AirMan PDS185S-6C1, Service Manual

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

Page 2: ...ie 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 Tsuru...

Page 3: ...unit If you should find any description which does not coincide with the instruction manual and parts catalog we request you to make sure to start the job after clarifying it Service personnel is req...

Page 4: ...arator 2 8 2 8 Change O Ring of Unloader 2 8 2 9 Check O ring and Needle valve of Auto relief valve and Vacuum relief valve 2 9 2 10 Performance check of Pressure control valve 2 9 2 11 Check Pressure...

Page 5: ...MPa 150 1 03 145 1 00 Ambient conditions temperature F 5 104 15 40 Ambient conditions altitude yd m less than 1 640 1 500 Engine Type NISSAN TD2714 Rated output hp min 1 kW min 1 44 8 2 500 33 4 2 50...

Page 6: ...scharge air temperature switch F more than 248 120 Fuel residual level gauge gal L less than about 3 8 14 5 Fuel filter drain gal ml about 0 03 0 05 120 170 to be drained Fuel consumption ratio At ful...

Page 7: ...05 120 170 Set value Air filter differential pressure psi kPa 0 9 6 23 Pressure control valve psi MPa 58 0 4 Actuating pressure of safety valve psi MPa 150 1 03 145 1 0 Unload starting pressure psi MP...

Page 8: ...1 Specification 1 4 1 3 Outline drawing A070357 Unit in PDS185S 6C1 VE PUMP Type D i s c o u n t E q u i p m e n t c o m...

Page 9: ...1 Specification 1 5 A070356 Unit mm PDS185S 6C1 VE PUMP Type D i s c o u n t E q u i p m e n t c o m...

Page 10: ...1 Specification 1 6 PDS185S 6C1R IN LINE PUMP Type A070195E Unit mm D i s c o u n t E q u i p m e n t c o m...

Page 11: ...gine For filtering the dust floating in the intake air 8 Engine oil filler port For supplying and replenishing engine oil to engine 9 Compressor oil filter For filtering compressor oil circulating in...

Page 12: ...or measuring compressor oil level 22 Radiator For cooling the coolant for engine because it is water cooled 23 Engine oil filter For filtering engine oil 24 Coolant drain valve For draining coolant fr...

Page 13: ...ch Purge control 4 Discharge air pressure 5 Fuel level gauge 6 Hour meter 7 Starter switch Indicator lamp 8 Glow 9 Auto idle Purge control Warning lamp 10 Charge 11 Compressor air filter clogging 12 E...

Page 14: ...uired to be checked Digital monitor After start d discharge air temperature is displayed It is possible to select such item by pressing the selector switch At each press d discharge air temperature E...

Page 15: ...ncreases Actuating resistance is more than 0 9psi 6 23kPa Clean Replace The compressor stops when the emergency stop lamp goes on Be sure to follow the measures shown below before starting the unit ag...

Page 16: ...erior of compressor air end becomes vacuum and vacuum noise is caused In order to prevent occurrence of vacuum noise it functions to open the vacuum relief valve detecting the secondary pressure of pr...

Page 17: ...essure regulator and speed regulator And when it decreases further the unloader valve closes gradually to raise intake negative pressure Negative pressure sensor PRS1 detects this rising negative pres...

Page 18: ...seconds Then digital monitor P flickers Adjust the purge release pressure VR3 to the set pressure value When pushing digital monitor selector switch 2 after having completed setting of VR3 the digita...

Page 19: ...1 Specification 1 15 1 7 Piping Diagram PC08091E D i s c o u n t E q u i p m e n t c o m...

Page 20: ...1 Specification 1 16 1 8 Fuel piping PDS185S 6C1 VE PUMP Type PC08018E D i s c o u n t E q u i p m e n t c o m...

Page 21: ...1 Specification 1 17 PDS185S 6C1R IN LINE PUMP Type PC08019 1E D i s c o u n t E q u i p m e n t c o m...

