AirMan SG Series User manual

Preface
Thank you for choosing “AIRMAN”
Keep this manual at hand and refer to it as necessary.
If this manual is missing or damaged, order a new copy from our office or your nearest dealer.
Make sure that the manual is included with the machine when it is handed over to another user.
The contents of this manual may differ from the machine as a result of design changes. If anything
is unclear or you want advisement, contact our office or your nearest dealer.
Refer to the Engine Operation Manual for engine handling, maintenance, and safety information.

Table of Contents
1. Major Components ----------------------------------------------------------------------------- 1-1
1.1 Internal Components --------------------------------------------------------------------------------------------- 1- 1
2. Transportation and Installation ------------------------------------------------------------- 2-1
2.1 Transporting Machine -------------------------------------------------------------------------------------------- 2- 1
2.2 Conditions of Installation ---------------------------------------------------------------------------------------- 2- 2
2.3 Grounding ----------------------------------------------------------------------------------------------------------- 2- 5
2.4 Selecting Cable ---------------------------------------------------------------------------------------------------- 2- 8
2.5 Fuel Pipe Selector Valve ---------------------------------------------------------------------------------------- 2- 9
3. Operation------------------------------------------------------------------------------------------- 3-1
3.1 Control Panel------------------------------------------------------------------------------------------------------- 3- 1
3.2 Connecting Loads ------------------------------------------------------------------------------------------------- 3- 3
3.3 Engine oil･Coolant･Fuel・DEF -------------------------------------------------------------------------------- 3- 7
3.4 Before Starting the Unit ------------------------------------------------------------------------------------------ 3-10
3.5 Operating Procedure --------------------------------------------------------------------------------------------- 3-16
3.6 Emergency Stop --------------------------------------------------------------------------------------------------- 3-23
3.7 SCR Cleaning ------------------------------------------------------------------------------------------------------ 3-24
3.8 SCR Inducement -------------------------------------------------------------------------------------------------- 3-25
3.9 How to activate Escape Mode---------------------------------------------------------------------------------- 3-26
4. Failure and Troubleshooting ---------------------------------------------------------------- 4-1
4.1 Protection device -------------------------------------------------------------------------------------------------- 4- 1
4.2 Troubleshooting---------------------------------------------------------------------------------------------------- 4- 3
5. Periodic Inspection----------------------------------------------------------------------------- 5-1
5.1 Important Items at Periodic Inspection and Maintenance ----------------------------------------------- 5- 1
5.2 Maintenance Schedule------------------------------------------------------------------------------------------- 5- 2
5.3 Periodic Replacement Parts ------------------------------------------------------------------------------------ 5- 3
5.4 Maintenance Items------------------------------------------------------------------------------------------------ 5- 4
6. Storage and Disposal-------------------------------------------------------------------------- 6-1
6.1 Preparation for Long-term Storage---------------------------------------------------------------------------- 6- 1
6.2 Disposal of Product ----------------------------------------------------------------------------------------------- 6- 1
7. Specifications ------------------------------------------------------------------------------------ 7-1
7.1 Specifications------------------------------------------------------------------------------------------------------- 7- 1
7.2 Outline drawing ---------------------------------------------------------------------------------------------------- 7- 2
7.3 Generator Wiring Diagram -------------------------------------------------------------------------------------- 7- 4
7.4 Engine Wiring Diagram ------------------------------------------------------------------------------------------ 7- 5
7.5 Piping Diagram----------------------------------------------------------------------------------------------------- 7- 7

Safety
S-1
This section explains safety precautions for operation, inspection, maintenance, installation, movement
and transportation. Read these safety requirements carefully and fully understand the contents before
starting the machine.
For better understanding of the precautions in this manual and on this machine, safety precautions are
classified into “DANGER”, “WARNING” and “CAUTION” messages with a warning symbol marked,
according to the degree of hazard.
When one of these messages is found, please take preventive measures for safety and carry out “SAFE
OPERATION AND PROPER MAINTENANCE OF THE MACHINE”.
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
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 machine, which has no concern to injury or accident of or to a
human body.
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.
PROPOSITION 65 WARNING
Breathing engine exhaust exposes you to chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust system.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary
For more information, go to www.P65warnings.ca.gov/diesel

Safety
S-2
◆If you have any questions about the machine, please contact our office or your nearest dealer.
Be sure to have your machine’s serial number to assist in providing the correct information for you.
A plate stamped with the model and serial number is attached to side of the machine.
A040491
※ Each illustrated figure (Fig.) has a number
(for instance, A040491) at the right bottom.
This number is not a part number, but it is
used only for our reference number.

