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AirMan SDG40S-8B1 Instruction Manual

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  • Page 1 ---> <--- www.discount-equipment.com...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak,...
  • Page 3 Preface 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.

  • Page 4: Table Of Contents

    Table of Contents 1. Safety ........................... 1-1 Caution before Operation ........................1-2 Caution during Operation ........................1-4 Caution during Inspection and Maintenance ...................1-6 Safety Warning Labels ........................1-8 2. Part Names ........................2-1 Internal Components........................2-1 3. Installation ........................3-1 Transporting Unit ...........................3-1 Conditions of Unit Installation ......................3-1 Grounding Method ..........................3-4 Selecting Cable ..........................3-7 Selector Valve of Fuel Pipe......................3-8...

  • Page 5: Safety

    1.Safety 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...

  • Page 6: Caution Before Operation

    1.Safety Caution before Operation Follow the safety instructions  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.
  • Page 7 1.Safety Safety outfit  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.

  • Page 8: Caution During Operation

    1.Safety 1.2 Caution during Operation Never touch the output terminals and interior of control board  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.
  • Page 9 1.Safety Do not touch hot parts  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, ...

  • Page 10: Caution During Inspection And Maintenance

    1.Safety Caution during Inspection and Maintenance Hang a “Now Checking and under Maintenance” tag  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.
  • Page 11 1.Safety Lighting apparatus  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.

  • Page 12: Safety Warning Labels

    1.Safety 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.
  • Page 13 1.Safety  The pasting position of safe warning label is as follows.

  • Page 14: Part Names

    2. Part Names 2.1 Internal Components A100416 SDG40S-8B1 Description Function Control panel For intensively controlling device of various meters and controls. Voltage selector switch For selecting output voltage. Equipped with three phase and single-phase terminal and Output terminals receptacle for single phase.

  • Page 15: Installation

    3. Installation Transporting Unit Transportation  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. ...
  • Page 16 3. Installation Installing the unit st such poorly-ventilated place  In case that the unit is installed inside any tunnel, make sure to provide fresh air and Exhaust fume Suction air is fed ventilate it. extension pipe by air blower. ...
  • Page 17 3. Installation  The machine should be operated in following conditions: Ambient temperature 5°F to 104°F( -15℃～＋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.

  • Page 18: Grounding Method

    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.
  • Page 19 3. Installation 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.
  • Page 20 3. Installation Grounding method Machine grounding terminal Load equipment Grounding rod Grounding rod A040174-1...

  • Page 21: Selecting Cable

    3. Installation 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 22: Selector Valve Of Fuel Pipe

    3. Installation Selector valve of fuel pipe  Always keep watching the fuel feeding conditions while feeding fuel from a separate fuel storage tank separately installed.  In order to use a separator fuel storage tank, be sure to change the handles of the selector valves to a predetermined position.

  • Page 23: Operation

    4. Operation 4.1 Instrument panel A100408 1. Monitor lamp (for details, see 4.2.1) 10. Manual-automatic change-over switch 2. Tachometer with hourmeter 11. Engine speed switch 3. Fuel gauge 12. Engine oil pressure gauge 4. Frequency meter 13. Coolant temperature gauge 5.

  • Page 24: Protection Device

    4. Operation 4.2 Protection device  For prevention of troubles during operation, this machine is provided with various protection devices. When the engine stops due to function of the protection devices and circuit breaker trips, get rid of the causes of trouble, referring to the trouble shooting clause and then restart operation. List of protection devices 4.2.1 ...
  • Page 25 4. Operation 4.2.2 Three-phase circuit-breaker  In case overload and short-circuited wire connection should occur, the circuit-breaker trips.  When this is tripped, stop the unit immediately and reset the circuit breaker after getting rid of the causes of trouble. ＜How to reset＞...
  • Page 26 4. Operation 4.2.4 Circuit protector (CP) for AVR protection AVR is equipped with circuit-protector (CP) for protection against overcurrent. Under the following cases, it happens to function.  In case the machine gets overloaded while engine speed is still lower. ...

  • Page 27: Connecting Load

    4. Operation 4.3 Connecting Load Electric shock and electric leak  Make sure not to connect the output terminal of the machine with the commercial power source from electric power company. It may cause an electric shock, machine troubles and even a fire. ...
  • Page 28 4. Operation  Install a switch between the output terminal and the Switch panel for switching on/off load load to switch on/off the load. Do not switch the load on/off directly by the circuit-breaker of the generator. It could cause damage to the circuit-breaker. ...
  • Page 29 4. Operation 4.3.2 Auxiliary AC Power GFCI RECEPTACLES BREAKER AUX. RECEPTACLES BREAKER Auxiliary AC Power will be available independently of Auxiliary AC Power the position of will be available only voltage selector when voltage switch. selector switch turned to 240/120V. A100414 GFCI RECEPTACLES AUX.RECECTACLES...

