Screw Compressor 6C2 Series 185S

Preface
This service manual explains about the cautions for maintenance jobs and is to serve a
guide for the electric system, and troubleshooting for service personnel.
In this book the fundamental matters and other things already mentioned in the
“Instruction Manual” and the “Parts Catalog” are omitted to avoid duplication.
Therefore, for the operation and handling of this unit, we request you to refer to the
instruction manual and caution plates, and further for the structure and components of
the unit, please refer to the “Parts Catalog” separately to be supplied with the unit.
If you should find any description which does not coincide with the instruction manual
and parts catalog, we request you to make sure to start the job after clarifying it.
Service personnel is required to safely take quick and proper countermeasures as well
as to use correct technology of maintenance in case of field services and periodical
maintenance. It is important that service personnel should have proper and sufficient
knowledge about the structure and function of the unit and should be well familiar with
such technique mentioned in them.
Regarding the part numbers mentioned in this manual, we request you to refer to the
Parts catalog separately supplied together with the unit, because the parts numbers in
this manual are sometimes changed.
Copies of this service manual are intended to be distributed to limited numbers

of our customers. The unauthorized reproduction or distribution of this service
manual is prohibited.
Table of Contents
1. Specification -------------------------------------------------------------------------------------- 1-1
1.1 Specifications ----------------------------------------------------------------------------------------------------------- 1-1
1.2 Set Value ----------------------------------------------------------------------------------------------------------------- 1-2
1.3 Outline drawing --------------------------------------------------------------------------------------------------------- 1-3
1.4 Internal Components and Part Names ---------------------------------------------------------------------------- 1-6
1.5 Instrument panel ------------------------------------------------------------------------------------------------------- 1-8
1.6 Capacity Control Device ---------------------------------------------------------------------------------------------- 1-11
1.7 Piping Diagram --------------------------------------------------------------------------------------------------------- 1-16
1.8 Fuel piping --------------------------------------------------------------------------------------------------------------- 1-18
2. Maintenance --------------------------------------------------------------------------------------- 2-1
2.1 Cautions for Overhauling --------------------------------------------------------------------------------------------- 2-1
2.2 Tightening torque ------------------------------------------------------------------------------------------------------ 2-2
2.3 How to adjust regulator and how to replace diaphragm ------------------------------------------------------ 2-7
2.4 Clean of element in sedimenter ------------------------------------------------------------------------------------ 2-10
2.5 Change Oil Separator ------------------------------------------------------------------------------------------------- 2-10
2.6 Change O-Ring of Unloader ----------------------------------------------------------------------------------------- 2-11
2.7 Check O-ring and Needle valve of Auto-relief valve and Vacuum relief valve -------------------------- 2-11
2.8 Performance check of Pressure control valve ------------------------------------------------------------------ 2-12
2.9 Check Pressure control valve O-Ring and Piston -------------------------------------------------------------- 2-12
2.10 Change of pellet assembly of by-pass valve -------------------------------------------------------------------- 2-13
2.11 Clean inside of Fuel Tank -------------------------------------------------------------------------------------------- 2-14
2.12 Values of Various Adjustments of Engine ------------------------------------------------------------------------ 2-14
3. Electric System ----------------------------------------------------------------------------------- 3-1
3.1 Control -------------------------------------------------------------------------------------------------------------------- 3-1
3.2 Alternator [Dynamo regulator (IC type)] -------------------------------------------------------------------------- 3-8
3.3 Starter --------------------------------------------------------------------------------------------------------------------- 3-10
3.4 Safety relay -------------------------------------------------------------------------------------------------------------- 3-11
3.5 Solenoid relay･Heater relay ----------------------------------------------------------------------------------------- 3-12
3.6 Purge/starting unloader solenoid valve --------------------------------------------------------------------------- 3-13
3.7 Stop solenoid ------------------------------------------------------------------------------------------------------------ 3-14
3.8 Engine oil pressure switch (For emergency stops) ------------------------------------------------------------ 3-15
3.9 Fuel air-bleeding electromagnetic pump ------------------------------------------------------------------------- 3-15
3.10 Discharge air temperature sensor･Coolant temperature sensor ------------------------------------------- 3-15
3.11 Pressure sensor (for Intake negative pressure and for service pressure) ------------------------------- 3-16
3.12 Fuel meter (Display) --------------------------------------------------------------------------------------------------- 3-16
3.13 Sending unit ------------------------------------------------------------------------------------------------------------- 3-17
4. Troubleshooting --------------------------------------------------------------------------------- 4-1
4.1 Repairing Procedures ------------------------------------------------------------------------------------------------- 4-1
4.2 Failures of compressor and engine -------------------------------------------------------------------------------- 4-3
4.3 Operation of emergency switch ------------------------------------------------------------------------------------- 4-10
4.4 Others --------------------------------------------------------------------------------------------------------------------- 4-13
4.5 Explanation of trouble diagnosis ----------------------------------------------------------------------------------- 4-14
5. References ----------------------------------------------------------------------------------------- 5-1
5.1 Comparison between consumable parts and electrical appliances ---------------------------------------- 5-1
5.2 Engine Wiring Diagram ----------------------------------------------------------------------------------------------- 5-3
1. Specification
1.1 Specifications
PDS185S-6C2
Item unit
Export model US model
●Weight・Mass
Overall length in.(mm) 116.5(2,960) 128.7(3,270)
Overall length (Bonnet only) in.(mm) 74.6(1,895) 74.6(1,895)
Overall width in.(mm) 65.0(1,650) 66.9(1,700)
Overall height in.(mm) 59.4(1,510) 59.8(1,520)
Net dry mass lb(kg) 1,896( 860) 1,896( 860)
Operating mass lb(kg) 2,116( 960) 2,116( 960)
●Compressor
Free air delivery cfm(m3/min) 185(5.2)
Working pressure psi(MPa)[bar] 100(0.69)[6.9]
Pressure of pressure control valve psi(MPa)[bar] 58(0.40)[4.0]
Burst pressure of safety valve psi(MPa)[bar] 150(1.03)[10.3]
Ambient conditions: temperature °F(℃) 5 to 104(-15 to +40)
Ambient conditions: altitude yd(ｍ) less than 1,640(1,500)
●Engine
Type YANMAR 4TNV88-BDHKS
hp/min-1
Rated output (Gross) 48.8/3,000(36.4/3,000)
(kW/min-1)
hp/min-1
Rated output (Net) 46.8/3,000(34.9/3,000)
(kW/min-1)
Fuel consumption g/kW･h 258
Rated RPM min-1 3,000
RPM at unload conditions min-1 1,300
Net dry mass lb(kg) 362(164)
●Lubricating oils
Engine oil capacity (H/L level) gal.(L) 1.95/1.06(7.4/4.0)
Compressor oil capacity
(including receiver tank and oil cooler gal.(L) 3.96(15)
etc.)
Ambient temperature：5°F to 104°F (-15℃ to +40℃)
Compressor oil capacity to be filled SHELL : SHELL CORENA OIL RS32 HULS : ANDEROL 3032
MOBIL : MOBIL RARUS 424 MOBIL : RARUS SHC 1024
NIPPON OIL CO.: FAIRCOL RA32 TEXACO: SYN-STAR DE32
Coolant capacity gal.(L) 1.53(5.8)
Fuel tank capacity gal.(L) 23.8(90)
●Fuel consumption ratio
(for reference only)
At purge operation gal./Hr(L/Hr) 0.53(2.0)
At no load gal./Hr(L/Hr) 0.71(2.7)
At 50% gal./Hr(L/Hr) 1.32(5.0)
At 70% gal./Hr(L/Hr) 1.66(6.3)
At full load gal./Hr(L/Hr) 2.51(9.5)
1-1
1. Specification
1.2 Set Value
PDS185S-6C2
Item unit
●Emergency stop devices
Actuating pressure of discharge air
°F(℃) 248(120)
temperature switch
Actuating temperature of water
°F(℃) 230(110)
temperature switch
Actuating pressure of oil pressure
psi(MPa)[bar] 7.3(0.05)[0.5]
switch
●Warning devices
Actuating pressure of discharge air
°F(℃) 239(115)
temperature switch
Actuating temperature of water
°F(℃) 221(105)
temperature switch
Battery failure When not charged
Actuating pressure of air filter
psi(kPa)[bar] 0.9(6.23)[0.0623]
indicator
●Set value
Pressure control valve psi(MPa)[bar] 58(0.40) [4.0]
Actuating pressure of safety valve psi(MPa)[bar] 150(1.03)[10.3]
Unload starting pressure psi(MPa)[bar] 100(0.69) [6.9]
Time for starting purge mode operation 10 to112
sec
(At AUTO IDLE operation mode) (Set at 10 sec. ex.works)
●Engine RPM
Rated RPM min-1 3,000
RPM at unload min-1 1,300
●Indications of gauges or instruments
during operation
Discharge pressure gauge
psi(MPa)[bar] 58 to 100(0.40 to 0.69)[4.0 to 6.9]
(at full load)
(at no load)
(at purge operation)
1-2
1. Specification
1.3 Outline drawing
(1) Export model
A100393E
Unit：mm
1-3
1. Specification
(2) US model
A100469
Unit：in.
1-4
1. Specification
(3) US model
A100468
Unit：mm
1-5
1. Specification
1.4 Internal Components and Part Names
1 2 3 4 5 6 7 8 9 10 11 12 13
19 18 17 16 15 14
A100417
Export model
No. Description Function

1 Oil separator For separating oil mist mixed in compressed air.
For keeping the receiver tank pressure higher than
2 Pressure control valve
58psi (0.4MPa) [4bar] in the tank.
For releasing compressed air to the atmosphere when the pressure rises
3 Safety valve
higher than the rated pressure.
Air filter
4 For filtering the dust floating in the intake air.
(For compressor air-end)
5 Speed regulator For regulating engine revolution speed.
6 Air filter (For engine) For filtering the dust floating in the intake air.
Air bleeding
7 For automatically bleeding air from fuel pipes.
electromagnetic pump
8 Fuel filter For filtering dust and foreign matter mixed or to be mixed in the fuel oil.
9 Fuel tank For storing diesel fuel oil.
10 Engine oil filler port For supplying and replenishing engine oil to engine.
11 Fuel pre filter For filtering dust and foreign matter mixed or to be mixed in the fuel oil.
12 Reserve tank For checking engine cooling water level and for replenishing cooling water.
13 Radiator For cooling the coolant for engine because it is water-cooled.
14 Sedimenter For separating water mixed or to be mixed in the fuel oil.
15 Engine oil filter For filtering engine oil.
16 Engine oil level gauge For checking engine oil level.
17 Fuel tank drain valve For draining condensate accumulated in fuel tank.
18 Pressure regulator For regulating intake air volume.
19 Battery For electrically starting engine.
1-6
1. Specification
20 21 22 23 24
31 30 29 28 27 26 25
A100418
Export model
No. Description Function

