AirMan SG User manual

Preface
A040491
Thank you for having selected our “AIRMAN” product.
◆ This manual explains about the proper operation and daily inspection and maintenance of this
machine.
◆ In order to use a machine safely, people with sufficient knowledge and sufficient technology need to
deal with it.
◆ Before operating the unit, read the manual carefully, fully understand its operation and
maintenance requirement. Maintain “SAFETY OPERATION AND PROPER MAINTENANCE OF
THE UNIT”.
Be sure to follow safety warnings and cautions given in the manual.
Unsafe operation could cause serious injury or death.
◆For details of handling, maintenance and safety of the engine, see the Engine Operation Manual.
◆Keep the manual available at all times for the operator or safety supervisor.
◆ If the manual is lost or damaged, place an order with your dealer for another copy.
◆ Be sure that the manual is included with the unit when it is handed over to another user.
◆ There may be some inconsistency in detail between the manual and the actual machine due to
improvements of the machine. Ask your dealer if you have any questions or problems.
◆ If you have any questions about the unit, please inform us the model and serial number. A plate
stamped with the model and serial number is attached to side of the unit.
◆ Each illustrated figure (Fig.) has a number
(for instance, A040491) at the right bottom.
This number is not a part number, but it is
used only for our reference number.

1.Safety
1-1
This manual explains and illustrates general requirements for safety and cautions for safety.
Please read these safety requirements carefully and fully understand the contents before starting the
machine.
For your better recognition, according to the degree of potential danger harmful to a human body,
safety messages are classified into three hierarchical categories, namely, , , and
with a caution symbol － attached to each message.
When one of these messages is found, please take preventive measures for safety to carry out “SAFETY
OPERATION AND PROPER MAINTENANCE OF THE UNIT ”.
DANGER indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury. This signal word
is to be limited to the most extreme situations.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be
used to alert against unsafe practices.
IMPORTANT indicates important caution messages for the
performance or durability of the unit, which has no concern to
injury or accident of or to a human body.
Follow warnings mentioned in this manual. This instruction manual does not describe all safety items.
We, therefore, advise you to pay special attention to all items (even though they may not be described in
the manual) for your safety.

1.Safety
1-2
PC002
D004
TR0093
1.1 Caution before Operation
Read each instruction plate which is displayed in the manual
or on the machine carefully, understand its content and
follow the indications thereof.
Keep the Safety Warning labels clean. When they are damaged
or missing, apply new ones.
Do not modify the machine without prior approval. The safety
may be compromised, functions may be deteriorated, or
machine life may be shortened.
Never use the machine for the other purposes than power
supply. Otherwise, serious accidents may occur.
Exhaust gas from the engine is poisonous, and could cause
casualties when it is inhaled.
Avoid using the machine in an insufficiently ventilated building
or a tunnel.
Keep flames away from battery.
Battery may generate hydrogen gas and may explode.
Battery electrolyte is dilute sulfuric acid.
In case of mishandling, it could cause skin burning.
Wear protective gloves and safety glasses when handling a
battery.
Dispose of battery, observing local regulations.
TR0086
Follow the safety instructions
Ventilation
Handling battery

1.Safety
1-3
TR0084
TR0085
TR0096
 When handling machine, do not wear;
 loose clothes
 clothes with unbuttoned sleeves
 hanging tie or scarf
 dangling jewelry
 Such outfit could be caught in the machine or dragged in
the rotating portion of the machine, and could cause a
serious injury.
 Do not operate the machine when you are tired or drunk or under the influence of drugs. Otherwise,
a hasty conclusion or careless handling may cause unexpected injury or accident. Manage your
physical and mental health and be cautious in handling the machine.
 Please wear protection implements, such as a helmet,
protection glasses, earplugs, safety shoes, a glove, and a
protection-against-dust mask, according to the contents of
work for safety.
 Have first-aid boxes and fire-extinguishers near the unit ready
for emergency situations such as injuries and a fire.
 It is advisable to have a list of phone numbers of doctors,
ambulance and the fire department available in case of
emergency.
 Such things as unnecessary equipment and tools, cables, hoods, canvas sheets and pieces of wood
which are a hindrance to the job, have to be cleared and removed. This is because operators and
personnel nearby may stumble on them and may be injured.
Safety outfit
Maintain both physical and mental health
Protection equipments
Safety fittings
Safety around the machine

