AirMan SDG25S-8B1 User manual

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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 of 7
digits (for instance, A040491) at the right
bottom. This number is not a part number, but
it is used only for our reference number.
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Table of Contents
1. Safety ---------------------------------------------------------------------------------------------- 1-1
1.1 Caution before Operation ......................................................................................................................1-2
1.2
Caution during Operation ......................................................................................................................1-4
1.3
Caution during Inspection and Maintenance ........................................................................................1-6
1.4
Safety Warning Labels ...........................................................................................................................1-8
2. Part Names -------------------------------------------------------------------------------------- 2-1
2.1 Internal Components ...............................................................................................................................2-1
3. Installation--------------------------------------------------------------------------------------- 3-1
3.1 Transporting Unit ....................................................................................................................................3-1
3.2
Conditions of Unit Installation ..............................................................................................................3-2
3.3
Grounding Method ..................................................................................................................................3-4
3.4
Selecting Cable ........................................................................................................................................3-7
3.5
Selector Valve of Fuel Pipe ..................................................................................................................3-8
4. Operation----------------------------------------------------------------------------------------- 4-1
4.1 Instrument panel .....................................................................................................................................4-1
4.2
Protection device ....................................................................................................................................4-2
4.3
Connecting Load ....................................................................................................................................4-5
4.4
Engine Oil・Coolant・Fuel ...................................................................................................................4-8
4.5
Check before Starting the Machine .....................................................................................................4-10
4.6
Unit Operation .........................................................................................................................................4-13
4.7
Stopping Procedures .............................................................................................................................4-17
4.8
Adjustment of frequency .......................................................................................................................4-17
4.9
Emergency Stop .....................................................................................................................................4-18
4.10
Air Bleeding .............................................................................................................................................4-18
5. Periodic Inspection/Maintenance -------------------------------------------------------- 5-1
5.1 Important items at Periodic inspection and Maintenance or after Maintenance ................................5-1
5.2
Daily Inspection and keeping Operation Log .......................................................................................5-2
5.3
Periodic Replacement of Parts .............................................................................................................5-2
5.4
Periodic Inspection List .........................................................................................................................5-3
5.5
Maintenance .............................................................................................................................................5-4
6. Maintenance/Adjustment ------------------------------------------------------------------- 6-1
6.1 Maintenance of Battery ............................................................................................................................6-1
6.2
Troubleshooting .......................................................................................................................................6-3
7. Storage of the Unit ---------------------------------------------------------------------------- 7-1
7.1 Preparation for Long-term Storage .............................................................................................................7-1
8. Specifications ---------------------------------------------------------------------------------- 8-1
8.1 Specifications ...........................................................................................................................................8-1
8.2 Outline drawing .....................................................................................................................................8-2
9. Wiring Diagram ---------------------------------------------------------------------------------- 9-1
9.1 Generator Wiring Diagram ......................................................................................................................9-1
9.2
Engine Wiring Diagram ...........................................................................................................................9-2
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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 per-
formance 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.
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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
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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
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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
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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 supply fuel up to the fuel cap. And then the fuel may
get spilt when the unit is moved, transported and it is vibrating.
 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
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1.Safety
1-6
SY001
TR0304
W009
W003
1.3 Cautions 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 fan belt is to be adjusted.
 If the machine is running, it might catch the operator’s hand
into the fan belts, and this could cause a serious injury.
 Be sure to stop the engine and remove the starter key
whenever the tension of the fan belt is to be adjusted.
 If the machine is running, it might catch the operator’s hand
into the fan 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 fan belt
Hands off from cooling fan
Cleaning by air-blow
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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 suffi-
ciently 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.
 During operation or immediately after the engine stops, its oil
is extremely hot and pressurized, so it may jet out when the
cap is loosened. Be careful not to scald yourself from it.
 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
Disposal of waste liquid, etc.
TR0206
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1.Safety
1-8
1.4 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
9
39178 88820
5 6 7 8
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1.Safety
1-9
 The pasting position of safe warning label is as follows.