20 Oil cooler For cooling compressor oil circulating in the system.
21 Engine For driving the compressor.
22 Compressor oil filter For filtering compressor oil circulating in the system.
23 By-pass valve For keeping compressor oil at proper temperature.
24 Air-end For compressing intake air.
Separator receiver tank From this portion where condensate is drained out of separator-receiver
25
drain valve tank.
26 Compressor oil filler port For supplying and replenishing compressor oil.
Compressor oil level
27 Scale for measuring compressor oil level.
gauge
28 Engine oil drain valve For draining engine oil for replacement of it and for maintenance.
29 Coolant drain valve For draining condensate from engine.
30 Oil cooler drain valve For draining compressor oil out of oil cooler and oil lines.
31 Exhaust muffler Equipment which muffles an engine exhaust sound.
1-7
1. Specification
1.5 Instrument panel
(1) Export model
Error code / Reset switch

When this switch is pushed on while lamp is
blinking, it shows error code. When starter switch is
placed to “STOP”, displayed screen is reset.
A100359E
Discharge air pressure gauge Starter switch

For indication of working For starting and
pressure stopping engine
Digital monitor
When power is supplied, revolution speed (lamp lighting) is indicated.
[ENG.SPEED] [DISCHARGE TEMP.] [WATER TEMP.] [HOUR METER]

(min-1) (℃) (℃) (Hr)
Push Push Push
Whenever indication selector switch is pushed every time, indication
screen is changed by turns as shown above.
※In case that discharge air temperature is below 20℃, “－－－L” is indicated on screen.
1-8
1. Specification
(2) US model
Error code / Reset switch
When this switch is pushed on while lamp is
blinking, it shows error code. When starter switch is
placed to “STOP”, displayed screen is reset.
A100444MMD
Auto idle switch (with indicator lamp) Discharge air pressure gauge Starter switch
This switch is used when fuel For indication of working For starting and
consumption is minimized at no load pressure stopping engine
operation.
Digital monitor
When power is supplied, revolution speed (lamp lighting) is indicated.
[ENG.SPEED] [DISCHARGE TEMP.] [WATER TEMP.] [HOUR METER]

(min-1) (°F) (°F) （Hr）
Push Push Push

Push
Whenever indication selector switch is pushed every time, indication
screen is changed by turns as shown above.
[COMPRESSURE LOAD FACTOR] [SERVICE PRESSURE]

(％) （PSI）

In case that discharge air temperature is below 68°F, “－－－L” is indicated on screen.

In case the compressor load factor is more than 50%, “b－－－” is indicated on screen.

The indication of service pressure / the compressor load factor is displayed only at the time of
purge driving.
1-9
1. Specification
1.5.1 Indicator lamp
[Indicator lamp] Turn the starter switch to “RUN” position. Then the lamp goes on.
Item Contents Measures Monitor

Press starter switch “GLOW” and the
GLOW lamp goes on and after preheating is
finished, the lamp will be off.
―
Lamp goes on when alternator is not Check wiring.
CHARGE
charging. Check alternator.
[Warning display] This displays such trouble of less importance when it occurs during
operation, but the unit continues operating.
When any abnormality happens, a trouble code lamp flickers. In this time when trouble code
switch is pressed, a failure code will be displayed.
Failure
Item Contents Measures
code
DISCHARGE Lamp flickers when the air temperature at the
A1
TEMP. H outlet of the air-end reaches 239°F (115℃).
WATER TEMP. Lamp flickers when coolant temperature See
A2
H reaches 221°F (105℃). “Troubleshooting”
Belt loosened and/or cut
CHARGE A5
Faulty generation of alternator
[Emergency display] When any trouble takes place during operation, this displays and it
stops as an emergency stop.
When any abnormality happens, a trouble code lamp flickers. In this time when trouble code
switch is pressed, a failure code will be displayed.
Failure
Item Contents Measures
code
DISCHARGE Lamp displays when the air temperature at
E1
TEMP. H the outlet of the air-end reaches 248°F (120℃).
WATER TEMP. Lamp displays when coolant temperature
E2
H reaches 230°F (110℃).
Lamp goes on when engine oil pressure drops.
ENG. OIL
E3 The function pressure is below See
PRESS.
7.3psi(0.05MPa)[0.5bar]. “Troubleshooting”
It is displayed when air temperature sensor at
DISCHARGE
E6 the outlet port of compressor air end is
TEMP.SENSOR
disconnected.
WATER It is displayed when engine coolant
E7
TEMP.SENSOR temperature sensor is disconnected.
1-10
1. Specification
1.6 Capacity Control Device
(1) Export model
PC11007E
Step Response
When starting operation, starting unloader valve opens. And compressed air is
sent to unloader chamber and speed regulator chamber . Thus pressure
Start in chamber and rises smoothly and closes unloader valve completely at
low pressure. And at the same time, engine speed drops by function of speed
regulator. Consequently, load at start-up will be saved.
Air volume sent to unloader chamber and speed regulator chamber
increases and decrease according to increase and decrease of delivery air
Load operation
pressure. Thus according as unloader valve position and engine speed change,
free air delivery is sleeplessly and automatically regulated from 0 to 100%.
When air consumption decreases and compressed air in separator receiver tank
exceeds rated pressure, it closes unloader valve by function of pressure
regulator and speed regulator and reduces engine speed down to unloaded
Suction port closing speed. Further, when interior of compressor air-end becomes extremely high
unload operation vacuum during unloaded operation, it causes vacuum noise. In order to prevent
vacuum noise which occurs in compressor air-end, it detects secondary pressure
in pressure regulator to open vacuum relief valve, thus preventing interior of
air-end from becoming high vacuum.
When stopping operation, it opens auto relief valve to relieve the compressed
Stop air in separator receiver tank to atmosphere, detecting the pressure inside
compressor air-end.
1-11
1. Specification
(2) US model
A100449E
1-12
1. Specification
Step Response
When starting operation, solenoid valve (SV1) opens. And compressed air is
sent to unloader chamber and speed regulator chamber .
Accordingly, the pressure in the chamber and rises soon to fully
Start
close unloader valve at low pressure. And then engine speed drops with
the function of speed regulator and it starts automatically starting
unloader operation. Thus it can reduce the load at start-up.
After starting operation, SV1 valve closes after 10 seconds have passed. The
air volume sent to the chambers and 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 decreases and compressed air in separator receiver
tank exceeds rated pressure, it closes unloader valve by function of pressure
regulator and speed regulator and reduces engine speed down to unloaded
Suction port closing speed. Further, when interior of compressor air-end becomes extremely high
unload operation vacuum during unloaded operation, it causes vacuum noise. In order to
prevent vacuum noise which occurs in compressor air-end, it detects
secondary pressure in pressure regulator to open vacuum relief valve, thus
preventing interior of air-end from becoming high vacuum.
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 an intake negative pressure sensor (PRS1), solenoid
valve (SV1) opens and it closes unloader valve. At the same time, it functions
Purge control
to relieve the compressed air from separator receiver tank to the atmosphere
At unload operation
and thus it lowers the pressure. Thus the compressor power is saved. When
air consumption increases, and the pressure used for load drops below the set
pressure, services pressure sensor (PRS2) detects it and it disengages the
purge control (solenoid valve SV1 closes) to start full load operation.
When stopping operation, it opens auto relief valve to relieve the compressed
Stop air in separator receiver tank to atmosphere, detecting the pressure inside
compressor air-end.
1-13
1. Specification
1.6.1 AUTO IDLE control (Purge control)
This model is equipped with auto idle control operation mode. 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, push on auto idle switch“1”.
② Then the indicator lamp auto idle“2”goes on.
③ In order to stop this operation mode, push again auto idle switch“1”goes out to disengage this
purge control.
1 2
A100444E-3
Function of auto idle control (Purge control)

Function Conditions of auto idle lamp
① First engine speed drops to the minimum speed by
pressure 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 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 valve operation gets Lamp goes on.
“OFF” and it is transferred to normal operation. In
this stage, the lamp “AUTO IDLE” goes on.
1-14
1. Specification
1.6.2 Setting of “AUTO IDLE” control (purge control) pressure/timer

How to change set value of auto idle pressure/ timer is shown below.
Range of set
No. Item Indication Unit Primary set value
values
PSI 86 70 to 100
1 Purge releasing pressure
kPa 60 50 to 70
Waiting time for transfer
2 sec 10 5 to 60
to purge mode operation
Load factor for transfer to
3 ％ 15 5 to 30
purge mode operation
＜Procedures of adjustment＞
When auto-idle switch is pressed longer (than 5 second), first L.(Purge releasing pressure) is
displayed.
Each time auto-idle switch is pressed, each indication will be selected. Then each time it is pressed
one time, T.(Waiting time for transfer to purge mode operation) is switched to b.(Load factor for
transfer to purge mode operation),according to the set orders.
[Purge releasing [Waiting time for transfer [Load factor for transfer
pressure] to purge mode operation] to purge mode operation]
UP DOWN UP DOWN UP DOWN
Press 3 Press 2 Press 1

times times after time after
after setting job setting job
setting job is finished. is finished.
i
1-15
1. Specification
1.7 Piping Diagram
(1) Export model
A100361E
1-16
1. Specification
(2) US model
A100446E
1-17
1. Specification
1.8 Fuel piping
US model is optional.
PC11013
1-18
2. Maintenance
2.1 Cautions for Overhauling
2.1.1 Precautions before starting work
(1) Work to be performed
It is very important to always plan in advance what facilities, tools, instruments, materials, oil,
etc. you will need to use; the exact locations and methods of performing inspection, adjustment,
or disassembly; and the key points of any repair work to be performed.
(2) Care not to spill oil
Use a pan to collect used compressor oil, engine oil when changing the oil or attaching or
detaching an oil line. If a large volume of oil is expected to flow out make, sure to drain any
accumulated oil from the reserve tank, engine oil pan in advance.
[Follow the designated regulations to dispose of compressor oil and engine oil.]
(3) Care when detaching parts
When disassembling a complicated part, put a matching mark to indicate the position of
detached parts for future reference. Make sure that the negative cable is detached from the
battery terminals before starting repair work.
(4) Tools to be prepared
①Measuring instruments (e. g. tester, insulation resistance gauge etc.)
②Tools
③Torque wrenches
④Jigs and specialized tools
⑤Sealing tape
⑥Molybdenum sulfide (tube type)
⑦Lithium extreme pressure type grease
CALTEX MULTIFAK EP1
MULTINOC SDX
⑧Diesel oil
⑨Compressor oil
⑩Cleaning cloths
⑪Literatures (such as manuals etc.)
2.1.2 Disassembly and assembly