1.Safety
1-4
H990208
TR0304
H990432
1.2 Caution during Operation
 Never touch the output terminals during operation.
 Notice that the voltage of several hundreds volt is applied to
the output terminal.
 When removing or connecting a connecting cable for changing
load, be sure to switch OFF the circuit breaker, remove the
starter key from the starter switch, then carry out a work. The
operator must keep the key during operation.
Neglecting the cautions mentioned above, and a third
party starting the machine during operation may cause
serious accidents such as electric shock.
 Keep hands off from the rotating portion or belts while running.
It could cause serious injuries if hands should be caught in.
 Do not, under any circumstance, open the radiator cap while
running or immediately after stopping operation. Otherwise
high temperature steam jets out and this could cause
scalding.
Never touch the output terminals and interior of control board
Hands off from rotating parts and belts
Do not remove radiator cap during operation

1.Safety
1-5
H990432
D004
H990433
Never work nearby hot portions of the machine while it
is running.
Do not touch hot portions of the machine while inspecting the
machine when running.
Such parts as engine, exhaust manifold, exhaust pipe, muffler,
and radiator are especially hot, so never touch those parts,
because it could cause scalding.
Coolant water and engine oil are also very hot and dangerous
to touch. Avoid checking or refilling them while the unit is
running.
Do not, under any circumstance, bring lit cigarettes or matches
near such oils as diesel fuel oil, and engine oil, etc.
They are extremely flammable and dangerous, so be careful
when handling.
Refilling oils should be done in an outdoor well-ventilated
place.
Refuel after stopping the engine, and never leave the fuel
nearby the machine. Do not spill. It may cause a fire. When it
is spilt, wipe it up completely.
Do not fill fuel oil up to the cap level. When fuel tank is
filled up to the cap level, fuel oil will be overfilled due to
volume expansion caused by rise of ambient temperature.
Further, fuel will be possibly spilled from fuel tank due to
vibration caused during movement and/or transportation
of machine.
Such parts as muffler and exhaust pipe can be extremely hot.
Remove twigs, dried leaves, dried grass and waste paper, etc.
from the exhaust outlet of the muffler.
Keep a fire extinguisher available by the machine in case of
unexpected fire.
Do not touch hot parts
Fire prevention

1.Safety
1-6
SY001
TR0304
W009
W003
1.3 Caution during Inspection and Maintenance
Before starting inspection, switch off the circuit breaker of this
machine, remove the starter key from the starter switch, and
then hang a “Now Checking and under Maintenance” tag
where it can be easily seen. The checker must keep the key
during checking and maintenance.
Remove the negative (–) side cable from the battery.
If the above procedure is neglected, and another person starts
operating the machine during check or maintenance, it could
cause serious injury.
Be sure to stop the engine and remove the starter key
whenever the tension of the belt is to be adjusted.
If the machine is running, it might catch the operator’s hand
into the belts, and this could cause a serious injury.
Be sure to stop the engine and remove the starter key
whenever the tension of the belt is to be adjusted.
If the machine is running, it might catch the operator’s hand
into the belts, and this could cause a serious injury.
When cleaning dust accumulated in such devices as the
air-filter, etc., by blowing compressed air, wear safety glasses,
etc. to protect your eyes.
Hang a “Now Checking and under Maintenance” tag
Adjusting tension of belt
Hands off from cooling fan
Cleaning by air-blow

1.Safety
1-7
H990432
H990432
It is recommended to use a lamp with safety guard fitted
where the site is dark. Operating the machine gropingly or by
relying on one’s intuition could cause unexpected accidents.
Any lamps without safety guard are not recommended since
they can be broken and they could ignite flammables such as
fuel, etc.
Be sure to stop the engine, and let the coolant water
sufficiently cool down before draining it.
If the drain valve is opened before the coolant water is cooled
enough, hot water could jet out, and it could cause scalding.
After stopping the engine, wait 10 to 20 minutes until the engine
oil cools off. Then check the level of the engine oil, or refill or
drain the oil.
The engine oil is very hot during operation and just after it
stops. Be careful because the hot oil also pressurized blows
off and it can cause burning.
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 trouble of the
instruments. Clean them by blowing compressed air.
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 the waste liquid from the
machine.
Be sure to follow the designated regulations when disposing of
oil, fuel, coolant (antifreeze), filter, battery or other harmful
materials.
Lighting apparatus
Opening coolant water drain valve
Refilling or draining of engine oil
Caution of the cleaning
Treatment of organic wastes
TR0206
A
100285

2. Part Names
2-1
2.1 Internal Components
No. Description Function
1 Generator main unit Device for generating AC power.
2 Engine For driving the generator main unit.
3 Engine oil filler port For supplying and replenishing engine oil to engine.
4 Engine oil level gauge Scale for measuring engine oil level.
5 Intercooler For cooling the air compressed by engine supercharger.
6 Exhaust muffler Equipment which muffles an engine exhaust sound.
7 Fuel tank Fuel oil container.
8 Battery For electrically starting engine.
9 Output terminals Outlet port for AC power.
A090435
1 2 3 4 5 6
9
8 7