Safety
S-3
[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

Safety
S-4
The locations of the safety warning labels are as follows.
A190013
13
1
A
11 10
9 8 7 6 3 2
5
4
VIEW A
Radiator Battery
12

Safety
S-5
W013
Never touch the control panel during operation. Be aware that a voltage of
several hundred volts is applied to the control panel.
Be sure to stop the engine and turn control power switch OFF whenever the
control panel has to be checked or operated. Disconnect the negative battery
terminal during checking and maintenance.
TR0086
Read each instruction plate which is displayed in the manual or on the
machine carefully, understand its content and follow the indications thereof.
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 machine for the other purposes than power supply. Otherwise,
serious accidents may occur.
TR0304
Keep hands off from the rotating machinery or belts while running. It could
cause serious injuries to hands.
M003
When cleaning dust accumulated in devices such as filters, etc., with
compressed air, wear safety glasses, etc. to protect your eyes

Safety
S-6
H990432
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 cool enough, hot
water could jet out, causing burns or scalding.
When washing the machine, cover the control panel, generator and its electric parts to prevent them
from being exposed to splashing water and avoid possible decrease in electrical insulation or other
troubles to the machine.
Dust, sand and dirt accumulated inside control panel could cause malfunction or difficulties with the
instruments. Clean them using compressed air.
A100285
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 pollute the
environment.
Be sure to use a container to hold 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.
The engine of this machine contains many electrical and electronic parts. Before welding, be sure to
disconnect all electronic control equipment.
Failure to do so could result in equipment malfunction due to excessive current.

1. Major Components
1-1
1.1 Internal Components
A190058
No. Description Function
1 SCR(Selective Catalytic Reduction) Selective reduction-type catalyst that uses DEF as a reducing agent.
2 Radiator Cooling the coolant for engine in the system.
3 Reserve Tank Checking coolant level and supplying it.
4 Air Filter Filtering dust from intake air.
5 Engine Oil Filler Port Supplying and replenishing engine oil to engine.
6 Engine Oil Level Gauge Checking the engine oil level and contamination
7 Fuel Filter Filtering foreign matter and dust mixed in fuel.
8 Alternator Generating AC power to be supplied.
9 Battery Electrically starting engine.
10 Fuel Pre-Filter Removing dust and water mixed in fuel.
11 Fuel Pipe Selector Valve Switching to supply fuel from outer tank.
12 Supply Module Pump unit for supplying DEF.
13 CCV(Coolant Control Valve) Valve for coolant to warm up DEF piping at cold temperature.
1 2 3 4 5 6 7 8
13 12 11 10 9

1. Major Components
1-2
A190059
No. Description Function
14 Control Panel Controlling device; various meters and controls.
15 Engine Driving the generator.
16 Intercooler Cooling the air compressed by engine supercharger.
17 DEF Tank Container for DEF
18 DOC(Diesel Oxidation Catalyst) Catalyst for oxidizing exhaust gas.
19 Fuel Tank Storing fuel.
20 Engine Oil Filter (By-pass) Filtering engine oil in the system.
21 Engine Oil Filter (Main)
22 Output Terminal Outlet port for AC power.
23 Receptacles Receptacles for AC power.
14 15 16
23
19 22 21 20 19 18 17

2. Transportation and Installation
2-1
2.1 Transporting Machine
When loading and unloading machine, be sure to use the lifting bail provided on the center of the
machine top.
2.1.1 Lifting
A180932
<Procedure>
1. Before lifting the unit up, make sure to check the
lifting bail [A] for any cracks or loosened bolts.
2. Connect the hook of the crane or shackle with lifting
bail fitted at the top center of the unit, and make sure
that there is no person standing around the unit.
Then perform hoisting operation.
Select an appropriate crane or truck by referring to
the mass and dimensions mentioned in
“Specifications”.
Only a qualified crane operator is allowed to operate
a crane.
Transportation
Never go underneath the unit when suspended because it is very dangerous.
Do not lift the unit while it is running. Otherwise, a fatal or serious accident may occur.
A