(1) Before removing nylon tubes, hydraulic/fuel hoses, it is necessary to clean the inside of machine
to prevent from entrance of dirt and foreign matters.
(2) Perform disassembly work in a dust-free location whenever possible.
(3) When disassembling parts, wash their outer surfaces and place them on a clean sheet of paper
or cloth, taking care not to contaminate or damage them.
(4) Wash disassembled parts with diesel oil (cleaning solvent) after checking for contamination or
discoloration. However, do not wash rubber parts with diesel oil.
(5) Be careful not to damage disassembled parts, they are precision built.
(6) Replace consumables such as oil seals, O-rings, filters, oil, etc. with new items when
reassembling parts.
(7) Apply “CALTEX MULTIFAK EP1” to O-ring surface and “MULTINOC SDX” to sliding portion
of oil seal.
(8) When reassembling parts, place each part in the order of assembly and take care that no parts
are missing or misassembled.
(9) When reassembling an assembled part (set part), be sure to replace it as an assembly.
(10) Contamination or rusting may occur due to dust or humidity if parts are left in disassembled or
partly disassembled condition for a long time. Therefore, be careful to prevent dust or rust from
affecting parts if you have to leave the repair incomplete for a long period of time.
(11) Check tightening torque and clearance when assembling parts.
(12) Check the direction of rotation, speed, and oil leakage after assembly.
(13) Before starting the machine after disassembly, run it at low idle to check for unusual noises, etc.
to prevent engine or generator damage.
2-1
2. Maintenance
2.2 Tightening torque
2.2.1 General bolts and nuts tightening torque
Fasten all the bolts and nuts with the specified tightening torque when assembling.
Kind Low or Middle carbon steel bolt High tensile strength bolt
(SS400B etc…) (SCM435 etc…)
Strength and 4.6～6.8（4T～6T） 8.8～12.9（7T～12T）
sorting
Width of
across flat･
Tightening Hexagon bolts Socket bolts Hexagon bolts
torque Tightening Tightening
Hexagon bolts torque Socket bolts Hexagon bolts torque
Bolt diameter Width of across Width of across Width of across
lbf･in.(N･m) lbf･in.(N･m)
in. (mm) flat in. (mm) flat in.(mm) flat in.(mm)
[kgf･cm] [kgf･cm]
0.24 (6) 0.39(10) 44.2( 5)[ 51] 0.20 (5) 0.39(10) 88.5( 10)[ 100]
0.31 (8) 0.51(13) 106.2( 12)[ 124] 0.24 (6) 0.51(13) 221.2( 25)[ 245]
0.39(10) 0.67(17) 221.2( 25)[ 245] 0.31 (8) 0.67(17) 433.6( 49)[ 485]
0.47(12) 0.75(19) 380.5( 43)[ 425] 0.39(10) 0.75(19) 752.2( 85)[ 845]
0.55(14) 0.87(22) 601.8( 68)[ 675] 0.47(12) 0.87(22) 1,194.7(135)[1,350]
0.63(16) 0.94(24) 938.1(106)[1,055] 0.55(14) 0.94(24) 1,858.4(210)[2,100]
0.71(18) 1.06(27) 1,283.2(145)[1,450] 0.55(14) 1.06(27) 2,566.4(290)[2,900]
0.79(20) 1.18(30) 1,814.2(205)[2,050] 0.67(17) 1.18(30) 3,628.3(410)[4,100]
0.87(22) 1.26(32) 2,477.9(280)[2,800] 0.67(17) 1.26(32) 4,955.8(560)[5,600]
0.94(24) 1.42(36) 3,053.1(345)[3,450] 0.75(19) 1.42(36) 6,283.2(710)[7,100]

For general sections such as bonnet
Applied sections. For specified sections.
and frame.

The above torque values in the table shall be applicable for the bolts and nuts used for machine

Generally, the abovementioned tightening torques should be followed, but in some points different
torque is specified. So use the tightening torque without fail. (See following pages.)

Make sure to remove rust and dust before tightening.
2-2
2. Maintenance
2.2.2 Tightening torque of such important quality parts as bolts and nuts
Strength
Tightening torque lbf･in.(N･m)[kgf･cm]
classification
Application parts & portions Torque Coarse thread / fine thread Remarks
Bolt Nut
section M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
１ Air end
44.2 106.2 380.5
10.9 ― 4.8 (5) (12) － (43) －－－－－－ for prevention of deformation of outer ring
① ・End cover [51] [124] [425]
44.2 106.2 380.5
12.9 ― 4.8 (5) (12) － (43) －－－－－－ for prevention of deformation of outer ring
[51] [124] [425]
292.0 566.4
② ・Plate holding pinion gear 12.9 ― 10.9 － (33) (64) －－－－－－－ for prevention from loosening
[325] [640]
88.5 221.2 433.6 752.2 1194.7 1858.4
・Others 12.9 ― 8.8 (10) (25) (49) (85) (135) (210) －－－－
[100] [245] [485] [845] [1350] [2100]
２ Mounting
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4
③ ・Mounting bracket 4.8 ― 4.8 － (12) (25) (43) (68) (105) (150) (210) －－ with spring washer
[124] [245] [425] [675] [1050] [1500] [2100]
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4
④ ・Vibration isolator ass'y ― 4.8 4.8 － (12) (25) (43) (68) (105) (150) (210) －－ with spring washer and thick washer
[124] [245] [425] [675] [1050] [1500] [2100]
３ Coupling portion between comp. air end and engine

106.2 221.2 380.5 601.8 929.2 1327.4 1858.4
⑤ ・Housing 4.8 ― 4.8 － (12) (25) (43) (68) (105) (150) (210) －－ with spring washer
[124] [245] [425] [675] [1050] [1500] [2100]
221.2 433.6 752.2 1194.7 1858.4 2477.9 3628.3
⑥ ・Coupling (for installing flywheel) 10.9/12.9 ― 8.8 － (25) (49) (85) (135) (210) (280) (410) －－ with spring washer
[245] [485] [845] [1350] [2100] [2800] [4100]
221.2 433.6 752.2 1194.7 1858.4 2477.9 3628.3
⑦ ・Coupling (for installing driving shaft) 12.9 ― 8.8 － (25) (49) (85) (135) (210) (280) (410) －－ with lock washer
[245] [485] [845] [1350] [2100] [2800] [4100]
221.2 433.6 752.2 1194.7 1858.4 2477.9 3628.3
⑧ ・Coupling (for installing gear of resin) 10.9 ― 8.8 － (25) (49) (85) (135) (210) (280) (410) －－ with spring washer and thick washer
[245] [485] [845] [1350] [2100] [2800] [4100]
４ Lifting portion
159.3 327.4 601.8 929.2 1327.4 1858.4
・Lifting bail (less than M20) 10.9 4.8 6.8 － (18) (37) (68) (105) (150) (210) －－－ with spring washer
⑨ [183] [365] [675] [1050] [1500] [2100]
1858.4 2477.9 3053.1
・Lifting bail (more than M20) 10.9 4.8 4.8 －－－－－－－ (210) (280) (345) with spring washer
[2100] [2800] [3450]
５ Pressure vessel and pipes

221.2 433.6 752.2 1194.7 1858.4 2477.9 3628.3 4955.8 6283.2
⑩ ・Separator cover 10.9 ― 8.8 － (25) (49) (85) (135) (210) (280) (410) (560) (710) with spring washer
[245] [485] [845] [1350] [2100] [2800] [4100] [5600] [7100]
221.2 433.6 752.2 1194.7 1858.4 2477.9 3628.3 4955.8 6283.2
⑪ ・Press.cont.body 10.9 ― 8.8 － (25) (49) (85) (135) (210) (280) (410) (560) (710) with spring washer ※2
[245] [485] [845] [1350] [2100] [2800] [4100] [5600] [7100]
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4 2477.9 3053.1
⑫ ・Press.cont.cover 10.9 ― 4.8 － (12) (25) (43) (68) (105) (150) (210) (280) (345) with spring washer
[124] [245] [425] [675] [1050] [1500] [2100] [2800] [3450]
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4 2477.9 3053.1
⑬ ・Flange for pipeﾞ First priority 4.8 4.8 4.8 － (12) (25) (43) (68) (105) (150) (210) (280) (345) with spring washer
[124] [245] [425] [675] [1050] [1500] [2100] [2800] [3450]
221.2 433.6 752.2 1194.7 1858.4 2566.4
⑬ ・Flange for pipe (less than M20) Second priority 10.9 8.8 ※3 8.8 － (25) (49) (85) (135) (210) (290) －－－ with spring washer
[245] [485] [845] [1350] [2100] [2900]
1858.4 2477.9 3053.1
⑬ ・Flange for pipe (more than M20) ※1 Second priority 10.9 4.8 4.8 －－－－－－－ (210) (280) (345) with spring washer
[2100] [2800] [3450]
６ Undercarriage
159.3 327.4 601.8 929.2 1327.4 1858.4 2699.1 3628.3 4690.3

⑭ ・Spring bracket 10.9 4.8 6.8 － (18) (37) (68) (105) (150) (210) (305) (410) (530) with spring washer
[183] [365] [675] [1050] [1500] [2100] [3050] [4100] [5300]
159.3 327.4 601.8 929.2 1327.4 1858.4 2699.1 3628.3 4690.3
⑮ ・U-bolt 10.9 4.8 6.8 － (18) (37) (68) (105) (150) (210) (305) (410) (530)
[183] [365] [675] [1050] [1500] [2100] [3050] [4100] [5300]
433.6 1194.7 1327.4 2477.9
⑯ ・Hub,wheel 10.9 8.8 10.9 －－ (49) (135) (150) (280) －－－－
[485] [1350] [1500] [2800]
159.3 327.4 601.8 929.2 1327.4 1858.4 2699.1 3628.3 4690.3
⑰ ・Draw bar 10.9 4.8 6.8 － (18) (37) (68) (105) (150) (210) (305) (410) (530) with spring washer
[183] [365] [675] [1050] [1500] [2100] [3050] [4100] [5300]
159.3 327.4 601.8 929.2 1327.4 1858.4 2699.1 3628.3 4690.3
⑱ ・Brake 10.9 4.8 6.8 － (18) (37) (68) (105) (150) (210) (305) (410) (530) with spring washer
[183] [365] [675] [1050] [1500] [2100] [3050] [4100] [5300]
106.2 221.2 380.5 601.8 929.2 1327.4 1858.4 2477.9 3053.1
⑲ ・Stand for storing drawbar 10.9 4.8 4.8 － (12) (25) (43) (68) (105) (150) (210) (280) (345) with spring washer
[124] [245] [425] [675] [1050] [1500] [2100] [2800] [3450]
※1　For larger than M20, tightening torque becomes so big, and so 4.8 or equivalent shall be used.
※2　When fixing parts of aluminum are used, lockwasher shall be used for avoiding damage.
※3　Nut shall be of S45C ( equivalent to 8.8 of strength classification ).
2-3
2. Maintenance
1 Air end
2 Mounting
3 Coupling portion between comp. air end and engine
⑤
⑥
COMP.SIDE ENG.SIDE
2-4
2. Maintenance
4 Lifting portion
⑨
⑨
5 Pressure vessel and pipes
⑫
⑬
⑩ ⑪
2-5
2. Maintenance
6 Undercarriage
⑱ ⑲
2-6
2. Maintenance
2.3 How to adjust regulator and how to replace diaphragm
2.3.1 Method of adjustment
Operation with compressed air supply port opened is prohibited


When adjusting regulator system, install a silencer to the air
delivery port and wear earplugs for protection of hearing damage.
D003

The speed regulator is already adjusted prior to delivery ex.works. Never change the setting of
the regulator by turning bolt and rod recklessly.

