AirMan PDS100S-6B4, Instruction Manual

Page 1: ...www discount equipment com D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...nie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...

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Page 4: ...1 3 2 Towing the Unit 3 2 4 Installation 4 1 4 1 Location and Installation 4 1 5 Periodic Inspection Maintenance 5 1 5 1 Important Items as Periodic Inspection and Maintenance or after Maintenance 5 1 5 2 Daily Inspection and Operation Log 5 2 5 3 Periodic Inspection List 5 3 5 4 Periodic Replacement of Parts 5 5 5 5 Items and Places of Inspection 5 6 5 6 Maintenance Items 5 7 6 Maintenance Adjust...

Page 5: ...ation which if not avoided 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 result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe ...

Page 6: ...cur TR0086 Maintain both physical and mental health Do not operate the machine you are tired intoxicated or under the influence of drugs Operation under these circumstances may cause unexpected injury or accident Maintain your physical and mental health and be cautious in handling the machine Air pressurized construction method prohibited Never use the unit directly or indirectly for the following...

Page 7: ...ain a near thing blows away or there is a possibility of a hose whipping causing a phenomenon and getting seriously injured In order to use it safely please read the handling of the work tools often used Transportation When loading and unloading unit be sure to use the lifting bail provided on the center of the unit top Never get under the unit which is suspended it is very dangerous When unit is ...

Page 8: ...ration 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 and LOWER level without any delay Do not charge a frozen battery Otherwise it may explode If the battery is frozen warm it up until the battery temperature ...

Page 9: ...ty TR0085 Safety fittings Have first aid kits and fire extinguishers near the unit ready for emergency situations It is advisable to have a list of phone numbers of doctors ambulance and the fire department available in case of emergency TR0096 Safety around the machine Unnecessary equipment and tools cables hoods covers which are a hindrance to the job have to be removed D i s c o u n t E q u i p...

Page 10: ...performing any maintenance W010 Draining during operation prohibited Do not under any circumstance open the items listed below during operation Separator receiver tank drain valve Coolant drain valve and plug Engine oil drain plug Oil cooler drain plug PK0028 Beware of cooling fan Never put your hand near the engine cooling fan during operation W009 Hands off from rotating parts and belts Keep han...

Page 11: ...t manifold exhaust pipe muffler radiator oil cooler compressor piping separator receiver tank and discharging pipe are especially hot so never touch those parts because it could cause serious burns Compressor oil coolant water and engine oil are also very hot and dangerous to touch Avoid checking or refilling them while the unit is running H990432 Operation with compressed air supply port opened i...

Page 12: ...Inspection and Maintenance Hang a Now Checking and under Maintenance tag Remove the starter key from the starter switch before starting inspection and hang up a Now 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 SY001 Refilling of compressor oil When you refill the separato...

Page 13: ...ot fail to make sure that there is no residual pressure in the air piping Then begin repair and maintenance Residual air under pressure can cause severe injury W010 Adjusting tension of fan belt Be sure to stop the engine and remove the starter key whenever the tension of the fan belt is to be adjusted Remove the negative side cable from the battery If the machine is running it might catch the ope...

Page 14: ... machine and allow time to cool Then loosen the radiator cap one notch After the coolant water is sufficiently cooled and the inner pressure is released take the cap off If this procedure is neglected the inner pressure can blow off the cap Steam jetting out of the radiator could result in scalding Follow this procedure under all circumstances H990432 Opening coolant water drain valve cap Be sure ...

Page 15: ...rm the periodical check of compressor oil and oil separator Neglecting checks could cause overheat of the oil resulting in a fire H990433 Disposal of waste liquid etc Waste liquid from the machine contains harmful material Do not discharge it onto the ground or into the river lake or sea Such material will contaminate the environment Be sure to use a container to hold the waste liquid from the mac...

Page 16: ...a new one to the original place 1 Caution exhaust gases 39176 73300 2 Caution radiator cap hot water 39176 69600 3 Lifting bail 39176 69300 4 Caution cooling fan 39176 73500 5 Caution high temp 39176 69500 6 Caution fan belt 39176 73800 7 Caution Fire 39176 69700 8 Caution residual pressure 39176 69800 9 No fire 39176 35600 10 Caution Do not inhale 39176 73600 11 Caution hose whipping 39176 73400 ...

