusted to be operated at the same discharge pressure and then piping work must be done. © If piping work is performed without a check vaive fitted, the fluidity in the pipe may have possiblity to be sent back into the machine during operation or when it stops. So much ‘care should be paid as it can result in damaging the compressor air-end. y CAUTION Check valve Unit No.4 High pressure equipment Unit No.2 pag Loe AD Check valve Check valve Parallel operation Operation for connection with a high pressure equioment ‘too 273.Operation 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: Error code switch When this switch is pushed on while lamp is blinking, it shows error code. When starter switch is placed to “STOP”, displayed screen is reset. 3XFor details of error code, please refer to 4.1 ‘AIBO561E Engine error diagnosis Ifthere is an abnormality, the failure diagnosis lamp will continue to light up. Constantly pushing the failure diagnosis switch causes the lamp blink: its blinking pattern indicates details regarding the trouble. Digital monitor ] When power is supplied, engine speed (lamp lighting) is indicated IgG] => [I => [TBS > Pes [ENG.SPEED] [ypu] [DISCHARGE TEMP] (WATER TEMP] [HOUR METER] (1,900min~) rin (00%) @5%) (1.2508) Push Push, Whenever indication selector switch is pushed every time, indication soreen is changed by turns as shown above. In ease that discharge air temperature is below 0'C,"———L" ig indicated on screen, a13.Operation = Coolant - Fuel 3.2. Lubricating oi 3.2.1 Engine oil Use engine oil recommended by us, Be sure to use CF-4 class or higher engine oil or superior clase (Using engine oil with poor quality may shorten the life of the engine). Classification API service classification CF class or higher Viscosity ‘SAE10W-30 © Viscosity of engine oil greatly affects startabilty, performance, oll consumption of the engine, a8 well as wear of the moving parts. Ambient temperature range and oil viscosity (SAE) bit tome enone Tos ‘ar0c293= © When two or more different brands of oll are mixed, its performance can be deteriorated. Do not mix ols. © Follow the designated regulations to dispose of engine oil. 3.2.2. Compressor oil Be eure 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. Range of applicable outside temp. and brand Outside Temp. (°C) -20 -10 6 o 10 20 30, 40. ‘AIRMAN Compressor Oil Long Life HP (Filled oil at factory before shipment) Hoo0066-3 © Do not mix oils of different brands, as they will deteriorate the properties and shorten the life of the compressor body © Follow the designated regulations to dispose of compressor oll. IMPORTANT]3.Operation 3.2.3. Coolant Use soft water of good quality such as tap water for coolant. When the unit is used in a cold region and possible freezing is expected, it is recommended to use LLC (Antifreeze) for the coolant. © When water with dir, sand, and/or dust contained, or hard water such as well water (ground water) is used, this will cause deposits inside radiator or on cylinder head, and will cause engine overheat due to poor flow of coolant. © Adjust mixing ratio of LLC (Antifreeze) with water according to the temperature. (When the machine is delivered from factory, itis filled with LLC (Antifteeze) of density 35%). © Use LLC (Antifreeze) within the range of its mixing ratio between 30 and 60%. (IFLLC (Antifreeze) in the water exceeds more than 60%, it may decrease its antifreezing effect.) © Follow the designated regulations to dispose of LLC (Antifreeze). IMPORTANT, 3.2.4 Fuel © As for fuel, use diesel fuel oil (having higher than 45 cetane number), © Uso of diese! fuel oil having lower than 45 cetane number will cause inferior function to engine and, what is worse, it will cause serious accident to the engine. © You will be punished if you use mixture of ight oil and heavy oil/coal oil or fuel other than light oll in region there is regulation for ilegat light ol © Follow the designated regulations to dispose of fuel. Ee 2 E Ss 4 = 33.3.Operation 3.3 Check before starting unit Be sure to check the unit before operation, When any abnormality is found, be sure to repair it before restarting the unit, Be sure to make daily ‘checks before operation. If the unit is operated without prior check and without noticing its abnormality, such operation could cause seizure of components or may even cause fire. 3.3.1. Check engine ‘Unit should be on level before checking oil level. When checking after driving the engine, please make sure to stop the engine and check the engine oil level after more than 10 to 20 minutes. il level © Pull out the oil level gauge “I” and wipe it with a clean cloth, © Then, re-insert the oil level gauge fully and pull it out again. If the cil level gauge shows the oil level between LOW and HIGH, it is normal, @ When the oil level is below its LOW, add engine oil from oil filler port “2”. © While checking oil evel, check also for contamination. If the oil is found dirty, contaminated or should it be changed according to the periodic inspection list, change the oil. (See 5.5.1) © To cause of the engine output reduction when oil level is too high, do not put oil in more than the upper limit. 1 2 When ol level is, within this zone, HIGH, C itis normel, lee : Low Oil level gauge i | Atsot0s 130108, 3-4 r T3.Operation 3.3.2. Check coolant level © Check the coolant level in the reserve tank. If it is lower than the limit, open the cap and replenish the coolant. (Level must be kept above LOW mark.) i (© When there is a little water or no water in the >) reserve tank, remove the radiator cap and make sure Sy 4 to check the water level. Then supply coolant to the Reserve tank Sep radiator and also the reserve tank, if necessary. (See 5.5.22) A1g0110 © When removing radiator cap, unfasten it to decrease internal pressure while unlocking first step. After checking internal pressure decreased, unfasten the radiator cap more until second step unlocked. If you fail to conduct these processes, it might causes blowing radiator cap by internal pressure or gushing hot scalding vapor. Ad CAUTION © Do not continue operation at low coolant level. Air bubble is mixed into radiator, and it causes damage to the radiator. IMPORTANT,3.Operation 3.3.3 Check compressor oil level Separator () receiver tank © Place the machine on level ground when checking the oil level, © After checking and confirming that the residual pressure in separator receiver tank is OMPa, replenish the tank with compressor oil so that the oil level is kept higher than the Lower limit of level gauge plate. Be sure to check the surface of compressor oil is in the range between upper limit, and lower limit when machine operating. (See 5.5.6) Supply of excessive oil can cause deterioration of oil separation performance and the lke. © When you fill the separator receiver tank with compressor oil, stop the engine, and make sure that the pressure gauge indicates OMPa and there is no residual pressure in it, and then gradually loosen the oil filer cap for refilling oil © Should any residual pressure be left in the separator receiver tank, hot compressed air and hot ‘compressor oil jetting out could cause burning or ‘serious injury to persons nearby. © Gradually opening the drain valve “1” fitted under the separator receiver tank as shown in the fig, drain the condensate CLOSE © Be careful not to fully open the drain valve. Otherwise, much oil may be lost. © After draining the oil completely, close the drain valve firmly. © Drain the condensate in container “2”, and then dispose of condensate according to the designated regulations, © Touch the fluid and check its viscosity to determine, whether itis condensate or compressor oll, and when it is difficult to distinguish between the two, OPEN ape AS = el Aie0010 © After stopping the engine, confirm that the pressure gauge indicates OMPa and there Is no residual pressure in it, then open the drain valve gradually to drain the compressor oi © Note residual pressure in the receiver tank could force both extremely hot compressed air and oil to jet 'H990432 | out and you may be scalded or seriously injured.3.3.5 Check fuel 3.Operation Before starting operation, make sure to check the level of residual fuel so that fuel shortage during ‘operation can be avoided. Drain condensate