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AirMan SG, Instruction Manual, Page: 2 / 66

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AirMan SG Instruction Manual Download Page 2

Preface 

 

A040491

Thank you for having selected our “AIRMAN” product.

 

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This manual explains about the proper operation and daily inspection and maintenance of this 
machine. 

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In order to use a machine safely, people with sufficient knowledge and sufficient technology need to 
deal with it. 

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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. 

 

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

 

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

 

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

 

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Be sure that the manual is included with the unit when it is handed over to another user. 

 

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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. 

 

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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. 

 
 
 
 
 
 
 
 

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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. 

 

Summary of Contents for SG

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Page 2: ...e 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 im...

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Page 4: ... 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 ...

Page 5: ...ortened 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 ...

Page 6: ...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 Su...

Page 7: ...ing 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 Otherwis...

Page 8: ...s 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...

Page 9: ...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...

Page 10: ... 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 ins...

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Page 13: ...or 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 ...

Page 14: ...iltering 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 ...

Page 15: ... 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 sit...

Page 16: ... 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 t...

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Page 18: ...50507 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 ...

Page 19: ...bles 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 r...

Page 20: ...d Common grounding method Leakage relay ground terminal E Machine grounding terminal Load equipment Grounding rod Grounding rod A090403E A090404E Leakage relay ground terminal E Machine grounding terminal Load equipment Grounding rod Grounding rod ...

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Page 22: ...valves factory arranged 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 When removing the piping connections make sure to return the handles to the original positions shown in Fig 1 and install the plugs 3 5 3 Installation of separate storage fuel t...

Page 23: ... gauge 4 Tachometer with hourmeter 5 Voltmeter 6 Ammeter 7 Panel light 8 Frequency meter 9 Circuit breaker dedicated to single phase 10 Circuit breaker 11 Leakage relay 12 Current selection 13 Voltage adjuster 14 Engine oil pressure gauge 15 Panel light switch 16 Frequency selection switch 17 Frequency adjuster switch 18 Operation mode selection switch 19 Starter switch ...

Page 24: ...r single phase circuit breaker trips Lamp display Monitor lamp Functions Engine oil pressure drop When engine oil pressure drops it functions Operating pressure lower than 78kPa Engine water temperature rises In case of abnormal rise of engine water temperature it functions temperature reaches 101 Over speed When engine rotates excessively it begins to function Function rotation 2 070min 1 69Hz Cl...

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Page 26: ...ld the button with such sharply pointed things as a screwdriver ball point pens etc 4 3 Check Frequency Selection Switch for AVR Never touch the interior of control panel during operation Notice that the voltage of several hundreds volts is applied in the control panel When checking or operating the interior of the control panel for changing AVR frequency be sure to stop the machine remove the sta...

Page 27: ...ongly connected or loosely connected it can cause burning to the generator body During operation never use switch Because it could cause electric shock and AVR protection device functions to make voltage fluctuation bigger to hinder normal generating operation When protection device works press white button of AVR to disengage protection device When you start operation the lamp of your selected vo...

Page 28: ...ath nor an inappropriate insulation cable to the voltage Secure connections between each cable terminal and input output terminal Otherwise it may be slackened during operation and may cause a fire or an electric shock accident Notice that the terminal O is not a grounding terminal of the generator Never connect a grounding wire to it Such connection may cause the generator main unit or the load t...

Page 29: ...f electric motor operated In case of different power factor take care not to be overloaded and reduce load Type Permissible current value 50Hz 200V 577A 60Hz 220V 577A 50Hz 380V 304A 50Hz 400V 289A 60Hz 440V 289A In case inverter load The inverter capacity input kVA of inverter should not exceed the following value within rated output 3 0 Also select generator so that the rated output kVA of gener...

Page 30: ...le current limit up to the rated current Adjust the load capacity so that each current value of each phase U V W may not be more unbalanced than 50 3 phase 4 wire type In case of using O phase In case of using single phase Type Permissible current value 50Hz 115V 200V 577A 60Hz 127V 220V 577A 50Hz 219V 380V 304A 50Hz 231V 400V 289A 60Hz 254V 440V 289A Allowable current limit up to the rated curren...

