Preface

Thank you for having selected our “AIRMAN” product.

◆ This manual explains about the proper operation and daily inspection and maintenance of this
machine.
◆ In order to use a machine safely, people with sufficient knowledge and sufficient technology need to
deal with it.
◆ Before operating the unit, read the manual carefully, fully understand its operation and
maintenance requirement. Maintain “SAFETY OPERATION AND PROPER MAINTENANCE OF
THE UNIT”.

Be sure to follow safety warnings and cautions given in the manual.

Unsafe operation could cause serious injury or death.

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

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

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

◆ Be 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 have any questions about the unit, please inform us the model and serial number. A plate
stamped with the 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
 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 Internal Components and Part Names ----------------------------------------------------------------------------------- 2-1

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

3.1 Transportation ------------------------------------------------------------------------------------------------------------------ 3-1
3.2 Installation ----------------------------------------------------------------------------------------------------------------------- 3-2

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

4.1 Instrument panel --------------------------------------------------------------------------------------------------------------- 4-1
4.2 Lubricating oil・Coolant・Fuel ---------------------------------------------------------------------------------------- 4-4
4.3 Check before Starting Unit -------------------------------------------------------------------------------------------------- 4-6
4.4 Operation ----------------------------------------------------------------------------------------------------------------------- 4-10
4.5 Stopping ------------------------------------------------------------------------------------------------------------------------ 4-14
4.6 Air Bleeding ------------------------------------------------------------------------------------------------------------------ 4-14
4.7 Capacity Control Device ------------------------------------------------------------------------------------------------ 4-15

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

5.1 Important Items as Periodic Inspection and Maintenance or after Maintenance ------------------------------- 5-1
5.2 Daily Inspection and Operation Log --------------------------------------------------------------------------------------- 5-2
5.3 Periodic Inspection List ------------------------------------------------------------------------------------------------------- 5-3
5.4 Periodic Replacement of Parts --------------------------------------------------------------------------------------------- 5-5
5.5 Maintenance Items ------------------------------------------------------------------------------------------------------------ 5-6

6. Maintenance ---------------------------------------------------------------------------------------------- 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

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

 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 symbol －attached to each message.

When one of these messages is shown, please take preventive measures and carry out
“SAFETY OPERATION 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
chambers pressurized by compressed air such as
respiratory air provided to persons working inside
TR0201-1
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

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 indications thereof.
Keep the Safety Warning labels clean. When they are
damaged or missing, apply new ones.
Do not modify the machine without prior approval. The
safety may be compromised, functions may be
deteriorated, or machine life may be shortened.
Never use the unit for the purpose of compression of TR0086

gases other than air, or as a vacuum pump. Otherwise,

serious accidents may occur.

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

1-2
 1.Safety

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.
When you deal with a battery, please be sure to wear protection
implements, such as protection glasses and a glove.
D004
Dispose of battery, observing local regulations.

TR0093

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 TR0088
separating and getting seriously injured.
Please remove after closing a service valve and extracting
pressure remained, in case piping or a hose is removed. If
pressure 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 TR0303A
tools often used.

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

1-3
 1.Safety

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.

Protection equipments
Please wear protection implements, such as a helmet,
protection glasses, earplugs, safety shoes, a glove, and a
protection-against-dust mask, according to the contents of
work for safety.

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,
ambulance and the fire department available in case of
emergency.

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
personnel 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. W010

Draining during operation prohibited

Do not, under any circumstance, open the portions below
during operation:
Separator receiver tank drain valve
Coolant drain valve and plug
Engine oil drain valve
Oil cooler drain valve
PK0028
Fuel tank drain vale and plug

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

Hands off from rotating parts and belts

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

TR0304

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.

H990432

1-5
 1.Safety

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

Do not touch hot parts


Never work nearby hot portions of the machine while it is
running.
Do not touch hot portions of the machine while inspecting the
machine when running.
Such parts as engine, exhaust manifold, exhaust pipe,
muffler, radiator, oil cooler, air-end, pipe, separator receiver
tank, and discharging pipe are especially hot, so never touch
those parts, because it could cause serious burns.
Compressor oil, coolant water, and engine oil are also very
hot and dangerous to touch. H990432
Avoid checking or refilling them while the unit is running.