If it is necessary to re-adjust the speed regulator due to overhauling or any trouble, adjust it in
accordance with the following procedures.
<Adjustment procedure> (For engine speed and pressure, see 1.2)
Pressure regulator
Pressure adjusting screw
Engine governor lever

Speed regulator
PC08021-1
Rod Left screw
High speed Low speed

side side
Right screw
PC10022
① Adjust the length of the rod connecting speed regulator so that engine governor lever can be pulled
toward high speed side, with compressor kept stopping.
(Making the rod length short, engine speed increases.)
② Adjust this system so that when unload starting pressure exceeds 100psi(0.69MPa)[6.9bar] by
turning pressure adjusting screw, speed regulator can start to function to lower engine RPM.
(Tightening the screw, the pressure rises, and loosening it, the pressure drops.)
2-7
2. Maintenance
2.3.2 Change diaphragm
B
Speed regulator (Bellophragm type)

<Procedure> A
① Remove the speed regulator from the bracket and
disassemble it.
② Replace diaphragms with new ones. D
③ Check A to D shown in figure for any burrs.
④ Diaphragm is delivered in different state from the C
Diaphragm
state in which it should be installed. So install
diaphragm which should be turned inside out, as
shown in the following Fig.
PC06037
[Delivered state] [State to be installed]
Locking nut Washer Diaphragm

Piston Shaft
Seal washer
PC11038
⑤ Internal face of body and cap and also both internal face and external face of diaphragm should
be coated with molybdenum sulfide spray.
How to spray molybdenum sulfide paste：The areas in oblique line should be sprayed with this
paste.
Diaphragm should be rolled up
Then it should be Inside of body should
and back face and piston
returned and be sprayed. be sprayed.
should be sprayed.
Inside face of body

※ Jointed portion should should be sprayed
be sprayed enough. till middle line.
PC11037-1
2-8
2. Maintenance
⑥Install diaphragm to shaft and piston and fasten it with a locking nut.
Tightening torque：70.8bf･in.(8N･m)[80kgf･cm]
Important：Be careful not to tighten the locking nut excessively. Excessive tightening can cause
washer to turn together and twisting diaphragm. The diaphragm will be damaged in
shorter period.
⑦Put in diaphragm to be settled equally in the body

using an assembly tool. Assembly tool
Important：Once diaphragm is settled in, turn slowly the Locking nut

tool for secure installation. When turning the Diaphragm
tool, hold the diaphragm not to be afloat.
Body
Shaft
⑧After diaphragm is set in, install the cap and then
assemble speed regulator.
Cap
Important：Before installing the cap, make sure again
that the portion of diaphragm shown in right
figure is seated intact. If diaphragm is afloat,
it can cause diaphragm to be caught in
when installing cap.
If the shaft is turned after installation is
Clearance
finished, it could damage diaphragm. Take
care.
Body
⑨After re-assembling the speed regulator, adjust it
according to the adjustment method of speed
regulator (See 2.3.1)
2-9
2. Maintenance
2.4 Clean of element in sedimenter
<Procedure>
ON 1 8
① Turn fuel selector valve“1”to“OFF”position.
② Loosen the drain valve“2”and drain out condensed
water inside.
③ Turn the cup“3”to the left and remove it. OFF
Be careful to remove the cup“3”because it is filled 7
with fuel. Wipe out split fuel completely. 6
④ Remove float“4”inside cup“3”
⑤ Washing element“5”and the cup inside with new
5
fuel.
3
⑥ Replace element“5”and O ring“6”,“7”if they are
found broken or damaged. 4
⑦ After finishing clean, assemble it in reverse
procedure.
2
If air is found still in fuel pipe, place starter switch to
“RUN”position and loosen air bleeding bolt“8”to
bleed air. After finishing air bleeding, tighten the air
bleeding bolt“8”.
Drain the condensate in container“9”,and then 9
dispose of condensate according to the designated
regulations. A100117
2.5 Change Oil Separator

When changing the oil separator, both cover and element must be replaced with new ones.

Even before the periodic interval time of replacement, replace the oil separator whenever the oil
consumption increases and also oil is found mixed in the discharge air.

When consumption of the oil is still unusual even after cleaning strainer in the scavenging orifice,
change the oil separator with a new one.
O-ring
Separator
casing
Element
Oil separator
Cover
Separator cover
A100463-1 A100371
[Tightening torque of separator cover bolt]
: 0.31 in. (8 mm)
: 433.6lbf･in.(49N･m)[485kgf･cm]
2-10
2. Maintenance
2.6 Change O-Ring of Unloader
<Caution during O-ring replacement>
Supply grease to O-ring“1”･“2”･“3”･“4”after replacement.

When reassembling, apply sufficient grease to O-ring Slot/O-ring 1
and sliding surface.
Use CALTEX MULTIFAK EP1 grease or equivalent. Grease of poor
quality will deteriorate the material.
2
1
A070337
2.7 Check O-ring and Needle valve of Auto-relief valve and Vacuum
relief valve

When reassembling, apply sufficient grease to O-ring Slot/O-ring and sliding surface.
Use CALTEX MULTIFAK EP1 grease or equivalent. Grease of poor quality will deteriorate the material.

Disassemble and clean the component, and
check O-ring“1”,“2”,“3” and needle valve
“4”. Then, replace O-ring“1”,“2”,“3” Auto-relief valve
4
and rubber on the needle valve“4”, if 3
hardened.
4
2 3
1
2
1
Vacuum relief valve
A070339
2-11
2. Maintenance
2.8 Performance check of Pressure control valve

When reassembling, apply sufficient grease to O-ring Slot/O-ring and sliding surface.
Use CALTEX MULTIFAK EP1 grease or equivalent. Grease of poor quality will deteriorate the material.
<Procedure>
① When closing stop valve and fully opening service valve
while the machine is running, make sure that the discharge
pressure gauge shows the figure between 49 to 68psi(0.34 to 1
0.47MPa)[3.4 to 4.7bar].
2
② When the pressure is lower than 49psi(0.34MPa)[3.4bar],
replace spring“3”with a new one. 3
③ When the indicator shows excessively higher pressure, you
will find that the piston does not move smoothly due to
4
foreign material and rust stuck inside valve. In such a case,
disassemble the component for checking and cleaning.
A100372-1
2.9 Check Pressure control valve O-Ring and Piston


After disassembling and cleaning pressure control valve, check O ring“1”･“2”and piston“4”.
When the rubber of these parts is found hardened, or damaged, replace them.

After replacement, run the machine to check its function, air-leak or any disorder.
2-12
2. Maintenance
2.10 Change of pellet assembly of by-pass valve
●By-pass valve fitted on this unit is of full bore type. While the unit is used for normal operation, it
is not to perform periodical replacement of the Inner pellet assembly, but when such trouble as
excessive rise of compressor oil temperature, it becomes necessary to replace it, in accordance with
the following procedures.
<Procedure>
① First stop the unit and make sure that there is no residual pressure left in the separator receiver
tank.
② After checking and confirming that the temperature of compressor oil has become amply low, open
drain valves on separator receiver tank and oil cooler to empty compressor oil completely.
③ After having drained oil completely, remove the pellet assembly of by-pass valve and O-ring.
④ Replace the pellet assembly and O-ring by new ones. Install O-ring coated thinly with compressor
oil.
⑤ Supply compressor oil through the filler port provided on the receiver tank.
(Refer to operation manual.)
⑥ Start operation and check the function of by-pass valve.
(It functions well when delivery air temperature will not rise abnormally.)
O-ring Pellets ASS’Y
To oil cooler
(when the oil temperature is high)
To oil filter
(when the oil temperature is low)
PC11033
To oil filter
To compressor air-end
Actuating temperature By-pass valve fully closing temperature
180±37°F (82±3℃) 192±36°F (89±2℃)
2-13
2. Maintenance
2.11 Clean inside of Fuel Tank

Condensate is caused and accumulated at the bottom of fuel tank, owing to churning of dust or dirt
mixed when fuel oil is fed and water drop caused while fuel oil tank is used for a long time. When
any condensate is found afloat and fuel filter gets clogged too fast, fuel oil tank should be cleaned
after condensate is removed from fuel oil tank even before the specified cleaning interval time.
<Procedure>
① Open drain valve to remove fuel oil from fuel tank.
② Remove side cover under door.
③ Remove fuel pipes and wires connected to fuel tank.
④ Remove belt holding fuel tank and remove tank.
⑤ Insert cleansing nozzle through fuel filler port or drain
port for cleaning tank.
⑥ After cleaning job is finished, install fuel tank from which
water or the like should be completely removed.
PC11008
2.12 Values of Various Adjustments of Engine

Item Unit PDS185S-6C2
Engine model YANMAR 4TNV88-BDHKS
lbf･in. First time 364.6 to 416.6(41.2 to 47.1)[420 to 480]
Tightening torque of head bolts (N･m)
Second time 755.2 to 807.2(85.3 to 91.2)[870 to 930]
[kgf･cm]
Valve Air intake in.(mm) 0.0079±0.020 (0.20±0.5) (when engine is cold)
clearance Discharge in.(mm) 0.0079±0.020 (0.20±0.5) (when engine is cold)
Firing order 1-3-4-2-1 (No.1 cylinder at flywheel side)
Injection timing (BTDC) ° FIT 14.5 [at lift 0.098in. (2.5mm)]
Nozzle injection pressure psi(MPa)[bar] 3,133±72.5(21.6±0.5)[216±5]
Standard psi(MPa)[bar] 470±14.5(3.24±0.1)[32.4±1]
Limited value 370±14.5(2.55±0.1)[25.5±1]
Compression Each
Working limit psi(MPa)[bar]
cylinder limit 29 to 43.5(0.2 to 0.3)[2 to 3]
value
Temperature for
°F(℃) 160±34.7 (71±1.5)
start of release
Thermostat Full open
°F(℃) 185 (85)
temperature
Valve lift in.(mm) More than 0.31 (8.0)
※For the details, see service manual supplied by engine manufacturer.
2-14
3. Electric System
3.1 Control
Part number: 46870 51901 (Export model)
Part number: 46870 54000 (US model)
PC10024E
3-1
3. Electric System
1.Exterior connection drawing
PC11009E-1
※：As engine oil pressure switch contact is B, the contact is ON when engine shuts down. After engine
starts, the contact becomes OFF due to rise of engine oil pressure. Oil pressure detecting circuit of
controller functions at circuit of contact A. After engine oil pressure switch is kept ON for 2 seconds,
engine is brought to emergency stop. (Engine oil pressure abnormality detecting circuit functions
10 seconds after it detects alternator generation signal.)
3-2
3. Electric System
2. Timing of each output relay
PC11010E-1
3. Warning・emergency display and emergency stop functions