Page 31: ... When water with dirt sand and or dust contained or hard water such as well water ground water is used this will cause deposits inside radiator or on cylinder head and will cause engine overheat due to poor flow of coolant When the unit is used in a cold region and possible freezing is expected it is recommended to use LLC Antifreeze for the coolant Adjust mixing ratio of LLC with water according ...

Page 32: ...e gauge shows the oil level between LOW and HIGH limits it is normal When the oil level is below its LOW add engine oil See 5 5 1 While checking oil level check also for contamination If the oil is found dirty contaminated or should be changed according to the periodic inspection list change the oil 4 7 2 Check coolant level Be sure to stop the machine first and then loosen the radiator cap slowly...

Page 33: ...pansion 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 4 7 4 Check sedimentor Check if the red float 1 in the water sedimentor rises up to the water drain level then drain water if it is near the drain level 2 Procedures Loosen the drain plug 3 to drain the water from the sedimentor...

Page 34: ... by fingers and adjust it Be careful not to leave any grease or LLC on a belt while changing it If any such material is left wipe it off completely 2 Check the water pump belt After loosening the nut fixing the tension pulley adjust the belt by moving the pulley with the adjusting bolt While adjusting the belt tension check it for any crack or wear and if any fault is found replace it Be careful n...

Page 35: ...low the relay function is normal if the circuit breaker is switched OFF To set the breaker ON once again push the leakage relay reset button 3 and set the breaker lever back to the OFF position 4 7 8 Cleaning the instruments inside control panel Before starting operation open control panel and check each breaker terminal plate and each controller for any dust sand and dirt accumulated If the machi...

Page 36: ...ese cautions it could cause burning to the unit and resulting in fire Furthermore should continue operation at the lower level than the standard rated frequency it could cause burns to the generator main unit and also the motor of the load Do not under any circumstance open the portions below during operation Coolant drain valve and plug Engine oil drain valve and plug After the engine starts up w...

Page 37: ...ition After finishing warming up operation check and confirm frequency meter 6 If the frequency is wrong turn frequency adjustment switch 7 If the frequency at load is adjusted higher than specified speed turn selector switch to LOW and if lower turn to HIGH and adjust it to rated speed rated frequency See 4 8 2 While watching the voltmeter 8 turn the voltage adjuster 9 knob to set the voltage to ...

Page 38: ...any air leak oil leak water leak or fuel leak etc The table above gives standard values They may vary slightly depending on the operating conditions and other factors In single phase load operation check the current of U V and W phase with the ammeter by turning the current selection switch When each current is unbalanced change load connections so that the current of U V and W can be equally bala...

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Page 40: ... tools could cause unexpected injury Be sure to use recommended fuel oil grease or antifreeze Do not disassemble or adjust engine compressor or part s for which inspection or maintenance is not referred to in this manual Use genuine parts for replacement Any breakdown caused by using unapproved parts or by wrong handling will be out of the scope of WARRANTY Do not pour water or steam on electrical...

Page 41: ... checked e Any damage wear or shortage of machine components and parts should be checked f Performance of each part or component should be proper Keep the operation log to record constant inspection of each component so that trouble of the machine can be easily discovered and preventive measures can be taken It is very useful to record information such as frequency temperature current maintenance ...

Page 42: ...Check sedimentor 4 11 Check fuel 4 11 Check engine oil level 4 10 Check coolant level 4 10 Check belt tension 4 12 In the case of NG it exchanges Check and clean clogging of air filter element 5 7 Perform cleaning when the monitor lamp glows Drain fuel tank 5 8 Change engine oil First time 5 4 Change engine oil filter First time 5 5 Check battery electrolyte 5 5 Check specific gravity of battery e...

Page 43: ...hite smoke out of the exhaust and it can cause damage and accident to engine Procedure Remove the drain plug 1 attached outside the plane open a drain valve 2 inside the plane and discharge engine oil drain When the oil is completely drained close a drain valve 2 after attaching a drain plug 1 remove the cap of an engine oil filler port 3 refill new engine oil After finishing the oil supply tighte...

Page 44: ...ning them with the center bolt 2 For replacement parts refer to 5 3 5 5 3 Check battery electrolyte and specific gravity of battery electrolyte Battery electrolyte every 250 hours Specific gravity of battery electrolyte every 500 hours If there seems to be a problem in starting an engine due to a flat battery carry out the checks by following the procedures below 1 Ordinary type battery Measure sp...

