Preface

◆ This manual explains and illustrates proper handling of the unit and the method of daily inspection and
maintenance thereto to enhance the performance of AIRMAN’s compressors.

◆ Before operating the unit, read the manual carefully and fully understand its operation and
maintenance requirement. Then keep “SAFETY OPERATION AND PROPER MAINTENANCE OF
THE UNIT”.

◆ For details of handling, maintenance and safety of an engine, see the Engine Operation Manual.

◆ Keep the manual available at all times for the operator or safety supervisor.

◆ In case the manual is lost or damaged, place an order with your dealer for another copy.

◆ Make sure that the manual is included with the unit when it is handed over to another user.

◆ There may be some inconsistency in detail between the manual and the actual machine due to
improvements of the machine. Ask your dealer if you have any questions or problems.

◆ If you need any inquiry about the unit, please inform us of the model and serial number of the unit too.
A plate stamped with type of model and serial number is attached to side of the unit.

◆ Each illustrated figure (Fig.) has a number ( for instance, A990054 ) at the right bottom. This number
is not a part number, but it is used only for our reference number.

A990054

Be sure to follow safety warnings and cautions given in the manual. Unsafe operation could cause
serious injury or death.
 Table of Contents
1. Safety ....................................................................................................................................................... 1-1
1.1 Caution before Operation ................................................................................................................ 1-2
1.2 Caution during Operation ................................................................................................................ 1-5
1.3 Caution during Inspection and Maintenance ................................................................................... 1-7
1.4 Safety Warning Labels .................................................................................................................... 1-10

2. Part Names .............................................................................................................................................. 2-1

2.1 Unit Appearance and Part Names ................................................................................................... 2-1
2.2 Internal Components and Part Names ............................................................................................ 2-2

3. Installation ............................................................................................................................................... 3-1

3.1 Transportation .............................................................................................................................. 3-1
3.2 Handling the Drawbar ................................................................................................................... 3-2
3.3 Towing the Unit ............................................................................................................................... 3-3
3.4 Location and Installation ................................................................................................................... 3-4

4. Operation ................................................................................................................................................. 4-1

4.1 Instrument panel ............................................................................................................................ 4-1
4.2 Door ................................................................................................................................................. 4-2
4.3 Check before Starting Unit ........................................................................................................... 4-3
4.4 Unit Operation ................................................................................................................................ 4-7
4.5 Stopping Procedures..................................................................................................................... 4-12

5. Periodic Inspection/Maintenance .......................................................................................................... 5-1

5.1 Important items as Periodic and Maintenance or after Maintenance .............................................. 5-1
5.2 Daily Inspection and keeping Operation Log ................................................................................... 5-2
5.3 Periodic Inspection List ................................................................................................................... 5-3
5.4 Periodic Replacement of Parts ......................................................................................................... 5-4
5.5 Maintenance ..................................................................................................................................... 5-5
5.6 Inspection on Separator Receiver Tank............................................................................................ 5-16

6. Maintenance/Adjustment ....................................................................................................................... 6-1

6.1 Maintenance of Battery ..................................................................................................................... 6-1
6.2 Troubleshooting ................................................................................................................................ 6-3

7. Storage of the Unit ................................................................................................................................. 7-1

7.1 Preparation for Long-term Storage ................................................................................................. 7-1

8. Specifications ......................................................................................................................................... 8-1

8.1 Specifications.................................................................................................................................... 8-1
8.2 Outline drawing .............................................................................................................................. 8-2

9. Wiring Diagram ....................................................................................................................................... 9-1 1

10. Piping Diagram ....................................................................................................................................... 10-1 1

 1.Safety
This manual explains and illustrates general requirements for safety.

Read all safety requirements carefully and fully understand the contents before starting the machine.

For your better recognition, according to the degree of potential danger, safety messages are classified
into three hierarchical categories, namely, , , and with a caution sym-
bol －attached to each message.

When one of these messages is shown, please take preventive measures and carry out “SAFETY OP-
ERATION AND PROPER MAINTENANCE OF THE UNIT”.

DANGER indicates an imminently hazardous situation 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 practices.

IMPORTANT indicates important caution messages for the performance or

durability of the unit.

Follow warnings mentioned in this manual. 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.

1-1
 1.Safety
1.1 Caution before Operation
Compressed air is prohibited to be used for human respiration

Compressed air by this unit contains poisonous

materials. Absorption of the compressed air can
cause serious injury. Never provide this compressed
air for human respiration.
This unit is not designed to be used for working
TR0201-1
chambers pressurized by compressed air such as
respiratory air provided to persons working inside
wells and tunnels such as pneumatic engineering
method and pneumatic caisson method. Should this
unit stop operation due to trouble, it can cause death
and serous injury to the working persons. Refrain
from using the compressed air for such pneumatic
engineering method or pneumatic caisson method.

A080001

Ventilation

Exhaust gas from the engine is poisonous, and could cause

death when inhaled.
Avoid using the machine in an insufficiently ventilated building
or tunnel.
PC002

Follow the safety instructions

Read each instruction plate which is displayed in the manual or

on the unit carefully, understand its content and follow the in-
dications thereof.
Keep the Safety Warning labels clean. When they are dam-
aged or missing, apply new ones.
Do not modify the machine without prior approval. The safety
may be compromised, functions may be deteriorated, or ma-
chine life may be shortened.
Never use the unit for the purpose of compression of gases
other than air, or as a vacuum pump. Otherwise, serious acci- TR0086
dents may occur.

Maintain both physicl and mental health

Do not operate the machine when you are tired or drunk or under the influence of drugs. Otherwise,
a hasty conclusion or careless handling may cause unexpected injury or accident.
Manage your physical and mental health and be cautious in handling the machine.

1-2
 1.Safety

Safety outfit

When handling machine, do not wear;

loose clothes
clothes with unbuttoned sleeves
hanging tie or scarf
accessories such as dangling jewelry
Such outfit could be caught in the machine or dragged in the
rotating portion of the machine, and this could cause a serious
injury.
TR0084

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 possibility of piping or a hose sepa-
rating and getting seriously injured.
TR0068
Please remove after closing a service valve and extracting
pressure remained, in case piping or a hose is removed. If pres-
sure remained should remain, 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. TR0303A

Handling battery

Keep flames away from battery.

Battery may generate hydrogen gas and may explode.
Battery electrolyte is dilute sulfuric acid.
In case of mishandling, it could cause skin burning.
Wear protective gloves and safety glasses when handling a
battery.
Dispose of battery, observing local regulations.
D004

TR0093

1-3
 1.Safety

Protection equipments

Please wear protection implements, such as a helmet, protec-

tion glasses, earplugs, safety shoes, a glove, and a protec-
tion-against-dust mask, according to the contents of work for
safety.

TR0085

Safety fittings

Have first-aid boxes and fire-extinguishers near the unit ready

for emergency situations such as injuries and a fire.
It is advisable to have a list of phone numbers of doctors, am-
bulance and the fire department available in case of emer-
gency.

TR0096

Safety around the machine

Such things as unnecessary equipment and tools, cables, hoods, covers and pieces of wood which
are a hindrance to the job, have to be cleaned and removed. This is because operators and/or per-
sonnel nearby may stumble on them and may be injured.
Place safety enclosures at the entrance of and around working site to prevent children or outside
people from entering the site.

1-4
 1.Safety

1.2 Caution during Operation

Do not replenish compressor oil during operation

Do not, under any circumstance, open the oil filler cap of

separator receiver tank while running or immediately after
stopping operation.
It is very dangerous because the oil filler cap could be blown
off and high temperature compressed air and oil could jet out
from the filler port, and cause serious injury.
WR011

Draining during operation prohibited

Do not, under any circumstance, open the portions below dur-

ing operation:
Separator receiver tank drain valve
Coolant drain valve and plug
Engine oil drain valve
Oil cooler drain valve
PK0028

Hands off from rotating parts and belts

Keep hands off from the rotating portion or belts while run-
ning.
It could cause serious injuries if hands should be caught in.