  • Page 30: Engine Oil・Coolant・Fuel

    (main terminals and receptacles) for both single or three phase settings. Values shown in the left column give the maximum current available at the 120V-20A GFCI receptacles compared to the value of the simultaneous current consumption from the main terminals. SDG40S-8B1 SDG45S-8B2 Single Phase...
  • Page 31 4. Operation 4.4.2 Coolant Quality of coolant and antifreeze  Use soft water of good quality such as tap water for coolant.  When water with dirt, sand, and/or dust contained, or hard water such as well water (ground water) is used, this will cause deposits inside radiator or on cylinder head, and will cause engine overheat due to poor flow of coolant.

  • Page 32: Check Before Starting The Machine

    4. Operation 4.5 Check before Starting the Machine Check before starting the unit  Be sure to check the machine before operation. When any abnormality is found, be sure to repair it before starting the unit.  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 33 4. Operation 4.5.3 Check fuel  Before starting operation, make sure to check the level of residual fuel so that fuel shortage during operation can be avoided.  Drain condensate accumulated at the bottom of fuel tank whenever necessary. Fire prevention ...
  • Page 34 4. Operation 4.5.6 Check belt tension  If belt tension too tight, it can cause shaft breakage or shorten the life of a bearing. If too loose, the belt may slip and will cause early breakage or damage to the belt. ...

  • Page 35: Unit Operation

    4. Operation 4.6 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.  After the engine starts up, warm up it under unload for approx.
  • Page 36 4. Operation <Automatic operation> Inspection and maintenance prohibited during automatic operation  Never put your hands close to the interior of the machine, because the generator can be started when start signal functions even while the machine is in stop position. ...
  • Page 37 4. Operation 2. Operating procedure ① Start the generator unit under the procedure of manual operation and adjust the frequency and voltage. ② Turn the starter switch to “STOP” position and stop the engine. ③ Turn the circuit breaker of output terminal “ON” after the generator unit stopped when you use the circuit breaker and single phase receptacle on the control panel.
  • Page 38 4. Operation  This machine is so designed for safety that operator may not touch the output terminal during operation. If you open the output terminal cover during operation with three-phase breaker switched “ON”, the three-phase breaker will be “OFF” to cut power supply to the output terminal. When starting operation, make sure that the output terminal cover is closed.

  • Page 39: Stopping Procedures

    4. Operation 4.7 Stopping Procedures <Procedure> ① Switch “OFF” the breaker on the operation panel of the generator. ② After performing cooling down operation about 5 minutes, place the starter switch to the“STOP” position to stop the engine. ③ While the machine is kept unused, keep the operation selector switch placed to the “OFF”position. 4.8 Emergency Stop ...

  • Page 40: Periodic Inspection/Maintenance

    5. Periodic Inspection/Maintenance 5.1 Important Items at Periodic Inspection and Maintenance or after 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 unit even if the above conditions are performed according to the intervals listed in the above table.

  • Page 41: Daily Inspection And Keeping Operation Log

    Use genuine part for replacement.  Part number changes upon modification. For replacement of parts, make sure whether the part number is correct or applicable. Part Number Part Name Quantity SDG40S-8B1 SDG45S-8B2 Air filter element 32143 11700 32143 11800 Engine oil filter 37438 08800 ←...

  • Page 42: Periodic Inspection List

    5. Periodic Inspection/Maintenance 5.4 Periodic Inspection List Such items marked shall be carried out by customers. ○ For the following items or clauses marked ●, contact us directly or our distributors because they require expert technical knowledge on them. The following table shows the intervals of inspection and maintenance under normal operation conditions. Inspection and maintenance should be done at either of the hour or the period mentioned in the remarks column, whichever comes earlier.
  • Page 43 5. Periodic Inspection/Maintenance Daily Every Every Every Every Page Remarks Maintenance 50 hours 250 hours 500 hours 1,000 hours Check condensate in the oil fence 4-12 ○ Check the terminal portion of electrical circuits and cable 5-10 Every 4 months ○...