accumulated at the bottom of fuel tank whenever necessary. © Refilling fuel tank should be done in an outdoor well-ventilated place. © Never let oil reach the filler pipe of the filler port. Oth to expand and spill out. Also, fuel may z é 5 & < 3.3.6 Drain fuel tank al qc Lose “opp iP i | H A160012 high temperature may cause fuel ill out due to vibrations during movement or carriat Do not, under any circumstance, bring lit cigarettes and/or matches to the fuel. The fuel is extremely flammable and dangerous. Be careful of fire because it is very likely to catch fire. Refuel only after stopping the engine, and never leave open fuel can near the machine. Do not spilt could cause a fire. When itis spilt, wipe it up completely. Never use alcohol-base cleaning fluid. If it sticks to such parts made of plastic, it causes degradation of liquid surface visibility, and in worst case, it leads to crack and fuel leak due to crack caused, Open drain valve “2” under fuel tank “1” and discharge drain. After drain is discharged completely, make sure to close drain valve “2”. Drain should be discharged to container “3” and disposed according to regulations.3.Operation 3.3.7. Drain check inside fuel pre-filter ‘The water separator is mounted below the fuel pre-filter. © Itis possible to judge the water level and amount of sediment by looking through transparent cap “1”. If there is any water or sediment collected at the bottom, set 2 container to catch the drain water under drain valve “2”, @ Loosen drain valve and drain the water. @ Tighten drain valve immediately after fuel oil begins to be drained. © Drain the condensate in container, and then dispose of condensate according to the designated regulations. 080102 © When checking, do not use alcoholic parts cleaner for cleaning. If it sticks to plastic parts, which might causes cracks and less visual recognition for fuel level. In worst case, which might causes cracks and fuel leaks. ‘Ad CAUTION 3.3.8 Check wiring of each part Check each wiring for any loose connection, damage to insulating sheathed portion, disconnection, and short-cireuit. 3.3.9 Check piping of each part Check each piping for any loose connection and also check each hose and pipe for any tear and leaks. 3.3.10 Check in the machine Check to be sure that there is no unwanted material, such as debris and combustibles, inside the machine. © Be sure to wear protector such as helmet, protective glasses, earplug, safety shoes, gloves and dust protective mask for safety operation conforming with details of work. @ Temperature of muffler and exhaust valve will become high. Be sure to remove combustibles such woodchip, dead leaf, waste paper nearby it © Just in case for fire, be sure to set fire extinguisher nearby machine. @ itis helpful to keep emergency contact numbers for urgent vist clinic, ambulance and firehouse. § 5 & < 383.Operation 3.3.11 Check belt tension Follow the procedure below to adjust tension of belt. Adjust the tension by gradually loosening the fastening bolt or nut of the alternator. ‘This deflection should | [Check] Renae be 10to 13mm © It is normal if the deflection between the alternator pulley and the fan pulley is about 10 to 13 mm (98N) by pushing with the finger. © Be careful not to leave any grease or LLC on a belt while changing it. If any such material is left, wipe Fan pulley it off completely. Alternator pulley [Adjustment] 110434 | © Loosen the bolts and nuts “I”, °2”, “3” and “4” Adjust the tension of the belt with about 10 to 18 mm [about 98N (10kg)] with nut "4” and move the alternator “s”. © Tighten the bolts and nuts “1”, “2”, fix the alternator “5”. and “4” and SS 8 110435, © Be sure to stop the engine and remove the starter key whenever the tension of the belts to be adjusted, © Remove the negative (-) side cable from the battery © Ifthe machine is running, it might catch the operator's hand into the belts, and this could cause a serious injury. © Be sure to stop the engine and remove the starter key whenever the tension of the belt is to be adjusted. © IF the machine is running, it ight catch the operator's hand into the belts, and this could cause a serious Injury. AX WARNING © Too tight belt tension could damage shaft and shorten bearing life. Too loose belt tension may result in damaging belt earlier and machine components due to overheat. IMPORTANT] 393.Operation | 3.3.12 Check of parking brake Please confirm if the parking brake functions normally. | Checking procedure> @ Handle the parking brake to check there is no | abnormal sound, © Pull the lever “1” and check if there is eufficient } pulling range up to the lock position. @ Release the lock and check that it can be released smoothly without rattling. © When the pulling range exceeds half of the brake lever travel range, it means the wire possibly started extending. Please promptly adjust length of the wire, ~ Release the parking brake. @ Please remove the nut “4” from the brake lever from loosen the lock nut “3” of the rod-end “2” of the brake wire tip that is attached to the left and right of the parking brake side axle. © Pall the brake wire, tighten rod-end several times until the bolt in rod-end fits the hole on the brake lever and then assemble it to the brake lever and fix ity nut, @ Please tighten lock nut of the rod-end. Conduct ® to @ at both side of the axle. Sy, / After adjustment of the left and right brakes, check | Pulling range] ~ whether the parking brake pulling margin is Brake lever travel range / eicetanial Aisoo4¢ | If the pulling range still exceeds half of lever travel range even after finish above mentioned steps, it is necessary to replace the brake wire. © Forreplacement of brake wire and support for other failures please contact our distributor. © To prevent the machine from moving during inspection and adjustment of the brake please park the machine at level place and use wheel blocks. Ad CAUTION Detail view of A 3103.Operation 3.4. Operation Pull the handle forward to open the door. Be sure to close the door tightly so that its latch is firmly caught. © Keep the door closed and locked while running the unit, © When the door has to be opened, be careful not to touch portions that are rotating or very hot AX WARNING 3.4.1 Procedure of starting When warming up operation, be sure to check if there is no loosening in each part of machine or any leaks of water, oil, fuel and air. Also check putting out of the lamp “ERROR DIAGNOSIS LIGHT" ® Make sure that the pressure gauge “I” indicates MPa. ® Close fully service valve. @ Turn the starter switch “2” to "RUN? position, and the glow lamp “3” goes on. @ As soon as the glow lamp has gone out, turn the starter switch fully clockwise to start up the engine After starting engine, starting unload operation automatically begins. Do not keep the starter turning for more than 16 seconds: otherwise, overheating or damage to the starter can result. Required time changes as mentioned in the following table according to discharge air temperature, when starting unloader operation is performed. Discharge air temperature Required time for starting unloeder operation Lower than 600 | le exceeds 120 seconds or 80 seconds or certain seconds until discharge alr temperature becomes 60°C _or more degrees which comes frst Higher than 60C | 30 seconds ‘¢ During the starting unloader operation, the engine speed changes depending on the discharge air temperatures as shown below. Discharge air temperature Engine speed Lower than 60°C 1,100min* Higher than 60C | _ 1,000min™ © Once the engine has started up, leave it running to warmup for 5 minutes. @© After finishing warming up operation, open the service valve provided at the outlet of compressed air and start service job. A160561E a13.Operation | 3.4.2 Method of changing the usage pressure © Check whether pressure gauge “I” indicates OMPa. @ Tum starter switch “2” to the “RUN” position. @ Check the LED of press switch “3”. f Teoms PDSF1000DP,DPC t When the lamp is ON LO3MPa ‘When the lamp is OFF 0.7MPa It is set as shown in the table above. @ When switching the pressure, press and hold the pressure switch “ pressure. to change the discharge © Do not change the operating pressure during operation of this machine. If switched during operation, the equipment on the load side may be damaged. Also, as there is a risk of damage due to damage of the equipment, make sure to stop the machine before switching pressure. When switching pressure, confirm the pressure specification of the load side equipment and use the equipment that meets the supply pressure, AGO561E, ‘The LED lights up when the usage pressure is 1.03MPa 3.4.3 Operating procedures when engine fails to start up on first attempt Ifthe machine does not start after performed steps D to ® in see 3.4.1, do not turn the starter switch for more than 16 seconds and return the starter switch to the “STOP” position once. Restart after waiting for approx. 