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.

Refuel after stopping the engine, and never leave the fuel
nearby the machine. Do not spill. It may cause a fire. When it
is spilt, wipe it up completely. D004


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 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. H990433

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
Maintenance” tag where it can be easily seen. The checker
must keep the key during checking and maintenance.
Remove the negative (–) side cable from the battery.
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. W010

Be careful of high-pressurized air blowout

After stopping the engine, make sure that pressure gauge

indicates 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.
W010

Draining separator receiver tank

After stopping the engine, confirm that the pressure gauge

indicates 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.

H990432

1-7
 1.Safety

Adjusting tension of belt


Be sure to stop the engine and remove the starter key
whenever the tension of the 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 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
whenever 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
sufficiently 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.

H990432

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.

The engine oil is very hot during operation and just after it
stops. Be careful because the hot oil also pressurized
blows off and it can cause burning.

H990432

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.

H990433

Treatment of organic wastes


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. A100285

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

1 2 3 4 5

6 7 8 9 10

11 12 13

1-10
 1.Safety

The pasting position of safe warning label is as follows.

11

A100099
12
2

8
4
10

13
3
1
VEIW-A
5

receiver tank
Separator
8

7
6
9

1-11
 2.1
111213 14 15 16 1 2 3

17 4

18 5
19
34 6
20
33
21
32 7
22
31 23

2-1
30
Internal Components and Part Names
2.Part Names

29 2827 26 25 24 10

A100100
 2.Part Names

No. Description Function

1 Speed regulator For adjusting engine speed in the system.
2 Engine For driving the compressor.
3 By-pass valve For keeping compressor oil at proper temperature.
4 Exhaust muffler Equipment which muffles an engine exhaust sound.
5 Radiator For cooling the coolant for engine because it is water-cooled.
6 Oil cooler For cooling compressor oil circulating in the system.
7 Fuel tank For storing diesel fuel oil.
8 Engine oil level gauge For checking engine oil level.(Right side of engine)
9 Coolant drain valve For draining engine coolant.
10 Air-end For compressing intake air.
11 Air filter(For compressor) For filtering the dust floating in the intake air.
12 Fuel filter For filtering diesel fuel oil.
Solenoid valve for AUTO
13 IDLE mode For reduction of power under unloaded operation
14 Engine oil filter For filtering engine oil
15 Air filter(For engine) For filtering the dust floating in the intake air.
16 Pressure control valve For keeping the receiver tank pressure higher than 58PSI in the tank.
For releasing compressed air to the atmosphere when the pressure rises
17 Safety valve higher than the rated pressure.
18 Engine oil filler port For supplying and replenishing engine oil to engine.
19 Pressure regulator For regulating intake air volume.
20 Oil separator For separating oil mist mixed in compressed air.
21 Separator receiver tank For separating compressor oil from compressed air sent into the tank.
22 Compressor oil filler port For supplying and replenishing compressor oil.
23 Compressor oil level gauge For checking compressor oil level.
24 Compressor oil drain valve For draining compressor oil from separator receiver tank.
25 Engine oil level gauge For checking engine oil level.(Operation side)
26 Engine oil drain valve For draining engine oil for replacement of it and for maintenance.
For draining condensate and water accumulated at the bottom of
27 Fuel tank drain valve the fuel tank.
28 Radiator drain valve For draining engine coolant at the bottom of radiator.
29 Oil cooler drain valve For draining compressor oil at the bottom of oil cooler.
30 Battery For electrically starting engine.
31 Sedimenter For separating water mixed in fuel oil.
32 Reserve tank For feeding engine coolant.
For air bleeding in fuel pipe system and also for fuel feeding to
33 Electromagnetic pump engine.
34 Compressor oil filter For filtering compressor oil circulating in the system.

