Related Manuals for AirMan SDG25S-3A3
Summary of Contents for AirMan SDG25S-3A3
- Page 1 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
- Page 2 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.
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Page 3: Table Of Contents
www.AirmanArizona.com REQUEST PARTS ON LINE Table of Contents 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 Names of Components ........................ ... -
Page 4: Safety
www.AirmanArizona.com REQUEST PARTS ON LINE 1. Safety 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, with a caution symbol −attached to each message. -
Page 5: Caution Before Operation
www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety 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. - Page 6 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Handling battery 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.
- Page 7 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Transportation 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.
- Page 8 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Safety around the machine 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.
- Page 9 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Stacking up box type machines 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.
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Page 10: Caution During Operation
www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety 1.2 Caution during Operation Keep away from output terminals 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. - Page 11 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Do not remove radiator cap during operation Do not, under any circumstance, open the radiator cap while running or immediately after stopping operation. Otherwise high temperature steam is released and this could cause scalding. ...
- Page 12 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Draining during operation prohibited Do not, under any circumstance, open these during operation: Coolant drain valve and plug Engine oil drain plug PK0028 Unbalance of overload and load Reduce the load if the circuit breaker actuates frequently during operation. When a single-load is used, check the current of each phase, and adjust the load so that each load value remains balanced.
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Page 13: Caution During Inspection And Maintenance
www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety 1.3 Caution during Inspection and Maintenance Hang a “Now Checking and under Maintenance” tag Before starting inspection, switch off the circuit breaker of the machine, remove the key from the starter key switch, hang a “Now Checking and under Maintenance”... - Page 14 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Lighting apparatus Do not attempt operating or servicing the machine in the dark. It is recommended to use a lamp which has a safety guard. Operating or servicing the machine in the dark may cause unexpected accidents.
- Page 15 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety Refilling or draining of engine oil After stopping the engine, wait until engine cools down. Then check the level of the engine oil, refill or drain the oil. Engine oil is very hot and highly pressurized during or just after engine operation, while draining oil, make sure engine is cool.
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Page 16: Safety Warning Labels
www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety 1.4 Safety Warning Labels SDG25S Following labels are attached to the machine. Keep them clean all ｔｈｅ times. If they are damaged or peeled off, immediately place an order with your nearest dealer for replacement., with the numbers indicated on the lower right corner of the label. - Page 17 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety SDG45S/60S Following labels are attached to the machine. Keep them clean all ｔｈｅ times. If they are damaged or peeled off, immediately place an order with your nearest dealer for replacement., with the numbers indicated on the lower right corner of the label.
- Page 18 www.AirmanArizona.com REQUEST PARTS ON LINE 1.Safety SDG75S/100S Following labels are attached to the machine. Keep them clean all ｔｈｅ times. If they are damaged or peeled off, immediately place an order with your nearest dealer for replacement., with the numbers indicated on the lower right corner of the label.
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Page 19: Names Of Components
www.AirmanArizona.com REQUEST PARTS ON LINE 2. Names of Components 2.1 Unit Appearance and Part Names SDG25S www.AirmanArizona.com REQUEST PARTS ON LINE... -
Page 20: Ｍａｉｎ Components And Part Names
www.AirmanArizona.com REQUEST PARTS ON LINE 2. Names of Components 2.2 Main Components and Part Names SDG25S H990172 SDG45S/60S H990173 ①Control panel ⑨Fuel air-bleeding electromagnetic pump ②Voltage selector switch ⑩Engine oil filter ③ Battery ⑪Fuel filter ④Engine oil dipstick ⑫Sedimenter ⑤Air filter ⑬Engine oil filler... - Page 21 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
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Page 22: Instrument Panel
www.AirmanArizona.com REQUEST PARTS ON LINE 2. Names of Components 2.3 Instrument Panel A010119 ⑨Hour meter ①Voltmeter ⑩Starter switch ②Ammeter ③Illumination lamp ⑪Glow lamp ④Frequency meter ⑫Warning lamp for charging ⑤Warning lamp for high coolant temp ⑬Engine running lamp ⑥Warning lamp for low engine oil pressure ⑭Three-phase breaker ⑦Warning lamp for overspeed ⑮Ammeter change-over switch... -
Page 23: Warning And Emergency Display
www.AirmanArizona.com REQUEST PARTS ON LINE 2. Names of Components 2.4 Warning and Emergency Display Warning and Emergency Display When a warning lamp turns on, stop the machine immediately and take appropriate measures to find the cause. Item Trouble Measures Reference * Engine oil Lamp turns on when the engine oil... -
Page 24: Gfci (Ground-Fault Circuit Interrupter) Receptacles
www.AirmanArizona.com REQUEST PARTS ON LINE 2. Names of Components 2.5 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. -
Page 25: Transportation
