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AirMan SDG100S-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 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 Part Names .............................. 2-1 Internal Components........................2-1 Installation ............................... 3-1 Transporting Unit ........................... 3-1 Conditions of Unit Installation ......................

  • 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, and radiator are especially hot, so never touch those parts, because it could cause scalding.

  • Page 10: Caution During Inspection And Maintenance

    1.Safety Cautions 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. 9 6 1 6 9 2 Fan shroud A070308 A070307 DETAIL OF INSTRUMENT PANEL SDG150S-8B1...

  • Page 14: Part Names

    2. Part Names 2.1 Internal Components A070314 SDG150S-8B1 Description Function Control panel Panel fitted with various meters and controllers. Voltage selector switch For selecting output voltage. Air filter Filtering device for filtering dust floating in intake air. Engine For driving the generator main unit. Generator main unit For generating AC power to be supplied.
  • Page 15 2. Part Names 15 16 A070315 SDG150S-8B1 Description Function Engine oil filter For filtering engine oil. Reserve tank For feeding cooling water. Engine oil filler port For supplying and replenishing engine oil to engine. Engine oil level gauge Scale for measuring engine oil level. Fuel filter Filtering device for filtering dust mixed in fuel oil.

  • Page 16: 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. 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.

  • Page 17: Conditions Of Unit Installation

    3. Installation Conditions of Unit Installation Ventilation 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.
  • Page 18 3. Installation How to locate the unit 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. ○ Private house ×...
  • Page 19 3. Installation Preparation of safety fences 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 Safety fences around the unit: A050507-1...

  • Page 20: 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 21 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 22 3. Installation Grounding method Machine grounding terminal Load equipment Grounding rod Grounding rod A040174-1...

  • Page 23: 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 24: 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 25: Operation

    4. Operation 4.1 Instrument panel 10 11 12 13 14 A080030 1. Monitor lamp (for details, see 4.2.1) 10. Manual-automatic change-over switch 2. Fuel gauge 11. Frequency adjuster switch 3. Tachometer with hourmeter 12. Engine speed switch 4. Frequency meter 13.

  • Page 26: 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 This machine is equipped with the following devices in the table.
  • Page 27 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＞ In order to reset the lever of circuit-breaker, press A070313 hard the lever downward till the lever sounds...
  • Page 28 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. In case the output voltage of generator is increased Reset higher than the specified voltage.

  • Page 29: 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. Make sure to ground the machine and the load.
  • Page 30 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. Connect the connecting cable to the load so that the output terminals should not touch each other.
  • Page 31 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. GFCI RECEPTACLES AUX.RECECTACLES A040170...
  • Page 32 4. Operation 4.3.3 The Maximum Combined Simultaneous Power Consumption Never exceed the maximum combined simultaneous power consumption. The following chart shows the maximum power available from the 120V-20A GFCI receptacles during simultaneous consumption (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.

  • Page 33: Engine Oil・Coolant・Fuel

    4. Operation 4.4 Engine Oil・Coolant・Fuel 4.4.1 Engine Oil Viscosity of engine oil greatly affects startability, performance, oil consumption of the engine, as well as wear of the moving parts. Choose appropriate oil based upon the table below according to the outside air temperature. Relation between viscosity (SAE) and temperature SAE Viscosity number Temperature...

  • Page 34: 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 35 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. If necessary, drain condensate accumulated at the bottom of the fuel tank. Fire prevention Do not, under any circumstance, bring lit cigarettes and/or matches to the fuel.
  • Page 36 4. Operation 4.5.5 Check Fan-belt Tension If Fan-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. Adjust the fan belt by the following procedure: <Procedures>...

  • Page 37: 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. five minutes. Warming up after starting up is necessary for smooth operation of the engine.
  • Page 38 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. Before starting inspection and maintenance job, make sure to place the selector switch of automatic starting panel to “MAN”...
  • Page 39 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 40: Stopping Procedures

    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 41: Emergency Stop

    4. Operation 4.8 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 . A040192 To reset the button, turn the button head in the direction of the arrow.

  • Page 42: Periodic Inspection/Maintenance

    5. Periodic Inspection/Maintenance 5.1 Important Items at Periodic Inspection and Maintenance or after Maintenance The manual shows proper interval for periodic inspection and maintenance under normally operating conditions. Inspection and maintenance should be performed more often under extremely harsh conditions . Hang a “...

  • Page 43: Daily Inspection And Keeping Operation Log

    5. Periodic Inspection/Maintenance 5.2 Daily Inspection and Keeping Operation Log Be sure to carry out daily inspection every morning before operation. See Chapter 4 “OPERATION” of the manual for the details of inspection. Pay attention to and carefully observe the following points during daily operation or inspection and maintenance work.