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 lifted up, 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.
Never lift unit which is still in operation, or it could cause critical damage to each component or lead to
serious accident.
When lifting unit up, make sure that all the fixing bolts on the bonnet are surely tightened because it is
feared that the unit may fall.

3.1.1 Lifting up
① Before lifting the unit up, make sure to check
the lifting bail for any crack and loosened
bolts.
② Connect the hook“1”of the crane or shackle
with lifting bail“2”eye fitted at the top center 1 2
of the unit, and make sure that there is no
person standing around the unit. Then
perform hoisting operation.
③ 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.
A090572

3.1.2 Movement with a forklift

Protect the package from damage with 4 3
cushion material“3”
Make sure to insert the fork“4”more
than half of the length of the unit for
security.

A090637
3.1.3 Mounting the unit on the truck bed
Be sure to put chocks“5”at the front and rear
frames to the machine.
Hook the rope“6”as shown in the figure. Thus
secure the unit on the truck bed. 6 6

5 5
A100101

3-1
 3. Installation
3.2 Installation

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 ･･･････ 5°F to 104°F( -15℃～＋40℃)
Humidity ･････････････････ Less than 90%
Altitude ･･････････････････ Lower than 1,500 m above sea level
Make sure to install the unit, keeping more space than 5 inches from any solid
object nearby, for prevention of cooling performance drop.
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.

3.2.1 Mounting the unit on the truck bed

Make sure to fix the unit, using
anchor hole“1”of frame as shown
in the fig.
Tightening torque of the bolts：
M12 : 43N・m

1 A090631

Size of anchor bolt holes Unit:in.

A090636-1

3-2
 4. Operation
4.1 Instrument panel

1 2 3 4 5 8 9

15

14

13

12 11 10
7 6

A090575-1

1. Discharge pressure gauge ＜Indicator lamp＞

(For pressure in separator receiver tank)
8. Glow
2. Fuel level gauge
9.Auto idle(Purge control)
3. Hour meter
＜Warning lamp＞
4. Digital ｍonitor indicator
(temperature/pressure/rate of suction press.) 10. Charge
5. Selector switch for digital monitor indication 11. Compressor air filter clogging
6. Starter switch 12. Engine air filter clogging
7. Auto idle switch(Purge control) ＜Emergency stop lamp＞
13. Discharge air temperature
14. Water temperature
15. Engine oil pressure

4-1
 4. Operation
4.1.1 Digital monitor indicator

Place starter switch “RUN” and then digital monitor indicator goes on.

Press monitor selector switch for selection of digital monitor display.

Digital monitor selector switch

These items indicate Even during operation it is

the item which is possible to display the item
displayed on digital which is required to be
checked.
monitor.

A090576-1

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 (Engine
water temp.) →P (discharge pressure) → C ( rate of suction
press.) are selected.

[Discharge air temperature] [Engine water temperature]

Push Push

[Rate of suction presss.] [Discharge pressure]

Push Push

4-2
 4. Operation
4.1.2 Indicator lamp
Indicator lamp
Turn the starter switch to “RUN” position. Then the lamp goes on.

Item Contents Measures Monitor

Turn the starter switch “GLOW”
and the lamp goes on and after
GLOW
preheating is finished, the lamp ―
will be off.
During operation,push the AUTO
AUTO IDLE IDLE switch (purge control) “ON”
and then lamp goes on.
― ―

Warning lamp
When some little trouble occurs during operation, the lamps will flickers.
When the warning lamp flickers, take appropriate measures to recover the situation swiftly.

Item Contents Measures Monitor

Lamp flickers when the air
DISCHARGE temperature at the outlet of the
TEMP. air-end reaches the set See
temperature of 239°F (115°C). “Troubleshooting”
Lamp flickers when coolant
WATER TEMP.
temperature reaches 225°F (107°C).
Lamp flickers when alternator is Check wiring.
CHARGE
not charging. Check alternator.
COMP. Lamp flickers when air filter gets
AIR FILTER clogged and suction resistance
Clean
increases.
Replace
ENG. AIR FILTER [Actuating resistance is more than
0.9psi(0.062bar).]