Item Indicator Sensor Actuation Detecting timing Time lag
Discharge temp. Lamp goes on at
A-1 Thermister － Always 1.0 sec
H 239°F(115℃)
Warning
Lamp goes on at
Water temp. H A-2 Thermister － Always 1.0 sec
221°F(105℃)
Charge signal disappears After starting
Charge A-5 －－ 5.0 sec
and lamp goes on. engine
Discharge temp. Lamp goes on at
E-1 Thermister － Always 1.0 sec
H 248°F(120℃)
Lamp goes on at
Water temp. H E-2 Thermister － Always 1.0 sec
230°F(110℃)
Emergency
Lamp goes on when oil

Pressure 10 seconds after
Eng. oil press E-3 A contact pressure is lower than 2.0 sec
SW engine starts
7.3psi(0.05MPa)[0.5bar]
Discharge temp. Disconnected and lamp After starting
E-6 Thermister － 20.0 sec
sensor goes on. engine
Water temp. Disconnected and lamp After starting
E-7 Thermister － 20.0 sec
sensor goes on. engine
・Emergency：Compressor continues to run.
・Warning：Compressor stops.
3-3
3. Electric System
4. Functions of each output relay
Mark Name Remark
When coolant temp. is lower than 32°F(0℃),
It goes ON when starter it becomes OFF 20 seconds later.
RY0 Relay for heater relay
SW is ON. When coolant temp. is higher than 32°F(0℃),
it becomes OFF 2 seconds later.
It goes ON for 1 second
RY1 Relay for solenoid relay
when starter SW is ON.
When coolant temp. is lower than 32°F(0℃),
Relay for starting It goes ON when starter or when 120 seconds pass, it becomes OFF.
RY2
unloader SW is ON. When coolant temp. is higher than 32°F(0℃),
it becomes OFF 10 seconds later.
It goes ON when starter
RY3 Relay for solenoid
SW is ON.
Abnormality output
RY4
relay
When switching to purge operation
Purge function relay Blinking during purge ･･･Blinks every 0.5 seconds
RY5
(US model only) function During purge operation
･･･Blinks every 1 second
5.Adjustment and inspection

Perform the detection and inspection of discharge air temperature, engine coolant temperature, and
setting unit by controller in the following steps.
(1) Connect resistance to controller as shown right.

Or use multi-speed variable resistance
(resistance value: 1.0kΩ) for VRc1, VRc2 and
VRc3.
PC10027E
(2) Gradually lower resistance values of VRc1 and VRc2 and measure them when they reach
abnormal values. Then check and confirm that they are within the following ranges.
Set temperature
Item Resistance(Ω)
(℃) (°F)
Warning 105 221 640±15

Engine coolant VRc1
Emergency 110 230 560±15
Warning 115 239 491±15
Discharge air temperature VRc2
Emergency 120 248 432±15
(3) Sending unit

Float position Resistance (Ω)
F 3.0±2.0
1/2 32.5
E 110.0±7.0
3-4
3. Electric System
6.List of functions
(1)Connector CN1
Line
Pin No. color Connection Remark
1 R/W CN1-12 Common
When starter switch is “ON”, and voltage is applied to
CN1-12 terminal, interior contact (RYO) is “ON”, and
voltage is outputted out of CN1-2 terminal to make a
heater relay function.
2 Y/R Heater relay [A] terminal
2 seconds later [when coolant temp. is lower than 32°F
(0℃), 20 seconds later] the interior contact (RYO)
becomes “OFF” to cut power supply to heater relay and
complete engine preheating.
For holding stop solenoid
CN1-12 terminal, interior contact (RY3) is “ON”, and
voltage is outputted from CN1-3 terminal to supply
3 W/B Stop solenoid [R] terminal power to R terminal for holding stop solenoid.
When starter switch is “OFF” or emergency stop
system functions, the interior contact (RY3) becomes
“OFF” to cut power supply to the stop solenoid and
consequently engine stops.
4 － NIL For outputting signal of abnormality
5 － NIL For outputting signal of abnormality
6 － NIL
3-5
3. Electric System

CN1-12 terminal interior contact (RY2) between CN1-9
and CN1-7 terminal becomes “ON” to supply power to
solenoid for purge/starting unloader to open the valve.
Thus this unit automatically starts starting unloader
operation when it starts up, consequently saving load
at start-up.
When controller CN2-8 terminal receives input of
alternator generation signal after engine starts,
controller timer begins to function and 10 seconds later
[ after whichever shorter time passes between the time
till water temperature rises higher than 32°F (0℃)
when it is lower than 32°F (0℃) and the time of 120
seconds later ] the interior contact (RY2) becomes
“OFF” to cut power supply to the purge/starting
unloader operation and then switched to normal mode
operation from starting unloader mode.
●Functions during AUTO IDLE (purge control) operation
When auto idle switch is switched on during operation,
auto idle lamp goes on and switched to purge control
operation. When this switch is pressed on again, auto
Purge/starting unloader
idle lamp goes out and this mode is released.
7 Y/G solenoid valve
When air consumption decreases and pressure
(US model only)
regulator begins to function, engine speed drops and at
the same time, unloader valve of compressor air-end
gradually begins to close and suction load increases.
Compressor load factor is shown as monitor indication
(See 1.5(2)) based on the suction load which is detected
by suction load sensor. When the load factor becomes
lower than the specified value [(set value prior to
delivery: 15% (See 1.6.2)], auto idle lamp blinks at
short intervals. When this situation continues for a
certain time (set time prior to delivery: 10 seconds), the
interior contact in controller (RY2) becomes “ON” to
make solenoid for purge function to start purge. Thus
receiver tank pressure drops to save machine power. At
this time the auto idle lamp blinks at long intervals.
Further, when air consumption increases and the
pressure at load becomes lower than the purge
releasing pressure (set value prior to delivery:
86psi(0.59MPa)[5.9bar] to cut power supply to the
solenoid for purge/starting unloader mode and then
switched to normal node operation. Auto idle lamp
changes from blinking to lighting.
For pulling stop solenoid
CN1-12 terminal, interior contact (RY1) is “ON”, and
voltage is outputted out of CN1-8 terminal to make the
8 Y/L Solenoid relay solenoid relay function. Thus power is supplied to W
terminal of stop solenoid and it pulls interior plunger. 1
second later, the interior contact (RY1) becomes “OFF”
to cut power supply to solenoid relay. Then stop
solenoid is switched to holding circuit.
9 R/W CN1-12 Common
No electrical connection found.
Auto idle function indicator When auto idle switch is “ON”, and power is supplied
10 W/G
(US model only) to CN2-2 terminal, interior contact (RY5) becomes
“ON” to make auto idle function indicator go on.
11 R/W CN1-12 (US model only) Power supply for auto idle function lamp lighting.
Starter switch [ACC] terminal
12 R/Ｗ Power supply
(Through 5A Fuse)
3-6
3. Electric System
(2)Connector CN2
Line
1 B Earth
When auto idle is switched “ON” to be electrically
AUTO IDLE switch
2 W connected, it will be switched to purge control
(US model only)
mode.
No electrical connection found.
When engine oil pressure drops, engine oil pressure
switch turns “ON” to electrical connection. When
※ electrical connection, interior contact (RY3)
G Engine oil pressure switch
3 between CN1-9 and CN1-3 terminal turns “OFF” to
cause emergency stop to engine.
●Set pressure of emergency stop oil pressure below
7.3psi(0.05MPa)[0.5bar]
4 － NIL
5 － NIL
6 B Earth
Service pressure sensor Vout
7 G Detection of service pressure.
terminal (US model only)
Input alternator frequency
8 W/R Alternator P terminal
(engine rotating speed signal)
Detection of discharge air temperature.
When it is higher than the emergency stop
actuating set temperature, interior contact (RY3)
between CN1-9 and CN1-3 terminals will be turned
9 G/W Discharge air temp. sensor
“OFF” to make engine emergency stop.
●Warning･Emergency stop set temperature
Warning temperature : 239°F(115℃)
Emergency stop temperature: 248°F(120℃)
10 － NIL
11 W/B Alternator L terminal For detecting abnormal charge
12 － NIL
13 － NIL
14 － NIL
Intake negative pressure sensor
15 R Power supply for intake negative pressure sensor
Vc terminal (US model only)
Service pressure sensor Vc
16 R Power supply for service pressure sensor
terminal (US model only)
Intake negative pressure sensor
17 Y Detection of intake negative pressure.
Vout terminal (US model only)
18 G/Y Sending unit For detecting residual fuel
Detection of engine coolant temperature.
When the set temperature of emergency stop
becomes higher, the interior contact (RY3) between
CN1-9 and CN1-3 terminals turns “OFF” to cause
19 Y/B Coolant temp. sensor
engine to emergency stop.
●Warning･Emergency stop set temperature
Warning temperature : 221°F(105℃)
Emergency stop temperature: 230°F(110℃)
20 G/B Earth
※：Abnormal oil pressure detection circuit of controller starts to function in 10 seconds after it detects
alternator generating signal with CN2-8 terminal.
3-7
3. Electric System
3.2 Alternator [Dynamo regulator (IC type)]
YANMAR part number: 129423-77200
Cable connection
PC10028E-1
(1)List of functions
Line
BAT R Starter motor B terminal Power for charging voltage.