TR0304

Never direct the compressed air to people and foods

Never blow compressed air directly at people.

Scattered impurities, dust, or foreign objects in the compressed
air may cause skin and eyes to be seriously injured.
Blowing compressed air on food is prohibited.

TR0092

Do not remove radiator cap during operation

Do not, under any circumstance, open the radiator cap while

running or immediately after stopping operation. Otherwise
high temperature steam jets out and this could cause scalding.

W005

1-5
 1.Safety

Do not touch hot parts

Never work nearby hot portions of the machine while it is run-

ning.
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, 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
W005
hot and dangerous to touch.
Avoid checking or refilling them while the unit is running.

Operation with 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 its air pressure could cause
injury to the people nearby.
When the machine has to be unavoidably temporarily operated
with its port open, be sure to mount a silencer to reduce noise
and wear protective materials such as earplugs to prevent
damage to hearing. D003

Fire prevention

Do not, under any circumstance, bring lit cigarettes or matches

near such oils as engine oil and compressor oil, etc.
They are extremely flammable and dangerous, so be careful
when handling.
Refilling oils should be done in an outdoor well-ventilated
place.
Do not fill fuel oil up to the cap lever. When fuel tank is
D004
filled up to the cap level, fuel oil will be overfilled due to
volume expansion caused by rise of ambient temperature.
Further, fuel will be possibly spilled from fuel tank due to
vibration caused during movement and/or transportation
of machine.
Such parts as muffler and exhaust pipe can be extremely hot.
Remove twigs, dried leaves, dried grass and waste paper, etc.
from the exhaust outlet of the muffler. W004
Keep a fire extinguisher available by the machine in case of a
fire.

1-6
 1.Safety
1.3 Caution during 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 Mainte-
nance” 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.
If the above procedure is neglected, and another person starts
operating the machine during check or maintenance, it could
cause serious injury.

SY001

Refilling of compressor oil

When you refill the separator receiver tank with compressor

oil, stop the engine, and make sure that the pressure gauge
indicates 0MPa and there is no residual pressure in it, and then
gradually loosen the oil filler cap for refilling oil.
Note residual pressure in the separator receiver tank could
force both extremely hot compressed air and oil to jet out and
you may be scalded or seriously injured. W011

Draining separator receiver tank

After stopping the engine, confirm that the pressure gauge in-
dicates 0MPa and there is no residual pressure in it, then open
the drain valve gradually to drain the compressor oil.
Note residual pressure in the separator receiver tank could
force both extremely hot compressed air and oil to jet out and
you may be scalded or seriously injured.

W005

Be careful of high-pressurized air blowout

After stopping the engine, make sure that pressure gauge in-
dicates 0MPa. Even when the gauge shows 0MPa, open a
service valve and further do not fail to make sure that there is
no residual pressure in the air piping. Then start such a job as
repair and maintenance.
Residual air under pressure will blow off and severely injure
operator. W011

1-7
 1.Safety

Adjusting tension of fan belt

Be sure to stop the engine and remove the starter key when-
ever 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 operator’s hand
into the fan belts, and this could cause a serious injury.

TR0304

Hands off from cooling fan

Be sure to stop the engine and remove the starter key when-
ever check or maintenance work is carried out near the cooling
fan.
If the cooling fan is rotating, it may catch the operator or part
of his body into the fan, and it could cause a serious injury.

W009

Cleaning by air-blow

When cleaning dust accumulated in such devices as the

air-filter, by blowing compressed air, wear safety glasses, etc.
to protect your eyes.

M003

Lighting apparatus

It is recommended to use a lamp with safety guard fitted where

the site is dark.
Operating the machine gropingly or by relying on one’s intuition
could cause unexpected accidents.
Any lamps without safety guard are not recommended since
they can be broken and they could ignite flammables such as
fuel, etc. TR0206

1-8
 1.Safety

Opening coolant water drain valve cap

Be sure to stop the engine, and let the coolant water suffi-
ciently cool down before draining it.
If the drain valve is opened before the coolant water is cooled
enough, hot water could jet out, and it could cause scalding.

W005

Refilling or draining of engine oil

After stopping the engine, wait for 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 oil is very hot and highly pressurized during or just af-
ter the operation. Hot oil could blow out of the tank and can
cause scalding.
W005

Fear of fire

Be sure to perform the periodical check of compressor oil and

oil separator.
Neglecting checks could cause overheat of the oil, resulting in
a fire.

W004

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 machine.
Be sure to follow the designated regulations when disposing of oil, fuel, coolant (antifreeze), filter,
battery or other harmful materials.

1-9
 1.Safety
1.4 Safety Warning Labels
Following labels are attached to the machine.
Keep them clean all the time. If they are damaged or peeled off, immediately place an order with
your nearest dealer for replacement, with the number indicated on the lower right corner of the
label. Adhere a new one to the original place.

7 10 5
11
4

8 6

A030281E

1. Caution, Do not inhale 3. Caution, hose whipping 5. Caution, radiator cap 7. Caution, high temp. 9. Caution, fire 11. Caution, fan belt
(39176 73600) (39176 73400) (39176 69600) (39176 69500) (39176 69700) (39176 73800)
2. Caution, exhaust gases 4. Parking brake 6. Caution, cooling fan 8. Caution, residual pressure 10. Lifting bail
(39176 73300) (39176 38700) (39176 73500) (39176 69800) (39176 69300)

1-10
 2. Part Names
2.1 Unit Appearance and Part Names

4 5 4

1 2

4 5 4
6
A030279

1. Lifting bail 5. Handle

2. Exhaust outlet 6. Service valve
3. Drawbar 7. Instrument panel
4. Door

2-1
 2. Part Names

2.2 Internal Components and Part Names

1 2 3 4 5 6 7 8 9 10 11 12 13 14 27 28 29 30 31

15

17

16

22 26 25 24 23 22 21 20 19 18 36 35 35 34 33 32

A030293

1.Header tank 10.Unloader regulator 19.Engine oil drain valve 28.Air filter element (engine)
2.Reserve tank 11.Safety valve 20.Compressor oil filler port 29.Engine oil filter
3.Engine 12.Vacuumrelief valve 21.Compressor oil level gauge 30.Coolant drain plug (engine)
4.Fuel filter 13.Auto-relief valve 22.Fuel tank 31.Compressor oil filter
5.Filter for fuel air-bleeding electromagnetic pump 14. Pressure regulator
23.Fuel tank drain valve 32.Exhaust muffler
6.Fuel air-bleeding electromagnetic pump 15.Differential pressure gauge for oil separator
24.Engine oil level gauge 33.Oil cooler
7.Water sedimenter 16.Pressure control valve
25.Coolant drain valve (radiator) 34.Oil cooler drain valve
8.Speed regulator 17.Separator Receiver Tank
26.Radiator 35.Battery
9. Engine oil filler port 18.Drain valve for separator receiver tank
27.Air filter element (compressor) 36.Compressor air-end

2－2
 3. Installation
3.1 Transportation

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, because it is very dangerous.
When unit is transferred or moved from working site, be sure to place it on truck bed, and fasten it by
ropes at the front and rear hooks.
Be sure to put one set of chocks to fix its wheels firmly on the truck bed. Never lift unit which is still in
operation, or it could cause critical damage to each component or lead to serious accident.