30 seconds. If the repeated procedure does not allow the engine to run, the following causes are suspected. Therefore, check the following: © No fuel © Lack of air bleeding in fuel line (See 3.4.8) © Clogging of fuel filter © Discharge of battery (Low cranking rotation speed) 3123.Operation 3.4.4 How to start the machine at low temperature © Use engine oil of a viscosity that meets the ambient temperature according to 8.2.1. © Use LLC (antifreeze). Use correct amount to provide freeze protection, according to the ambient temperature according to 3.2.3. © Battery should always be kept fully charged. © Close fully service valve. @ Start the engine through the normal start procedure. © Should change a different types of engine oil, compressor oil, LLC, or fuel when operating a machine in cold weather. A CAUTION 3.4.5 Gauge indication while operating Be sure to check at times to see if gauges or each component of the unit are properly working, or if there is any airleak, oil-leak, water-leak or fuel-leak etc. During normal operation, each indication of instruments ia shown in the table below. Refer to the table for daily checks © The above table gives standard values. They may vary slightly depending on the operating conditions and other factors, Tndicator lamp Operating | Discharge pressure cae na Display ngine faire eondit gauge (MPS) Lease of ENG, speed] SIO | Charging | Fuel diagnosis Starting 7 (On turning the : i e Oe e starter switeh to one on OFF “RUN A St unload e @ Changes Eee Approx0.1IMPa | Approx.1,000min? | ope | opp | depending on the o | oe | misiae Noload 2 PS qwantity | Lights up in gf Unload J DRMMPS | srrox,000mint | OFF | OF case of failure 3 £ (See 4-1 for 5 details) | Pullload | 04t01.05MPa | Approx.,900min? | GP | ep _L 3 1:This lamp will be OFF in 0 to 20 seconds, (varying upon ambient temperature ) :2:Depends on the display switching, See page 3-1 for details. K3:Even if the discharge air temperature once rises at 60°C or more, then the temperature drops to around 55°C, the engine speed may reach 1,100 min”. 8-133.Operation Upper tit | | Lower limit Ad CAUTION rise, = Zz & Ss 2 = Separator receiver tank -A160009 © When the machine is in operation under load, check to see that the compressor's oil level falls within the range between the lower limit and upper limit of the level gauge if the level is found to be insufficient, replenish the oil. 3K Keep the operation log to record constant inspection of ‘each component, so that trouble of the machine can be easily discovered and preventive measures can be taken. © Do not open the valves below listed when operating © Separator receiver tank drain valve © Coolant drain valve ¢ Engine oil drain valve © Oil cooler drain valve ¢ Fuel tank drain valve © Discharge pressure level must be kept 0.4MPa or more when operating, © Continuing equipment operation at a lower pressure than the above pressure may cause overheating, since it affects the separation of lubricating oil inside the oil separator and reduces the oil flow to the compressor air-end, resulting in temperature3.Operation 3.4.6 Performance check of safety valve Be sure to check the safety valve “I” performance once a day. © Close the service valve completely and pull the test ever “2” to check the performance. It is performing normally when the compressed air jets out with slight force. © Sot Pressure Safety valve set pressure 1.35MPa 10376 © Keep face or hand away from the discharging outlet of safety vaive. Itis very dangerous because high-pressure compressed air jets out = © Never work nearby hot portions of the machine while itis running © Do not touch hot portions of the machine while inspecting the machine when running. F # Such parts as engine, exhaust manifold, exhaust i, pipe, muffler, radiator, oil cooler, air-end, pipe, zm Separator receiver tank, and discharging pipe are especially hot, so never touch those parts, because it ‘could cause serious burns. Compressor oil, coolant water, and engine oil are also very hot and dangerous to touch. Avoid checking or refiling them while the machine is running, & 2 3 <4 3.4.7 Stopping ® Chose the service valve completely and operate the machine about 5 minutes, until it coola down. @ Tum the starter switch to “STOP” position to stop the engine. @© Remove the key from the compressor every time when you stop the engine. Koop the key and be careful not to lose it3.Operation 3.4.8 Fuel line air bleeding device Ifmaintained the fuel system by regular replacement and maintenance etc,, remove air as following, © Fill up the fuel pre-filter (main filter, eub-filter) with fuel. (Do not put fuel directly into the fuel filter.) @ Loosen the air bleeding plug “I” of the fuel filter head. © Loosen the thumbscrew “S” that fixes the lever “2” of the priming pump. @ Repeatedly operate the lever “2” and confirm that the fuel comes out of the air bleeding plug “I” after the air bubble. © Tighten the air bleeding plug “I”. © Loosen the air bleeding plug “4” of the fuel filter head. © Repeatedly operate the lever “2” and confirm that the fuel comes out of the air bleeding plug “4” after the air bubble. © Tighten the air bleeding plug “s” © Loosen the air bleeder “5” of the supply pump. ® Operate the lever "2" until the fuel comes out of the air bleeder “s”, and when the fuel comes out, tighten the air bleeder “5” and then operate the lever “2” several times until the counterforce becomes great. @ Tighten the thumbscrew “3” and firmly fix the lever “2’ © Do not rotate the starter for more than 15 seconds at a time. © Ifthe starting operation is performed continuously, the starter will not be completely stopped, so the pinion ring gear of the starter will be damaged. It will cause failure of the starter. g 5 & < 3163.Operation — $cc 3.5 Operation of after cooler type 3.5.1 Draining of after cooler ‘The condensed water drained from after-cooler contains a little bit of oil. So take care how to dispose of it. | [In case that any condensate is found in discharged air] | ‘© Check and confirm that air is emitted from the drain port of after-cooler during operation. When any condensate is found mixed in the air, clean the silencer “1” at the discharge port and the orifice “2”. Ifheavily stained, replace them. When cleaning and replacing it, contact directly us or distributor because it requires expert technical knowledge. “After cooler cose cf | Re Warmer valve ‘Ateo0z0-1 3.5.2 Drain warmer valve © This valve “3” is provided to prevent condensate water from getting frozen when draining water separated by the drain separator “4”. Run the machine with the valve being open when ambient temperature is lower than 5°C.But when freezing is impossible, the machine can be operated more difficently if the valve is closed. 