5A Fuse It detects battery voltage, and it controls rotor coil
IG R/B
(Through joint connector) electromagnetic current.
It makes warning lamp go on when battery charging
L W/B Controller CN2-11 terminal
function is abnormal.
※ Output alternator frequency
W/R Controller CN2-8 terminal
P (engine rotating speed signal)
E － Earth Earth
※:For diagnosing P terminal, check the generating voltage between P-E terminal and it is normal if the
voltage detected is about DC2.2V.
(2) Judgement of alternator functions

Checking method by measuring battery terminal
Normal Value
at full load operation
Measure the battery terminal voltage at
13 to 15V
1,500min-1.
3-8
3. Electric System
(3) Diagnosing when battery charging warning lamp lights
Abnormal
Measure battery voltage : less than 12V
Recharging battery.
when engine stops.
Normal: 12V
Abnormal
: same voltage as battery
Measure the voltage of voltage when stopping. Repairing alternator because it is
alternator BAT terminal faulty.
during operation.
Normal: 13 to 15V
Abnormal
Check and confirm battery : higher than15.5V Repairing alternator because it is
voltage at 1,500min-1. faulty.
Normal: 13 to 15V
Disconnected check and confirm

Check charging warning lamp Cable disconnected
waning lamp circuit (L terminal -
circuit.
controller CN2-11 terminal).
Not cable disconnected
Repairing alternator because it is

faulty.
3-9
3. Electric System
3.3 Starter
YANMAR part number: 129242-77010
PC10036E PC10030E
Cable connection
(1)List of functions
Line
For supplying power to starter which enables

B B Battery + terminal
starter pinion to turn.
For supplying power to make starter pinion to
spring out and also a little power to make pinion
S W Safety relay B terminal
turn for smooth engagement between pinion gear
and ring gear when they are in contact.
(2) Judgement of starter functions

Checking method by measuring battery terminal
Normal Value
at full load operation
During normal operation at normal temperature 7.7V, 400A and pinion RPM: lower than 1,400min-1.
3-10
3. Electric System
3.4 Safety relay
Part number:44346 16400
PC11011
PC10003E
(1) Specification (2) Chart of function
Rated voltage DC12V

Range of voltage at which unit is used DC10 to 15V
Range of temperature at which -22～+176°F
unit is used (-30 to +80℃)
Rated load MAX 40A
Power input of alternator ※frequency
(P terminal) signal
Interior Engine speed for
contact 1350±210min-1
contact
disconnection PC10031E
between A and
Engine speed for
B terminal 650±150min-1
recovery
※ For the details, see engine service manual.
(3) List of functions

Line
Pin No. Connection Remark
color
1(C) R/B Starter switch ACC terminal Power supply
2 － NIL
Signal of start is inputted
When starter switch is turned to “START” and
voltage is applied to E terminal the contact between
terminal A and B is switched to “ON” to supply
power to starter motor S terminal to turn starter
motor. When alternator P terminal frequency
3(E) B/W Starter switch C terminal inputted to terminal H exceeds 250 Hz (at engine
speed of 1350min-1), the contact between terminal A
and B is switched to “OFF” and power supply to
starter motor is cut to stop engine. And after starting
is secured, the contact between terminal A and B is
kept “OFF” to prevent overrun and plunging of
pinion gear.
4 － NIL
5(G) B Earth
Input alternator frequency
6(H) W/R Alternator P terminal
(engine rotating speed signal)
A R Starter motor B terminal For excitation terminal of starter motor magnet
B W Starter motor S terminal switch excitation coil.
3-11
3. Electric System
3.5 Solenoid relay･Heater relay
YANMAR part number:119650-77910
Cable connection
PC10005
(1) Specification
Rated voltage DC12V
Continuous rating 1min
Coil resistance (between No.1 and No.2 terminal) 13Ω
(2-1) Solenoid relay functions list

Line
1 Y/L Controller CN1-8 terminal

2 B Earth See“CN1-8 terminal of NO.6 List of function of
3 G 30A Fuse No.3.1 Controller”.
4 Y Stop solenoid W terminal
(2-2) Heater relay functions list

Line
1 Y/R Starter switch R2 terminal When starter switch is turned to “GLOW” or

“START”, power is supplied to switch the contact
2 B Earth between No.3 and No.4 terminal to “ON”.
50A Fuse
3 R (Through alternator BAT When the contact between No.3 and No.4 terminal is
terminal) “ON”, preheating begins.
4 L Glow plug
3-12
3. Electric System
3.6 Purge/starting unloader solenoid valve
Clip
Tube Ass’y
Coil Ass’y
Plunger Ass’y
O-ring
Return spring
Body
IN OUT IN OUT
(Rc1/4) (Rc1/4)
･Opened while electricity
is supplied (NC) PC10037
(1) Specification
Rated voltage DC12V
Function Power is supplied. It is ON (NC)

For details of functions, see“NO.6 List of function (CN1-7 terminal) of No.3.1 Controller”.
3-13
3. Electric System
3.7 Stop solenoid
PC10012E
(1) Specification
Rated voltage DC12V
Rated current 36.5A
Suction coil
Resistance 0.33Ω±10％
Rated current 0.49A
Holding coil
Resistance 24.5Ω±10％

Line
Pin No. color Connection
30A Fuse (Power supply)
W Y
[Suction power supply]
Controller CN1-3
R W/B
[Holding power supply]
B B Earth
※For details of functions, see“No.6 List of function (CN1-7 and CN1-8 terminal) of No.3.1
Controller”.
3-14
3. Electric System
3.8 Engine oil pressure switch (For emergency stops)
PC10013
Specification
Setting pressure 7.3psi(0.05MPa)[0.5bar]
Contact type B contact switch (Contact “OFF” in excess of set pressure)
･10 seconds after engine starts.
Time lag
･2 seconds during operation ※
※When such situation under operation pressure continues longer than 2 sec.
It brings engine to emergency stop.
3.9 Fuel air-bleeding electromagnetic pump

Specification
Rated voltage 12V
Operating current 1.5A (MAX)
More than 0.11 to 0.29gal/min
Delivery capacity
(0.4 to 1.1 L/min)
PC10014
3.10 Discharge air temperature sensor･Coolant temperature sensor

PC08033
《Note》Take care not to tighten excessively. Less than 17.7lbf･in.(2N･m)[20kgf･cm]
※For temperature characteristic of resistance, see“No.5.Adjustment and inspection of No.3.1

Controller”.
3-15
3. Electric System
3.11 Pressure sensor (for Intake negative pressure and for service pressure)
Trouble diagnosis of pressure sensor itself

Check and confirm that output voltage between ②-③ is DC0.5±
0.1V when 5V is applied between ①-③ terminals at an
atmospheric pressure.
Pressure and output voltage(for reference only)

Electric wire Signal
①VCC Power supply ( 5V)
②VOUT Output
Pressure 0psi (0MPa) [0bar] DC0.5V
Pressure 14psi (0.1MPa) [1bar] DC0.9V
Pressure 85psi (0.6MPa) [6bar] DC2.9V
Pressure 100psi (0.69MPa) [6.9bar] DC3.3V
Pressure 142psi (0.98MPa) [9.8bar] DC4.5V
③GND Earth
PC08035
3.12 Fuel meter (Display)
A100359E
PC10033E
Relation between indicator lamp (LED) and residual fuel level

Indicator lamp Remaining fuel gal. (L) Remark
LED No.1 OFF (Red) 4.2(16) E
LED No.2 ON (Red) 6.1(23)
LED No.3 ON (Green) 7.9(30)
1/2
Full 23.8(90) F
3-16
3. Electric System
3.13 Sending unit
PC08069E
※For resistance at float position, see“No.5.Adjustment and inspection of No.3.1 Controller”.
3-17
4. Troubleshooting
4.1 Repairing Procedures
When performing failure diagnosis, pay special attention to the followings, observing general
cautions.
4.1.1 Safety caution

(1) Removing such cap and/or plug for receiver tank, fuel tanks and pipes where pressure is
loaded, stop the machine and relieve all the interior pressure. Install measuring
instruments connected firmly.
(2) When doing the job with co-worker(s) together, make sure to give signal to the other person(s) and
do not allow other persons to come near to the job site.
(3) Take care not to touch hot portions and not to be involved in turning portions.
4.1.2 Caution during failure diagnosis

(1) Do not make haste to disassemble the unit
If the unit is disassembled urgently.
①You may disassemble the other portions which are not related with the trouble.
②The cause of trouble may be missing.
The unnecessary reparations require more spare parts and man-hours, and reparation costs will
increase more. What is worse, you will lose reliance or trust from clients，operators and users.
Therefore, it is absolutely necessary to investigate the trouble more carefully in advance and to
follow the required procedures for failure diagnosis.
(2) Ask the clients about the trouble in details

In order to prevent misunderstanding and incorrect judgment about the trouble, it is necessary to
ask users or operators about the following questions.
①Is there any other disorder than the trouble he has informed?
②Anything abnormal occurred before this trouble?
③Did this trouble happen unexpectedly? Or the unit had been operated in bad conditions before?
④When and how did this trouble occur?
⑤Had he repaired the unit before this trouble occurred?
⑥Did he not experience similar trouble before?
(3) Inspection items before starting diagnosis

Sometimes such trouble may be caused owing to routine mishandling of the unit. Before
starting failure diagnosis, check the following items.
①The engine runs short of engine oil or its oil is not dirty?
②Check each wire connection for any disconnection.
③Check the other portions for any damage.
(4) Confirmation of trouble

Discuss with user(s) and/or operator(s) sufficiently about the trouble. As a result, judge whether
their judgment is based on the numerical comparison or sentimental basis. Make him (them)
understand well the reparation or correction you have finished.
Then check and confirm by yourself the cause of the trouble.
Note) Never proceed any investigation or measurement which may cause further greater damage.
4-1
4. Troubleshooting
(5) Procedures of diagnosis

When you become well experienced, you can find out the cause easily during the process of
confirmation (4). But easy understanding could cause unexpected failure. So check and judge it
according to the following procedures.
①Check the easiest thing or portion first.
②Investigate the most possible cause.
③Check the other things connected to the trouble.
④Check for the possibility of any other troubles.
⑤Start proper and careful investigation on this trouble.
(6) Prevention of repeated occurrence of similar trouble

Even if you have repaired the trouble, unless you get rid of the fundamental cause of the
trouble, it will repeatedly occur. Therefore, perform full investigation of the trouble, and it is
absolutely necessary to remove the basis of the trouble.
4.1.3 How to use the failure diagnosis
ＮＯ
OK 1 2 3
ＮＯ
OK
ＮＯＯＫ
OK
① In the troubleshooting column something abnormal is mentioned in lined parenthesis.
② In the troubleshooting column the cause of the said trouble is mentioned in dotted parenthesis.
③ In the troubleshooting column the countermeasures or treatment are mentioned in the double lined
parenthesis.
④ 1 under each column means the index of explanation.

For details, see 4.5 “Explanation of trouble diagnosis”
4-2
4. Troubleshooting
4.2 Failures of compressor and engine
4.2.1 At start-up, starter rotates slowly
※1
Battery specific gravity
Check battery voltage and Faulty Re-charge and supply
too low or electrolyte
specific gravity. water or replace
short
Normal
Volt: more than 12V
Gravity: more than 1.26
Faulty Replace terminal or
Check battery cable. Faulty cable assembly
Normal
Repair or replace
Faulty starter motor assembly
※1：When starter switch is placed at the “START” position, the battery is not normal if B terminal
voltage decreases by 10V.
4.2.2 Starter turns, but engine will not start

Not exists
Check fuel. Shortage of fuel Supply fuel
Exists
Clogging
Check air filter for clogging. Element clogging Clean or replace it
Normal
It will not
Check function engine stop work Faulty engine stop
solenoid. Repair or replace it
solenoid
It works
Check function fuel air It will not

work Faulty fuel air
bleeding electromagnetic bleeding Repair or replace it
pump. electromagnetic pump
It works
Clogging
Check fuel filter. Fuel filter clogging Replace it
Normal
Faulty Repair pipes and
Check fuel pipes. Faulty fuel pipes
bleed air
Normal
Abnormal Repair the trouble

Check and confirm engine. Trouble of engine and get rid of the
cause
4-3
4. Troubleshooting
4.2.3 Engine revolutions will drop before pressure rises up to rated one
Check whether valve for Open Close the valve for
starting at low temperature Forgot to close valve starting at low
is open or close. temperature
※ Closed
Check setting of purge More than 15% Faulty adjustment of

Re-adjust load factor
operation load factor. load factor
[at AUTO IDLE operation]
15％
Less than 100psi(0.69MPa)[6.9bar]
Check function of Solenoid valve opens
purge/starting unloader Check power supplied between
solenoid valve. CN1-9 and CN1-7 terminal of
[at AUTO IDLE operation] controller (interior contact RY2)
Less than 100psi(0.69MPa)[6.9bar] No conduction exists.