2. Transportation and Installation
2-2
2.2 Conditions of Installation
SG0110
The machine has to be installed on a dry, firm, and
level area.
The machine should be operated in the following
conditions:
Ambient temp: -5°F to 104°F (-15°C to 40°C)
Humidity: Less than 85%
Altitude: Lower than 1,000m above sea level.
※ Using the machine outside the above conditions may
cause serious failure.
If more than two units are placed parallel in
operation, keep enough distance so that exhaust air
from the one does not affect the other one.
Keep enough space around the unit for inspection
and maintenance access.
PC002
Exhaust gas from the engine is poisonous, and it could cause
casualties if inhaled.
Avoid using the machine in an insufficiently ventilated building or
a tunnel.
Do not position the exhaust gas outlet in the direction of a person
or a house.
A050506-1
In case that the unit is installed inside any tunnel, make sure to
provide fresh air and ventilate it.
In this case, make sure to extend the exhaust fume pipe
outdoors, and also make sure to prevent any leak from any
connection pipes.
1,000mm or more
1,000mm or more
Exhaust pipe Using Blower
○
×
1,000mm or more
Exhausted
gas

2. Transportation and Installation
2-3
A050505
Never locate the unit with the exhaust muffler facing
any private house.
As the exhaust gas from the engine is poisonous,
never direct it to any other persons passing by.
A090641-1
In case that the machine is installed indoors
In case that the unit is installed indoors for operation,
suction air port and exhaust fume outlet port should be
provided for better air ventilation.
Make sure to secure enough space in front of air
suction port and to secure it after exhaust fume outlet
port so that the engine will not get overheated.
An exhaust pipe or the like should be provided at the
exhaust outlet port so as to send exhaust fumes
outdoors.
The cooling air outlet port of radiator should have
access to the outdoors through a duct or the like for air
ventilation.
○
×
Extended exhaust pipe
Air Inlet
Private house
Exhaust gas
outlet port
Exhausted
gas

2. Transportation and Installation
2-4
SG0103-1
The unit should be installed within 5 ﾟdegree
inclination.
If installation site is not flat, put square bar under the
unit so as to install it horizontally.
Avoid installing the unit in a damp place or a place
where water collects. Such an installation could cause
electric shock.
When installing the unit at the sea shore, make sure
that it is not exposed directly to sea water because
there is a risk of the change to the insulation
resistance of the generator assembly or control panel
inside. To request a model with measures against salt
damage, please consult the nearest sales office.
When installing the unit at a sandy place, make sure
that exhaust from the generator or radiator does not
blow the sand up in the air or into the machine.
A050507-1
In order to prevent from any persons other than those
engaged in the job site from using or interacting with
the machine, please prepare for safety fences around
the unit.
Safety Fence

2. Transportation and Installation
2-5
2.3 Grounding
2.3.1 Ground Terminal
A180933
The ground terminal [A] on the AC output terminal
board is connected to the earth ground of this unit
and to the earth terminal of each outlet.
Grounding method
A180934
2.3.2 Grounding System
AIRMAN’s generators have a system ground that connects generator frame components to the ground
terminals in the AC output receptacles. The AC neutral wire (N) is connected to the system ground.
A
Grounding Terminal [A]
Grounding Rod
Grounding Rod
Load
Load Switch

2. Transportation and Installation
2-6
2.3.3 GFCI Receptacles
All of the 20 ampere 120 volt receptacles on the generator are protected by a GFCI (Ground-fault
circuit interrupter) for protection against the hazards of ground fault currents. An example of
ground-fault current is the current which would flow through a person who is using an appliance
with faulty insulation and, at the same time, is in contact with an electrical ground such as a
plumbing fixture, wet floor, or earth.
The ground-fault circuit interrupter will not protect against short circuits or overloads. The circuit
breaker in the control panel which supplies power to the circuit provides that protection.
The ground-fault circuit interrupter can be identified by the TEST and RESET buttons. The
receptacles on the GFCI can be tested with the TEST and RESET buttons.
TEST BUTTON: To test, depress the “TEST” button. (Power is turned off)
RESET BUTTON: To restore power, depress the “RESET” button.
Perform this test monthly or every 250 hours operation, whichever comes first, in order to ensure
proper operation of the GFCI receptacle. If the generator is stored outdoors, unprotected from the
weather, test the GFCI receptacle before each use. Record your test on the GFCI test card provided
on the control panel.
A040270
Using the generator in rain, snow or near water can lead to death from electric shock.
Keep the generator dry.
Test Button
Reset Button

2. Transportation and Installation
2-7
2.3.4 Connections to a Building's Electrical System
Connections for standby power to a building’s electrical system must be made by a qualified
electrician. The connection must isolate the generator power from utility power and must comply with
all applicable laws and electrical codes.
Improper connections to a building’s electrical system can allow electrical current from the generator to
backfeed into the utility lines. Such backfeed may electrocute utility company workers or others who are
in contact with the lines during a power outage. Consult the utility company or a qualified electrician.
Improper connections to a building’s electrical system can allow electrical current from the utility
company to backfeed into the generator. When utility power is restored, the generator may explode,
burn, or cause a fire in the building’s electrical system.