Lifting up
① Before lifting the unit up, make sure to check the lifting
bail “2”for any crack and loosened bolts.
② Connect the hook“1”of the crane or shackle with lifting bail
1
“2”eye fitted at the top center of the unit, and make sure
2
that there is no person standing around the unit. Then 3
perform hoisting operation. 3
③ Use auxiliary ropes“3”to prevent the unit from swinging
and/or twisting, giving signs and signals each other.
④ Select a truck or a crane with capacity sufficient for weight
and size of the unit by referring to the values shown in
Chapter 8 “Specifications“ of the manual.
A030117
⑤ Never lift the unit while it is running, or this could cause
a serious accident.

Mounting the unit on the truck bed

Be sure to fasten the unit with ropes“1”as shown in the
figure right, and securely fix it on the truck bed.
Be sure to put one set of chocks“2”to the wheels pull the
parking brake lever it firmly after the unit is loaded on the
truck bed.

1 2 2 1

A010190

3-1
 3. Installation
3.2 Handling the Drawbar
Precautions on handling drawbar

When the drawbar“1”is raised up for transportation, be sure to

secure it by engaging the drawbar hook“3”with the holder“2”without
1 2 4
fail.
If the drawbar hook comes off the drawbar falls down, causing
serious injury. Lock position
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, 3 H000466
the hook“3”could come off the holder“2”, causing the drawbar“1”
to fall down. Release position
Handle the hook“3”holder“2”and stopper“4”so carefully to prevent
your fingers from being caught and injured.

M970092

3.2.1 How to secure the drawbar

① Place the drawbar“1”to the front of the machine so that 1
the wheel tires can be aligned.
② 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 so the drawbar
cannot be firmly fixed. (See Fig.2)
③ Make sure that drawbar hook“3”is securely engaged with
the holder“2”.
④ Make sure that the stopper “ 4 ” stays at the lock
H000480
position.(See Fig.1)

1 2 4 Release position

Lock position

3
H000466 M970098

Fig.1 Fig.2

3-2
 3. Installation
3.2.2 How to release the drawbar
Push the fixed drawbar “ 1 ” against the machine in the
direction of arrow mark.(See Fig.3)
Turn the stopper“4”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“1”.
Return the stopper“4”to the lock position. Fig.3
1
3
4

M970095

3.3 Towing the Unit

When towing unit, make sure there is no person or obstacle at

both front and rear sides and under the unit.
Although the machine is designed to be drawn, drawing is
allowed only in construction site.
Towing speed should be within 20 km/h.

H000467

Caution for towing unit

Be sure to use a vehicle with enough capacity to tow the unit in operating weight.
Standard pressure for a tire is at 0.45MPa.
Be sure not to use wrong size or type of tire in changing.
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 unit is being towed.
Make sure if there is no deform or damage on the drawing vehicle and the drawbar of the unit.
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.

3-3
 3. Installation
3.4 Location and Installation

Ventilation

Exhaust gas from the engine is poisonous, and could cause

death when inhaled.
Avoid using the machine in an insufficiently ventilated building or
tunnel.
Do not position the exhaust gas outlet in direction of a person or
a house. PC002

The machine should be operated in following conditions:

Ambient temperature ･･･････ -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 in operation, keep enough distance so that exhaust
air from one machine does not effect the other one.
Also, a machine has to be installed in the environment where fresh air is always available.
Keep enough space around the unit for inspection and maintenance access.

3.4.1 Installation

The machine has to be parked horizontally on a level place.

In case the machine has to be parked on a slope, place it
across grade so that the machine does not tend to roll downhill.
Following grades on a slope for the machine are recom-
mended within 15 degrees
In case of trailer type, be sure to put one set of chocks“1”
to the wheels.
This parking brake is a device exclusively used to hold the unit 1 1
when it is parked. It is not for use as a stopping brake during its
A010189
transportation (while being drawn by a vehicle).

3.4.2 Service valve

A090558
Air chuk：10A

Discharge port : 20A(Rc3/4B)×2 Discharge port : 50A(Rc2B)×1

[Taper male screw] [Taper female screw]

3-4
 4. Operation
4.1 Instrument Panel

1. Discharge air pressure 12 1 2 3 4 5 ＜Indicator lamp＞

gauge 10.Preheating
2. Tachometer ＜Warning lamp＞
(with hourmeter)
11.Compressor oil filter
3. Fuel level gauge 13
12.Charging
4. Coolant temperature 14
gauge ＜Emergency stop lamp＞
15
5. Discharge air 13.Engine oil pressure
16
temperature gauge 14.Coolant temperature
6. Panel light switch 11 10 9 8 7 6 15.Discharge air temperature
7. Starting unloader valve 16.Engine speed down
A030294
8. Starter switch
9. Emergency stop button
Indicator lamp

Item Trouble Measures Monitor

Press starter switch “ON” and the lamp
Preheating goes on and after preheating is finished,
the lamp will be off.

Warning lamp
When the lamp goes on, take appropriate measures to recover the situation swiftly.

Item Trouble Measures Monitor

Lamp goes on when the differential
Compressor pressure increases due to oil filter clog-
Replace.
oil filter ging. The function pressure is than
0.12MPa.
Lamp goes on when alternator is not Check wiring.
Charging charging. Check alternator.

Emergency stop lamp

The compressor stops when the emergency stop lamp goes on.
Be sure to follow the measures shown below before starting the unit again.

Item Trouble Measures Monitor

Lamp goes on when engine oil pressure
Engine oil See
drops.
pressure “Troubleshooting”
The function pressure is below 0.15MPa
Coolant tem- Lamp goes on when coolant temperature See
perature reaches 102℃. “Troubleshooting”
Lamp goes on when the air temperature
Discharge air See
at the outlet of the air-end reaches the
temperature “Troubleshooting”
set temperature of 115℃.
Engine speed Lamp goes on when engine speed drops See
down below 900min-1. “Troubleshooting”

4-1
 4. Operation
4.2 Door

4.2.1 Open/Close the Door

Keep the door closed and locked while running the unit.
When the door has to be opened, be careful not to touch por-
tions that are rotating or very hot.
Careless touch may 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.

4-2
 4. Operation
4.3 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 prior check and without
noticing its abnormality, such operation could cause seizure of components or may even cause fire.

4.3.1 Check Engine Oil Level

Unit should be on level before checking oil level.
When you check oil level after you have once started opera-
tion, wait 10 to 20 minutes after stopping engine, before
checking the oil level. Oil level gauge

(Procedure)
① Pull out the oil level gauge“1”, and wipe it with a clean
When oil level is
cloth. within this zone, HIGH
② Then, re-insert the oil level gauge“1”fully and pull it out it is normal.
again. If the oil level gauge shows the oil level between
LOW and HIGH, it is normal.
③ When the oil level is below its LOW, add engine oil from oil
filler port“2”.
LOW
(See 5.5.1)

While checking oil level, check also for contamination. If the A020407
oil is found dirty, contaminated or should it be changed ac-
cording to the periodic inspection list, change the oil.
(See 5.5.1)
Never fill oil more than HIGH level.

1 2

A030296

4-3
 4. Operation
4.3.2 Check Coolant Level

Taking off the Header tank 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 radiator could result in causing
scalding. Follow this procedure under all circumstances.

W005

Do not continue operation at low coolant level. Air bubble is mixed into radiator, and it causes
damage to the radiator.

Check the coolant level in the reserve tank “1”. If it is lower than the limit, open the cap “2” and re-
plenish the coolant. (Level must be kept above MIN mark.)
When there is a little cooling water in reserve tank “1” (lower than MIN. level), replenish both re-
serve tank “1” and header tank “3” with cooling water (see 5.5.13).
If little coolant is left in the reserve tank, replenish the radiator with cooling water.

3 1

This zone, it is
normal.