Solenoid valve closes
Trouble of
solenoid valve for
Repair or replace it
purge/starting
unloader
Exists Trouble of
controller or Repair or replace it
intake negative
pressure sensor
Check adjustment of Adjustment Faulty adjustment of

pressure regulator. Re-adjust pressure
pressure
Faulty adjustment
Change pressure gauge for Adjustment

replacement one, and Faulty pressure gauge Replace it
re-adjust pressure gauge.
Faulty adjustment
Faulty needle valve or Replace pressure

Check needle valve of Faulty
needle valve seat
pressure regulator. regulator assembly
spring
Normal
Disassemble / clean or
Faulty unloader
Replace
1
※ Items in dotted square show failure diagnosis items for US model auto idle operation
mode.
4-4
4. Troubleshooting
4.2.4 Engine will not turn to meet rated revolutions
Not at high
Check if engine governor
speed side Faulty adjustment of
lever stays at high speed Re-adjust rod
side. speed regulator rod
At high speed side
Clogging
Check air filter. Faulty air filter Clean or replace it
Normal
Water collected
Check sedimenter. Water mixed in fuel Separate water
Normal
Clogging
Faulty element in
Clean or replace it
sedimenter
Clogging
Check fuel filter. Faulty fuel filter Replace it
Normal

Check fuel pipes. Faulty fuel pipes
bleed air
Normal
Abnormal Repair the trouble

Check and confirm Engine output drops and get rid of the
engine. cause
Check adjustment of pressure Faulty Faulty adjustment of Re-adjust pressure

regulator. pressure
Normal
Check unloader recovery pipe Clogging Faulty of unloader

for any clogging. recovery pipe Repair pipe
4-5
4. Troubleshooting
4.2.5 Minimum speed not available even upon no-load operation
Check if engine governor At low speed

lever stays at low speed side Faulty adjustment of
Re-adjust rod
side. speed regulator rod
Not at low
speed side
Check function of speed Malfunction Faulty diaphragm of
Replace it.
regulator. speed regulator
Normal
Air leaks from speed
Repair pipe
regulator control pipe
4.2.6 Safety valve bursts out during unloaded operation

Check and confirm that It bursts at less
safety valve functions at pressure
lower pressure than set Faulty safety valve Replace it
pressure.
It bursts out 2
at set pressure
Check function of pressure Adjustment Faulty adjustment of

regulator and it is properly Re-adjust pressure
pressure
adjusted.
Faulty adjustment
Change pressure gauge for Adjustment

replacement one, and Faulty pressure gauge Replace it
re-adjust pressure gauge.
Faulty adjustment
Bleed pressure regulator Air leak Faulty diaphragm of Replace pressure

and check for air leak. pressure regulator regulator assembly
No air leak
Check pipe to pressure Air leak
regulator for leak. Faulty pipes Replace parts
No air leak
It functions
Not at low in good
Check if engine speed side Check function order. Faulty
governor lever stays of speed adjustment Re-adjust rod
at low speed side. regulator of rod
At low speed side Malfunction

Speed regulator Replace the
diaphragm is damaged or diaphragm or
air leaks from control pipe repair piping
Faulty seat of Disassemble /

unloader valve clean or Replace
3
4-6
4. Troubleshooting
4.2.7 Oil mixed found in delivery air
Too much Arrange oil level to
Check compressor oil level. Oil level too high
specified lever
Proper level Lower than
49psi(0.34MPa)
[3.4bar] Faulty pressure
Check discharge air pressure. Replace spring
control valve
More than
49psi(0.34MPa)[3.4bar]
Check separator collection Clogging
Not collection Clean or replace it
orifice and strainer.
No clogging
Faulty oil separator Replace it
4.2.8 Discharge air is insufficient

Clogging is large
Check air filter for clogging. Faulty air filter Clean or replace it
Normal
Check purge solenoid valve Air leak Faulty seat of purge
Repair or replace it
for any air leak solenoid valve
Normal Not shrunk
to high
Check if engine speed side. Long Faulty
Check rod length Re-adjust rod
governor lever adjustment
of speed regulator
stays at high of rod
speed side. Normal
Faulty
Faulty
at high speed side. Check needle valve seating pressure
Replace it
of pressure regulator regulator
Too long,
narrow and
Check whether pressure
Normal Check air air leaking Pressure drop
Re-selection of airline
rises up to the rated one line up to and defects of
smoothly soon after air tools and repair air leak
air leaking
service valves are closed
quickly from full load Normal
Re-selection of air
operation.
compressor
Late
Clogging
Check fuel filter. Faulty fuel filter Replace it
Normal
Check fuel pipes Faulty fuel pipes
bleed air
Normal
Faulty Repair the trouble and
Check and confirm engine. Faulty engine
get rid of the cause
Normal
Difference is
Check difference in pressure large
Faulty oil separator Replace it
between at front and rear of
oil separator.
Normal
Unloader valve does Replace defective
not open well parts by new ones
4-7
4. Troubleshooting
4.2.9 Purge control operation will not start even if AUTO IDLE (purge control)
switch is pressed. (US model only)
Check service piping for any Air leak Service air piping
Repair air piping
air leak. leaking
No air leak
Lower than
Check setting of purge 15％ Faulty setting of purge
operation load factor (b). Adjust (See 1.6.2)
operation load factor (b)
15％
Set time is too Faulty setting of the
Check setting of the time long time required for
required for switching to switching to purge Adjust (See 1.6.2)
purge operation (T). operation (T)
10sec Disconnection or
Cable
defective contact of
Check AUTO IDLE switch disconnected
cable connection Repair connection
cable connection. between controller-auto
Not cable disconnected idle switch-ground
※1 connection
Check intake negative Abnormal output
pressure sensor output voltage found Trouble of intake
voltage of “Key ON when negative pressure Replace it
stopping” and “At sensor
unload”(See 3.11)
Key ON when stopping：DC0.5V
At unload：less than DC0.5V
Cable Disconnection and
Check cable connection
disconnected faulty contact between
between intake negative
controller and intake Repair connection
pressure sensor and
negative pressure
controller.
sensor
At no load：
Check electrical connection to electrically Trouble of solenoid
solenoid valve for connected
valve for purge/starting Repair or replace it
purge/starting unloader. unloader
At no load：
electrically connected
Cable disconnected or
Check cable between Cable defectively connected
controller and solenoid valve disconnected between controller and
solenoid valve for
Repair connection
for purge/starting unloader,
and fuses. purge/starting unloader,
and fuses
※2
Abnormal
Check function of controller. Trouble of controller Repair or replace it
※1：As the output voltage of intake negative pressure sensor at unload operation is very little, it is
better to check the function of purge control operation after replacing the sensor with new one, if
it is found difficult to diagnose the trouble.
※2：For details of controller functions, see“No.3.1 Controller”.
4-8
4. Troubleshooting
4.2.10 Even when the pressure at consumer’s side drops, it will not recover from
purge control operation. (US model only)
Purge releasing
Check setting of purge pressure too low Faulty setting of purge
Adjust (See 1.6.2)
releasing pressure (L) releasing pressure (L)
80psi(0.55MPa)[5.5bar]
Service pressure
and output voltage
Check output voltage of will not meet Trouble of service
service pressure sensor pressure sensor Replace it
(See 3.11)
Output voltage normal
Disconnection or
Check cable connection Cable disconnected faulty contact between
controller and service Repair connection
between service pressure
sensor and controller. pressure sensor
Trouble of controller Repair or replace it
4-9
4. Troubleshooting
4.3 Operation of emergency switch
4.3.1 Discharge air temperature indication lamp glows and engine stops.
More than
104°F(40℃) Unsuitable place of
Check ambient temperature. Relocation
installation
Lower than 104°F(40℃)
Shortage
Check compressor oil level. Shortage of oil Replenish or replace
Proper
Check Check resistance Abnormal
indication of Faulty sensor Replace it
of discharge air
discharge air temperature
temperature sensor.
gauge.
5
4 Normal
More than No
Check electric conduction
248°F(120℃)
conductance exists Disconnection
Repair wire connection
between controller between
and sensor. controller and
sensor
6
Exists
Faulty controller Repair it.
Faulty Tension not acceptable

Check belt tension. Adjust or replace
or faulty belt
Normal
Soiled
Check oil cooler fin tubes. Fin tubes much soled Wash or clean
Normal
Faulty
Check compressor oil filter. Filter clogging Replace it.
Normal
No difference
Check and confirm the found Abnormality by-pass Check by-pass valve
difference between valve
temperature at the inlet of
by-pass valve and at the
outlet.
Difference found
Abnormality
Disassemble or repair
compressor air end
4-10
4. Troubleshooting
4.3.2 Engine oil pressure emergency indication lamp glows and engine stops
Shortage
Check engine oil level. Shortage of oil Replenish or replace
Proper
Faulty
Check engine oil filter. Filter clogging Replace it
Normal
Check engine oil pressure Faulty Faulty oil pressure

switch. Replace it
switch
Normal 7
Check engine Normal Check wire Faulty Faulty wire

connection to Repair wire connection
oil pressure. connection
engine oil pressure
Abnormal switch.
8
Faulty of engine Repair the trouble and

lubrication system get rid of the cause
4-11
4. Troubleshooting
4.3.3 Engine coolant temperature lamp glows and engine stops
More than
104°F(40℃) Unsuitable place of
Check ambient temperature. Relocation
installation
Check water quantity and Shortage Shortage of coolant and

Replenish or replace
quality in radiator. bad quality
Normal
Lower than
230°F(110℃)
Check Abnormal
Check water Replace it
resistance of Faulty sensor
temperature.
water
more than temperature
230°F(110℃) 5
Normal
No
Check electric conduction
conductance exists. Disconnection
between Repair wire connection
between controller
and sensor. controller and
sensor
6
Exists
Faulty controller Repair it
Faulty Tension not acceptable