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Page 48: ...ction of three phase output terminal plate Main circuit of circuit breaker Terminal connection on control box Each terminal connection of each instrument Checking points of electrical circuits on the engine side Portion of connectors to the engine Check for looseness of terminal connections 5 5 12 Clean the strainer provided inside the engine feed pump Every 1 000 hours Periodically remove the str...

Page 49: ...m that the hook of cap fixing latch 2 is surely installed Then tighten it 5 5 14 Check vibration isolator rubbers Every 1 year or every 1 000 hours The vibration isolation rubber 1 is used for the support of generator and engine Check the rubber for any damage or deterioration due to oil sticking 5 5 15 Check each rubber hose Every 1 year or every 1 000 hours Check all the rubber hoses for being h...

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Page 52: ...and also it may cause explosion as well as reduction of battery life Add distilled water so that the liquid level may reach the middle level between the UPPER and LOWER level without any delay Do not charge the frozen battery Otherwise it may explode If the battery is frozen warm it up until the battery temperature becomes 16 C to 30 C Battery electrolyte is dilute sulfuric acid In case of mishand...

Page 53: ...eplaced be careful not to connect and terminals backwards Such wrong connection will cause spark and damage to each component Procedure for using a booster cable Stop the engine Connect one end of the cable to the terminal of the machine battery Connect the other end of the cable to the terminal of the external battery Connect one end of the cable to the terminal of the external battery Connect th...

Page 54: ...l fuel oil 5 Air mixing in fuel piping Disassemble clean and change Call your nearest dealer Call your nearest dealer Replenish fuel Bleed air Engine oil pressure drop monitor lamp glows 1 Engine oil shortage 2 Engine oil filter clogging 3 Engine oil pump malfunction 4 Oil pressure switch malfunction 5 Loosened or disconnected wiring or connector Replenish fuel Change Change Change Check repair Co...

Page 55: ...e operated 9 CP1 for protection of generator functions Check change Check repair Check repair Check change Check change Check repair Check repair Check select Reset Too high voltage generated when set at the rated frequency 50Hz 60Hz Voltage will not drop even when the voltage regulator controlling knob is turned 1 Loosened or disconnected wiring or connector to AVR 2 Faulty AVR 3 Broken wire or p...

Page 56: ... 1 and emergency lamp 2 goes on They go out soon after engine starts When anything abnormal is found either of the lamps goes on So continue pressing trouble diagnosis switch 3 Trouble conditions are displayed in the flashing pattern warning lamp or emergency lamp Examples of reading and confirming diagnostic codes 1 2 3 A120704E Long interval blinking 2 times and short interval blinking 3 times m...

Page 57: ...ontrol valve fails Engine oil pressure system fails 19 Atmospheric pressure sensor Atmospheric pressure sensor fails 21 Water temperature sensor Disconnection short circuit of harness between ECU and water temperature sensor 22 Rack sensor Emergency lamp Control rack position sensor fails 23 Timer control valve Warning lamp Disconnection short circuit of harness between ECU and timer control valve...

Page 58: ... port of engine and other openings like the muffler with a vinyl sheet packing tape etc to prevent moisture and dust from getting in the unit Measure the insulation resistance of the generator and make sure that it is more than 1MΩ See 5 5 4 Be sure to repair any trouble and maintain the unit so that it will be ready for the next operation When stacking up the machines for storage only two units s...

Page 59: ...2 set 4 shares in total 1 65 2 set 4 shares in total Model MITSUBISHI FUSO TRUCK BUS CORPORATION 6D24 TLE2B Type 4 cycle water cooled direct injection turbo charged air to air intercooled Number of cylinders 6 Total displacement L 11 94 Rated output kW 181 199 Revolution per minute min 1 1 500 1 800 Lubricating oil capacity L 37 Coolant capacity including radiator L 39 Battery 170F51 2 24V Engine ...

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Page 63: ...10 Piping Diagram 10 1 10 1 Fuel piping A090427E ...

Page 64: ... OPERATION LOG REMARKS INSPECTION PART CHANGE HISTORY ETC OUTPUT CURRNT A ENG OIL REPLACEMENT HOUR h ENG OIL PRESS kPa OPERATION DATE OPERATION TIME COOLANT TEMP OUTPUT VOLTAGE V TOTAL OPERATION HOURS h AMBIENT TEMP FREQUENCY Hz ...

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