  • Page 44: Periodic Inspection List

    5. Periodic Inspection/Maintenance 5.3 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. ◎Refer to engine operation manual for inspection and maintenance of an engine. (Unit : Hour) Daily 1,000...

  • Page 45: Periodic Replacement Of Parts

    5. Periodic Inspection/Maintenance 5.4 Periodic Replacement of Parts Use our genuine elements Air filter is a crucial component for the performance and the life of a unit. Use genuine part for replacement. Part number changes upon modification. For replacement of parts, make sure whether the part number is correct or applicable.

  • Page 46: 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. Engine oil is very hot and highly pressurized during or just after the operation.

  • Page 47: Panel

    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 48: Check Gfci Receptacles

    5. Periodic Inspection/Maintenance 5.5.4 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.

  • Page 49: Check And Clean Clogging Of Air Filter Element

    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 When an element that is clogged or has holes or cracks is used, dust or foreign material will get in the engine.

  • Page 50: Change Fuel Filter And Fuel Pre-Filter

    5. Periodic Inspection/Maintenance 5.5.8 Check Battery electrolyte and specific gravity of battery electrolyte Battery electrolyte : every 250 hours Specific gravity of battery electrolyte : every 500 hours If there to be a problem in starting an engine due to a flat battery, carry out the checks by following the procedures below: 1.Ordinary type battery: Measure specific gravity of battery electrolyte, and if it shows below 1.24, recharge the battery...

  • Page 51: Clean Outside Of Radiator And Intercooler

    5. Periodic Inspection/Maintenance 5.5.11 Clean outside of Radiator and Intercooler [Every 500 hours] When the fin tubes“3”of radiator“1”and inter cooler “2” 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 52 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 fuel pipes and electric wire connected to the fuel tank. ② Remove 8 pieces of the bolts connecting oil fence and the machine with the lifting eye hooked with the crane.
  • Page 53 5. Periodic Inspection/Maintenance 5.5.15 Change Coolant [1,000 hours or 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 54: Check Rubber Hose

    5. Periodic Inspection/Maintenance 5.5.16 Change Air Filter Element [Every 1,000 hours] Be sure to properly clean air filter element When an element that is clogged or has holes or cracks is used, dust or foreign material will get in the engine.

  • Page 55: 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 56 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. Be sure to read the operation manual of the battery charger to know if it is applicable, before using it.

  • Page 57: 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 58 6. Maintenance/Adjustment Symptom Cause Counter measures 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 generator main unit generated. (4)Faulty AVR Check/change (5)Faulty silicon rectifier (mounted on Check/change generator rotor)
  • Page 59 6. Maintenance/Adjustment 6.2.1 Engine trouble This unit is equipped with a device of controller which memorizes contents of engine trouble. When engine fails, trouble diagnosis lamp “1” goes on. For the details of the trouble, press trouble diagnosis switch “2” and then it displays the conditions of the failure, lamp blinking.

  • Page 60: 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. Put the unit in a temporary cabin if it is stored outside.

  • Page 61: Specifications

    8. Specifications Specifications Model SDG100S-8B1 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 ISUZU 4HK1X 4-cycle, water-cooled, direct injection, turbo charged, Type intercooled Number of cylinders Total displacement cu.

  • Page 62: Specifications

    8. Specifications Model SDG125S-8B1 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 ISUZU 4HK1X 4-cycle, water-cooled, direct injection, turbo charged, Type intercooled Number of cylinders Total displacement cu.
  • Page 63 8. Specifications Model SDG150S-8B1 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 ISUZU BH- 6HK1X 4-cycle, water-cooled, direct injection, turbo charged, Type intercooled Number of cylinders Total displacement cu.

  • Page 64: Outline Drawing

    8. Specifications Outline drawing SDG100S-8B1...
  • Page 65 8. Specifications...
  • Page 66 8. Specifications SDG125S-8B1...
  • Page 67 8. Specifications...
  • Page 68 8. Specifications SDG150S-8B1...
  • Page 69 8. Specifications...

  • Page 70: Wiring Diagram

    9. Wiring Diagram Generator Wiring Diagram A070284...

  • Page 71: Engine Wiring Diagram

    9. Wiring Diagram 9.2 Engine Wiring Diagram SDG100,125S-8B1 A080043-2...
  • Page 72 9. Wiring Diagram A080043-1...
  • Page 73 9. Wiring Diagram SDG150S-8B1 A080032...
  • Page 74 9. Wiring Diagram A080033...
  • Page 75 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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Sdg125s-8b1Sdg150s-8b1

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