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 Contents Measures Monitor

Lamp goes on when the air
DISCHARGE temperature at the outlet of the
TEMP. air-end reaches the set
temperature of 248°F (120℃).
Lamp goes on when coolant See
WATER TEMP.
temperature reaches 230°F (110℃). “Troubleshooting”
Lamp goes on when engine oil
pressure drops.
ENG. OIL PRESS.
[The function pressure is below
7.3psi(0.5bar).]

4-3
 4. Operation
4.2 Lubricating oil・Coolant・Fuel
4.2.1 Engine oil

Oil should use the recommendation 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.
＊Unit is delivered ex. factory, filled with engine oil recommended by engine manufacturer.

4.2.2 Compressor oil

Oil should use the recommendation oil


Be sure to use recommended oil listed below.
Maker and Brand of Recommended Oil

Maker Brand
HULS ANDEROL 3032
MOBIL RARUS SHC 1024
TEXACO SYN-STAR DE32


Even continuous oil replenishment cannot improve its deteriorated condition. Be sure to change the oil
completely at every scheduled interval.

Do not mix it with other brand oil, or it will cause poor performance and shorten the life of the
compressor 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
accident 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.

＊Unit is delivered ex. factory, filled with “AIRMAN OIL LONG LIFE”.

4-4
 4. Operation
4.2.3 Coolant

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 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%.
(Upon delivery from the factory, LLC density is 55%)
If LLC (Antifreeze) in the water exceeds more than 60%, it may decrease its antifreezing effect.
Follow the designated regulations to dispose of LLC.

4.2.4 Fuel

Choose appropriate

Be sure to use diesel fuel oil.

（Using other oil will cause low power output or damage 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.

4-5
 4. Operation
4.3 Check before starting unit
Check before starting unit
Be sure to check the unit before operation.
When any abnormality is found, be sure to repair it before restarting the unit.
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

<Procedure> 1
In case of checking and confirming oil level with level gauge at operation panel side.
Place the machine on level ground when
checking the oil level.
① Make sure to check and confirm that oil level is
between “FULL” and“LOW”.
② In case that oil level is lower than“ LOW” ,
replenish engine oil through oil filler port“1”.
Unit should be on level before checking oil level.
When you check oil level after you have once
started operation, wait 10 to 20 minutes after
stopping engine, before checking the oil level.

Unless unit is placed on

level, correct oil level
cannot be checked and
confirmed.

A100014

<Procedure> In case of checking and confirming oil level with engine level gauge.
① Pull out the oil level gauge“2”,and wipe it with a clean cloth.
② Then, re-insert the oil level gauge“2”fully and pull it out again. If the oil level gauge“2”
shows the oil level between LOW and FULL, it is normal.
③ When the oil level is below its LOW, add engine oil from oil filler port“1”.
While checking oil level, check also for contamination. If the oil is found dirty, contaminated or
should it be changed according to the periodic inspection list, change the oil. (See 5.5.1)
Never fill oil more than FULL level.

Oil level gauge

When oil level is

within this zone,
it is normal.
FULL
2
LOW A100103

4-6
 4. Operation
4.3.2 Check Coolant Level

Taking off the radiator cap

Be sure to stop the machine and allow time to cool. Then

loosen the radiator cap one notch. After the coolant water is
sufficiently cooled and the inner pressure is released, take the
cap off.
If this procedure is neglected, the inner pressure can blow off
the cap. Steam jetting out of the radiator could result in
causing scalding. Follow this procedure under all H990432

circumstances.