Page 22: ...e to prevent from entrance of dirt and foreign matters 2 Perform disassembly work in a dust free location whenever possible 3 When disassembling parts wash their outer surfaces and place them on a cle...

Page 23: ...1 8 0 67 17 421 485 0 47 12 0 75 19 370 425 0 39 10 0 75 19 734 845 0 55 14 0 87 22 586 675 0 47 12 0 87 22 1172 1350 0 63 16 0 94 24 916 1055 0 55 14 0 94 24 1823 2100 0 71 18 1 06 27 1260 1450 0 55...

Page 24: ...ssor kept stopping Making the rod length short engine speed increases Make adjustment so that such a little clearance which will never touch each other should be reserved between the high speed side s...

Page 25: ...00psi 0 69MPa by turning pressure adjusting screw speed regulator can start to function to lower engine RPM Tightening the screw the pressure rises and loosening it the pressure drops IMPORTANT Make s...

Page 26: ...body and cap and also both internal face and external face of diaphragm should be coated with molybdenum oxide spray How to spray molybdenum oxide paste The areas in oblique line should be sprayed wit...

Page 27: ...that the portion of diaphragm shown in right figure is seated intact If diaphragm is afloat it can cause diaphragm to be caught in when installing cap If the shaft is turned after installation is fini...

Page 28: ...Procedure Separate the sensor connector 1 provided at the lower part of fuel filter from the main wiring portion Loosen the drain valve 2 and then drain condensate and residual fuel staying inside th...

Page 29: ...n consumption of the oil is still unusual even after cleaning strainer in the scavenging orifice change the oil separator with a new one Tightening torque of separator cover attachment bolt 0 31 in 8...

Page 30: ...hile the machine is running make sure that the discharge pressure gauge shows the figure between 49 68psi 0 34 0 47MPa When the pressure is lower than 49psi 0 34MPa replace spring 3 with a new one Whe...

Page 31: ...odical replacement of the Inner pellet assembly but when such trouble as excessive rise of compressor oil temperature it becomes necessary to replace it in accordance with the following procedures Pro...

Page 32: ...35 in warm season Valve clearance Discharge in mm 0 014 0 35 in warm season Firing order 1 3 4 2 Injection timing BTDC 5 Nozzle injection pressure psi MPa 1422 9 81 Standard psi MPa 427 2 94 Rotation...

Page 33: ...tted less compared with inline pump Fluctuation among cylinders is reduced because of one set plunger only used 2 Excellent reliability VE pump has been originally developed to be used for diesel engi...

Page 34: ...lve Plunger Stop solenoid Control lever Governor spring Governor sleeve Collector lever Idol spring Tension lever Full load adjusting screw Governor lever ass y Stop solenoid Cam disk Plunger Ball hea...

Page 35: ...lectric System 3 3 3 1 2 Control Part number 46879 41400 PDS185S 6C1 VE PUMP Type for USA Part number 46879 45700 PDS185S 6C1R IN LINE PUMP Type for Asia PC08026E D i s c o u n t E q u i p m e n t c o...

Page 36: ...3 Electric System 3 4 1 Exterior connection drawing 1 PDS185S 6C1 VE PUMP Type PC08027E D i s c o u n t E q u i p m e n t c o m...

Page 37: ...3 Electric System 3 5 2 PDS185S 6C1R IN LINE PUMP Type PC08028E D i s c o u n t E q u i p m e n t c o m...

Page 38: ...3 Electric System 3 6 2 Function timing upon starting PC08029E D i s c o u n t E q u i p m e n t c o m...

Page 39: ...oat SW b contact Lamp goes on when 0 03 0 05gal 120 170 mL condensate is accumulated Always 10 sec Warning Compressor stops Emergency Compressor continues to run 2 PDS185S 6C1R IN LINE PUMP Type Item...

Page 40: ...resistance for detecting rise of discharge air temperature CN2 2 and of coolant temperature CN2 11 1 Connect resistance to controller as shown right Or use multi speed variable resistance resistance v...