2. Part Names
2-2
No. Description Function
10 Radiator Device for engine cooling water.
11 Fuel filter Filtering device for filtering dust mixed in fuel oil.
12 Air filter Filtering device for filtering dust floating in intake air.
13 Control panel Panel fitted with various meters and controllers.
14 Engine oil filter For filtering engine oil.
15 Sedimentor For separating water mixed in fuel oil.
16 Fuel pipe change-over system For fuel supply from outside set fuel tank.
17 Reserve tank For feeding cooling water.
A090436
10 11 12 13
17
16 15 14

3. Installation
3-1
A090402
A090400
A090401
3.1 Transporting Unit
 Use the lifting bail“1”at the center of bonnet for hoisting up
and down the machine.
Since the rope hook is not strong enough to be used for
hoisting, never use it to prevent falling accident.
 When transporting the machine, be sure to put it on the
truck bed and use the rope hooks“2”to secure it with rope.
 Do not hoist up the machine while it is running.
Otherwise, a fatal trouble or serious accident may occur.
3.1.1 Lifting
 Use the lifting bail“1”fitted on center of bonnet.
 Adjust the lifting point position, according to the fuel volume filled.
 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.
3.1.2 Securing a machine on truck bed when transporting

When moving or transporting a machine from site,
place it on truck bed and fasten it by ropes“3”at two
hooks“2”on both right and left sides and 4 points on
the common frame.
1
1
2
2
4
3
Transportation
2
Lifting point position when fuel is not filled up.
Lifting point position when fuel is filled up.
Front
(at side of fuel tank)

3. Installation
3-2
A090641
A050506-1
PC002
3.2 Conditions of Unit Installation
 Exhaust gas from the engine is poisonous, and it could cause
casualties when it is inhaled.
Avoid using the machine in an insufficiently ventilated building
or a tunnel. When the machine is unavoidably used in such
insufficiently ventilated place, ventilation devices and ventilation
pipe should be provided for better ventilation.
 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 also to secure it after
exhaust fume outlet port so that the engine
may not get overheated.
 Exhaust fume pipe extension should be
provided to send exhaust fume out of the
installation place.
 Outlet port of radiator cooling air should be equipped outdoors with a duct or the like provided so
that cooling air can be exhausted outdoors.
(Engine blowby gas is exhausted together with cooling air through a duct.)
 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.
In case that the unit is installed indoors
Exhaust fume
(or gas)
Exhaust fume
outlet port
Exhaust fume
extension
p
i
p
e
Suction air
inlet port
Installing the unit st such poorly-ventilated place
○
×
Exhaust fume
extension pipe
Exhaust fume
(or gas)
Suction air is fed
by air blower.
Exhaust
Ventilation

3. Installation
3-4
A050507
 In order to prevent from entering the jobsite or touching
the equipment any other persons than the persons
engaged in the job, please prepare for safety fences
around the unit:
Preparation of safety fences
Safety fences

3. Installation
3-5
3.3 Leakage Protection Device and Grounding Method
Make sure to perform grounding connection of the external body of load. If such grounding connection is
neglected or fails, it can cause electric shock to human body by leaked current, leading to serious
accident as death.
Grounding terminal for residual current relay and grounding terminal of the package of the machine can
be connected to both independent grounding base and to common grounding base.
This ground fault circuit interrupter does not function to protect such electric shock accident caused
between these two wires (cables).
3.3.1 Leakage protection device
This machine is equipped with a leakage relay which detects leakage caused by a defective
insulation of working load to prevent an accident such as an electric shock by shutting down the
circuit. However, for additional safety, install ground fault circuit interrupter (GFCI) for each load
equipment close to the load equipment. The sensitivity current of the leakage relay is 30 mA.
3.3.2 Grounding method
<Procedure>
Connect a lead wire fitted with a ground rod to the leakage relay grounding terminal (E) of the
three-phase output terminal board.
① Connect the generator machine ground terminal of the package to ground.
② Be sure to ground the package of the load equipment as well.
③ These grounding must be carried out in accordance with local regulations.
Caution on Grounding

3. Installation
3-6
Independent grounding method
Common grounding method
Leakage relay
ground terminal(E)
Machine grounding
terminal
Load equipment
Grounding rod
Grounding rod
A
090403E
A090404E
Leakage relay
ground terminal(E)
Machine grounding
terminal
Load equipment
Grounding rod
Grounding rod