H000474

A030297

4-4
 4. Operation
4.3.3 Check Compressor Oil Level

Refilling of compressor oil

When you refill the separator receiver tank with compressor oil,
stop the engine, and make sure that the pressure gauge indi-
cates 0MPa and there is no residual pressure in it, and then
gradually loosen the oil filler cap for refilling oil.
Note residual pressure in the receiver tank could force both ex-
tremely hot compressed air and oil to jet out and you may be
scalded or seriously injured.
W011

Place the machine on level ground when checking the oil

level.
Check the oil level of the compressor. Correct oil level is be- 1/2
tween upper and lower limit of the gauge, when the unit stops. 1/2
If the gauge shows lower than the middle level, replenish oil.
(See 5.5.5)
H000037

4.3.4 Drain Separator Receiver Tank

Draining of Separator receiver tank

After stopping the engine, confirm that the pressure gauge indi-
cates 0MPa 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 ex-
tremely hot compressed air and oil to jet out and you may be
scalded or seriously injured.

W005

Gradually opening the drain valve “ 2 ” fitted under the

separator receiver tank“1”as shown in the fig, drain the
condensate.
1
Be careful not to fully open the valve. Otherwise, much oil
may be lost.
After draining the oil completely, close the drain valve“2”
firmly. 2
Drain the condensate in container“3”, and then dispose of
condensate according to the designated regulations.

CLOSE OPEN FULLY

OPEN
3
A020409

4-5
 4. Operation
4.3.5 Check Fuel level
Fire prevention
Do not, under any circumstance, smoke cigarettes or light matches
during fueling.
Fuel is extremely flammable and dangerous. It therefore, could catch
fire should it flame or other sources of ignition be brought near fuel.
Refuel only after stopping the engine, and never leave an open fuel
can near the machine. Do not spill. It could cause a fire. When it is
spilt, wipe it up completely.
Refilling fuel tank should be done in an outdoor well-ventilated place.
Do not fill fuel oil up to the cap lever. When fuel tank is filled up
to the cap level, fuel oil will be overfilled due to volume expan-
sion caused by rise of ambient temperature. Further, fuel will be D004
possibly spilled from fuel tank due to vibration caused during
movement and/or transportation of machine.

Choose appropriate fuel

Be sure to use diesel fuel oil for diesel engine use.
(Using other oil will cause low power or damage to the engine.)
As for fuel, use diesel fuel oil (having higher than 45 cetane number).
Use of diesel 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.
Check fuel level gauge before operation. Replenish enough fuel to prevent fuel shortage during op-
eration, if the level is low.
Be sure to fasten the fuel tank cap firmly after replenishment. If fuel is spilt, wipe it up completely.

4.3.6 Drain Fuel Tank

Opening the drain valve“2”fitted under the fuel tank“1”,
drain the condensate from the tank.
When completely drained, firmly close the drain valve“2”.
Drain the condensate in container“3”,and then dispose of 1
condensate according to the designated regulations. 2

CLOSE OPEN FULLY

4.3.7 Drain Water Sedimenter OPEN
3
Check if the red float“ 1”in the water sedimenter rises up to
A020410
the water drain level“ 2”, then drain water if it is near the
drain level.
In case of this
2 condition,
(Draining procedure)
drain cooling
①Loosen the drain plug“3”and drain out condensed water water.
1
inside.
②After draining condensed water, close the drain plug“3”
3
without fail.
Turning this bolt to left,
Drain the condensate in container, and then dispose of it can be loosened.
A000064
condensate according to the designated regulations.

4-6
 4. Operation
4.3.8 Check V-Belt Tension

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.

Follow the procedure below to adjust tension of fan belt and

V-belt for alternator. Depress the middle of
the belt with a finger.
(Procedure)
① Adjust the tension by gradually loosening the fastening Then check the
deflection of the
bolt of the alternator. belt and make
② Visually check if there are any cracks or tears in the belt. sure that it shall
③ Loosen the fastening bolt of the alternator until the play of be 10 to 15mm.
the belt reaches 10 to 15mm[98N(10kgf)] when pushed by
fingers, and adjust it.
④ Be careful not to leave any grease or LLC on a belt while
changing it. If any such material is left, wipe it off com-
pletely. A010181

4.3.9 Check Wiring of Each Part

Check each wiring for any loose connection, damage to insulating sheathed portion, disconnection, and
short-circuit.

4.3.10 Check Piping of Each Part

Check each piping for any loose connection and also check each hose and pipe for any tear and leaks.

4.4 Unit Operation

Operation with 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 its air pressure could cause
injury to the people nearby.
When the machine has to be unavoidably temporarily operated
with its port open, be sure to mount a silencer to reduce noise
and wear protective materials such as earplugs to prevent
damage to hearing. D003

Quick Glow System

Turn the starter switch to the “RUN” position, and the preheating will be completed in several
seconds and the preheating lamp will go out. Then, turn the Starter Switch to the Start position to
start up the engine.
When the engine is already warm, the preheating operation is automatically omitted. Even though
the preheating lamp lights up momentarily, ignore the lamp status, and start up the engine.

4-7
 4. Operation
4.4.1 Procedure to Start the Unit

Be sure to warm-up
Be sure to let unit warm-up after starting for smooth operation of the engine and the compressor.
Do not operate the engine at full load immediately after it starts up. This will shorten the equipment life.
During the warm-up operation, examine the different parts of the equipment for any looseness, leakage
of water, oil, fuel, and other irregularities.
Also, make sure that warning lamps are off.

(Procedure)
① Close fully service valves“1”.
② Set the starting unloader valve“2”to “START” position.
③ Turn the starter switch“3”to “RUN" position, and the preheating lamp“4”goes on.
④ As soon as the preheating lamp“4”has gone out, turn the starter switch“3”fully clockwise to
start up the engine.
⑤ Once the engine has started up, leave it running to warm-up for 5 minutes. The discharge air
pressure gauge“5” in this condition ranges from 0.46 to 0.7MPa.
⑥ After warm-up of the unit, put the starting unloader valve “2”back to its “RUN” position, and
open the service valve The unit is now ready to operate.

Be sure to turn the starting unloader valve“2”to “RUN” position prior to work. The discharge

pressure does not increase as long as the starting unloader valve stays at “START” position.
It is normal when the
pressure gauge indicates
the pressure between
0.46MPa and 0.7MPa.

STOPRUN Starting unloader

START START

RUN

4 5 3 2

1 A030298

4-8
 4. Operation
4.4.2 Operating Procedures when Engine Fails to Start up on First Attempt
When the engine fails to start up even after performing the startup procedures ① to ④, do not
keep the starter running, but set the starter switch back to ”STOP” and wait about 30 seconds.
Then, repeat the startup procedure once again.
If the repeated procedure does not allow the engine to run, the following causes are suspected.
Therefore, check the following:
No fuel
Clogging of fuel filter
Clogging of filter inside the fuel air bleeding electromagnetic pump
Discharge of battery (Low cranking speed)

4.4.3 Fuel Line Air Bleeding Device

If the unit runs out of fuel, the electromagnetic pump attached to the unit will automatically
bleed air out of the fuel system. (After draining sediment from water sedimenter or changing
fuel filter with a new one, bleed the air in the same procedure as below.)
(Procedure)
①Supply fuel.
②Turning the key of starter switch“1”to “Operation” position, the solenoid valve starts to bleed
air in the fuel piping system automatically.
③Air bleeding will be completed about 20 to 30 seconds.
④Start the machine following the starting procedures mentioned in 4.4.1. If starting fails one
time, repeat the abovementioned procedures.

STOPRUN Starting unloader

START
START

RUN

A030299

4-9
 4. Operation
4.4.4 How to Start the Unit at Low Temperature

Operation under Cold Weather Conditions below -5°C

Use SAE10W-30 (CD class) for the engine oil.
Use LLC (antifreeze). Use correct amount to provide freeze protection, according to the ambient tem-
perature.
Battery should always be kept fully charged.