2. Transportation and Installation
2-8
2.4 Selecting Cable
Select a cable with sufficient diameter by considering the permissible current on the cable and the
distance from the generator to the load.
If the current flowing to the load exceeds the permissible current of the cable, resultant overheating
may burn the cable. Similarly, if the cable is too small in thickness to the length, the input voltage
to the load will fall to cause the load input power to drop, as a result, the performance of the
machine cannot be displayed.
A180935
Simplified formula to seek voltage drop or cross-sectional area of the cable from cable length and
working current. Select such a cable length and thickness so that the voltage drop will remain
within 5%.
Output System Voltage Drop Cross-sectional area of Cable
e: Voltage drop(V)
e’:Voltage drop between
outside line or one line of
each phase and neutral
line.
A: Cable thickness (mm²)
L: Cable length (m)
I: Working current (A)
3 Phase, 3 Wire e30.8    
1000 

A30.8    
1000  
3 Phase, 4 Wire e′  17.8    
1000 

A17.8    
1000  󰆒
The following tables show the relations between the cable length and the cable thickness (nominal
cross-sectional area) suited to the working current.
(Based on the condition that working voltage is 200 V, with voltage drop of 10V.)
Single-Conductor Cable
(Unit: mm2)
Length
Current 165ft (50m) 246ft (75m) 328ft (100m) 410ft (125m) 492ft (150m) 656ft (200m)
400A 125 125 150 200 200 250
600A 200 200 200 250 150×2 200×2
1,000A 125×2 125×2 150×2 200×2 250×2 200×3
Three-ConductorCable (Unit: mm2)
Length
Current 165ft (50m) 246ft (75m) 328ft (100m) 410ft (125m) 492ft (150m) 656ft (200m)
400A 60×2 60×2 60×2 80×2 100×2 125×2
600A 100×2 100×2 100×2 125×2 150×2 200×2
1,000A 150×3 150×3 150×3 150×3 200×3 200×3
Cable Thickness A (mm2)
Cable Len
g
th L (m)
Load Switch
Working
Current I (A)

2. Transportation and Installation
2-9
2.5 Fuel Pipe Selector Valve
2.5.1 Overview
This valve is designed to feed fuel directly from an external fuel tank or from the installed fuel tank as
described below.
2.5.2 Operation method
<Procedure>
1. Machine is delivered from factory with fuel line piping and selector valves built in as shown in the
following Fig.1. When operating a machine, using installed fuel tank, run the machine with the fuel
line piping and the handles of selector valves factory-arranged.
2. When using a separate storage tank, remove the plug fitted at the connections to the separator tank
and make piping as shown in Fig.2. And then turn the handles of the selector valve as shown in
Fig.2.
3. When removing the piping connection, make sure to return the handles to the original positions
shown in Fig.1 and install the plugs.
2.5.3 Installation of Separate Storage Fuel tank and piping method
<Procedure>
1. Use oil resistant hoses with an inside diameter of 8mm to 10mm.
2. Install the fuel tank so that the fuel level of the tank is between 0 and 2.5m high from the machine
installation level.
3. In order to avoid suction of water and sediment together, install the suction pipe so that the inlet
port of suction pipe may be kept between 15mm and 20mm higher than the bottom line of the tank.
Also install the outlet port of the return pipe inside the tank. (See Fig.2･A)
4. When refilling fuel in the tank, take great care to not allow water and sediment in.
A180948
In case the mounted
fuel tank is used
In case the fuel tank
separately provided is used
Inlet
Outlet
Selector handle
Inside
Outside
Plug
Outlet Inlet
Selector handle
Inside
Outside
Piping hose
Outlet Inlet
Suction side
Return side
A
15 to 20mm
The ground plane of generator
Separator
storage tank
(External fuel
connection port)
Fig1 Fig2