3.5.3 To prevent freezing © Im case the machine operates in winter season and before the machine storage, be sure to open service valve 2 to 3 times in order to remove accumulated water drop in air piping for after-cooler ete. B173.Operation 3.5.4 Selection of service air By switching the switching valves A and B, two types of air can be taken out, low-temperature air and normal air, in accordance to the use. >KIf both valves A and B are closed, air will not come out. 18019041 Open Operation ois4 Failure cause and measures 4.1 Indicator lamp and Warning / Emergency play [Indicator lamp] Turn the starter switch to "RUN" position. Then the lamp goes on. Tem Contents Measures Monitor ross starter switch “GLOW” and the lamp Glow goes on and after preheating is finished, - 06 the lamp will be off Lamp goes on when alternator is not Check wiring, Charge | charging Check alternator, Es 4.1.1 Warning display ‘This displays such trouble of less importance when it occurs during operation, but the unit continues operating. When any abnormality happens, a trouble code lamp flickers, In this time when trouble code switch is pressed, a failure code will be displayed. Item Ps Contents Measures Displayed when the discharge temperature DISCHARGE TEMP.H AL at the outlet port of compressor air-end Ss reaches 125°. eTreableanacts - -9 | Displayed when the water temperature ee on WATER TEMP HT ae teaches 98°C. COMP.AIR FILTER ‘A-3 | Displayed when the air Slter gets clogged and suction resistance increases. Clean or replace ENG. AIR FILTER a Av4 _| tActuating resistance is more than 6.2kPa] 7 Belt loosened and/or cut CHARGE A'S | Fautty generation of alternator See 4.2 DISCHARGE AIR TEMP. |, | Displayed when the air temperature at the | “Troubleshooting” AT SEPARATOR H outlet of the separator reaches 125°C. 414 Failure cause and measures | 4.4.2 Emergency display When any trouble takes place during operation, this displays and it stops as an emergency stop. } When any abnormality happens, a trouble code lamp flickers. In this time when trouble code switch is pressed, a failure code will be displayed. Failure sae Contents ‘Measures | Displayed when the discharge temperature E+1_| at the outlet port of compressor air-end reaches 130. Displayed when the engine water temperature reaches 103°C. Displayed when the engine oil pressure, DISCHARGE TEMPE. WATER TEMPE B2 ENG, OIL PRESS 3. | drops. [The function pressure? 0.049MPa.] DISCHARGE AIR TEMP. |p, | Displayed whon the aix tomporature at the ‘AT SEPARATOR & outlet port of separator reaches 130°. Stop once the integrating time of engine | cog 4 speed 400 to 800min” becomes 15sec. ; ; ENG. SPEED DOWN +5 | When the engine epeed becomes less than | *°Ubleshooting’ 800min* after the engine speed increased once and then stops in 10sec, Displayed when the discharge temperature pr eeateneee E-6 | sensor at the outlet port of compressor air-end is disconnected. } Displayed when the engine water temperature sensor is disconnected. WATER TEMP. SENSOR | E-7 DISCHARGE AIR TEMP. | Displayed when the separator outlet air SENSOR AT ¥° | temperature sensor is disconnected SEPARATOR = | +24 Failure cause and measures 4.1.3. Engine trouble ‘This is equipped with controller which memorizes engine troubles. In case that any abnormality occurs to engine, error diagnosis light “2” continues to lighting. When the diagnosis switch °3” is continuously pressed, it displays trouble contents by flickering patterns, ba Se © Turn the starter switch “1” to “RUN" position. f Bead @ Incase that any abnormality or trouble occurs, the error diagnosis light “2” continues to light. @ When error diagnosis switch “3” is continuously pressed, it displays the contents of the trouble by flickering patterns. (When no trouble is found, error diagnosis light “2" lights on 0.5 seconds and lights off 2 seconds continuously. This cycle is repeated.) =n! | Case of code 122 oO O98 © ® ON 2see. | [7] 0.5e00, 0.5 2sec, OFF ! Blinking signal with short interval once, twice, twice means code!122) (0 Ee es | | case ofcoe234 FO OHO HOH _weae teint teeta 0.5800 ON sec, som Atooas7E 1 Blinking signal with short interval twice, three, four times means codel234). |[List of 4 Failure cause and measures diagnostic codes] Some examples of diagnostic codes are mentioned in the following table. Concerning the codes of trouble conditions, they are grouped into decades of the trouble kinds. For the details and countermeasures, contact our office nearby or distributor because technical knowledge is required. Code Details Condition of machine Tagine does not start. Abnormal of engine controller inside ey as Sees arene open ‘Abnormal of boost pressure sensor output 122 | Sottage high Output drops. 131 | Abnormal of throttle voltage high Low idling is fixed. 195 | Abnormal of hydraulic sensor output ‘ngine burns or No signal of engine hydraulic voltage high detection “Abnormal of water temp. sensor output 5 144 | Sotone high Cold start performance is not good. 146 | Engine overheat Output drops. ‘Abnormal of boost temp. sensor output, 153. | Sottage high Drop of output or Black smoke when speed up a1 | Abnormal of atmospheric temp. Sensor | Drop of output or Black smoke when speed up output voltage high Discharge temp. increases at high altitude 234 | Engine over speed Engine revolution changes dramatically. 95g | Abnormal of fuel temp. sensor output 968)\| ate tisk Output drops sometimes. ‘apply pump | QvtPut drops 27g | Abnormal of breaking of fuel suprly PUmP (Engine stops with abnormal PCV2 simultaneously.) ‘Abnormal of breaking or short circuit of 922 | ester anstem Output drops “Abnormal of power voltage high of engine 386 | control sensor supply power 1 Engine performance is not good. (@5V + CN-J1 connector pin NO.83) 442 | Abnormal of power voltage high Engine revolution unstable 418 | Drop of engine oil pressure Output and revolution drops. ‘Abnormal of common rail pressure sensor 451. | osu waking Mig Engine performance is not good. oq | Abnormel of exmmon rll presere 10" | Gagine performance isnot good. 58 | eae ere es Pee 10" | Engine performance is not good g555 | Abnormal of breaking of intake heater | Preheating does not work ? || sub-relas Cold start performance is not good. ‘Abnormal of EGR valve lif sensor output fil | vatesinis Output drops 444 Failure cause and measures 4.2 Troubleshooting Iany trouble occurs during operation, do not leave it. Investigate the cause and take appropriate measures, Read the manual carefully and fully understand what to do in case of trouble. © The better you understand the construction and function of the machine, tho faster you can find a problem and solution, © This chapter describes the symptom, cause and countermeasures of important troubles in detail: Water found mixed in air. (Condensate separation malfunctioned.) For after-cooler type only drain outlet, (2)Clogging of the pipe occurs between the after cooler and the silencer, ()Drain valve under drain separator is closed Symptom Cause Countermeasures | ()Faulty battery. Check battery — Charge (2)Failure of battory charging Change Low starter revolution speed. (9)Failure of alternatar (DRailure of starter ()Fuel filter clogging. Disassemble/Clean/Change The start rintes nemally | (eae er SOBs Raalvepleniahmont Dut the engine does not start. | )4:> entry into fuel line aystem Bleed the air (5)Nozale clogging _ Disassemble/Clean (@)Pressure regulator insufficient Re-adjust (Fasten) | ‘The discharge air prescure adjustment, will not rise. (2)Trouble of solenoid valve for starting Change unloader @Faulty engine controller Call your nearest dealer (2)Unloader orifice clogging Disassemble/Clean The engine does not reach the | (3)Accelerator controller trouble Call your nearest dealer rated revolution speed. (Faulty rotation sensor Call your nearest dealer (6)Engine trouble Call your nearest dealer (Ruel filter clogging Disassemble/Change itis Gackage ooonaal (Preaure rgultor insullicient Re-adjust (Fasten) not increase to the specified (Trouble of. latins Ch: ue ‘rouble of pressure regulat ange (3)Unloader orifice clogging Disassemble/Check Engine does not reach (Faulty engine controller Call your nearest dealer minimum revolution at (2)Trouble of rotation sensor Call your nearest dealer unload. (()Pressure regulator insufficient Re-adjust (Loosen) Safety valve relieves at adjustment asic’. (2)Unloader valve damaged/Faulty seat | Call your nearest dealer - (3)Faulty safety valve Change (4)Faulty controller Call your nearest dealer (Q)Scavenging orifice strainer clogging | Disassemble/Clean (2)Excessive oil in separator receiver Drain to its proper level Oil mixes in air. tank (Poor oil separation) (3)Low discharge pressure Disassemble and check of pressure control valve (Oil separator deteriorated Check/Replace (Clogging of silencer at after cooler | Disassemble/Clean/Change Disassemble/Clean Open warmer valve4 Failure cause and measures Symptom Cause Countermeasures Insufficient free air delivery. (Air filter element clogging (2)Unloader valve cannot fully open (@)Engine does not reach rated speed Clean or change of element Call your nearest dealer (See4-7) (Faulty battery. Check battery > Charge Change Warning of inferior charge | (2)Tvouble of alternator Check and replace indicates. alternator (6)Abnormal of charging circuit Checie electrie eystem (charging circuid) ‘(Engine al shortage Replenish oil Exror code of engine hydrauli | (2)Engine ail filter clogging Change abnormal indicates and (3)Faulty oil pressure sensor Change engine stope. (Loose wiring, connectors and Check/Pasten disconnection WRadiator clogging. lean | femp. or abnormal errer code | (31 oy coolant level Replenish, error code indicates.) pica (Coolant temp. sensor is disconnected. | Repair/Replace (DOil cooler clogging, Clean (@)0i Slter clogging. Change (Faulty discharged air temp. sensor. | Disassemble/Check (Loose wiring connectors and Check/Fasten Warning of discharge air tomp. or separator discharge temp. or abnormal error code disconnection. (8)Slippage of belt, Reradjust tension barra ale (Shortage of compressor oil. Replenish oil Ging stops when abnormal | (DOPeration error of by-pass valve. Check/Repair peeiepie pa abo (®)Discharge air temp. sensor is Repair/Replace disconnected. (Separator clogging Change (Warning of separator discharge air temp. and abnormal indicates only.) @WLoose wiring connectors and Check/Fasten Abnormal error code of engine revolution speed drop indicates and engine stops. disconnection, (Shortage of feeding fuel caused due to fuel filter and feed pump strainer clogging (Air mixed in fuel line system (Output reduction due to clogged engine air filter Replace filter and/or clean the strainer Blood the air Clean and replace air filter eee | © Contact our office nearby or distributor if you find it difficult to repair by yourselves © Refer to the engine operation manual for trouble concerning the engine. 465.Periodic inspection/Maintenance 5.1 Important Items at Periodic Inspection and Maintenance or after Maintenance ‘The following table shows the inspection and maintenance intervals under normal operation conditions. When used or operated under hard environmental conditions, it is impossible to warrant the unit even if the above conditions are performed according to the intervals listed in the above table. © Posse wear protection implements, such as a helmet, protection glasses, earplugs, safety shoes, a glove, and a protection-against-dust mask, according to the contents of work for safety. © Do not touch hot portions of the machine while inspecting the machine when running, Such parts as engine, exhaust manifold, exhaust pipe, muffler, radiator, oil cooler, air-end, pipe, separator receiver tank, and discharging pipe are especially hot, so never touch those parts, because it could cause serious burns. Hang a “Now Checking and under Maintenance” tag © Remove the starter key from the starter switch -= before starting inspection, and hang up a "Now G Checking and under Maintenance” tag where it can be easily seen. The checker must keep the key during checking and maintenance. © Remove the negative (-) side cable from the battery Ifthe above procedure is neglected, and another svoor | Pefson starts operating the machine during check or maintenance, it could cause serious injury AXWARNING Prevention of oil separator from catching fire © Be sure to perform following periodic inspection and maintenance: 4. Check and change compressor oil quantity 2. Change oll separator Ad CAUTION 110290 BLn/Maintenance 5.Periodic inspec’ Directions: Prohibition of any other jobs or works than directed herein © Be sure to use recommended fuel, oi, grease, and antifreeze © Do not disassemble or adjust engine, compressor air-end or part(s) for which inspection or maintenance is not referred to in this manual © Use genuine parts for replacement. © Any breakdown, caused by using unapproved parts or by wrong handling, will be out of the scope of WARRANTY”. © Keep the electrical components away from water or steam. © Waste from machines contains harmful material. Do not dispose of such harmful fuids to the ground, rivers, lakes or ponds, and sea. It contaminates the environment, © When draining waste fluid from machines, use leak proof containers to hold such fluids from machine. © Be sure to follow the designated regulations when disposing of oll, fuel, coolant, fers, battery and other harmful things. IMPORTANT 5.2 Inspection on Separator Receiver Tank Periodic inspection of separator receiver tank © Be sure to carry out the following cleaning and inspection of the separator receiver tank at least once every year. (1) Any damage found on the tank. (2)Any excessive wear found to fastening bolts on the cover. (3) Any damage found to pipes and valves etc. e = = fm S = =5.Periodic inspection/Maintenance 5.3 Periodic Inspection List (Unit:tfous) Mainionsce —_ [pais] ae sr Fae [Eas Fea Bes or Pa (Check compressor oll level o 36 Drain separator receiver tank ° 36 a and wear and tear of pipe (Check oi, water, fuel and air leak 3 Check functions ofa instruments and devices | _O Performance check of safety valve O (Check and lean dogging air fier element o Change compressor ol lineal © (Change compressor oil Alter ltnseaal © saul Change ar filter element 3 eu [Clean strainer in the scavenging orifice i ° 2 (Clean outside ofthe ol cooler o 5d | | Clean outside of ater cooler f 8 | After cooler type ) | ° 54 | Check and clean drain outlet port falar Sleocier x10 515 (After cooler type) Change oil separator e Sar Change nylon tubes xe 5:18) Change rubber hoses xe 518 - (Change O-ring ofthe ualoader xe 5:19 Check and change th unloader bushing R20 xe 5:9) [Change diaphragm of pressure regulator xe 519 (Chock consumable parts of autoreit valve xe 5:19) Check consumable parts of vacwusyralif valve xe 5:9) Perbrance cock ofpresureeantel vale J e 520 (Chock O-ring and piston of pressure control =e valve Change rubber coupling © [sar (Chango cil seabcaring @ [oa (Change solenoid valve © [oa Such items marked O shall be carried out by customers. For the items marked @, contact our office nearby or distributor because technical knowledge is required. Regarding the item marked %1-When water is found mixed in the discharged air, perform cleaning work even before the specified interval comes. Regarding the item marked 3X2,check the function of the unloader. In case the unloader malfunctions, change O-ring or bushing of unloader. This is because elther of both parts may be worn out, ‘The items or parts marked y¢ should be replaced every two years even if they are not in disorder within thelr Beriodical maintenance interval because their materials will change or become dearaded over the course of as time passes. Also for the same reason, the parts marked #_ should be replaced every three years. @ Ihe indicated replacement periods are rough estimates. Depending on the usage conditions or envifonment, inspection/maintenance should be conducted earlier. 535.Periodic inspection/Maintenance ORefer to engine operation manual for inspection and maintenance of an engine. For the details, contact our office nearby or distributor. Meintonance Jose] Bap [Pa [fois | S03 [Boo (Check engine oil level o Check coolant level oO Check fuel a [Drain fuel tank 3° Drain check inside fuel pre-filter oo Check looseness in pipe connectors, terminals | C, a and tear in wiring (Cheek belt tension o 38 | Change engine oil. es 56 Change engive of filter cial 57 (Check battery electrolyte | ° 57 (Check and clean clogging of air filter element { ° 50. «9 Check apecifi gravity of battery electrolyte Q 51 4 [Change air filter element Oo ell | Change fuel pre-filter oO 5:12) Change fuel pre-filter element oO 513 Clean the strainer provided inside the fuel feed ° a! od Change of corrosion register oO 513 Change fuel filter ° 514 | Clean outside of the radiator and intercooler o 514 Cheek the engine breather drain o 515 Clean inside of radiator e 5:14) Change coolant xO 5-16) ‘Clean inside of fuel tank e 5:18 (Change intercooler hose xe 518 Change fuel hose xe 5:18 Change radiator hoses 5:18 ‘Change wiring harness © [59 The items or parts marked _3x_should be replaced every 2 years even if they are not in disorder within their riodical maintenance interval because their materials will change or become dearaded as tim . ©The indicated replacement periods are rough estimates. Depending on the usage conditions or ‘environment, inspection/maintenance should be conduc lier. (Wnit‘How) Maintenance Day | Byer’ | Bree’ | Be | ane | sos | sooy (Pe mn Check looseness of tire mounting nuts oO S| Cheek of pasking brake ° e 310 : ‘Supply grease to trailer hub bearing. 0 5-15 | & | Supply grease to leaf spring pin. ° 515] FB | Check and confirm that the muts with ae ea which tires are fixed are properly tightened. scant 545.Periodic inspection/Maintenance 5.4 Periodic Replacement of Parts Part number changes upon modification. For replacement of parts, make sure whether the part number is correct or applicable. Part Name Part Number Quantity : 37496 08500 Engine cil flter KOMATSU 600-211-1340 1 ‘i fer clement Onter element "3" 32149 16000 I (For engine) Toner element "4" 32143 15901 1 ‘hr filter clement Outer element“ 32143 09400 i (or compressor airend) [Taner clement “I” 32148 09500) L ‘Compressor ol filter 37498 09600 1 7 43543 02400 shatter KOMATSU 600-319-3841 | : ; 43549 01500 iserre ae KOMATSU 600-319-4540" Fuel pre-Glter clement 43541 01400 i ; 37498 09100 Corrosion resistor KOMATSU 600-411-1151 2 Soloncid valve for starting unload 46811 20500 L Solenoid valve for unloader spring chamber 46811 28700 1 Pressure switching solenoid valve 46811 32600 1 i Separator" 34200 03100 1 pa Casket "2" 34235 08000 2 Oring TP 03402 15090 1 i svene Oza 21441 06000 I ressure control vale Teflon ring 22505 03300 L Piston 35303 09901 L Diaphragm for pressure regulator eS 96497 02101 1 Pressure regulator assy (for low pressure) seem Ful food pump gasket KOMATSU 07005-01412 2 Belt KOMATSU 04121-22267 Tot 5-55.Periodic inspection/Maintenance 5.5 Maintenance Items 5.5.1. Change engine oil [At 250 hours for the first change and at every 500 hours thereafter © Open the drain valve “I” located inside the machine in order to drain the oil. © When all oil is discharged, close the drain valve “I” firmly and remove the cap of the engine oil filler port “2” in order to refill the oil. [Quantity of oil : approx. 38L] @Atter refilling fuel, tighten filler port eap properly. ‘Then, remove oil level gauge “3” and wipe it by cloth, @ Then, insert the oil level gauge fully and pull it out again. If the dipstick shows the oil level between LOW and HIGH, it is normal. @®As you finish refilling, make sure to close the cap of the engine oil filler port “2” and to firmly reinsert oil Tevel gauge “3”. ‘130108 CLOSE OPEN ao Ho Fm within this zone, HIGH it is normal. Oillevel gauge Drain container| 60015 Caution in filling or discharging engine oil © After stopping the engine, wait of 10 to 20 minutes until the engine oil cools off. Then check the level of ‘the engine oil, or refill or drain the oil. © Engine cli very hot and highly pressurized during or just after the operation. Hot oil could blow out of A Ws @ the tank and can cause scalding. pe A © Never supply more engine oil than the proper level inoooas2 Too much oil could cause white smoke out of the exhaust, and it can cause damage and accident to engine Ad CAUTION5.Periodic inspection/Maintenance 5.5.2. Change engine oil filter {At 250 hours for the first change and at every 500 hours thereafter Remove the filter “I”, using a filter wrench. @Screw in the new filter “I” with the gasket “2” coated slightly with oil. (For part number, See .4) @After the packing touches the sealing face, tighten another 1 turn by hand. @After installing the oil filter, check it for any leak during operation. Ho00049 5.5.3 Check battery electrolyte and specific gravity of battery electrolyte [Battery electrolyte: every 250 hours| If there seems to be a problem in starting an engine due to a flat battery, carry out the checks by following the procedures below: © Ordinary type battery: Check battery electrolyte level and if the level is not within the specified level, add distilled water. Measure specific gravity of battery electrolyte, and if it shows below 1.24, recharge the battery immediately. (See 5.5.4) © Enclosed type battery: Check the indicator on top surface of the battery. If the indicator shows that charge is needed, recharge the battery immediately. If specific gravity of battery electrolyte does not rise in spite of replenishing distilled water or charging battery, be sure to replace battery with new one quickly. BT5.Periodic inspection/Maintenance 5.5.4 Maintenance of Battery Battery may generate hydrogen gas and may explode. ‘Therefore, recharging should be done at a well-ventilated place. © Do not check the battery by short-circuiting the positive and negative terminals with a metallic piece. © Never operate the machine nor charge the batteries with the battery liquid level being kept lower than the lower level. Continuing operation at this lower level will cause deterioration of such parts as pole plates etc., and also it may cause explosion as well as reduction of battery life. Add distilled water so that the liquid level may reach the middle level between the “UPPER LEVEL” and “LOWER LEVEL” without any delay. © Wear protective gloves and safety glasses when handling a battery. © When such battery electrolyte contacts your clothes or skin, wash it away with large amount of water immediately. © If the battery electrolyte gets into your eyes, wash it away immediately with plenty of water and see a doctor at once, because it is feared that eyesight might be lost. Handling battery © Keep flames away from battery. © Do not spark near the battery nor light a match, nor bring lit cigarette and match close to the battery © Do not charge the frozen battery. Otherwise it may explode. Ifthe battery is frozen, warm it up until the battery temperature becomes 16°C to 30°C. © Battery electrolyte is dilute sulfuric acid. In case of mishandling, it could cause skin burning, © Dispose of battery, observing local regulations, [Charge battery] © Use the battery charger after make sure to confirm whether it’s fulfill a condition with the battery you charge. © Disconnect the cable between battery and the machine, and charge the battery with a 12V battery charger. Do not charge two batteries at the same time, © Be sure not to connect (+) and (.) terminals backwards. 585.Periodic inspection/Maintenance [How to use booster cable] Stop the engine. Connect one end of the (+) booster cable to the (+) terminal of the machine battery. @ Connect the other end of the (+) booster cable to the (+) terminal of the external battery. Connect one end of the (-) booster cable to the (-) terminal of the external battery. © Connect the other end of the (~) booster cable to the engine block of the machine. @Start up the engine. @®Disconnect the booster cable by following the procedure back in the reverse order. Connect to the engine block Machine battery Booster cable se0196-1 Do not reverse the cable connection © When a booster cable has to be used or when cables are connected again after an battery is replaced, be careful not to connect (+) and (-) terminals backwards, ‘Such wrong-connection will cause spark and damage to each component. 5.5.5 Check and clean clogging of air filter element [Every 260 hours] © After removing the cup “I” by loosening its cup fixing latch “2” and butterfly nut “7”, clean its interior properly. @ Clean with removing outer element “3” and “8” only. Do not remove inner element “4” and “Q”. @ Replace inner element “4” and “9” together when replacement of outer element “3” and “8”. Replace both inner and outer element when cleaning and replacing outer element “3” and “8” 4% times. @ Inner element cannot re-use with cleaning. Make sure not to get any dust into secondary side when inner clement “4” and “9” remove © When cup is installed after it is cleaning, push O-ring “5” surely in the case “6” so that it will not be extruded and confirm that the hook of cap fixing latch is surely installed. ‘Then tighten it. (Make sure to tighten butterfly nut properly.) © Ifthe element is found heavily dusty, replace it with a new one. (For part number, See 5.4) © Clogged or cracked or pitted element could allow entrance of dust into engine and compressor air-end to cause earlier wear of moving parts. Periodical inspection and cleaning of element should be performed to maintain life of compressor air-end and engine long, IMPORTANT 595.Periodic inspection/Maintenance 5.5.6 Change compressor [At 250 hours for the first change and at every 600 hours thereafter © For prevention of fire caused due to deteriorated oil separator, in principle change of compressor oil is to be performed in accordance with the schedule mentioned in the regular maintenance table. However, it is heavily influenced by operation conditions and environmental conditions. If it has been found more dirty and corrupted, it should be changed. © If machine is continuously operated in such bad conditions, it could damage bearings and degraded oil sticks oil separator to cause accumulated oxidation heat of reaction to lead cil separator fire. For this reason, regular maintenance work should be done surely and perfectly. © Conduct changing compressor oil after checking machine stoppage for about 2 to 8 minutes and dropping pressure of separator receiver tank to zero, After stop this unit, make sure to release remained compressed air inside separator tank completely. Remove fuel filler port cap “1” slowly and open drain valve “2” and drain compressor oil. Open drain valve “4” of oil cooler and drain remaining oil inside cooler. @After draining compressor oil, close drain valves “2” and “4” firmly. ‘Fill the tank with new compressor oil up to the height Fuel limit | indicated by the dotted line (Fuel Limit). Then, close filler cap. Inspect O-ring “3” of filler cap and replace it with a new one if any hardening or damage is found. @aAfter starting operation, check and confirm that il level is within red lines of oil revel gauge. Quantity of oil between the red lines Quantity of change oil “Approx.110L OPEN Drain container 160018, © 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 ait-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, itis 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 cil IMPORTANT5.Periodic inspection/Maintenance 5.5.7 Change compressor oil filter \t 250 hours for the first change and every 500 hours thereafter] Be sure to use genuine oil filter. Remove the cartridge “1”, using a filter wrench, @Screw in the new cartridge with the packing “2" coated slightly with oil. (For part number, See 5.4) @ After the packing touches the sealing face, tighten another 3/4 to 1 turn with a filter wrench. @ After installing the oil filter element, check it for any leak during operation. Ho00049 © Poor quality ol fiter does not trap dust sufficiently and will cause damage to the bearings in a short period. Be sure to use genuine parts. 5.5.8 Change air filter element Every 500 hours| Be sure to use genuine air filter element. After removing the cup “1” by loosening its cup fixing latch “2” and butterfly nut “7”, clean its interior properly, @Remove element “3”, “4”, “8” and “9", and replace it with new one. In general, replace the inner element at the time when the outer element is cleaned for the fourth time (approximate guide). When removing the inner clement, take care that dust and dirt do not enter the secondary side. (For part number, See 5.4) @When cup is installed after it is changed, push O-ring “8? surely in the case “6” so that it will not be extruded and confirm that the hook of cap fixing latch is surely installed. ‘Then tighten it. (Make sure to tighten butterfly nut properly.) © When used or operated under bad conditions, it is better to remove all the elements, check them, clean them and replace them earlier before the intervals listed in maintenance table, if they are found difficult to be repaired. © Air fiter is an important part which is crucial to machine's performance and life. Be sure to use genuine parts,5.Pel dic inspection/Maintenance 5.5.9 Clean strainer Every 500 hours| the scavenging orifice 7 Remove the pipe “1”, using a spanner. © First remove the bushing “2”. @ Then remove the strainer “3' @ Wash the removed strainer in diesel oil and blow out 3——a . “dust” by air blowing, 0 @ After finishing the cleaning, install the strainer again in the reverse procedure. Separator receiver tank- Aisotes 5.5.10 Change fuel pre-filter [Every 500 hour: Set a saucer for fuel drain under fuel filter “1”. Remove transparent cap “2” with left turn by a filter wrench (cap can be re-use), @Remove fuel filter with left turn by a filter wrench. @®Remove transparent cap from sealing “3” and clean it. In case transparent cap damaged, replace to new one. © Coat new fuel or oil on new sealing a little and install it to transparent cap. @ Install transparent cap to new fuel filter. ©@Make sure to tighten drain valve “4” under transparent cap properly. ® Clean filter head and put fuel on new fuel filter. Cost oil on surface of packing a little. Then, install it to fuel filter head. @Tighten with 9/4 turn after surface of packing touches surface of filter head sealing when install. © For the details of replacement, refer to engine operation manual. 180017 © Make sure to refill fuel from 8 points of dirty side of small holes “A” without removing center cap “B” © After refiling fuel, remove center cap “B" and install fuel fter. © Do not mix fuel with new and dirty fuel such as alien substance. Especially, center part is clean side. Refill fuel without removing cap "B” and make sure not to mix dust into center clean side. IMPORTANT 125.Periodic inspection/Maintenance 5.5.11 Change fuel pre-filter element Every 500 hours| 070455 © Take out the cover and element inside the fuel pre‘filter by turning T-handle “1”. @ Install a new fuel pre-filter element by pressing it up to the fuel shut-off valve at the bottom. (For part number, See 5.4) @ Install the T-handle and cover, and then tighten it by turning T-handle, 3 Tighten it after checking and confirming that O-ring is not caught in the cover. 5.5.12 Clean the strainer provided inside the fuel feed pump. Every 1,000 hours Joint bolt Ai10437 5.5.13 Change of corrosion register [Every 1,000 hours| 00049 © Periodically remove the strainer “I” inside the feed pump, and clean it © Remove the strainer by loosening the joint bolt and clean it with diesel fuel oil, and also using high air pressure blow. At this time be sure to replace gasket. (For part number, See 6.4) © ‘Then after finishing all cleaning jobs, install it again in reverse steps. © Close stop valve “I” of corrosion register. @ Remove cartridge “2” by a filter wrench. @When cleaning the filter base and installing a new cartridge, apply oil thinly to the packing “3” and screw it in, After the packing touches the sealing face, tighten another 2/8 turn with a filter wrench, (For part number, See 5.4) @ After assembling the cartridge, open the valve of the corrosion rogister.5.Periodic inspection/Maintenance 5.5.14 Change fuel filter [Every 1,000 hours| Remove the filter “1”, using a filter wrench. @Screw in the new filter with the packing “2” coated slightly with fuel (For part number, See 5.4) @After the packing touches the sealing face, tighten another 2/3 turn with a filter wrench. @Bleed the air of fuel. @ After installing the fuel filter, check it for any leak during operation, 5.5.15 Clean outside of the radiator: oll cooler and intercooler Every 1,000 hours © When the fin tubes “I” of a radiator, oil cooler and are intercooler clogged with dust or other foreign materials, the heat exchange efficiency drops and this will raise coolant temperature and engine suction air temperature. These tubes and fins should be cleaned depending on the state of clogged tubes diaphragm, even before maintenance schedule. © Do not use a high pressure washer to protect fin tubes from being damaged. ‘A160500 5.5.16 Clean outside of the after cooler (After-cooler type) [Every 1,000 hours| © When the fin tubes “I” of the after-cooler get clogged with dusts and dirt, it can cause deterioration of heat exchanger effectiveness to be lowered so that cold air can not be produced. in order to prevent such trouble, clean them, depending the clogging conditions of the fin tubes, even before the scheduled periodic cleaning time. © Do not use a high pressure washer to protect fin tubes “I” from being damaged. 