When it is difficult to start engine in cold weather, take

CLOSE FULLY OPEN
the following measures.
3 Open
(Procedure)
①Close all the service valves“1”and set the starting
unloader valve“2”to the starting position.
② Fully open the relief valve “ 3 ” just in front of a Close
separator receiver tank. 1
③ With emergency stop button“4”pressed in, turn the
starter switch“5”to the starting position and perform H000475
cranking 4 to 5 seconds two times.
④ Reset the emergency stop button“4”.
⑤ Perform usual starting operation. When the engine Separator
starts, gradually close a relief valve“3”, watching receiver tank
engine revolution rise. In the state after the valve is
A030286
fully closed, perform warming-up operation.

Starting unloader
Emergency stop START
START
RESET
RUN

4 5 2

1 A030300

4-10
 4. Operation
4.4.5 Gauge Indication while Operating

Minimum discharge air pressure is 0.46MPa during operation

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 rise.
Make sure that RPM is higher than 1,100min-1 at no load (or low load) operation. Long continuous
operation at the lower speed than 1,100min-1 could cause damage to each part by vibration. When
the speed becomes lower than 1,100min-1, stop the machine soon.

Be sure to check at times to see if gauges or each component of the unit are properly working, or if
there is any air-leak, oil-leak, water-leak or fuel-leak etc.
During normal operation, each indication of instruments is 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 condi-
tions and other factors.

Indicator
Emergency stop Lamp Warning Lamp
Protection lamp
device Engine
Engine oil Coolant Discharge air Compressor
speed Charging Preheating
pressure temperature temperature down oil filter

Monitor

Starter ※
Starting

switch set
n n n n ● ○ ●
to “RUN”
position OFF OFF OFF OFF OFF ON OFF

In Operation n
OFF
Note: ※Lamp goes off after preheating completed.

Discharge air pressure

In Operation

At Unload 0.7～1.0MPa

At Full Load 0.46～0.7MPa

4.4.6 Panel light

The instruments are provided with transmission type illuminators. Switch “ON” the panel light so
that they may light on.
When illumination is not necessary, turn “OFF” the light. (If the machine is always operated with
the lamp switched “ON”, the lamp life can be shortened.)

4-11
 4. Operation
4.4.7 Performance Check of Safety Valve

Keep face or hand away from the discharging outlet of safety valve.
It is very dangerous because high-pressure compressed air jets out.

Make sure to check the safety valve“1”performance once a day. 2

Close the service valves completely and pull the test lever“2”to
check the performance. It is performing normally when the com-
pressed air jets out with turning by slight force at a discharge
pressure between the following pressures 0.7～1.0MPa.
The safety valve is set at the following pressure 1.0MPa.

1
H000476

4.4.8 Check Clogging in Oil Separator

When the differential pressure gauge of oil separator shows red range, replace the oil separator.
（See 5.5.17）

Pointer

Green zone Red zone

It is normal when It should be re-
the pointer is placed when the
within this zone. pointer enters
this red zone.

4.5 Stopping Procedures

H000477

① Close the service valve completely and operate the machine about 5 minutes, until it cools down.
② Turn the starter switch to “STOP” position to stop the engine.
③ Remove the key from the compressor every time when you stop the engine. Keep the key and be
careful not to lose it.

Unless all the service valves are fully closed upon stopping operation, the compressed air will be
sent in reverse direction in the hoses (pipes) connected to air tools and relieved to atmosphere con-
tinuously through the auto-relief valve. Further, when re-starting operation next time, compressed
air will be jetted out through service valves.

4-12
 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.

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 Mainte-
nance” 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.
If the above procedure 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
SY001
their slippage.

Prevention of oil separator from catching fire

Be sure to perform oil change basically according to the speci-

fied interval. But if such oil is found much more contaminated
before the interval, change the oil even before the specified pe- 2
riod comes. In doing so, replace the oil completely and use our
recommended oil.
Be sure to perform following periodic inspection and mainte-
nance:
1. Check and change compressor oil
2. Change oil separator
1
Never mix the oil of different brands, or the mixed oil may dete-
riorate the oil quality. A000174

5-1
 5. Periodic Inspection/Maintenance

Precautions for check and maintenance

Be sure to use recommended fuel, oil, grease, and antifreeze.

Do not disassemble or adjust engine, compressor 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 fluids to the ground,
rivers, lakes or ponds, and sea. It contaminates the environment.
When draining waste fluid from machines, use leakproof containers to hold such fluids from machine.
Be sure to follow the designated regulations when disposing of oil, fuel, coolant, filters, battery and other
harmful things.

5.2 Daily Inspection and Operation Log

Be sure to carry out daily inspection every morning before operation. See Chapter 2 “Operation” 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 compo-
nent not described in the manual, ask your nearest dealer for information.

(a)Controls and instruments function properly.

(b)Quantity and any leak of water, fuel, and oil or any con-
tamination should be checked.
(c)Appearance, abnormal noise or excessive heat should be
checked.
(d)Loose bolt or nut should be checked.
(e) Any damage, wear or shortage of machine components and
parts should be checked.
(f)Performance of each part or component should be proper.
TR0049

Keep the operation log to record constant inspection of each component, so that trouble of the unit
can be easily discovered and preventive measures can be taken.
It is very useful to record information such as discharge pressure, oil level, as well as running hour,
maintenance items and replenishment of lubricant on a daily maintenance log.

5-2
 5. Periodic Inspection/Maintenance
5.3 Periodic Inspection List
Such items marked ○ shall be carried out by customers.
For such items marked ●, please contact our nearest dealers or us.
◎Refer to engine operation manual for inspection and maintenance of an engine.
(Unit:Hour)
Maintenance Daily 250 300 500 1,000 2,000 3,000 6,000 12,000 Page
Check compressor oil level. ○ 4-5
Drain separator receiver tank. ○ 4-5
Check looseness in pipe connecting part, and
○ 4-7
wear and tear of pipe.
Check oil, water, fuel and air leak. ○ 4-11
Check performance of gauge and indication
○ 4-11
lamps.
Performance Check of Safety Valve. ○ 4-12
○
Change compressor oil. First time ○ 5-8
○
Change compressor oil filter. First time
○ 5-9
Clean strainer in the scavenging orifice. ○ 5-10
○ ○
Clean and change air filter element. Clean Change 5-7
Compressor

Clean outside of the oil cooler. ○ 5-12

Supply grease to trailer spring pin ○ 5-14
Change speed regulator diaphragm. ●
Change unloader regulator diaphragm. ●
Change oil separator. ○ 5-15
Change nylon tubes. ●
Change pressure regulator. ●
Check rubber hoses. ●
Check diaphragm of auto-relief valve. ●
Clean butterfly valve (unloader) ●
Change diaphragm of vacuum-relief valve ●
Change o-ring of vacuum-relief valve ●
Replace the parts of pressure control valve
(spare kit).
●
Change rubber coupling. ●
Change oil seal/bearing ●

5-3
 5. Periodic Inspection/Maintenance
(Unit:Hour)
Maintenance Daily 50 250 500 1,000 2,000 3,000 6,000 Page
Drain fuel tank
○ 4-6
(Including sedimenter).
Check fuel level ○ 4-6
Check engine oil level. ○ 4-3
Check coolant level. ○ 4-4
Check looseness in pipe connectors, terminals
○ 4-7
and tear in wiring.
Check V-belt tension. ○ 4-7
○
Change engine oil. First time ○ 5-5
○
Change engine oil filter. First time ○ 5-6
Check battery. ○ 5-7
Clean and change air filter element. ○ ○
Clean Change
5-7
Clean and change filter inside the fuel ○
Engine

