AirMan SDG25S-3A3 User manual

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Preface
 This operation manual explains and illustrates proper handling of the unit and the method of daily
inspection and maintenance which will enhance the performance of AIRMAN’s generators.
 Before operating unit, read the manual carefully and fully understand its operation and maintenance
requirement. Then maintain “SAFETY OPERATION AND PROPER MAINTENANCE OF THE UNIT”.
 Keep the manual available at all times for the operator or safety supervisor.
 In case the manual is lost or damaged, place an order with your dealer for another copy.
 Make sure that the manual is included with the unit when it is handed over to another user.
 There may be minor 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 need parts or service information about the unit, please give your dealer model and serial
number of the unit. A plate stamped with model type and serial number is attached to the right hand
side of the instrument panel of the unit.
MODEL:
SER.NO.:
Be sure to follow safety warnings and cautions given in the manual. Unsafe operation could cause
serious injury or death.
A
010053
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Table of Contents
TOC-1
1. Safety.................................................................................................................................................. 1- 1
1. 1 Caution before Operation........................................................................................................... 1- 2
1. 2 Caution during Operation...........................................................................................................
1- 7
1. 3 Caution during Inspection and Maintenance..............................................................................
1-10
1. 4 Safety Warning Labels...............................................................................................................
1-13
2. Names of Components ..................................................................................................................... 2- 1
2. 1 Unit Appearance and Part Names........................................................................................... 2- 1
2. 2
Ｍａｉｎ Components and Part Names ......................................................................................... 2- 2
2. 3 Instrument Panel........................................................................................................................
2- 4
2. 4 Warning and Emergency Display...............................................................................................
2- 5
2. 5 GFCI (GROUND-FAULT CIRCUIT INTERRUPTER) RECEPTACLES.....................................
2- 6
3. Transportation ................................................................................................................................... 3- 1
4. Installation.......................................................................................................................................... 4- 1
4. 1 Place and Conditions of Unit Installation.................................................................................... 4- 1
4. 2 Selecting Cable..........................................................................................................................
4- 2
4. 3 Connecting Load........................................................................................................................
4- 2
4. 4 Grounding Method .....................................................................................................................
4- 5
5. Operation............................................................................................................................................ 5- 1
5. 1 Check before Starting the Unit................................................................................................... 5- 1
5. 2 Unit Operation............................................................................................................................
5- 6
5. 3 Stopping Procedures..................................................................................................................
5-10
5. 4 Operating Procedures when Engine Fails to Start up on First Attempt......................................
5-10
5. 5 Adjustment of frequency ............................................................................................................
5-11
5. 6 Emergency Stop.........................................................................................................................
5-12
5. 7 Air Bleeding................................................................................................................................
5-12
6. Periodic Inspection and Maintenance ............................................................................................. 6- 1
6. 1 Important Items at Periodic Inspection and Maintenance or after Maintenance........................ 6- 1
6. 2 Daily Inspection and Keeping Operation Log.............................................................................
6- 2
6. 3 Inspection and Location of Componets......................................................................................
6- 3
6. 4 First Maintenance at Initial 50 Hours..........................................................................................
6- 5
6. 5 Maintenance Every 250 Hours...................................................................................................
6- 7
6. 6 Maintenance Every 300 Hours...................................................................................................
6- 9
6. 7 Maintenance Every 500 Hours...................................................................................................
6-10
6. 8 Maintenance Every 600 Hours...................................................................................................
6-11
6. 9 Maintenance Every 1000 Hours.................................................................................................
6-12
6.10 Maintenance Every 2000 Hours.................................................................................................
6-14
6.11 Periodic Inspection List..............................................................................................................
6-15
7. Maintenance/Adjustment..................................................................................................................
7- 1
7. 1 Automatic Shut-Down System ................................................................................................... 7- 1
7. 2 Maintenance of Battery..............................................................................................................
7- 1
7. 3 Adjusting controller for automatic starting..................................................................................
7- 2
7. 4 Troubleshooting .........................................................................................................................
7- 3
8. Storage of the Unit............................................................................................................................ 8- 1
8. 1 Preparation for Long-term Storage ............................................................................................ 8- 1
9. Specifications .................................................................................................................................... 9- 1
10. Wiring Diagram..................................................................................................................................10- 1
10. 1 Generator Wiring Diagram.........................................................................................................10- 1
10. 2 Engine Wiring Diagram..............................................................................................................10- 5
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1. Safety
1-1
This operation manual explains and illustrates general requirements for safety ａｎｄ cautions for
safety.
Read these safety requirements carefully and fully understand the contents before starting the
machine.
For better understanding, 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.
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.
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1.Safety
1-2
1.1 Caution before Operation
 Make sure not to connect the output terminal of the
machine with commercial power source from electric
power company. It may cause electric shock, machine
problems and even a fire.
 Any source of high voltage is a source of potential
LETHAL voltage. Maintain all electrical cords and
connections in proper condition. Do not operate the unit
in the rain, around standing water or when wet. Always
ground the generator properly before operating.
Never allow untrained or unqualified individuals to
operate or remain in the vicinity of the equipment when
it is operating.
 When connecting a cable to the load, do not use a
cable with damaged covering or with inappropriate
insulation.
 Make sure connections between input/output
terminals are tight. Otherwise, it may loosen during
operation which may cause a fire or electric shock
accident.
 Exhaust gas from the engine is poisonous, and could
cause death when inhaled.
Avoid using the machine in an insufficiently ventilated
building or tunnel.
SG0101
Ventilation
H990208
PC002
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1.Safety
1-3

Keep flames away from battery.

Batteries generate hydrogen gas and may explode.

Therefore, recharging should be done in a well-ventilated
place.