Page 17: ... Operation 2 1 2 1 Unit Appearance and Part Names A030132 1 Exhaust outlet 2 Lifting bail 3 Door 4 Handle 5 Service valve 6 Drawbar 7 Instrument panel PDS185S 6B4 D i s c o u n t E q u i p m e n t c o m ...

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Page 21: ...cause serious injury PK0028 Pull the handle forward to open the door Be sure to close the door tightly so that its latch is firmly caught 2 6 Check before Starting Unit Check before starting the unit Be sure to check the unit before operation When any abnormality is found be sure to repair it before restarting the unit Be sure to make daily checks before operation If the unit is operated without p...

Page 22: ...eck coolant level 4 Drain water sedimenter 5 Draining of separator receiver tank 6 Check compressor oil level 7 Drain fuel tank 8 Check engine oil level Check wiring of each part Check piping of each part 6 5 7 8 1 2 3 4 PDS185S 6B4 PDS100S 6B4 PDS130S 6B4 1 D i s c o u n t E q u i p m e n t c o m ...

Page 23: ...ange the oil See 5 6 1 Never fill oil more than HIGH level 2 6 3 Check Coolant Level Taking off the radiator cap Be sure to stop the machine and allow time to cool Then loosen the radiator cap one notch After the coolant water is sufficiently cooled and the inner pressure is released take the cap off If this procedure is neglected the inner pressure can blow off the cap Steam jetting out of the ra...

Page 24: ...the middle level replenish oil See 5 6 5 2 6 5 Draining of Separator Receiver Tank Draining of Separator receiver tank After stopping the engine confirm that the pressure gauge indicates 0 psi 0 bar and there is no residual pressure in it then open the drain valve gradually to drain the compressor oil Note residual pressure in the receiver tank could force both extremely hot compressed air and oil...

Page 25: ... Be sure to use diesel fuel oil for diesel engine use Using other oil will cause low power or damage to the engine Check fuel level gauge before operation Replenish enough fuel to prevent fuel shortage during operation if the level is low When refueling fill a fuel tank up to the base of fuel filler port 4 Never overfill fuel because it may cause fuel leakage Be sure to fasten the fuel tank cap fi...

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Page 27: ... 6 0 to 8 0 mm when pushed by fingers and adjust it Be careful not to leave any grease or LLC on a belt while changing it If any such material is left wipe it off completely Long life coolant PDS185S 6B4 Procedure Adjust the tension by gradually loosening the fastening bolt of the alternator Visually check if there are any cracks or tears in the belt Loosen the fastening bolt of the alternator unt...

Page 28: ...ed with its port open be sure to mount a silencer to reduce noise and wear protective materials such as earplugs to prevent damage to hearing D003 Since this equipment is provided with a quick glow system quick preheating device you do not have to turn the starter switch counterclockwise from STOP position Turn the starter switch to the RUN position and the preheating will be completed in several ...

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Page 30: ...s pumping and automatically bleed air caught in the fuel pipes Air bleeding will be completed within 40 to 50 seconds Start the machine following the starting procedures mentioned in 2 7 1 If starting fails one time repeat the abovementioned procedures After finishing the air bleeding operation never leave the starter switch placed on Run position because the battery is discharging 2 7 4 Operation...

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Page 32: ... chains and use correct tow hitch Check operation of lights and brakes before towing Check wheel lug nuts for proper torque Lifting up Before lifting the unit up make sure to check the lifting bail ２ for any crack and loosened bolts Connect the hook 1 of the crane or shackle with lifting bail 2 eye fitted at the top center of the unit and make sure that there is no person standing around the unit ...

Page 33: ...uts Abnormal wear or damage to the tires Damage of drawbar Be sure to use a vehicle with enough capacity to tow the unit in operating weight Do not tow the unit without unfastening tool equipment and hoses Keep hands and fingers clear during hook up or unhooking drawbar If you do not follow the above instructions it could cause serious injury or big damage D i s c o u n t E q u i p m e n t c o m ...