Clean and 5-11

air-bleeding electromagnetic pump. Change

Clean strainer of fuel air-bleeding

○ 5-12
electromagnetic pump.
Change fuel filter. ○ 5-11
Checking for looseness of fixing belts of heat
insulating material used for exhaust ○ 5-10
flexible pipe.
Clean the strainer provided inside the engine
○ 5-14
feed pump.
Change coolant. ○ 5-13
Clean outside of radiator. ○ 5-12
Check fuel hose. ○ 5-14
Clean inside of radiator. ●
Clean inside of fuel tank. ●
Change radiator hoses. ●
Change wiring harness. ●

5.4 Periodic Replacement of Parts

5.4.1 Filters
Part Name Part Number Quantity
Engine oil filter Hino motors 15607－2190 1
Compressor oil filter 37438 05400 1
32143 15000 (inner cyl.)“1” 1
Air filter element (engine)
32143 15100 (outer cyl.)“2” 1
32143 15200 (inner cyl.)“3” 1
Air filter element (compressor)
32143 15300 (outer cyl.)“4” 1
Fuel filter Hino motors 23401-1341 1
Separator“1” 34220 12501 1
Oil separator
Gasket“2” 34235 06700 2
Fuel air-bleeding electromagnetic pump filter 43541 00100 1
Fuel feed pump gasket 43531 00700 3

5-4
 5. Periodic Inspection/Maintenance
5.5 Maintenance
5.5.1 Change Engine Oil
(At 50 hours for the first change and at every 500 hours thereafter)

Caution in filling or discharging engine oil


After stopping the engine, wait for 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 oil is very hot and highly pressurized during or just after the
operation. Hot oil could blow out of the tank and can cause scalding.
W005

－ How to choose engine oil －


Viscosity of engine oil greatly affects startability, performance, oil consumption of the engine, as well
as wear of the moving parts.

Choose appropriate oil based upon the table below according to the outside air temperature.
Ambient temperature range and oil viscosity (SAE)

A100293E


Use engine oil recommended by us.
Classification API service classification CD class or higher
Viscosity SAE10W-30

Be sure to use CD class engine oil or superior class. (Using engine oil with poor quality may shorten the
life of the engine).

Follow the designated regulations to dispose of engine oil.
(Procedure)
① Loosen the drain valve“2”located outside of the frame to drain out the
used oil.
② When the oil is completely drained, close the drain valve“2”firmly and
refill new engine oil through the engine oil filler“1”.
③ After supplying oil, pull out the oil level gauge and wipe it out.
④ Insert the oil level gauge again and pull it out to make sure the oil level 1
is between LOW and HIGH levels. When the oil level is between both
levels, it is normal.

When oil level is HIGH Oil level gauge

within this zone,
it is normal.

LOW
2

5-5
 5. Periodic Inspection/Maintenance

5.5.2 Change Engine Oil Filter

(At 50 hours for the first change and at every 500 hours thereafter)

(Procedure)
① Remove the cartridge“1”, using a filter wrench. 2
② Screw in the new cartridge“1”with the packing“2” coated
slightly with oil. (Refer to 5.4 clause.)
③ After the packing touches the sealing face, further tighten it
by turning it 3/4 or 1 time with the filter wrench.
④ After installing the oil filter, check it for any leak during
operation.

H000049

Filter wrench
Tighten it by turning it
3/4 or 1 time with the
Remove filter wrench.

Install

Engine oil filter

A030301

5-6
 5. Periodic Inspection/Maintenance
5.5.3 Check Battery
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:

1. Enclosed type battery:

Check the indicator on top surface of the battery.
If the indicator shows that charge is needed, recharge the battery immediately.

2. Ordinary type battery:

Measure specific gravity of battery electrolyte, and if it shows below 1.24, recharge the battery
immediately.
Refer to 6.1. for method of specific gravity measurement and recharging the battery.

5.5.4 Check and clean Air Filter Element

Cleaning of Air Filter Element should be perfectly performed

Clogged or cracked or pitted element could allow entrance of dust into engine and compressor to
cause earlier wear of moving parts. Periodical inspection and cleaning of element should be per-
formed to maintain life of compressor and engine long.

Remove both external shell“ 2”and“4”, and clean them.

Replace both internal shell“1” and“ 3”once in the
2
proportion of replacing external ones four times. The 1
internal ones can never be reused even after they are 4
cleaned. 3
When it is found that they cannot be repaired even after
being cleaned, replace the elements. (See 5.5.8) (For engine)
When installing a new element, pay attention to the
followings. (For compressor)
Put the element fully into the case.
A030308
Make sure there is no foreign matter at the contact face of
the case.
Make sure to install it correctly not to push out O-ring of the cup.

5-7
 5. Periodic Inspection/Maintenance
5.5.5 Change Compressor Oil

Refilling of compressor oil

When you refill the separator receiver tank with compressor oil,
stop the engine, and make sure that the pressure gauge indi-
cates 0MPa (0kgf/cm2) and there is no residual pressure in it,
and then gradually loosen the oil filler cap for refilling oil.
Note residual pressure in the receiver tank could force both ex-
tremely hot compressed air and oil to jet out and you may be
scalded or seriously injured.
W001

Do not mix compressor oil

Be sure to use recommended oil listed below.
Viscosity of the oil varies depending on the temperature and other environmental conditions.
Select one from the recommended oil listed below.
Maker and Brand of Recommended Oil
Brand Maker
SHELL CORENA OIL RS32 SHELL

MOBIL RARUS 424 MOBIL

FAIRCOL RA32 NIPPON OIL CO.

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 cause poor performance and shorten the life of the compres-
sor oil. (But fresh compressor oil could accept a mixture of small amount of different brands.)
Running the unit with old and deteriorated compressor oil will cause damage to bearings, or serious ac-
cident like ignition in a separator receiver tank. Be sure to change the oil completely at every scheduled
interval.
Follow the designated regulations to dispose of compressor oil.

5-8
 5. Periodic Inspection/Maintenance
(Procedures)
① Remove the oil filler cap“2”of separator receiver tank“1”.
② Open drain valve“3”to discharge waste oil from the tank.
③ In case of replacement, completely discharge all the oil left
in the compressor body, separator receiver tank“1”, pipes
and oil cooler. If wasted oil is left in the unit, this residual 1
oil will greatly shorten the life of the newly replenished oil. 2
④ Be sure to close drain valve“3”after the wasted oil is com-
pletely discharged.
⑤ Fill the designated quantity of new oil into the oil filler port. 3
⑥ After oiling, tighten the cap“2”in its place while paying
attention not to let dust get in the tank.
⑦ Start the engine for a short while, then replenish the oil to
fill shortage. Repeat this procedure for 2 to 3 times to check CLOSE OPEN FULLY
if the oil level has reached its appropriate point. Be careful OPEN

not to overfill the oil.

A020409

5.5.6 Change Compressor Oil Filter

(At 300 hours for the first change and every 500 hours thereafter)

Use our genuine oil filter

Poor quality oil filters do not trap dust sufficiently and will cause damage to the bearings in a short pe-
riod.

(Procedure)
① Use a filter wrench to remove the cartridge“1”.
② Spread thin film of oil on a packing“2”of a new cartridge “1”and screw it in.(For replacement
parts, refer to5.4)
③ After a packing touches the sealing face, tighten it 3/4 or 1 time turn, using filter wrench.
④ After installing oil filter, be sure to check for oil leak during the operation.

2 Filter wrench

Remove

Install

Tighten it by turning it
3/4 or 1 time with the
filter wrench.