5.5.17 Clean inside of radiator Every 1,000 hi © When the inside of a radiator and water conduits of an engine are dirty with scale and rust, its cooling efficiency will be deteriorated. Clean the interiors of such components periodically. © When cleaning it, contact directly us or distributor because it requires expert technical knowledge. corydic inspection/Maintenance 5.5.18 Check and clean drain outlet port of after cooler (After-cooler type) Every 7,000 hours| See 3.5.1 for after cooler drain. Cleaning it completely and keeping it cleaned ‘@ When any water is found mixed in compressed air, silencer and air pipe could be clogged. Periodically carry out inspection and cleaning of it 5.5.19 Supply grease to trailer hub bearing Every 1,000 hours| Bearing © When replenishing grease to the trailer hub bearing, contact our office nearby or distributor. Grease: Chassis arease ‘TROZSO-t 5.5.20 Supply grease to leaf spring pin Every 1,000 hours| © Supply grease through grease nipples positioned at Leaf spring pin a the bottom. Grease: Chassis grease TR02608 5.5.21 Check the engine breather drain Every 1,000 hours| © Open the engine breather drain valve “1” in the tire housing in increments so as to discharge the drain. In cold seasons, moisture in the piping may freeze, thereby damaging the engine. © Drain should be discharged to container “ disposed according to regulations. and 5-155.Periodic inspection/Maintenance 5.5.22 Change coolant Be sure to stop the machine and loosen the radiator cap slowly after the coolant water is sufficiently cooled and the inner pressure is released, and then take the cap off. © Drain coolant water with loosing drain valve “2” after removing of the radiator cap “1”. ® Loosen the drain plug “3” provided on engine body to drain. @ Drain coolant of reserve tank. @ After draining, fasten drain valve and fasten drain plug of engine body, then replenish coolant from radiator water inlet and reserve tank water inlet. [Quantity of water : approx. 64L] © After changing the coolant, operate the machine for 5 minutes at the unloaded condition and stop it. Then check the coolant level again, and replenish if itis short. © For the details of replacement, refer to engine operation manual. 130137 ‘a160030 Caution changing coolant ‘When removing radiator cap, unfasten it to decrease ternal pressure while unlocking first step. After checking internal pressure decreased, unfesten the radiator cap ‘more until second step unlocked. Ifyou fail to conduct these processes, it might causes blowing radiator cap by SHG, internal pressure or gushing hot scalding vapor. LLC (Antifreeze) isa toxic material noosa | © Ifitshould be swallowed by mistake, itis necessary to see a doctor immediately instead of being sent out enforced, When a person gets LLC (Antifreeze) in his eyes, wash the eyes with clean running water and make him see a doctor immediately. When LLC (Antifreeze) is stored, put iin a container with an indication saying "LLC (Antifreeze) inside" and seal it up, then Keep it in a place away from children. Beware of lames 5-165.Periodic inspec: n/Maintenance 5.5.23 Change oil separator [Every 2,000 ho Replace the oil separator, in case consumption of compressor oil is too much and also compressor oil is mixed in discharged air even before timing of replacement. When replacing oil separator, contact directly us or distributor because it requires expert technical knowledge. (© When replacing oil separator “1”, make sure to replace gasket “2” at the same time. (For part number, See 5.4) © The ol separator “1” is made from electrically conducting material in order to be anti-static. ‘Also gaskets “2” are treated for conduction by using staplers. Make sure to use our genuine parts for replacement. ‘In order to pull out the separator, remove the bolts (6 pieces) fixing the top cover on the separator cover. @ Remove nylon tubes and copper pipes connected to the pipes and parts fitted on the soparator cover, using a spanner. @At first remove the flange joint (@) between separator outlet and pressure control valve. @ Remove the fixing bolts (10 pes.) of separator cover, using an impact wrench ete @ Screw two lifting eyebolts (M16) for the 2 threaded holes provided on the separator cover. @ Hook rope to lifting bolts, and remove separator cover while lifting with crane. Then pull out the separator. Lifting bolt (M16) | Separator cover fixing bolts Separator cover = Lifting bolt (M16) al et L Tightening torque of the bolts 210N- m (2, 100kgfcm) © When service valve open fully under operation, make sure pressure gauge of separator receiver inside shows O.4MPa. ® When the pressure is lower than 0.4MPa, replace spring with a new one.(For part number, See 5.4) @® When the indicator shows excessively higher pressure, you will find that the piston does not move smoothly due to foreign material and rust stuck inside valve. In ‘such a case, disassemble the component for checking and cleaning. © When replacing it, contact directly us or distributor because it requires expert technical knowledge. © When reassembling, apply sufficient grease to O-ring Slot/O-ring and sliding surface. Use CALTEX MULTIFAK EP1 grease or equivalent. Grease of poor quality will deteriorate the material.5.Periodic inspection/Maintenance ee 5.5.38 Check O-ring and piston of pressure control valve 6,000 hours or every 3 years) After disassembling and cleaning pressure control valve, check O ring “1”, “2” teflon ring “3” and piston “4”, (See 6.6.37) When the rubber of these parts is found hardened, or damaged, replace them. (For part number, see 5.4) When replacing it, contact directly us or distributor because it requires expert technical knowledge. 5.5.39 Change rubber coupling [Every 12,000 hours| When replacing it, contact directly us or distributor because it requires expert technical knowledge. 5.5.40 Change oil seal/bearing. Every 12,000 hours] When replacing it, contact directly us or distributor because it requires expert technical knowledge. 5.5.41 Change solenoid valve. ‘very 12,000 hours, ‘When replacing it, contact directly us or distributor because it requires expert technical knowledge.6. Storage of the Machine and Disposal of Product 6.1 Preparation for Long-term Storage When the machine is left unused or not operated longer than half a year (6 months), store it at the dry place where no dust exists after the following treatments have been done to it. © Put the machine in a temporary cabin if it is stored outside. Avoid leaving the machine outside with a sheet cover directly on the paint for a long time, or this will cause rust to the machine. © Perform the following treatments at least once every three months. © Drain existing lubricant from the engine oil pan. Pour new lubricant in the engine to clean its inside. After running it for a while, drain it again. ® Completely charge the battery and disconnect grounding wires. Remove the battery from the machine, if poseible, and store it in a dry place. (Charge the battery at least once every month) © Drain coolant and fuel from the machine, @ Seal the engine, air-intake port and other openings like the muffler with a vinyl sheet, packing tape, etc., to prevent moisture and dust from entering the machine. @® Be sure to repair any breakdowns and maintain the machine so that it will be ready for the next operation. 6.2 Disposal of Product In case of disposal of this machine, at first drain the cooling water and cils, When you have anything unclear or you want to advise us, contact our office nearby or distributor. 617.Specifications 7.1 Specifications Model PDSF1000DP-4C5, Ree | ‘Type stage oil cooled, screw type compressor og, | Preeai delivery 275 | & | Working pressure 1.03/0.7 & | Lubricating eystem Forced Lubrication by comproseed pressure Z | Driving system | Direct driving with rubber coupling ” | Receiver tank oxpacloy mt 0.224 Lubricating oil capacity L 110 Model KOMATSU SAA6D125E-5-A. ae “‘reyele, water-cooled, direct injection type with turbo charged doucter™ Gyindercieke, | ™ eupdsd g | Total displacement L 11.04 & | Rated output kWimint 247/1,900 © | Lubricating oil capacity L 41 Gnaluling raat) L ba Battery 170F61%2 (24V) equivalent Fuel tank capacity L 600 care = 4.00 df 8 | oth dwn ded up) am ‘70 5 (wih deer aid down) =m oa B | Overall width mm 2,000 & | Overall height mm 2,290 5 | Net dry mass kg 4.990 5,100 Operating mass _ [ie L 5,680 5,7907.Specifications 7.2 Outline drawing t SHE, ‘008 TRIES ‘0d.fy J9|009 saye arg 40} Ayres6 JO Ja1U30 ay) SeIBOPU] (3K ae Tero