Page 41: ...e No 1 terminal When starter switch is switched ON and voltage is applied to CN1 6 terminal interior contact RY3 between CN1 9 and CN1 3 turns ON to get electrically connected and to open the solenoid...

Page 42: ...re switch It is electrically connected during normal operation When engine oil pressure drops engine oil pressure switch turns OFF to cut electrical connection When electrical connection is cut interi...

Page 43: ...ases fuel level switch turns ON and gets electrically connected the contact RY1 between CN1 4 and CN1 8 terminals turns OFF to make engine emergency stop Residual fuel volume for emergency stop less t...

Page 44: ...al For separating starter motor When frequency of P terminal exceeds 190 10Hz starter relay contact is switched through controller and it disengages starter motor E B Earth For diagnosing P terminal c...

Page 45: ...g alternator because it is faulty Normal about 7 2V Abnormal less than 7 2V Check charging warning lamp circuit Disconnected check and confirm waning lamp circuit P terminal controller CN2 17 terminal...

Page 46: ...ter temperature 3 B Earth 4 L W Controller CN2 14 terminal Ignition of pre heating pre glow pre glow lamp 5 Y R Glow relay No 3 terminal Power supply for glow relay When voltage is applied to No 7 ter...

Page 47: ...ll be released from starting unloader operation mode and returns to normal operation AUTO IDLE SWITCH ON Pressing auto idle switch during operation it will be switched to purge control operation mode...

Page 48: ...emp F Resistance k Permissibl e Value 176 80 1300 7 203 95 840 6 230 110 560 5 239 115 490 6 Specification Setting pressure 8 7psi 0 06MPa Contact type A contact switch Contact ON in excess of set pre...

Page 49: ...gal L E 95 5 3 20 1 2 32 5 14 5 55 F 7 21 1 80 2 List of functions Pin No Line color Connection Remark 1 IG R Y 10A Fuse Power source for fuel gauge 2 U Y B Sending unit Detector for remaining fuel 3...

Page 50: ...em 3 18 3 1 10 Sending unit With fuel level switch Part number 36159 04100 PC08037E Pointer position Resistance Remaining fuel gal L E 110 5 3 20 1 2 32 5 14 5 55 F 3 21 1 80 D i s c o u n t E q u i p...

Page 51: ...ating switch inside filter gets ON for electrical connection to controller CN2 15 terminal After electrical connection to stop solenoid continues 10 seconds and it is cut it causes engine emergency st...

Page 52: ...ve it it is better to contact Bosch Service Department or injection pump assembly 2 Position of strainer installment inside VE pump Injection pump is equipped with a strainer in connector of fuel retu...

Page 53: ...number 44358 01200 PC08040 List of functions Pin No Line color Connection P1 L B Stop motor relay No 6 terminal NC P2 L Y Stop motor relay No 5 terminal NO E B Earth A R B Stop motor relay No 3 termi...

Page 54: ...elay 2 Engine starts PC08042E 1 When closing the ACC contact by handling the starter switch Operation position the circuit of controller inside contact between CN1 8 terminal and CN1 4 terminal stop m...

Page 55: ...erminal is connected to the grounding side Further it follows that the armature of the motor gets short circuited and so it is electrically braked so that the contact plate stops surely at the constan...

Page 56: ...on shown Fig e to the 360 position in Fig a via Fig f position At the same time when the contact plate rotates the wire is pulled to close fuel line circuit by the fuel line connected to injection pum...

Page 57: ...for failure diagnosis 2 Ask the clients about the trouble in details In order to prevent misunderstanding and incorrect judgment about the trouble it is necessary to ask users or operators about the...

Page 58: ...lar trouble Even if you have repaired the trouble unless you get rid of the fundamental cause of the trouble it will repeatedly occur Therefore perform full investigation of the trouble and it is abso...

Page 59: ...ity more than 1 26 1 Faulty Error in operation Turn valve to operation side Start side Operation side Faulty adjustment of pressure Re adjust pressure Faulty pressure gauge Faulty adjustment Adjustmen...

Page 60: ...ure regulator Replace it Faulty adjustment of pressure Re adjust pressure Check adjustment of pressure regulator Adjustment Change pressure gauge for replacement one and re adjust pressure gauge Fault...

Page 61: ...le clean Clogging Normal Check nozzle injection Faulty Replace it Normal Normal Repair the trouble and get rid of the cause Check engine compression Check unloader orifice for clogging Check rod lengt...

Page 62: ...semble clean or replace parts Faulty safety valve It burst at higher pressure Replace it Faulty diaphragm of pressure regulator Air leak No air leak No air relieved Air relieved Faulty pressure regula...

Page 63: ...ore than 49psi 0 34MPa Proper level Too much Arrange oil level to specified lever Check separator collection orifice and strainer Clogging Replace it No clogging Clean or replace it Faulty pressure co...

Page 64: ...it Repair the trouble and get rid of the cause Repair the trouble and get rid of the cause Filter clogging Normal Normal Normal Normal Faulty Faulty Faulty Check engine compression Check whether pres...

Page 65: ...le disconnected Key ON when stopping DC0 5V At unload less than DC0 5V Trouble of purge starting unloader solenoid valve At no load electrically connected Repair or replace Check wiring connection bet...

Page 66: ...voltage normal Service pressure and output voltage will not meet Replace it Not cable disconnected Repair connection Repair or replace Faulty setting of purge releasing pressure VR3 Trouble of servic...

Page 67: ...tion exists Unsuitable place of installation Faulty by pass valve Replace it Faulty compressor air end Repair More than 176 F 80 Lower than 176 F 80 Shortage of oil Replenish or replace Check fan belt...

Page 68: ...lace it Faulty oil pressure switch Replace it Normal Normal Proper Faulty Faulty Check engine oil pressure Faulty of engine lubrication system Repair the trouble and get rid of the cause Normal Abnorm...

Page 69: ...Soiled Wash and clean Normal Normal Normal Faulty Adjust or replace Relocation Check water quantity and quality in radiator More than 104 F 40 Lower than 104 F 40 Check radiator fin tubes Faulty sens...

Page 70: ...densate and perform air bleeding Condensate found Detective portion of fuel filter sensor or defective cable connection short circuited Faulty controller No condensate found Repair fuel filter or cabl...

Page 71: ...ature and coolant temperature sensor See 3 1 6 Engine could stop even due to disconnection of thermo sensor or thermo sensors short circuit 6 Check conductance between controller and discharge air tem...

Page 72: ...Switching OFF engine oil pressure switch enables engine emergency stop 9 Faulty of engine cooling system When any trouble is not found in thermostat coolant pump can be in disorder For the temperatur...

Page 73: ...SSAN 16403 J5500 Filter for fuel air bleeding electromagnetic pump 43540 05600 NISSAN 16400 H8501 Air control Speed regulator 36400 21400 36400 21900 36400 21400 Diaphragm 36437 01500 Pressure regulat...

Page 74: ...67 90063 Glow relay GR 44346 07200 Starter relay SR 44346 07200 Motor stopper 44358 01200 NISSAN 19801 90011 Motor stopper relay MSR 44346 07300 NISSAN 25230 C9900 Fuse 10A 46934 03200 Fuse 20A 46934...

Page 75: ...5 3 5 2 Engine Wiring Diagram PDS185S 6C1 VE PUMP Type PC08046E D i s c o u n t E q u i p m e n t c o m...

Page 76: ...5 4 PDS185S 6C1 VE PUMP Type PC08047E D i s c o u n t E q u i p m e n t c o m...

Page 77: ...5 5 PDS185S 6C1R IN LINE PUMP Type PC08048E D i s c o u n t E q u i p m e n t c o m...

Page 78: ...5 6 PDS185S 6C1R IN LINE PUMP Type PC08090E D i s c o u n t E q u i p m e n t c o m...

Page 79: ...D i s c o u n t E q u i p m e n t c o m...