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

<Procedure>
Check the coolant level in the reserve tank. If it is lower than
the limit, open the cap and replenish the coolant.
(Level must be kept above LOW mark.)
When there is a little water or no water in the reserve tank,
remove the radiator cap and make sure to check the water
level. Then supply coolant to the radiator and also the tank,
LOW
if necessary. (See 5.5.14)
A090226

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
indicates 0MPa and there is no residual pressure in it, and then
gradually loosen the oil filler cap for refilling oil.
Should any residual pressure be left in the separator receiver
tank, hot compressed air and hot compressor oil jetting out could
cause burning or serious injury to persons nearby. W010

Place the machine on level ground when checking the oil level.
Check the oil level of the compressor. Correct oil level is
between upper and lower limit of the gauge, when the unit
stops.If the gauge shows lower than the middle level,
replenish oil. (See 5.5.5) 1/2
1/2

H000037

4-7
 4. Operation
4.3.4 Drain separator receiver tank

Draining of Separator receiver tank

After stopping the engine, confirm that the pressure gauge
indicates 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
extremely hot compressed air and oil to jet out and you may be
scalded or seriously injured.

H990432

Gradually opening the drain valve“2”fitted under the

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

A100102

4.3.5 Check fuel

Before starting operation, make sure to check the level of residual fuel so that fuel shortage during
operation can be avoided.
If necessary, drain condensate accumulated at the bottom of the fuel tank.

Fire prevention

Do not, under any circumstance, bring lit cigarettes

and/or matches to the fuel.
The fuel is extremely flammable and dangerous. Be
careful of fire because it is very likely to catch fire.
Refuel only after stopping the engine, and never leave
open fuel can near the machine. Do not 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 expansion 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.

4-8
 4. Operation
4.3.6 Drain fuel tank
Opening the drain valve“1”fitted under the fuel
tank, drain the condensate from the tank.
When completely drained, firmly close the drain
valve“1”.
Drain the condensate in container“2”, and then
dispose of condensate according to the
designated regulations.

2 1
A100104

4.3.7 Check sedimenter for condensate

When red float“2”under element“1”in sedimenter is raised up to upper level, drain water.

<Procedures>
① Turn fuel selector valve“3”to“OFF”position. ON 3
② Loosen the drain valve“4”and drain out
condensed water inside.
③ Make sure to tighten the drain valve“4”securely, OFF
after draining the condensate.
Drain the condensate in container“5”, and then
dispose of condensate according to the designated 1
regulations.

2 1

A090228-3

4.3.8 Check wiring of each part

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

4.3.9 Check piping of each part

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

4-9
 4. Operation
4.3.10 Check 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 belt for fan and alternator.

Adjust the tension by loosening the fastening bolt of the alternator.
<Procedure>
① Visually check if there are any cracks or
tears in the belt. Change the belt if it is
damaged.
② Adjust the belt tension by loosening the
1
fixing bolt“1”of the alternator so that the
belt can deflect 0.39 to 0.55in.(10 to 14 mm) This deflection
when pressed at the center of the belt with should be 0.39
approx.22lbf (98N) force. to 0.55in.
③ Be careful not to leave any grease or LLC on
Depress the middle
a belt while changing it. If any such material of the belt with a
is left, wipe it off completely. finger.

A090635
4.4 Operation

Operation with compressed air supply port opened is prohibited


Do not operate the machine with air valves 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


Keep the door closed and locked while running the unit.

When the door has to be opened, be careful not to touch portions
that are rotating or very hot.
Careless touch may cause serious injury.

Pull the handle forward to open the door.

Be sure to close the door tightly so that its latch is firmly caught.

PK0028

4-10
 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 monitor lamps are off.

<Procedure>
① Close fully air valves“1”.
② Keep starter switch“2”turned to“GLOW”position, then glow lamp“3”goes on. (Preheating time
is about 15 seconds.)
③ As soon as the glow lamp“3”has gone out, turn the starter switch“2”fully clockwise to start up
the engine.
④ Once the engine has started up, leave it running to warm-up for 5 minutes.
⑤ After finishing warming up operation, open the air valve“1” provided at the outlet of compressed
air and start service job.

3 2

A090578-1

[Explanation on automatic starting unloader]

Automatic starting unloader starts sutomatically.
This system keeps the pressure in separator receiver tank at the pressure of approx.58 pdi (4 bar)
for 10 seconds after engine starts. Then it proceeds to ordinary unloader operation.