www.AirmanArizona.com REQUEST PARTS ON LINE 3. Transportation Use the lifting bail in the center of bonnet for hoisting the machine. When towing or transporting the machine from a job site, securely fix it with tie-downs. Only qualified personnel should operate a crane. If machine is towed with trailer, reduce travelling speed to a safe level. -
Page 26: Installation
www.AirmanArizona.com REQUEST PARTS ON LINE 4. Installation 4.1 Place and Conditions of Unit Installation Ventilation Exhaust gas from the engine is poisonous, and could cause death when inhaled. Avoid using the machine in an insufficiently ventilated building or tunnel. PC002 Installation The machine must be installed on dry, firm and level... -
Page 27: Selecting Cable
www.AirmanArizona.com REQUEST PARTS ON LINE 4. Installation 4.2 Selecting Cable Select a cable with sufficient diameter by considering the maximum current to be used. The distance from the generator to the load is also a determining factor. If the current flowing to the load exceeds the maximum current of the cable, resultant overheating may burn the cable. - Page 28 www.AirmanArizona.com REQUEST PARTS ON LINE 4. Installation 4.3.1 Proper Connection of Three-phase Four-wire Type Terminal Never use voltage selector switch during operation. During operation, do not operate voltage selector switch. Voltage selection during operation may cause abnormal voltage on the load side to damage the load and may cause a fire.
- Page 29 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
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Page 30: Grounding Method
4.4.3 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. -
Page 31: Operation
www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.1 Check before Starting the Unit Check before starting the unit Be sure to check the unit before operation. If any abnormality is found, be sure to repair it before starting the unit. Make sure daily checks are done before operation. - Page 32 www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation SDG75S/100S H990339 ①Check clogging of air filter element. ⑥Check fuel. ②Check engine oil level. ⑦Drain fuel tank. ③Check V-belt tension. Check wiring of each part. ④Check coolant level. ⑤Check condensation in water sedimenter. 5.1.2 Check Engine Oil Level Unit should be on level ground before checking oil level.
- Page 33 www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.1.3 Check Coolant Level Taking off the radiator cap Be sure to stop the machine and allow time to cool. Loosen the radiator cap one notch. After the coolant water is sufficiently cooled and the inner pressure is released, slowly remove the cap.
- Page 34 www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.1.5 Drain Fuel Tank Open drain valve at the bottom of the fuel tank to discharge condensation left in the tank. With condensation completely drained, firmly close the drain valve. Dispose properly according designated regulations.
- Page 35 www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.1.7 Check Clogging of Air Filter Element Be sure to properly clean air filter element When an element is clogged or damaged, dust or foreign material will contaminate the engine. This will cause accelerated wear in each sliding part of the engine. Daily checking or cleaning is required to ensure engine long life.
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Page 36: Unit Operation
www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.2 Unit Operation Keep the door shut and locked when machine is in operation. If opening the door is necessary, be careful not to touch rotating or hot parts. Burns or serious injury could result. - Page 37 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
- Page 38 www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation Engine starting time chart A010137 A010138 If the engine will not start even after you have tried to crank the engine three times, it stops starting. In the case, switching off the starter switch, locate such cause of disorder as (shortage of fuel or faulty cable connection etc.) and correct it.
- Page 39 www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.2.2 Meter and Indicator Lights while Operating During normal operation, each indication of instruments is shown in the table below. Refer to the table for daily checks. Note; The values marked ※ vary with location of the voltage selector switch. Warning Lamp Display Lamp Frequenc...
- Page 40 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
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Page 41: Adjustment Of Frequency
www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.5 Adjustment of frequency When it is necessary to adjust frequency during operation, take the following steps. (Procedure) ① Loosen the locknut of the engine governor adjusting bolt. ② Watching the frequency meter, adjust the frequency to the value mentioned in 5.2.2 by turning the adjusting bolt. -
Page 42: Emergency Stop
www.AirmanArizona.com REQUEST PARTS ON LINE 5. Operation 5.6 Emergency Stop The Emergency Stop button should be used only for emergency stop. Regularly check the operating performance. If it is necessary to stop the generator for emergency, press the Emergency Stop button . -
Page 43: Periodic Inspection And Maintenance
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.1 Important Items at Periodic Inspection and Maintenance or after Maintenance The manual shows proper intervals for periodic inspection and maintenance under normal operating conditions. Inspection and maintenance should be performed more often under extremely harsh conditions. -
Page 44: Daily Inspection And Keeping Operation Log
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.2 Daily Inspection and Keeping Operation Log Carry out daily inspection every morning before operation. See Chapter 5 "Operation" of the manual for details of inspection. Pay attention to and carefully observe the following points during daily operation or inspection and maintenance work. - Page 45 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
- Page 46 www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance SDG75S/100S H990340 Clean and change air filter element. Check battery. ① ⑤ Change engine oil. Change engine oil filter ② ⑥ Change fuel filter. Change coolant. ③ ⑦ ④ Change filter of fuel air-bleed Clean inside and outside of radiator.