Do not allow sparks, lighted match, or lit cigarette close to
the battery.
 Do not check the battery by short-circuiting the positive and
negative terminals with a metallic object.

Do not charge the frozen battery. Otherwise it may explode.
If the battery is frozen, warm it up until the battery
temperature becomes 61° Fto 86° F (16℃to 30℃).

Battery electrolyte is diluted sulfuric acid.
In case of mishandling, it could cause skin burning.

Wear protective gloves and safety glasses when handling a
battery.

If battery electrolyte contacts your clothes or skin, rinse with
large amounts of water immediately.

If the battery electrolyte gets into your eyes, rinse
immediately with plenty of water and see a doctor at once,
because eyesight could be damaged.

Dispose of battery, observing local regulations.

Read each instruction plate which is displayed in the
manual and on the unit carefully, understand its content and
follow all rules and warnings.

Keep the Safety Warning labels clean. When they are
damaged or missing, apply to your dealer for new ones.

Do not modify the machine without prior approval. Safety of
the machine may be compromised, functions may be
deteriorated, or machine life may be shortened.

Never use the unit for purposes other than power supply.
Otherwise, serious accidents may occur.

Do not operate the machine if you are tired, impaired or under the influence of drugs. Otherwise,
careless handling may cause an unexpected injury or accident. Manage your physical and
mental health and be cautious in handling the machine.
Handling battery
Follow the safety instructions
Maintain both physical and mental health
D004
W010
TR0086
TR0093
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1.Safety
1-4

Use the lifting bail (1) in the center of bonnet for hoisting up
and down the machine. Since the rope hook (2) in 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 to secure it with rope(3) in the
center of bonnet. Apply chocks(4) to fix the machine on the
truck bed when necessary.

Select an appropriate crane and truck by referring to the mass
and dimensions shown in “Specifications” in Chapter 9.

Only the qualified crane operator is allowed to operate a crane.

Do not hoist up the machine while it is running. Otherwise, a
fatal trouble or serious accident may occur to the machine parts.

The machine must be installed on dry, firm and level area.
 In case the machine has to be installed on a slope, keep
the inclination angle less than 5 degrees.
 Avoid installing the machine in a place such as a damp
area or a place where puddles might form after rain. Such
an installation could cause electric shock.

Do not direct the exhaust gas outlet to nearby personnel or
houses in the vicinity.

When installing the machine at salt water areas or on a ship,
make sure the machine is not exposed directly to sea water.

When installing the machine at sandy areas, make sure that
exhaust from the generator or radiator does not blow the
sand in the air, or into the machine.

The machine should be operated in following conditions:
 Ambient temperature 5°
Fto 104° F
(–15℃to +40℃)
 Humidity Less than 85%
 Altitude Lower than 1,640ft (500 m) above sea level
Transportation
Installation
SG0103
3 4
2
1
SG0102
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1.Safety
1-5

Such things as unnecessary equipment, tools, cables, hoods, covers and wood pieces which are
a hindrance to the job, must be cleared and removed. Operators and/or personnel nearby may
stumble on them and could be injured.

Be sure to check the unit before operation.
When any abnormality is found, be sure to repair it before restarting the unit.

Be sure to make daily checks before operation. If the unit is operated without prior checking and
a potential problem was not found, operation of the unit may cause seizure of components or
cause a fire.

When operating the machine, do not wear;
 loose clothes
 clothes with unbuttoned sleeves
 hanging tie or scarf
 loose fitting jewelry
Such outfit may get caught into the machine rotating parts
and this could cause a serious injury.

Wear helmet, safety glasses, earplugs, safety shoes, safety
gloves and a mask, according to the requirements of each
operation.

Have first-aid boxes and fire-extinguishers near the unit
ready for emergency situations such as injuries or fire.

It is advisable to have a list of phone numbers for doctors,
ambulance and the fire department available in case of
emergency.
Safety around the machine
Safety equipment
Safety aids
Check before starting the unit
Safety outfit
TR0084
TR0085
TR0096
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1.Safety
1-6

When stacking up the machines for storage, only two
units stacking is acceptable.The mass of the lower
machine should be larger than that of the upper one.

Select a leveled floor with sufficient strength for stacking
up the units.

Before stacking the machines up, check the machine for
any deformation of bonnet, looseness or missing of bolts,
and other parts.

When stacking the units up, be sure to fix them as shown
in the figure so that the balanced weight is applied to
each squared lumber (1) for preventing a sideslip or a
collapse.

Never operate the machines with stacking conditions. It
is very dangerous.

It is dangerous to stack the machines, because they
could fall down due to sideslip or collapse when an
earthquake happens. Pay careful attention to the storage floor for safety.
Stacking up box type machines
1
SG0104
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1.Safety
1-7
1.2 Caution during Operation

Never touch the output terminals during operation.

Pay attention that high voltage is present at the output
terminals.

When removing or connecting a "load" cable, be sure to
switch OFF the circuit breaker. Turn off the machine,
remove the starter key from the starter switch, then change
cables. The operator must hold the key during cable
changing.
Neglecting the cautions mentioned above, and a third party
starting the machine during operation may cause serious
accidents such as electric shock.

Never touch the interior of the control panel during
operation.

Pay attention that high voltage is present at interior of the
control panel.

Authorized personal only to open control panel.

Keep hands clear from the rotating portion or belts while
running. It could cause serious injuries if hands should be
caught.

Never put your hand near the engine cooling fan during
operation. It could cause serious injury if a hand should be
caught.
Never touch the interior of control panel
H990208
Hands off from rotating parts and belts
TR0304
Beware of cooling fan
W009
Keep away from output terminals
H990208
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