4-11
 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 ③, 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
Discharge of battery (Low cranking speed)
Low ambient temperature

4.4.3 How to start the unit at low temperature

Operation under Cold Weather Conditions below23°F( -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
temperature.
Battery should always be kept fully charged.

When it is difficult to start engine in cold weather, take the following measures.
<Procedure>
① Fully close the air valve, and fully open the 1
valve “1” which is provided at the top of
separator for starting under the conditions
of low temperature.

② Perform normal starting operation first

and gradually close the low temperature
starting air valve “1”, watching the rising
engine speed. Oil
separator

Close

Low temperature Open

starting valve
A100105

4-12
 4. Operation
4.4.4 Gauge Indication while Operating

Minimum discharge air pressure is approx.58psi (4bar) during load 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.

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 values mentioned in following table are standard ones, so they sometimes vary
upon operation conditions.

Emergency stop Lamp Warning Lamp

Protection device Discharge Water Engine oil Compressor Engine
temperature temperature pressure Charge air filter air filter

Monitor

Starter switch
Starting

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

In Operation n
OFF

Indicator lamp
Protection device
Glow Auto idle

Monitor AUTO IDLE

Starter switch
Starting

set to “RUN” n n
position OFF OFF

In Operation n Note)※ 1： The lamp lights on when AUTO IDLE is

※1 OFF
selected.

Discharge air
pressure gauge
58-100 psi
Full load
In operation

(4-6.9 bar)
104-131 psi
Unload
(7.2-9.0 bar)
50-65 psi
Auto idle
(3.5-4.5 bar)

4-13
 4. Operation
4.5 Stopping

The unit is equipped with a built-in check valve. Therefore, some pressure will be left in pipes after the
unit stops. Be sure to release such residual pressure from the pipes by opening the air valve gradually
after the unit stops.

<Procedure>
① Close the air valves 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.

4.6 Air Bleeding in fuel pipe

Should the machine stop due to the shortage of fuel, perform the air bleeding operation
according to the following procedures.
<Procedure>
① Replenish fuel.
② Turning the starter switch to “RUN” position, the electromagnet pump functions to bleed the
air in fuel pipe system automatically.
③ The air bleeding operation can be finished within 1 minuite.

4-14
 4. Operation
4.7 Capacity Control Device

A100111E

Step Response
When starting operation, purge solenoid valve SV1 opens.
And compressed air is sent to unloader chamber A and speed regulator
chamber B . The pressure in chamber A rises soon, and unloader
Start
valve fully closes due to low pressure. Thus the load required for starting
is reduced.The pressure in chamber B rises soon too.and speed regulator
fully stroke to unload position.

After starting operation, SV1 valve closes after 10 seconds have passed.
The air volume sent to the chambers A and B from pressure regulator
Load operation increases or decreases according to the rise and drop of discharge air
pressure. Thus according as unloader valve position and engine speed
change, free air delivery is steplessly and automatically regulated from
0 to 100%.
When air consumption is reduced, and the pressure exceeds the rated
one, speed regulator functions to lower the engine speed in proportion to
Suction port closing the pressure rise and, at the same time, to close unloader valve.
unload operation Under unloaded operation, the interior 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 pressure regulator and thus it prevents high
vacuum state inside the compressor air end from being caused.

4-15
 4. Operation

During unloaded operation, when the certain set time(it can be changed.)
has passed at lower pressure than the set negative pressure, detecting
the negative pressure inside the compressor air end with a pressure
sensor PRS1, solenoid valve SV1 opens and it closes unloader valve. At
AUTO IDLE the same time, it functions to relieve the compressed air from separator
(Purge control) receiver tank to the atmosphere and thus it lowers the pressure. Thus
operation the compressor power is saved. When air consumption increases, and the
pressure used for load drops below the set pressure, pressure sensor
PRS2 detects it and it disengages the purge control (SV1 closes) to start
full load operation.

When stopping operation, it opens Auto relief valve to relieve the

Stop compressed air in separator receiver tank to atmosphere, detecting the
pressure inside compressor air-end.