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Page 47: First Maintenance At Initial 50 Hours
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.4 First Maintenance at Initial 50 Hours 6.4.1 Change Engine Oil (At 50 hours for the first change and every 250 hours thereafter) Refilling or draining engine oil After stopping the engine, be sure to wait 10 to 20 minutes until the engine oil cools down. - Page 48 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
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Page 49: Maintenance Every 250 Hours
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.5 Maintenance Every 250 Hours 6.5.1 Change Engine Oil Follow the same procedure for changing engine oil as mentioned in 6.4.1. 6.5.2 Check Insulation Resistance When the generator has not been operated for a long time or moisture has entered inside the machine, be sure to measure the insulation resistance. - Page 50 www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.5.3 Check GFCI Receptacles Check GFCI receptacles monthly or 250 hours operation, whichever comes first. If the generator is stored outdoors, unprotected from the weather, test the GFCI receptacle before each use. In case the GFCI has tripped due to the hazard of ground fault currents, investigate the cause and correct it.
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Page 51: Maintenance Every 300 Hours
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.6 Maintenance Every 300 Hours 6.6.1 Check Battery Handling battery Keep flames away from the battery. Batteries may generate hydrogen gas and may explode. Therefore, recharging should done well-ventilated place. Do not allow sparks, lighted match, or lit cigarette close to the battery. -
Page 52: Maintenance Every 500 Hours
Even before 500 hours, if the indicator for air filter shows RED, take the element out, check and clean it, or replace it with new one if it can not be serviced. Element Part No.: AIRMAN genuine SG0132 SDG25S 32143... -
Page 53: Maintenance Every 600 Hours
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.7.4 Change Filter of Fuel Air-bleeding Electromagnetic Pump (SDG45S /60S ) Turn the cap counterclockwise to remove it, change the filter inside. As the fuel inside spills out when it is removed, Filter prepare a container to catch fuel. -
Page 54: Maintenance Every 1000 Hours
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.9 Maintenance Every 1000 Hours 6.9.1 Change Coolant Taking off the radiator cap Be sure to stop the machine and allow time to cool. Loosen the radiator cap one notch. After the coolant water is sufficiently cooled and the inner pressure is released, remove the cap. - Page 55 www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance (Procedure) Radiator cap Radiator ① To drain coolant, prepare a drain pan, remove the radiator cap, then loosen the drain plug. ② Be sure to also unfasten the drain plug on the engine cylinder block for drainage. ③ When the coolant is completely drained out, close each drain plug, and supply new coolant into the radiator filler port.
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Page 56: Maintenance Every 2000 Hours
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.10 Maintenance Every 2000 Hours 6.10.1 Clean Inside the Radiator When the inside of radiator and water pipings of an engine are dirty with scale and rust, its cooling efficiency will drop. Clean the cooling system periodically. Ask you nearest dealer for cooling system cleaning. -
Page 57: Periodic Inspection List
www.AirmanArizona.com REQUEST PARTS ON LINE 6. Periodic Inspection/Maintenance 6.11 Periodic Inspection List ● means change △ means check/clean Every Every Every Every Every Every Maintenance Daily 50 hrs 250 hrs 300 hrs 500 hrs 600 hrs 1,000 hrs 2,000 hrs △... -
Page 58: Maintenance/Adjustment
www.AirmanArizona.com REQUEST PARTS ON LINE 7. Maintenance/Adjustment 7.1 Automatic Shut-Down System 7.1.1 Location of Switches Engine oil pressure switch Coolant temperature switch Ask your nearest dealer for checking the performance or changing each switch. SG0135 7.2 Maintenance of Battery 7.2.1 Measure Specific Gravity (Applicable to standard battery) When the fluid level is found below the lower limit without a trace of electrolyte leakage, refill with distilled water so the level will be between upper... -
Page 59: Adjusting Controller For Automatic Starting
www.AirmanArizona.com REQUEST PARTS ON LINE 7. Maintenance/Adjustment 7.2.3 How to Use Jumper Cables Do not connect the cable reversely If a jumper cables has to be used or when cables are connected at battery replacement, be careful not to connect (+) and (−) terminals backwards. Such a miss-connection will causes a spark or damage to each component. -
Page 60: Troubleshooting
www.AirmanArizona.com REQUEST PARTS ON LINE 7. Maintenance/Adjustment 7.4 Troubleshooting Should any trouble occur during operation, do not disregard the trouble. Investigate the cause and take appropriate measures. Read the manual carefully and fully understand what to do in case of trouble. The more you understand about the construction and function of the unit, the faster you can find a cause and solution to the problem. - Page 61 www.AirmanArizona.com REQUEST PARTS ON LINE 7. Maintenance/Adjustment Symptom Cause Countermeasures Even when operated Faulty voltmeter Check/change at rated speed, no Poor tightening of terminals Check/tighten voltage or low Broken or short-circuited winding of Check/repair voltage generated. generator main unit Faulty (Automatic Voltage Check/change...