A020419

5-9
 5. Periodic Inspection/Maintenance
5.5.7 Clean Strainer in the Scavenging Orifice
(Procedure)
① Remove the pipe “1”, using a spanner.
② Take it off from the portion of bushing “2”.
③ Remove the strainer “3”, using a screw-driver.
④ Wash the strainer “3” in diesel oil (gas oil) and
then clean dirt and dust by air blow , 1
⑤ After cleaning, install the strainer “3” in
3 2
reverse procedures.

Remove it using a
screwdriver set in slit.

A030302
5.5.8 Checking for looseness of fixing belts of heat insulating material used
for exhaust flexible pipe.
When any looseness on fixing belt “3”wound
around exhaust flexible pipe“ 1” is found, 1 2 3 3 2 3
retighten it.
When any damage on heat insulating mate-
rial“ 2”is found, it is necessary that it should
be replaced.
Please contact our distributor or us directly.

5.5.9 Change Air Filter Element A090645

Use our genuine part

Air filter is an important part which is crucial to machine's performance and life.
Be sure to use genuine parts.
Even before 500 hours of use, if it is used under harsh
conditions, remove the element“1”,“2”,“3”,“4”check 2
and clean it. If it is found difficult to restore it, change it
1
a little earlier. (For replacement parts, refer to 5.4.) 4
When installing a new element, pay attention to the 3
followings.
Put the element fully into the case.
Make sure there is no foreign matter at the contact (For engine)
face of the case.
(For compressor)
Make sure to install it correctly not to push out O-ring
A030308
of the cup.

5-10
 5. Periodic Inspection/Maintenance
5.5.10 Change Fuel Filter
(Procedure)
① Remove the cartridge“1”, using a filter wrench.
② Spread thin film of oil on a packing“2”of a new cartridge“1”and screw it in. (For replacement
parts, refer to 5.4)
③ After a packing touches the sealing face, tighten it by turning 2/3 times using a filter wrench.
④ After installing a fuel filter, be sure to check for oil leak during operation.
⑤ Bleed air out of fuel line. (Refer to 4.4.3)

Filter wrench

Remove

Install
1

Tighten it by turning 2/3 A030303

times using a filter
wrench.

5.5.11 Clean and change filter inside the fuel air-bleeding electromagnetic pump
（Procedure）
① In order to clean the filter“1”, remove the case“4”with the filter wrench caught on the nut“3”
after closing the valve“2”.
② Take out filter“1”from the case“4” and wash it in clean diesel oil (gas oil).
③ After washing of the filter is finished, be sure to close the valve“2”without fail.
This filter can be washed twice for use. It should be replaced from third time washing.
(For replacement parts, refer to 5.4)

Close it

3
4
1 A030304

5-11
 5. Periodic Inspection/Maintenance
5.5.12 Clean strainer of fuel air-bleeding electromagnetic pump
Fuel air-bleeding electro-
（Procedure） magnetic pump
① Remove the hose“ 1”fitted at the inlet of the 2
Fuel air-bleeding electromagnetic pump.
② Remove the strainer“2”. Inlet
③ Wash the removed strainer“2”in diesel oil
(gas oil), and clean it by air blow.
④ After cleaning it, install it in reverse
1
procedures.
⑤ Install the hose“1”at the original position.

A030305

5.5.13 Clean outside of the Radiator･Oil Cooler

When the fin tubes“1”of a radiator, an oil cooler
are clogged with dust or other foreign materials,
the heat exchange efficiency drops and this will
raise coolant temperature and discharge air
temperature. These tubes and fins should be
cleaned depending on the state of clogged tubes
“1”even before maintenance schedule.
Do not use a high pressure washer to protect fin 1
tubes“1”from being damaged.

Radiator

Water
Hose

A020424

5-12
 5. Periodic Inspection/Maintenance
5.5.14 Change Coolant

Taking off the radiator cap (header tank)

Be sure to stop the machine and allow time to cool. Then loosen
the radiator cap (header tank) 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 causing
scalding. Follow this procedure under all circumstances. W005

How to handle LLC (Antifreeze)

LLC (Antifreeze) is a toxic material.

When a person has drunk LLC (Antifreeze) by accident, make him vomit and see a doctor im-
mediately.
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 it in a container with an indication saying “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 flow of coolant.
When replacing coolant, be sure to install a coolant filter and add 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.
Adjust mixing ratio of LLC (Antifreeze) with water according to the temperature.
Use LLC (Antifreeze) within the range of its mixing ratio between 35 and 60%.
If LLC (Antifreeze) in the water exceeds more than 60%, it may decrease its antifreezing effect.
(Upon delivery from the works, LLC density is 35%)
Follow the designated regulations to dispose of LLC (Antifreeze).

5-13
 5. Periodic Inspection/Maintenance
(Procedure)
① To drain coolant, remove cap“1”of header tank on
1
radiator top and open the drain valve“2” to drain
3
it.
② Also be sure to drain engine by loosening the drain
plug “3”without fail.
③ After completing drainage, close the drain valve“ 2”
2
and drain plug“3”and then supply coolant through
the filler port of the header tank.
④ After coolant is filled up, run unit at unload condi- CLOSE OPEN
tion for 2 or 3 minutes and stop it. Then check
H000491
coolant level. When the level is low, replenish it.

5.5.15 Supply grease to trailer spring pin

Supply grease through grease nipples positioned at the bot-
tom.
Grease: Chassis grease

TR0260B

5.5.16 Check Fuel hose

When any crack or wear is found on the hoses, change it even before the scheduled time.
Ask your nearest dealer for its replacement.

5.5.17 Clean the strainer provided inside the engine feed pump
Joint bolt
Periodically remove the strainer“1”inside the feed pump,
and clean it.
Remove the strainer“1”by loosening the joint bolt and clean
it with diesel fuel oil, and also using high air pressure blow. 1
At this time be sure to replace gasket. (For part numbers,
refer to 5.4.) Then after finishing all cleaning jobs, install it
again in reverse steps.

A030291

5-14
 5. Periodic Inspection/Maintenance
5.5.18 Change Oil Separator
(Procedure)
① The separator can be removed through the hole provided on the bonnet top of the separator
cover after loosening the bolts of the cover (8pcs).
② Remove the nylon tubes fitted on the piping of separator cover, using a spanner etc.
③ Remove the air pipe, by loosening the fixing bolts (10pcs) of the air pipe.
④ Remove the fixing bolts (10pcs.) of separator cover, using an impact wrench etc.
⑤ Screw two lifting eyebolts for the two threaded holes provided on the separator cover.
⑥ Pass a rope or wire rope through the eyes of the lifting bolts and lift the separator up by a crane
etc.
If even before scheduled interval of 2000 hours operation, consumption of compressor oil is unusu-
ally high. and the differential pressure gauge of the oil separator reaches Red range, change the oil
separator.(Refer to 4.4.8) But note that the differential pressure gauge shows correct indication
only in full load operation and minimum pressure.
When replacing oil separator“1”, be sure to replace gasket “2”too. (For part numbers, refer to 5.4.)

If you have any problem, please contact your nearest distributor.

Lifting bolt (M12)

Tightening torque of the bolts

Separator cover 115N-m(1150kgf-cm)

Air pipe
Lifting bolt (M12)

These 20pcs. bolts

should be removed.
2

A030306

5-15
 5. Periodic Inspection/Maintenance
5.6 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.
(Place to check)
(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.

5-16
 6. Maintenance/Adjustment
6.1 Maintenance of Battery

Handling battery

Keep flames away from battery.

Battery may generate hydrogen gas and may explode.
Therefore, recharging should be done at a well-ventilated
place.
Do not spark near the battery nor light a match, nor bring
lit cigarette and match close to the battery.
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 D004
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 explo-
sion 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 the frozen battery. Otherwise it may explode. If
the battery is frozen, warm it up until the battery temperature
becomes 16°C to 30°C.
Battery electrolyte is dilute sulfuric acid.
W010
In case of mishandling, it could cause skin burning.
When you deal with a battery, please be sure to wear protec-
tion implements, such as protection glasses and a glove.
When such battery electrolyte contacts your clothes or
skin, wash it away with large amount of water immedi-
ately.
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.
Dispose of battery, observing local regulations.

TR0093

6-1
 6. Maintenance/Adjustment
6.1.1 Charge Battery
Disconnect the cable between battery and the unit, 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.
Be sure to read the operation manual of the battery charger to
know if it is applicable, before using it.

H000060
6.1.2 How to Use Booster Cable

Do not connect the cable reversely

If a booster cable has to be used or when cables are connected at battery replacement, be careful not to
connect (+) and (–) terminals backwards. Such a wrong-connection will cause spark and damage each
component.

(Procedure for using a booster cable)

① Stop the engine. Connect to the engine block
② Connect one end of the (+) cable to the (+) terminal of the
Battery of the unit
machine battery.
③ Connect the other end of the (+) cable to the (+) terminal of
the external battery.
④ Connect one end of the (–) cable to the (–) terminal of the
external battery.
⑤ Connect the other end of the (–) cable to the engine block of
the machine.
⑥ Start up the engine.
⑦ Disconnect the booster cable by following the procedure
back in the reverse order. External battery (12V)

M980196E

6-2
 6. Maintenance/Adjustment
6.2 Troubleshooting
Should any trouble occur during operation, do not leave it. Investigate the cause and take appro-
priate 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 unit, the faster you can find a prob-
lem and solution.
This chapter describes the state, cause and countermeasures of important troubles in detail:

Symptom Cause Countermeasures

Low starter (1) Battery malfunction. Check battery→
revolution speed. Charge, change
(1) Fuel filter clogging. Disassemble, clean, and
change
Starter rotates but engine
(2) Malfunction of fuel cut sole- Check fuse
does not start.
noid. Change solenoid
Check connector
Discharge air (1) Pressure regulator insufficient Re-adjust (Fasten)
pressure does not reach adjustment.
0.7MPa. (2) Starting unloader valve is left Place it at “RUN” position
at its start position.
(1) Improper length in speed Re-adjust
regulator rod.
Engine does not reach its (2) Unloader orifice clogging. Disassemble/Clean
maximum speed. (3) Faulty speed regulator. Disassemble/Check
(4) Engine trouble. Call your nearest dealer
(5) Fuel filter clogging. Disassemble/Change
Revolution drops before dis- (1) Pressure regulator insufficient Re-adjust (Fasten)
charge air pressure reaches adjustment.
0.7MPa. (2) Trouble of pressure regulator. Change
(3) Unloader orifice clogging. Disassemble/Check

Engine does not reach mini- (1) Improper length in speed Re-adjust
mum revolution at regulator rod.
unload. (2) Faulty speed regulator. Disassemble/Check
(1) Pressure regulator insufficient Re-adjust(loosen)
adjustment.
(2) Speed regulator diaphragm Change
damaged.
Safety valve
(3) Unloader valve damaged and Change
relieves at unload.
seat malfunction.
(4) Faulty safety valve. Change
(5) Improper length of speed Re-adjust(elongate)
regulator rod
(1) Scavenging orifice strainer Disassemble/Clean
Oil mixes in Air. clogging.
(Poor oil separation) (2) Low discharge pressure. Disassemble/pressure
Contol valve/check
(3) Oil separator deteriorated. Disassemble/Change
(1) Air filter element clogging. Clean element or change
(2) Unloader valve cannot fully Call your nearest dealer
Insufficient free air delivery. open.
(3) Engine does not reach rated
speed.

6-3
 6. Maintenance/Adjustment

Symptom Cause Countermeasures

(1) Engine oil shortage. Replenish oil
(2) Engine oil filter clogging. Change
Engine oil (3) Malfunction of engine oil pump Change
pressure lamp goes on. (4) Faulty oil pressure switch. Change
(5) Loosened or disconnected wir- Check/Fasten
ing or connector.
(1) Radiator clogging. Clean
(2) Faulty thermostat. Change
(3) Faulty coolant temp. switch. Change
Coolant temp. lamp goes on. (4) Low coolant level. Replenish
(5) Fan belt slippage. Re-adjust tension
(6) Loose wiring, connectors and Check/retighten
desconnection
(1) Oil cooler clogging. Clean
(2) Oil filter clogging. Change
(3) Faulty discharged air temp. Check/inspect
switch.
(4) Loose wiring connectors and Check and retighten
Discharge air temp. goes on.
disconnection.
(5) Slippage of fan belt. Re-adjust tension
(6) Shortage of compressor oil. Replenish oil
(7) Malfunction of oil check valve. Disassemble/check
(8) Malfunction of by-pass valve. Check/change
(1) Speed regulator insufficient Re-adjust
adjustment.
(2) Trouble of controller. Change
Engine speed down (3) Shortage of feeding fuel caused Replace filter and/or clean the
goes on. due to fuel filter and gauze fil- gauze filter
ter clogging
(4) Air mixed in fuel line system Bleed the air
(5) Drop of engine power output Clean and/or replace air filter
Contact your nearest dealer if you find it difficult to repair by yourselves.
Refer to the engine operation manual for trouble concerning the engine.

6-4
 7. Storage of the Unit
7.1 Preparation for Long-term Storage

When the unit is to be kept unused in storage for a long time, be sure to follow the preparations
below and put the unit in a dry and less dusty place.

Put the unit in a temporary cabin if it is stored outside. Avoid leaving the unit outside with a sheet
cover directly on the paint for a long time, or this will cause rust to the unit.
Perform the following treatments at least once every three months.

(Procedure)
① 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.
② Spread lubricant on moving parts like speed regulator and rod end, beforehand.
③ 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.)
④ Drain coolant and fuel from the unit.
⑤ 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 getting in the unit.
⑥ Be sure to repair any trouble and maintain the unit so that it will be ready for the next
operation.

7-1
 8. Specifications
8.1 Specifications
Model PDS750S-4B1
Type Single-stage oil cooled, screw type compressor
Free air delivery m3/min 21.2
Compressor

Working pressure MPa 0.7

Lubricating system Forced Lubrication by compressed pressure
Driving system Direct driving with rubber coupling
Receiver tank capacity m3 0.189
Lubricating oil capacity L 80
Model Hino motors Itd. J08C-UT
Type 4-cycle, water-cooled, direct injection type with turbo charged
Number of cylinders,
6 – 114 mm × 130 mm
bore stroke
Total displacement L 7.961
Rated output kW/min-1 144.5/2,100
Lubricating oil capacity L 23
Coolant capacity
L 29
(including radiator)
Engine

Battery 115F51 (equivalent) ×2

Fuel tank capacity L 310
Overall length
mm 3,650
(with drawbar folded up)
Overall length
mm 4,960
(with drawbar laid down)
Overall width mm 1,685
Overall height mm 2,070
Net dry mass kg 2,950
Operating mass kg 3,300

8-1
 8. Specifications
8.2 Outline drawing

A030283

8-2
9. Wiring Diagram

A090562E-1

9-1
10. Piping Diagram

A030290E-1

10-1
 OPERATION LOG
OPERATION TIME
TOTAL DISCHARGE DISCHARGE ENG.OIL REMARKS
OPERATION AMBIENT COOLANT RATED RPM COMP.OIL
OPERATION AIR AIR TEMP. -1 REPLACEMENT (INSPECTION/PART CHANGE
DATE START STOP TEMP.(℃) TEMP.(℃) (rpm,min ) SUPPLY(L)
HOURS (h) PRESS.(MPa) (℃) HOUR (h) HISTORY ETC.)
TIME TIME

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 2006年 2月 27日 初版

2003年 4月 20日 改訂

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