Check belt tension. Adjust or replace
or faulty belt
Normal
Soiled
Check radiator fin tubes. Fin tubes much soiled Wash and clean
Normal
Repair the trouble
Faulty of engine
and get rid of the
cooling system
cause
9
4-12
4. Troubleshooting
4.4 Others
4.4.1 Indicator lamps will not glow, but engine stops.
(Starter switch is not set in contact, and blown fuse trouble is exempted.)
Not exists
Check fuel Shortage of fuel Supply fuel
Exists
Clogging
Check air filter for clogging. Element clogging Clean or replace it
Normal
It will not
Check function engine stop work Faulty engine stop
solenoid. solenoid Repair or replace it
It works
Check function fuel air It will not

work Faulty fuel air
bleeding electromagnetic bleeding Repair or replace it
pump electromagnetic pump
It works
Clogging
Check fuel filter Fuel filter clogging Replace it
Normal
Check fuel pipes Faulty fuel pipes
bleed air
Normal
Check indicator lamp wire Cable short

circuit Check each item of
connection (Emergency stop Faulty wire connection emergency stop
circuit). functions.
Normal 10
Faulty Defective controller or Replace controller or
Check controller
faulty cable connection repair cable connection
Repair the trouble

Faulty engine and get rid of the
cause.
4-13
4. Troubleshooting
4.5 Explanation of trouble diagnosis
No. Item Cause Remedy
1 Faulty unloader. Unloader valve cannot be Disassemble unloader valve to check
open. function of valve and piston. Further
check recovery pipe for any clogging.
2 Check and confirm Check and locate pressure In case of malfunction of safety valve,
that safety valve maladjustment or defective safety valve assembly should be
functions at lower safety valve. replaced.
pressure than set
pressure for safety
valve.
3 Faulty seat of Faulty seat of unloader Disassemble unloader valve, and clean
unloader valve valve or faulty sliding seat surface and check function of valve
function of valve and piston. and piston.
4 Check discharge air Check whether actual rise of
temperature, using discharge air temperature
digital monitor. stops engine or any failure
of electrical circuit stops
engine.
5 Check the resistance For resistance Even disconnection of thermo sensor or
of discharge air characteristics of discharge its short-circuit causes engine to stop.
temperature/coolant air temperature and coolant
temperature sensor. temperature sensor, See
3.10.
6 Check conductance Check whether there is any Connect variable resister (1kΩ) as
between controller and disconnection or shown in the following figure and
discharge air short-circuit in cable gradually lower resistance value of
temperature connection between variable resister. And when it displays
sensor/coolant controller, discharge air abnormality, measure the value and
temperature sensor. temperature sensor and check whether it is within the range of
coolant temperature sensor. resistance of set temperature.
Clarify whether the trouble (See No.5.Adjustment and inspection of
is caused by faulty cable No.3.1)
connection or defective
controller. When discharge
air temperature/coolant
temperature exceeds the set
temperature
[248°F(120℃)/230°F(110℃)]
, interior contact (RY3)
between controller CN1-9
and CN1-3 terminals turns
OFF to cut electrical
connection to stop solenoid
and making engine stop.
4-14
4. Troubleshooting
No Item Cause Remedy

.
7 Check engine oil For actuation pressure of oil
pressure switch. pressure switch, See 1.2
“List of set values”.
8 Check for any Check and make sure that
defective connection. no disconnection has been
found for engine oil pressure
switch.
(Switching “ON” engine oil
pressure switch enables
engine emergency stop.)
9 Faulty of engine When any trouble is not For the temperature at which
cooling system. found in thermostat, coolant thermostat valve opens, refer to 2.12.
pump can be in disorder.
10 Check indicator lamp It sometimes happens that
wire connection. emergency stop circuit is
active, but warning lamp
will not light on because its
circuit is in trouble. Try to
locate its cause.
4-15
5. References
5.1 Comparison between consumable parts and electrical appliances
Part Number
Item
●Element / Filter
Air filter ASS’Y (For compressor) 32100 44900 ←
Air filter element (outer) 32143 11800 ←
Air filter element (inner) 32143 13000 －
Air filter ASS'Y (For engine) 32100 40700 ←
Air filter element (outer) 32143 11700 ←
Air filter element (inner) 32143 12900 －
Oil separator 34220 16101 ←
O-ring for oil separator 03402 15140 ←
Compressor oil filter ASS'Y 37400 16100 ←
Oil filter cartridge 37438 08900 ←
41290 01100
Engine oil filter cartridge (YANMAR:119005-35151)
←
43543 01400
Fuel filter cartridge (YANMAR:129907-55801)
←
Fuel pre-filter ASS'Y 43540 08100 －
43541 02400
Element －
(YANMAR:41650-550800)
O-ring (YANMAR:123325-36140) －
O-ring (YANMAR:24311-000120) －
43550 02900 ←
Sedimenter ASS'Y (YANMAR:129242-55700)
Element (YANMAR:129242-55730) ←
O-ring (YANMAR:24311-000160) ←
O-ring (YANMAR:24321-000750) ←
●Air control
Speed regulator 36400 21901 ←
Diaphragm 36437 01500 ←
Pressure regulator 36400 19000 ←
Auto relief valve / Vacuum relief valve (built-in unloader) (built-in unloader)
Needle valve 36429 00801 ←
O-ring 03402 25008 ←
O-ring 03402 25021 ←
O-ring 21221 02100 ←
Unloader valve 22100 41201 ←
O-ring (2 pieces) 03402 10125 ←
O-ring 03402 10070 ←
O-ring 21441 04800 ←
O-ring 21441 04900 ←
Pressure control valve 35300 17000 ←
O-ring 03402 15075 ←
O-ring 03402 25032 ←
Spring 22144 07700 ←
Piston 35303 03300 ←
5-1
5. References
Part Number
Item
●Oil line
By-pass valve ASS'Y
－－
(Built-in compressor oil filter)
Pellet 37231 02100 ←
O-ring 03402 25045 ←
●Electrical appliances
Controller 46870 51901 46870 54000
44346 16400
Safety relay (YANMAR:119802-77200)
←
44327 05000
Solenoid relay (YANMAR:119650-77910)
←
44327 05000
Heater relay (YANMAR:119650-77910)
←
Purge/starting unloader solenoid valve － 46811 24100
Fuse 30A(FUSE1) 44470 02600 ←
Fuse 5A(FUSE2) 44470 02100 ←
Intake negative pressure sensor － 44328 20600
Service pressure sensor － 44328 20600
Discharge air temp. sensor 44364 06500 ←
Coolant temp. sensor 44364 06500 ←
44328 21800
Engine oil pressure switch (YANMAR:114250-39450)
←
Purge control switch － 46242 21500
Sending unit 36159 02202 ←
Fuel air-bleeding electromagnetic pump 43650 02700 ←
●Instruments on panel
Starter switch 44322 07300 ←
Pressure gauge 36141 15503 36141 18600
5-2
5. References
5.2 Engine Wiring Diagram
(1) Export model
A100392E
5-3
5. References
(2) US model
A100445E
5-4
This text book contains the most recent information available at the time of
printing, and the contents of the list are based on information in effect at that
time and are subject to change without notice.
2006年 2月 27日初版
2003年 4月 20日改訂
発行　　北越工業株式会社
本社工場
新潟県燕市下粟生津3074
TEL ０２５６－９３－５５７１
FAX ０２５６－９４－７５６７
(無断複写・転載を禁ず)
ＨＯＫＵＥＴＳＵＩＮＤＵＳＴＲＩＥＳ　ＣＯ., ＬＴＤ.
8TH FLOOR SHINJUKU SAN-EI BLDG,

22-2 NISHI-SHINJUKU 1-CHOME,SHINJUKU-KU
TOKYO 160-0023 JAPAN
TEL:81-3-3348-7281
FAX:81-3-3348-7289
URL:http//www.airman.co.jp
Copyright(C)2011 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved　
NPC-0086
PRINTED IN JAPAN 2011. 9

Screw Compressor 6C2 Series 185S

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Preface

Copies of this service manual are intended to be distributed to limited numbers

No. Description Function

No. Description Function

Error code / Reset switch

Discharge air pressure gauge Starter switch

When power is supplied, revolution speed (lamp lighting) is indicated.

[ENG.SPEED] [DISCHARGE TEMP.] [WATER TEMP.] [HOUR METER]

When power is supplied, revolution speed (lamp lighting) is indicated.

[ENG.SPEED] [DISCHARGE TEMP.] [WATER TEMP.] [HOUR METER]

Push Push Push

[COMPRESSURE LOAD FACTOR] [SERVICE PRESSURE]

Item Contents Measures Monitor

Function of auto idle control (Purge control)

UP DOWN UP DOWN UP DOWN

Press 3 Press 2 Press 1

2.1.2 Disassembly and assembly

0.55(14) 0.87(22) 601.8( 68)[ 675] 0.47(12) 0.87(22) 1,194.7(135)[1,350]

0.63(16) 0.94(24) 938.1(106)[1,055] 0.55(14) 0.94(24) 1,858.4(210)[2,100]

0.71(18) 1.06(27) 1,283.2(145)[1,450] 0.55(14) 1.06(27) 2,566.4(290)[2,900]

0.79(20) 1.18(30) 1,814.2(205)[2,050] 0.67(17) 1.18(30) 3,628.3(410)[4,100]

0.87(22) 1.26(32) 2,477.9(280)[2,800] 0.67(17) 1.26(32) 4,955.8(560)[5,600]

0.94(24) 1.42(36) 3,053.1(345)[3,450] 0.75(19) 1.42(36) 6,283.2(710)[7,100]

３ Coupling portion between comp. air end and engine

５ Pressure vessel and pipes

159.3 327.4 601.8 929.2 1327.4 1858.4 2699.1 3628.3 4690.3

3 Coupling portion between comp. air end and engine

5 Pressure vessel and pipes

Operation with compressed air supply port opened is prohibited

<Adjustment procedure> (For engine speed and pressure, see 1.2)

Engine governor lever

High speed Low speed

Speed regulator (Bellophragm type)

[Delivered state] [State to be installed]

Locking nut Washer Diaphragm

Inside face of body

⑦Put in diaphragm to be settled equally in the body

Important：Once diaphragm is settled in, turn slowly the Locking nut

2.5 Change Oil Separator

Vacuum relief valve

2.9 Check Pressure control valve O-Ring and Piston

O-ring Pellets ASS’Y

Actuating temperature By-pass valve fully closing temperature

180±37°F (82±3℃) 192±36°F (89±2℃)

2.12 Values of Various Adjustments of Engine

3. Warning・emergency display and emergency stop functions

Lamp goes on when oil

5.Adjustment and inspection

(1) Connect resistance to controller as shown right.

Warning 105 221 640±15

(3) Sending unit

When starter switch is “ON”, and voltage is applied to

BAT R Starter motor B terminal Power for charging voltage.

(2) Judgement of alternator functions

Disconnected check and confirm

Repairing alternator because it is

For supplying power to starter which enables

(2) Judgement of starter functions

Rated voltage DC12V

ＨＯＫＵＥＴＳＵＩＮＤＵＳＴＲＩＥＳ　ＣＯ., ＬＴＤ.

Copyright(C)2011 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved　