AirMan SG Series Instruction Manual
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AirMan SG Series Instruction Manual

Engine generator
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  • Page 1 www.discount-equipment.com...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,...
  • Page 3 Preface Thank you for choosing “AIRMAN”  Keep this manual at hand and refer to it as necessary.  If this manual is missing or damaged, order a new copy from our office or your nearest dealer. Make sure that the manual is included with the machine when it is handed over to another user.

  • Page 4: Table Of Contents

    Table of Contents 1. Major Components ----------------------------------------------------------------------------- 1-1 Internal Components --------------------------------------------------------------------------------------------- 1- 1 2. Transportation and Installation ------------------------------------------------------------- 2-1 Transporting Machine -------------------------------------------------------------------------------------------- 2- 1 Conditions of Installation ---------------------------------------------------------------------------------------- 2- 2 Grounding ----------------------------------------------------------------------------------------------------------- 2- 5 Selecting Cable ---------------------------------------------------------------------------------------------------- 2- 8 Fuel Pipe Selector Valve ---------------------------------------------------------------------------------------- 2- 9 3.
  • Page 5 Safety This section explains safety precautions for operation, inspection, maintenance, installation, movement and transportation. Read these safety requirements carefully and fully understand the contents before starting the machine. For better understanding of the precautions in this manual and on this machine, safety precautions are classified into “DANGER”, “WARNING”...
  • Page 6 Safety ◆ If you have any questions about the machine, please contact our office or your nearest dealer. Be sure to have your machine’s serial number to assist in providing the correct information for you. A plate stamped with the model and serial number is attached to side of the machine. ※...
  • Page 7 Safety [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.
  • Page 8 Safety  The locations of the safety warning labels are as follows. VIEW A A180753-1...
  • Page 9 Safety  Never touch the control panel during operation. Be aware that a voltage of several hundred volts is applied to the control panel.  Be sure to stop the engine and turn control power switch OFF whenever the control panel has to be checked or operated. Disconnect the negative battery terminal during checking and maintenance.
  • Page 10 Safety  Be sure to stop the engine and let the coolant water sufficiently cool down before draining it.  If the drain valve is opened before the coolant water is cool enough, hot water could jet out, causing burns or scalding. H990432 ...

  • Page 11: Major Components

    1. Major Components 1.1 Internal Components 15 14 A180755 Description Function Control Panel Controlling device; various meters and controls. Alternator Generating AC power to be supplied. Output terminals Outlet port for AC power. Air Filter Filtering dust from intake air. Engine Driving the generator.

  • Page 12: Transportation And Installation

    2. Transportation and Installation 2.1 Transporting Machine When loading and unloading machine, be sure to use the lifting bail provided on the center of the machine top. 2.1.1 Lifting <Procedure> 1. Before lifting the unit up, make sure to check the lifting bail [A] for any cracks or loosened bolts.

  • Page 13: Conditions Of Installation

    2. Transportation and Installation 2.2 Conditions of Installation The machine has to be installed on a dry, firm, and level area.  The machine should be operated in the following conditions: Ambient temp: -5°F to 104°F (-15°C to 40°C)  Humidity: Less than 85% ...
  • Page 14 2. Transportation and Installation  Never locate the unit with the exhaust muffler facing ○ any private house.  As the exhaust gas from the engine is poisonous, never direct it to any other persons passing by. × Private house A050505 In case that the machine is installed indoors ...
  • Page 15 2. Transportation and Installation  The unit should be installed within 5 ﾟ degree inclination.  If installation site is not flat, put square bar under the unit so as to install it horizontally.  Avoid installing the unit in a damp place or a place where water collects.

  • Page 16: Grounding

    Load Grounding Rod Grounding Rod A180758 2.3.2 Grounding 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 (N) is connected to the system ground.
  • Page 17 2. Transportation and Installation 2.3.3 GFCI Receptacles  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.
  • Page 18 2. Transportation and Installation 2.3.4 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.

  • Page 19: Selecting Cable

    2. Transportation and Installation 2.4 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.

  • Page 20: Fuel Pipe Selector Valve

    2. Transportation and Installation 2.5 Fuel Pipe Selector Valve 2.5.1 Overview This valve is designed to feed fuel directly from an external fuel tank or from the installed fuel tank as described below. 2.5.2 Operation method <Procedure> 1. Machine is delivered from factory with fuel line piping and selector valves built in as shown in the following Fig.1.
  • Page 21 2. Transportation and Installation  Always keep watching the fuel feeding conditions while feeding fuel from the external fuel storage tank.  Make sure to change the handles of the selector valves to the predetermined positions. If you make a mistake in turning the handles, it can burst the fuel pipe and cause overflowing.

  • Page 22: Operation

    3. Operation 3.1 Control Panel A180744E 1. Voltmeter 10. Single-phase circuit breaker 2. Monitor lamp (for details, See 4.1.1) 11. Current selector 3. Water temperature gauge 12. Voltage regulator 4. Fuelmeter with hourmeter 13. Starter switch 5. Voltmeter 14. Engine Speed selector switch 6.

  • Page 23: Simultaneous Usage Of Three-Phase And Single-Phase Power

    3. Operation 3.2 Simultaneous usage of three-phase and single-phase power This generator is capable of simultaneously outputting three-phase and single-phase power with no need to switch output settings. [3Φ, 4 wire and 1Φ, 3 wire setup for simultaneous use]  Make sure that the combined three-phase and single-phase output does not exceed the total allowable current for the unit (see sample table below).

  • Page 24: Connecting Loads

    3. Operation 3.3 Connecting Loads Select a cable with sufficient diameter by considering the load capacity and the distance from the generator to the load. Use terminals for connection and securely fasten them. (See 2.4)  After checking phase number and voltage of the load, Single-phase output terminal make sure to connect them correctly.
  • Page 25 3. Operation 3.3.1 Auxiliary AC Power AUX. RECEPTACLES GFCI RECEPTACLES BREAKER BREAKER CON1 CON2 CON3 GFCI RECEPTACLES. AUX.RECECTACLES A180748 120V 20AMPS 240/120V 30AMPS 120V 120V 240V 120V A040270 A040271 <How to use GFCI Receptacles> <How to use aux. receptacles> 1Φ/120V power from GFCI receptacles is 1Φ...
  • Page 26 3. Operation 3.3.2 Connecting a single-phase load (1Φ, 3 wire / receptacles) The table below shows the maximum load for each output terminal. A180778E  The maximum rated output (kVA) of each terminal/receptacle is shown in the table below. Be sure not to connect loads exceeding the maximum rated output.

  • Page 27: Engine Oil･Coolant･Fuel

    3. Operation 3.4 Engine Oil・Coolant・Fuel 3.4.1 Engine Oil Use engine oil recommended below. Be sure to use CF class or higher engine oil or superior class. (Using engine oil with poor quality may shorten the life of the engine). Classification API service classification CF class or higher...
  • Page 28 3. Operation 3.4.2 Coolant Coolant freezing could cause cracks of cylinder and radiator. Be sure to always use mixture of LLC (antifreeze) and soft water (like tap water) of good quality.  When water with dirt, sand, or dust, or hard water such as well water (ground water) is used, deposits can form inside the radiator or on the cylinder head and resulting in engine overheat from poor coolant flow.

  • Page 29: Before Starting The Unit

    3. Operation 3.5 Before Starting the Unit Be sure to check the unit before operation. When any abnormality is found, be sure to repair it before starting. Be sure to make daily check before operation. If the unit is operated without prior check and without noticing its abnormality, such operation could cause seizure of components or may even cause fire.
  • Page 30 3. Operation 3.5.2 Check Coolant Level  Check the coolant level in the surge tank. If it is lower than the limit, open the cap and refill the coolant. (Level must be kept above LOW.)  If the coolant in the surge tank is exceedingly low or empty, remove the radiator cap and check the amount of coolant in the radiator.
  • Page 31 3. Operation 3.5.3 Check Fuel Before starting operation, make sure to check the level of residual fuel so that fuel shortage during operation can be avoided. If necessary, drain condensate accumulated at the bottom of the fuel tank.  Refilling fuel tank should be done in an outdoor well-ventilated place. ...
  • Page 32 3. Operation 3.5.5 Check Oil Fence Drain Drain port in oil fence is provided on the side of oil fence.  Open drain valve [A] to drain out the condensate in the oil fence.  After making sure that all condensate is completely drained out, close drain valve.
  • Page 33 3. Operation 3.5.8 Check Belt Tension Adjust the belt by the following procedure: Unfasten the mounting bolts of the alternator to adjust the alternator belt. <Procedure> 1. Visually check there are no cracks or wear or other Press the center damage to the belt.
  • Page 34 3. Operation 3.5.9 Check Thermo Label of Alternator Thermo-label on the stator irreversibly changes its color from white to brown by reaching or exceeding 212°F ( 100℃), that signalize overload during operation. Do not overload the generator.  Remove the trash and dust from the generator inside by compressed air blowing.

  • Page 35: Operating Procedure

    3. Operation 3.6 Operating Procedure Make sure that all enclosure doors are closed before starting. 3.6.1 Operating Procedure To start, please follow the procedure below. <Engine starts> 1. Make sure that Three-phase circuit breaker [A] and Single-phase circuit breaker [B] are [OFF].
  • Page 36 3. Operation <Check frequency and voltage> 1. After finishing warming up operation, check and confirm frequency meter [F]. 2. While watching the voltmeter [G], turn the voltage adjuster [H] knob to set the voltage to the rated. (See 3.6.2) 3. The power indicator light [I] is lighted green during operation. <Operation with Load>...
  • Page 37 3. Operation  Be sure to check at times to see if gauges or each component of the machine are properly working, or if there is 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.
  • Page 38 3. Operation 3.6.3 Panel light  The control panel is equipped with an LED light. Turn the panel light switch [ON] to use.  When illumination is not necessary, turn the light [OFF]. If the machine is always operated with the lamp switched [ON], the lamp life can be reduced.

  • Page 39: Emergency Stop

    3. Operation 3.7 Emergency Stop 3.7.1 Emergency stopping procedures  If it is necessary to stop the generator for emergency, press the Emergency Stop button located under the control panel. When shutting down with the emergency stop button, the machine will stop immediately.

  • Page 40: Failure And Troubleshooting

    4. Failure and Troubleshooting 4.1 Protection device To prevent issues during operation, this machine is equipped with various protection devices. 4.1.1 List of protection devices This machine is equipped with the following devices in the table. Repair and make necessary treatment in accordance with the item ○. Circuit Warning Abnormality...
  • Page 41 4. Failure and Troubleshooting 4.1.2 Emergency stop function  This unit is equipped with the following protection devices. According to the kinds of trouble, the glow/trouble indicator lamp indicates each trouble by the pattern of flickering and also functions to stop engine in emergency.
  • Page 42 4. Failure and Troubleshooting 4.1.3 Circuit Breaker  In case of an overload or short-circuited wire connection, the circuit-breaker trips.  When the breaker is tripped, stop the machine immediately and reset the circuit breaker after resolving the cause of the trouble. <How to reset>...

  • Page 43: Troubleshooting

    4. Failure and Troubleshooting 4.2 Troubleshooting Should any trouble occur during operation, do not leave it. Investigate the cause and take appropriate measures. Read the manual carefully and fully understand what to do in case of trouble.  The better you understand the construction and function of the machine, the faster you can find a problem and solution.
  • Page 44 4. Failure and Troubleshooting Symptom Cause Counter measures (1) The condensate (fuel, engine oil and Drain the condensate Oil fence monitor coolant) is accumulated in the oil fence. lamp glows. (2) The liquid surface level detecting switch Check/change does not function good. Circuit breaker (1) Overloaded Reduce the load...
  • Page 45 4. Failure and Troubleshooting 4.2.2 Engine body In case engine trouble occurs, refer below table and do appropriate check and maintainance. Phenomenon Cause Treatment method (1)Check fuel tank and remove impurities and water (1)Fuel would not flow (2)Check fuel filter and replace it if it is dirty (1)Check pipe and tightening band and replace it with new one or...

  • Page 46: Periodic Inspection

    5. Periodic Inspection 5.1 Important Items at Periodic Inspection and Maintenance The following table shows the inspection and maintenance intervals under normal operation conditions. When used or operated under hard environmental conditions, it is impossible to warrant the machine even if the above conditions are performed according to the intervals listed in the above table.

  • Page 47: Maintenance Schedule

    5. Periodic Inspection 5.2 Maintenance Schedule Such items marked ○ shall be carried out by customers. For the following items or clauses marked ●, contact your nearest dealer because they require expert technical knowledge on them. The following table shows the intervals of inspection and maintenance under normal operation conditions.

  • Page 48: Periodic Replacement Parts

    5. Periodic Inspection Every Every Every Maintenance Remarks 1,000hours 1,500hours 3,000hours Check engine valve clearance. ● Please contact nearby Adjust fuel injection nozzle ● distributor or engine distributor for inspection Check of turbocharger ● and maintenance. Check fuel injection timing ●...

  • Page 49: Maintenance Items

    5. Periodic Inspection 5.4 Maintenance Items 5.4.1 Change Engine Oil (Change the engine oil filter at the same time) At 50 hours for the first change and every 250 hours thereafter When checking, replenishing, and draining the engine oil, be sure to wait more than 10 minutes after engine stops to allow it to cool down.
  • Page 50 5. Periodic Inspection 5.4.2 Change Engine Oil Filter Element At 50 hours for the first change and every 250 hours thereafter <Procedure> 1. Take out the oil filter element [A] using a filter wrench. 2. After coating fuel on the new oil filter element packing [B], screw it in.
  • Page 51 5. Periodic Inspection 5.4.4 Maintenance of Battery Battery may generate hydrogen gas and may explode. Therefore, recharging should be done at a well-ventilated place.  Do not check the battery by short-circuiting the positive and negative terminals with a metallic piece.
  • Page 52 5. Periodic Inspection [How to use booster cable] <Procedure> To engine block 1. Stop the engine. 2. Connect one end of the (+) booster cable to the (+) Booster Booster cable (+) terminal of the machine battery. cable (-) 3. Connect the other end of the (+) booster cable to the (+) terminal of the external battery.
  • Page 53 5. Periodic Inspection 5.4.6 Check Accumulations in Exhaust System Every 250 Hours When a diesel engine driven generator is continuously operated with less than 30% load or no load for a long time, carbon will be stuck inside the exhaust pipes, exhaust muffler, and engine body. Unburned fuel may also come out from connected portions of exhaust pipe and outlet port of the exhaust muffler.
  • Page 54 5. Periodic Inspection 5.4.8 Check Insulation Resistance Every 2 months or 250 Hours <Procedure> 1. Remove the load side cable from the output terminal board. 2. Remove the connector [A] inside the generator control panel. 3. Remove the 3 lead wires [B] from the lower side of the terminal block in the control panel.
  • Page 55 5. Periodic Inspection 5.4.9 Check Thermo-Label on the Generator Every 2 months or 250 Hours Thermo-label on the rotor bearing irreversibly changes its color from white to blue by reaching or exceeding 176°F (80°C). Be sure to check the bearing for abnormal noise and vibration if it has changed color.
  • Page 56 5. Periodic Inspection 5.4.12 Clean outside of Radiator Every 500 Hours  When the fin tubes [A] of radiator are clogged by dust or other foreign materials, the heat exchange efficiency drops and this will raise coolant temperature. These tubes and fins should be cleaned depending on the state of dirt inside the tubes even before maintenance schedule.
  • Page 57 5. Periodic Inspection 5.4.14 Check Exhaust Flexible Pipe Every 4 months or 500 Hours  Check the flexible pipe between the exhaust muffler Exhaust flexible pipe and engine exhaust outlet for cracks and exhaust gas Crack leakage  If any leak is found, avoid getting burned by the exhaust gas.
  • Page 58 5. Periodic Inspection 5.4.16 Check Engine/Generator Mount Every year or 1,000 Hours  The vibration isolation rubbers [A] are used for the support of generator and engine. Check the rubber for any damage or deterioration due to oil sticking. A170106 5.4.17 Check Each Rubber Hose Every year or 1,000 Hours...
  • Page 59 5. Periodic Inspection 5.4.20 Change Coolant Every 2 years When removing the radiator cap, be sure to stop the machine and wait until the coolant cools down. <Procedure> 1. To drain coolant, remove the radiator cap [A], then loosen the drain valve [B]. 2.

  • Page 60: Storage And Disposal

    6. Storage and Disposal 6.1 Preparation for Long-term Storage When the machine is left unused or not operated longer than half a year (6 months), store it in a dry place free of dust after the following treatments have been done to it. ...

  • Page 61: Specifications

    7. Specifications 7.1 Specifications Model SDG13LAX-8E1 Exciting system Brushless Frequency Rated Output kVA (kW) 12.5 (10.0) Voltage 3 phase 4 wire Power Factor Amps Rated Output kVA (kW) Voltage 120-240 Single-phase 3 wire Power Factor Amps Model KUBOTA D1503-M-E4 Type 4-cycle, water-cooled, swirl chamber type No.

  • Page 62: Outline Drawing

    7. Specifications 7.2 Outline drawing [Unit : in.] A180764E...
  • Page 63 7. Specifications [Unit : mm] A180764E...

  • Page 64: Generator Wiring Diagram

    7. Specifications 7.3 Generator Wiring Diagram A180765E...

  • Page 65: Engine Wiring Diagram

    7. Specifications 7.4 Engine Wiring Diagram A180766E...

  • Page 66: Piping Diagram

    7. Specifications 7.5 Piping Diagram A180920E...
  • Page 68 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,...
  • Page 69 Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 70 ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. Copyright(C)2019 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved. 39600 02640 Printed AUG.2019 AIRMAN HOKUETSU INDUSTRIES CO., LTD.

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