  • Page 44: Maintenance

    5. Periodic Inspection/Maintenance 5.5 Maintenance 5.5.1 Change engine oil [At 50 hours for the first change and every 500 hours thereafter] Caution in filling or draining engine oil  When checking, replenishing, and draining the engine oil, be sure to wait 10 to 20 minutes after engine stops until it cools down. ...
  • Page 45 5. Periodic Inspection/Maintenance 5.5.2 Change engine oil filter [At 50 hours for the first change and every 500 hours thereafter] <Procedure> ① When installing a new oil filter “ 1” , spread oil over the packing“2”, and then screw it in. When the packing touches the sealing surface, further tighten the filter by approximately two-thirds turn with a filter wrench.
  • Page 46 5. Periodic Inspection/Maintenance 5.5.4 Check Insulation resistance [Every 250 hours]  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. If resistance is lower than 1MΩ, it could cause an electrical leakage or fire.
  • Page 47 5. Periodic Inspection/Maintenance 5.5.6 Check and Clean clogging of air filter element [Every 250 hours] Be sure to properly clean air filter element  W hen an element that is clogged or has holes or cracks is used, dust or foreign material will get in the engine.
  • Page 48 5. Periodic Inspection/Maintenance 5.5.9 Change fuel filter [Every 500 hours] <Procedure> ② Take out the cartridge by using a filter wrench. ③ After coating fuel on the new cartridge“1”packing“2”, screw it in. (For part number, see 5.4) ④ When the packing“2”touches the seal face, tighten it by approximately two-thirds turn using a filter wrench.
  • Page 49 5. Periodic Inspection/Maintenance 5.5.12 Check the terminal portion of electrical circuits and cable connections [Every 4 months or every 500 hours] Check for any looseness on the cables and any damages on insulated covers and disconnection, disconnected cables, or short-circuit etc. [Checking points of electrical circuits on the generator side] ...
  • Page 50 5. Periodic Inspection/Maintenance 5.5.14 Clean inside of the oil fence and check it for any rust [Every 1 years] <Procedure> ① Remove the oil filler cap cover, fuel pipes and electric wire connected to the fuel tank. ② Remove 6 pieces of the bolts connecting oil fence and the machine with the lifting eye hooked with the crane.
  • Page 51 5. Periodic Inspection/Maintenance 5.5.15 Change Coolant [Every 2 years] Upon changing coolant  Be sure to stop the machine and loosen the radiator cap slowly, after the coolant water is sufficiently cooled and the inner pressure is released, then take the cap off. If the following procedures are neglected, the radiator cap could be blown by the internal pressure or hot moisture air be blown out to cause burning.
  • Page 52 5. Periodic Inspection/Maintenance 5.5.17 Check vibration isolator rubbers [Every 1 year or every 1,000 hours]  The vibration isolation rubber “1” is used for the support of generator and engine. Check the rubber for any damage or deterioration due to oil sticking. 5.5.18 Check each rubber hose A080466-2 [Every 1 year or every 1,000 hours]...

  • Page 53: Periodical Load Operation To Be Performed

     Increase the load factor, step by step, paying attention to the exhaust conditions. Also watch the surroundings because sometimes sparks of fire can come out from the exhaust pipe and the like. Type SDG40S-8B1 SDG45S-8B2 Frequency Rated voltage Load current...

  • Page 54: Maintenance/Adjustment

    6. Maintenance/Adjustment 6.1 Maintenance of Battery Handling battery  Keep flames away from battery.  Battery may generate hydrogen gas and may explode.  Therefore, recharging should be done at a well-ventilated place.  Do not spark near the battery nor light a match, nor bring lit cigarette and match close to the battery.
  • Page 55 6. Maintenance/Adjustment 6.1.1 Charge Battery  Disconnect the cable between battery and the unit, and Battery charge the battery with a 12 V battery charger. Do not charge two batteries at the same time.  Be sure not to connect (+) and (–) terminals backwards. ...

  • Page 56: Troubleshooting

    6. Maintenance/Adjustment 6.2 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 unit, the faster you can find a problem and solution.
  • Page 57 6. Maintenance/Adjustment Symptom Cause Counter measures Circuit breaker (1)Overloaded Reduce the load trips. (2)Short-circuit occurred at the load side. Get rid of cause of short-circuiting. Even when (1)Faulty voltmeter Check/change operated at a rated (2)Poor tightening of terminals Check/repair speed, no voltage (3)Broken or short-circuited winding of Check/repair or too low voltage...
  • Page 58 6. Maintenance/Adjustment 6.2.1 Engine trouble  This unit is equipped with a controller which memorizes details of engine troubles. When the engine fails, the diagnosis lamp“1”glows. Diagnosis lamp lighting pattern indicates the states of engine failure and it causes engine to emergency stop.

  • Page 59: Storage Of The Unit

    7. Storage of the Unit 7.1 Preparation for Long-term Storage When the unit is left unused or not operated longer than half a year (6 months), store it at the dry place where no dust exists after the following treatments have been done to it. ...

  • Page 60: Specifications

    8. Specifications Specifications Model SDG40S-8B1 Brushless Exciting system Star with Neutral ZigZag Armature connection Phase number Three Single Power factor Frequency Rated output Rated output 30.4 Voltage 240/120 Current 91.4 45.7 91.4 Model KUBOTA V3300-BG 4-cycle, water-cooled, swirl chamber type...

  • Page 61: Specifications

    8. Specifications Model SDG45S-8B2 Brushless Exciting system Star with Neutral ZigZag Armature connection Phase number Three Single Power factor Frequency Rated output Rated output Voltage 240/120 Current Model KUBOTA V3800DI-T 4-cycle, water-cooled, direct injection, turbo charged Type Number of cylinders Total displacement cu.

  • Page 62: Outline Drawing

    8. Specifications Outline drawing...
  • Page 63 8. Specifications...

  • Page 64: Wiring Diagram

    9. Wiring Diagram Generator Wiring Diagram A100400...

  • Page 65: Engine Wiring Diagram

    9. Wiring Diagram 9.2 Engine Wiring Diagram SDG40S-8B1 A100426...

  • Page 67: Fuel Piping

    10. Piping Diagram 10.1 Fuel piping A100427E 10-1...
  • Page 68 ° °...
  • Page 69 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mayco, Toro/Stone, Diamond Products, Magnum, Airman, Mustang, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand Brothers, Essick, Miller Spreader, Skyjack, Lull, Skytrak,...

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