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Page 62: Storage Of The Unit
www.AirmanArizona.com REQUEST PARTS ON LINE 8. Storage of the Unit 8.1 Preparation for Long-term Storage When the unit is to be unused in storage for a long time, be sure to follow the preparations below and store the unit in a dry and clean area. (1) Temporarily cover the unit if it is stored outside. - Page 63 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
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Page 64: Specifications
www.AirmanArizona.com REQUEST PARTS ON LINE 9. Specifications SDG45S Overall length in.(mm) 83(2,100) Exciting system Brushless system Overall width in.(mm) 33(830) Phase number Three-phase, four-wire system Overall height in.(mm) 47(1,185) Power factor Net dry ｍass lb(kg) 2,400(1,090) Frequency Operating ｍass lb(kg) 2,670(1,210) Rated output Fuel tank capacity... - Page 65 www.AirmanArizona.com REQUEST PARTS ON LINE www.AirmanArizona.com REQUEST PARTS ON LINE...
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- Page 67 www.AirmanArizona.com REQUEST PARTS ON LINE 9. Specifications SDG100S Overall length in.(mm) 109(2,760) Exciting system Brushless system Overall width in.(mm) 39(1,000) Phase number Three-phase, four-wire system Overall height in.(mm) 55(1,400) Power factor Net dry ｍass lb(kg) 3,815(1,730) Frequency Operating ｍass lb(kg) 4,300(1,950) Rated output Fuel tank capacity...
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Page 68: Wiring Diagram
www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram 10.1 Generator Wiring Diagram SDG25S Molded case circuit breaker (three-phase) Molded case circuit breaker MCB1〜4 (single-phase) Shunt coil Ammeter Voltmeter Frequency meter Illumination lamp Current transformer Thermal relay Automatic voltage regulator Hand trimmer (voltage regulator) Ammeter change-over switch A040196 www.AirmanArizona.com... - Page 69 www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram SDG45S/60S Molded case circuit breaker (three-phase) Molded case circuit breaker MCB1〜5 (single-phase) Shunt coil Ammeter Voltmeter Frequency meter Illumination lamp Current transformer Thermal relay Automatic voltage regulator Hand trimmer (voltage regulator) Ammeter change-over switch A0300005 www.AirmanArizona.com REQUEST PARTS ON LINE...
- Page 70 www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram SDG75S/100S Molded case circuit breaker (three-phase) Molded case circuit breaker MCB1〜5 (single-phase) Shunt coil Ammeter Voltmeter Frequency meter Illumination lamp Current transformer Thermal relay Automatic voltage regulator Hand trimmer (voltage regulator) Ammeter change-over switch A020249 www.AirmanArizona.com REQUEST PARTS ON LINE...
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Page 71: Engine Wiring Diagram
www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram 10.2 Engine Wiring Diagram SDG25S A040197 www.AirmanArizona.com REQUEST PARTS ON LINE 10-4... - Page 72 www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram SDG45S A030350 www.AirmanArizona.com REQUEST PARTS ON LINE 10-5...
- Page 73 www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram SDG60S A030351 www.AirmanArizona.com REQUEST PARTS ON LINE 10-6...
- Page 74 www.AirmanArizona.com REQUEST PARTS ON LINE 10. Wiring Diagram SDG75S/100S A0300004 www.AirmanArizona.com REQUEST PARTS ON LINE 10-7...
- Page 75 REQUEST PARTS ON LINE ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. 12TH FLOOR SHINJUKU SAN‑EI BLDG, 22‑2 NISHI‑SHINJUKU 1‑CHOME,SHINJUKU‑KU TOKYO 160‑0023 JAPAN TEL:TOKYO 813(3348)7281 FAX:TOKYO 813(3348)7289 URL:http//www.airman.co.jp 39600 53520 PRINTED IN JAPAN 2004. 4 www.AirmanArizona.com REQUEST PARTS ON LINE...
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