4.7.1 AUTO IDLE (Purge control)

This model is equipped with AUTO IDLE (Purge control ).
This operation mode is recommendable for such use.
Not so much air consumption is required and it is used continuously and also power
consumption under unloaded operation is required to be saved.
Use this mode, depending upon the need and demand. For the selection of this mode, switch on
“AUTO IDLE” on the operation panel.

Select this operation mode freely, according to required air consumption.

<Procedure>
① During operation(After start up the 1 2
engine), push on the switch“1” “AUTO
IDLE”.
② Then the indicator lamp “AUTO IDLE” “2”
goes on.
③ In order to stop this operation mode, push
again “AUTO IDLE” switch “1”
and then the lamp “2” goes out to
disengage this purge mode.
As “AUTO IDLE” mode is reset when key
switch “STOP”is switched on, it is necessary
to select it whenever starting operation.

A090638

[Explanation on AUTO IDLE]

This system is for reduction of fuel consumption, which is attained by lowering the pressure loaded
in separator receiver tank during unloaded operation
Separator receiver tank internal pressure in AUTO IDLE：approx.58psi(4bar)

4-16
 4. Operation
[Function of AUTO IDLE (Purge control)]
Function Conditions of “AUTO IDLE” lamp
① First engine speed drops to the minimum
speed by speed regulator, owing to
reduction of air consumption. Later the air
consumption is reduced further, the
unloader valve gradually closes and intake
negative pressure increases. In this stage, Lamp flickers at short intervals.
the pressure sensor detects the intake
negative pressure. Then when the intake
negative pressure becomes higher than the
set pressure, the “AUTO IDLE” lamp
flickers at short intervals.
② When this condition continues for a
certain time, the solenoid valve (SV1)
functions to start purge mode operation.
Consequently, the pressure inside
Lamp flickers at longer intervals.
separator receiver tank drops and reduces
the power of compressor air end. In this
stage, the lamp “AUTO IDLE” flickers at
longer intervals.
③ Next, when the pressure for load down to
the purge releasing pressure owing to the
increase of air consumption, the solenoid
Lamp goes on.
valve (SV1) operation gets “OFF” and it is
transferred to normal operation. In this
stage, the lamp “AUTO IDLE” goes on.

[Standard set values prior to delivery ex-works ]

Setting Set prior to delivery
Item knob ex-works Setting range
Purge releasing pressure VR3 80 psi (5.5bar) 50-95 psi (3.5 – 6.6bar)
Purge starting rated of suction
VR2 30％ 0 - 80%
pressure
Timer for purge mode operation VR1 10 seconds 10 - 112 seconds

4-17
 4. Operation
4.7.2 How to adjust setting values of AUTO IDLE(Purge control)

AUTO IDLE(Purge control) is already arranged prior to delivery from factory. Therefore,
it is not necessary to perform any adjustment in usual case.
For adjustment of VR1, VR2 and VR3, follow the under-mentioned procedures.
For adjusting set value with knob, turning the knob to left lowers the set value, while
turning the knob to right raises the value.

<Procedure>
① Remove the cover “1”.
② Place the starter switch “RUN”.
③ At first keep pressing digital monitor selector switch “2”for 5 seconds.
④ Then, digital monitor “P” flickers. Adjust the purge releasing pressure (VR3) to the set
pressure value.
⑤ Then push digital monitor selector switch “2” the digital monitor “C” flickers. Then adjust the
purge starting suction pressure (VR2) to the set value.
⑥ Then push digital monitor selector switch “2” the digital monitor “I” flickers. Then adjust the
time (VR1) for purge mode operation to the set value.
⑦ Then push the digital monitor selector switch “2” the digital monitor returns to display
discharge air temperature.
⑧ Install the cover “1” .

Adjustment example Digital monitor 2

flickers.

“ ”flickers. Setting knob

Setting purge releasing pressure (VR3) to 80psi

Push

“ ”flickers. 1

Setting purge starting suction pressure (VR2) to 30%.

Push

“ ”flickers.
Setting time for purge mode operation (VR1) to 10 seconds.
A090640
Push

Return to display discharge air temperature.

4-18