AirMan PDS185S-6C1, Service Manual

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2. Maintenance
2-1
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.
(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
①
Measuring instruments (e. g. tester, insulation resistance gauge etc.)
②
Tools
③
Torque wrenches
④
Jigs and specialized tools
⑤
Sealing tape
⑥
Molybdenum sulfide (tube type)
⑦
Lithium extreme pressure type grease (CALTEX MULTIFAK EP1)
⑧
Diesel oil
⑨
Compressor oil
⑩
Cleaning cloths
⑪
Literatures (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) Install O-ring and oil seal which should be coated with clean lithium extreme pressure type
grease (CALTEX MULTIFAK EP1).
(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.
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