Page 34: ...ithin 15 degrees Be sure to put one set of chocks 1 to the wheels A000054 The machine should be operated in following conditions Ambient temperature 5 F to 104 F 15 C to 40 C Humidity Less than 90 Altitude Lower than 1 500 m above sea level Install the machine in a place with good ventilation lower temperature and with surroundings as dry as possible If more than two machines are placed parallel i...

Page 35: ...ocedure is neglected and another person starts operating the machine during check or maintenance it could cause serious injury Use tools appropriate for the inspection and maintenance Any makeshift or improper tools could cause unexpectedly injury by their slippage SY001 For protecting oil separator from fire accident Be sure to perform oil change basically according to the specified interval But ...

Page 36: ...ion of the manual for the details of inspection Pay attention to and carefully observe the following points during daily operation or inspection and maintenance work If any trouble or abnormality is found immediately investigate its cause and make repairs If the cause is unknown or not traceable or if the trouble involves a part or component not described in the manual ask your nearest dealer for ...

Page 37: ...alve of auto relief valve 5 16 Such items marked shall be carried out by customers For the following items or clauses marked contact us directly or our distributors because they require expert technical knowledge on them The following table shows the inspection and maintenance intervals under normal operation conditions In case the unit is operated under harsh environmental conditions and operatio...

Page 38: ...ectromagnetic pump PDS185S only Change 5 12 Clean and change air filter element Clean Change 5 11 Change fuel filter 5 11 Change sedimenter element and O ring PDS100S 130S only 5 12 Change coolant 5 14 Clean inside of radiator 5 13 Clean outside of radiator 5 13 Change rubber hose 5 15 Clean inside of fuel tank 5 15 Engine Change radiator hoses 5 16 The items or parts marked show that they should ...

Page 39: ... PDS130S 6B4 SHIBAURA 052100440 1 Fuel filter Element PDS185S 6B4 NISSAN 16403 J5500 1 Element 4 SHIBAURA 130366110 1 O ring 5 PDS100S 6B4 SHIBAURA 052100440 1 Element 4 SHIBAURA 130366110 1 Sedimenter O ring 5 PDS130S 6B4 SHIBAURA 052100440 1 Separator 34220 12801 1 Oil separator O ring 03402 15140 1 Filter for electromagnetic pump PDS185S 6B4 43540 05600 1 5 4 2 Diaphragms O Rings Part Name Part...

Page 40: ...e fuel filter 9 Clean outside of the radiator and oil cooler 10 Clean inside the radiator 11 Change coolant 12 Change oil separator 13 Clean strainer in the scavenging orifice 14 Check O ring and needle valve in the auto relief valve 15 Change compressor oil 16 Check battery 17 Change compressor oil filter 18 Clean inside the fuel tank Change nylon tubes Change rubber hoses and pipes 1 2 3 5 9 10 ...

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Page 43: ...g on the temperature and other environmental conditions Select one from the recommended oil listed below Maker and Brand of Recommended Oil Maker Brand HULS ANDEROL 3032 MOBIL RARUS SHC 1024 TEXACO SYN STAR DE32 Even continuous oil replenishment cannot improve its deteriorated condition Be sure to change the oil completely at every scheduled interval Do not mix it with other brand oil or it will c...

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Page 47: ...nd fins should be cleaned depending on the state of clogged fin tubes 1 even before 1 000 hours maintenance schedule Do not use a high pressure washer to protect fin tubes from being damaged 5 6 14 Clean inside of Radiator Every 1 000 hours 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 ...

Page 48: ...ng LLC Antifreeze inside and seal it up then keep it in a place away from children Beware of flames Quality of coolant and antifreeze Use soft water of good quality such as tap water for coolant When water with dirt 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...

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Page 51: ...d to be re adjusted such as when the unit has been disassembled Ask your nearest dealer if you have any questions Procedure Stop the compressor and adjust the length of the rod 3 which is connected to the speed regulator 2 until its engine governor lever 1 is pulled fully to its high speed side By shortening length of L the regulator increases high speed If the engine governor lever 1 does not rea...

Page 52: ... 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 and LOWER level without any delay Do not charge a frozen battery Otherwise it may explode If the battery is frozen warm it up until the battery temperature becomes 61 F to 86 F 16 C ...

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Page 54: ...sion Check Fasten Discharge air temperature lamp goes on 1 Oil cooler clogging 2 Oil filter clogging 3 Faulty discharged air temperature switch 4 Looseness disconnection of wiring or connectors 5 Slippage of fan belt 6 Shortage of compressor oil 7 Malfunction of by pass valve Clean Change Check Change Check Fasten Adjust tension Replenish oil Fuel residual level lamp goes on 1 Fuel runs short 2 Ma...

Page 55: ... clogging 3 Faulty speed regulator 4 Engine trouble 5 Fuel filter clogging Re adjust Disassemble Clean Disassemble Check Call your nearest dealer Disassemble Change Revolution drops before discharge air pressure reaches 100 psi 6 9 bar 1 Pressure regulator insufficient adjustment 2 Trouble of pressure regulator 3 Unloader orifice clogging Re adjust Fasten Change Disassemble Check Engine does not r...

Page 56: ...he engine oil pan Pour new lubricant in the engine to clean its inside After running it for a while drain it again Spread lubricant on moving parts like speed regulator and rod end beforehand Completely charge the battery and disconnect grounding wires Remove the battery from the unit if possible and store it in a dry place Charge the battery at least once every month Drain coolant and fuel from t...

Page 57: ...m Direct driving with gear coupling Operating mass lb kg 1 907 865 Receiver tank capacity cu in m3 1 833 0 030 Fuel tank capacity gal L 18 5 70 Compressor Lubricating oil capacity gal L 3 7 14 Model SHIBAURA S773L C Type Water cooled 4 cycle pre chamber type Number of cylinders bore stroke in mm 3 3 03in 3 19in 3 77mm 81mm Total displacement cu in L 69 1 131 Rated output hp rpm kW min 1 27 1 3 425...

Page 58: ... with gear coupling Operating mass lb kg 2 116 960 Receiver tank capacity cu in m3 1 833 0 030 Fuel tank capacity gal L 18 5 70 Compressor Lubricating oil capacity gal L 3 7 14 Model SHIBAURA N843L C Type Water cooled 4 cycle direct injection Number of cylinders bore stroke in mm 3 3 31in 3 94in 3 84mm 100mm Total displacement cu in L 101 1 662 Rated output hp rpm kW min 1 37 5 3 000 28 0 3 000 Lu...

Page 59: ...t driving with gear coupling Operating mass lb kg 2 480 1 125 Receiver tank capacity cu in m3 1 833 0 030 Fuel tank capacity gal L 24 90 Compressor Lubricating oil capacity gal L 4 2 16 Model NISSAN TD27 Type Water cooled 4 cycle pre chamber type Number of cylinders bore stroke in mm 4 3 78in 3 62in 4 96mm 92mm Total displacement cu in L 162 5 2 663 Rated output hp rpm kW min 1 51 6 2 600 45 7 2 4...

Page 60: ...9 Wiring Diagram 9 1 PDS100S 6B4 PDS130S 6B4 A050044E D i s c o u n t E q u i p m e n t c o m ...

Page 61: ...9 Wiring Diagram 9 2 PDS185S 6B4 A030125 D i s c o u n t E q u i p m e n t c o m ...

Page 62: ...10 Piping Diagram 10 1 PDS100S 6B4 A050211 D i s c o u n t E q u i p m e n t c o m ...

Page 63: ...10 Piping Diagram 10 2 PDS130S 6B4 A050222E 1 D i s c o u n t E q u i p m e n t c o m ...

Page 64: ...10 Piping Diagram 10 3 PDS185S 6B4 A050228 D i s c o u n t E q u i p m e n t c o m ...

Page 65: ...nie Terex JLG MultiQuip Mayco Toro Stone Diamond Products Magnum Airman Mustang Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Brothers Essick Miller Spreader Skyjack Lull Skytrak Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...