8
3
5
4
6 7
1 2
A080467
DETAIL OF INSTRUMENT PANEL
9
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2. Part Names
2-1
2.1 Internal Components
A070138
No. Description Function
1 Control panel Panel fitted with various meters and controllers.
2 Fuel filter Filtering device for filtering dust mixed in fuel oil.
3 Engine oil filter For filtering engine oil.
4 Air filter Filtering device for filtering dust floating in intake air.
5 Engine For driving the generator main unit.
6 Engine oil filler port For supplying and replenishing engine oil to engine.
7 Reserve tank For feeding cooling water.
8 Radiator For cooling engine.
9 Exhaust muffler Equipment which muffles an engine exhaust sound.
10 Fuel tank Fuel oil container.
11 Battery For electrically starting engine.
12 Engine oil level gauge Scale for measuring engine oil level.
13 Selector valve of fuel pipe For supplying fuel oil from the tank provided outside.
14 Sedimentor For separating water mixed in fuel oil.
15 Generator main unit For generating AC power to be supplied.
16 Output terminals Equipped with three phase and single phase terminal and
receptacle for single phase.
1 2 3 4 5 6 7 8
15 14 13 12 11 10
9
16
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3. Installation
3-1
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 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.
 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.
1
A
040151
A
040151
1
Transportation
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3. Installation
3-2
A050511
A050506-1
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.
PC002
 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.
 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
operated under exhaust air pressure, make
sure to install the exhaust pipe to be
supported.
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
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3. Installation
3-3
A050505
 Never locate the unit with the exhaust muffler facing any
private house:
 As the exhaust fume (gas) from the engine is poisonous,
never direct it to any other persons passing by.
 The machine has to be installed on dry, firm, and level
area.
 The machine should be installed within 5ﾟdegree inclination.
 Avoid installing the machine in a place such as a damp
place or a place where puddles are apt to be formed
after rain. Such installation could cause electric shock.
 When installing the machine at the sea shore or on a
ship, make sure that the machine should not be
exposed directly to sea water.
 When installing the machine 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.
 In case that the unit has to be installed inevitably on any
rough and uneven ground; it is necessary to insert
square wooden bars under the unit for levelling it.
 The machine should be operated in following conditions:
 Ambient temperature －15℃to +40℃
 Humidity Less than 85%
 Altitude Lower than 500 m above sea level
 If more than two machines are placed parallel in
operation, keep enough distance so that exhaust air
from one machine does not effect the other one.
 Keep enough space around the unit for inspection and
maintenance access.
1000 or more
1000 or more
1000 or more
SG0110
Unit : mm
SG0103-1
How to locate the unit
×
Private house
○
Installation
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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:
3.3 Grounding Method
3.3.1 Ground Terminal
The generator ground terminal“1”is connected to the
frame of the generator, metal non-current-carrying
generator parts and the ground terminals of each
receptacle.
3.3.2 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 contact 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.
3.3.3 Ground 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 is connected to the system
ground.
Preparation of safety fences
Safety fences
1
A
040172-1
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3. Installation
3-5
3.3.4 GFCI (Ground-fault circuit interrupter) Receptacles

Using the generator in rain, snow or near water can lead to death from electric shock. Keep the
generator dry.
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
Test button
Reset button
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3. Installation
3-6
Grounding method
A080433
Machine grounding
terminal
Load equipment
Grounding rod
Grounding rod
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3. Installation
3-7
3.4 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.
 Simplified three-phase three-wire formula to seek voltage drop from cable length and working
current. Select such a cable length and thickness so that the voltage drop will remain less
than 5%.
Output system Voltage drop
Three-phase 3-wire Type
Three-phase 4-wire Type
 The following tables show the relations between the cabtyre 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 Cabtyre Cable Unit:mm2
Three-Conductor Cabtyre Cable Unit:mm2
50m 75m 100m 125m 150m 200m
50A 8 14 22 22 30 38
100A 22 30 38 50 50 60
50m 75m 100m 125m 150m 200m
50A 14 14 22 22 30 38
100A 38 38 38 50 50 60
Cable Length L(m)
Length
Current
Current
A080434
Length
Cable Thickness A (mm2)
Working
Current I (A)
e:Voltage drop(V)
e :Voltage drop between an outside
line or one line of each phase,
and a neutral line (V)
A ：Cable thickness (mm2)
L ：Cable length (m)
I ：Working current (A)
e ＝1,000×A
e ＝ 17.8×L×I
1,000×A
’
’
30.8×L×I
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