AirMan SDG40S-8B1, Instruction Manual

Page 1: ... www discount equipment com D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...nie 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 Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...

Page 3: ...engine see the Engine Operation Manual Keep the manual available at all times for the operator or safety supervisor If the manual is lost or damaged place an order with your dealer for another copy Be sure that the manual is included with the unit when it is handed over to another user There may be some inconsistency in detail between the manual and the actual machine due to improvements of the ma...

Page 4: ...on 4 13 4 7 Stopping Procedures 4 17 4 8 Emergency Stop 4 17 4 9 Air Bleeding 4 17 5 Periodic Inspection Maintenance 5 1 5 1 Important items as Periodic and Maintenance or after Maintenance 5 1 5 2 Daily Inspection and keeping Operation Log 5 2 5 3 Periodic Replacement of Parts 5 2 5 4 Periodic Inspection List 5 3 5 5 Maintenance 5 5 5 6 Periodical Load Operation to be Performed 5 14 6 Maintenance...

Page 5: ... which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe pract...

Page 6: ...e machine for the other purposes than power supply Otherwise serious accidents may occur Exhaust gas from the engine is poisonous and could cause casualties when it is inhaled Avoid using the machine in an insufficiently ventilated building or a tunnel Keep flames away from battery Battery may generate hydrogen gas and may explode Battery electrolyte is dilute sulfuric acid In case of mishandling ...

Page 7: ... helmet protection glasses earplugs safety shoes a glove and a protection against dust mask according to the contents of work for safety Have first aid boxes and fire extinguishers near the unit ready for emergency situations such as injuries and a fire It is advisable to have a list of phone numbers of doctors ambulance and the fire department available in case of emergency Such things as unneces...

Page 8: ...ting the cautions mentioned above and a third party starting the machine during operation may cause serious accidents such as electric shock Keep hands off from the rotating portion or belts while running It could cause serious injuries if hands should be caught in Do not under any circumstance open the radiator cap while running or immediately after stopping operation Otherwise high temperature s...

Page 9: ...en handling Refilling oils should be done in an outdoor well ventilated place Refuel after stopping the engine and never leave the fuel nearby the machine Do not spill It may cause a fire When it is spilt wipe it up completely Do not fill fuel oil up to the cap level When fuel tank is filled up to the cap level fuel oil will be overfilled due to volume expansion caused by rise of ambient temperatu...

Page 10: ... Be sure to stop the engine and remove the starter key whenever the tension of the belt is to be adjusted If the machine is running it might catch the operator s hand into the belts and this could cause a serious injury Be sure to stop the engine and remove the starter key whenever the tension of the belt is to be adjusted If the machine is running it might catch the operator s hand into the belts...

Page 11: ... hot oil also pressurized blows off and it can cause burning When washing the machine cover the control panel generator and its electric parts to prevent them from being exposed to splashing water and avoid possible decrease in electrical insulation or other troubles to the machine Dust sand and dirt accumulated inside control panel could cause malfunction or trouble of the instruments Clean them ...

Page 12: ...clean at all times If they are damaged or missing immediately place an order with your nearest dealer for replacement Part numbers are indicated on the lower right corner of the label Adhere a new one to the original location 1 2 3 4 9 39178 50820 5 6 7 8 D i s c o u n t E q u i p m e n t c o m ...

Page 13: ...1 Safety 1 9 The pasting position of safe warning label is as follows A100401 1 2 4 8 7 6 3 DETAIL OF INSTRUMENT PANEL 5 9 D i s c o u n t E q u i p m e n t c o m ...

Page 14: ...rve tank For checking coolant level and supplying it 10 Radiator For cooling the coolant for engine in the system 11 Exhaust muffler For silencing the noise caused before discharging the air 12 Fuel tank For storing fuel 13 Selector valve of fuel pipe For supplying fuel oil from the tank provided outside 14 Sedimenter For separating water mixed or to be mixed in the fuel oil 15 Engine oil filler p...

Page 15: ...led Avoid using the machine in an insufficiently ventilated building or a tunnel When the machine is unavoidably used in such insufficiently ventilated place ventilation devices and ventilation pipe should be provided for better ventilation PC002 In case that the unit is installed indoors for operation suction air port and exhaust fume outlet port should be provided for better air ventilation Make...

Page 16: ...the machine in a place such as a damp place or a place where puddles are apt to be formed after rain Such installation could cause electric shock When installing the machine at the sea shore or on a ship make sure that the machine should not be exposed directly to sea water When installing the machine at a sandy place make sure that exhaust from the generator or radiator does not blow the sand up ...

Page 17: ...distance so that exhaust air from one machine does not effect the other one Keep enough space around the unit for inspection and maintenance access In order to prevent from entering the jobsite or touching the equipment any other persons than the persons engaged in the job please prepare for safety fences around the unit 1000 or more 1000 or more 1000 or more SG0110 Unit mm Preparation of safety f...

Page 18: ...em can allow electrical current from the generator to backfeed into the utility lines Such backfeed may electrocute utility company workers or others who contact the lines during a power outage Consult the utility company or a qualified electrician Improper connections to a building s electrical system can allow electrical current from the utility company to backfeed into the generator When utilit...

Page 19: ...nterrupter will not protect against short circuits or overloads The circuit breaker in the control panel which supplies power to the circuit provides that protection The ground fault circuit interrupter can be identified by the TEST and RESET buttons The receptacles on the GFCI can be tested with the TEST and RESET buttons TEST BUTTON To test depress the TEST button power is turned off RESET BUTTO...

Page 20: ...3 Installation 3 6 Grounding method A040174 1 Machine grounding terminal Load equipment Grounding rod Grounding rod D i s c o u n t E q u i p m e n t c o m ...

Page 21: ...ltage drop Three phase 3 wire Type Three phase 4 wire Type The following tables show the relations between the cabtyre cable length and the cable thickness nominal cross sectional area suited to the working current Based on the condition that working voltage is 200 V with voltage drop of 10V Single Conductor Cabtyre Cable Unit mm2 Three Conductor Cabtyre Cable Unit mm2 50m 75m 100m 125m 150m 200m ...

Page 22: ...ry arranged When using a separate storage tank remove the plug fitted at the connections to the separator tank and make piping as shown in Fig 2 And then turn the handles of the selector valve as shown in Fig 2 When removing the piping connections make sure to return the handles to the original positions shown in Fig 1 and install the plugs 3 5 3 Installation of separate storage fuel tank and pipi...

Page 23: ...ent panel 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 9 10 Manual automatic change over switch 11 Engine speed switch 12 Engine oil pressure gauge 13 Coolant temperature gauge 14 Ammeter for battery charge 15 Voltage regulator 16 Ammeter change over switch 17 Main circuit breaker The voltage selector switch is provided inside the unit See page 2 1 No 2 A100408 D i s c o u n t E q u i p m e n t c o m ...

Page 24: ... 230 F 110 Over crank This lamp goes on when operator fails to start engine during automatic operation mode Clogging of air filter When air filter is clogged and it becomes necessary to clean it it functions Oil Fence When more condensate fuel engine oil and coolant than 1 3 of capacity in the oil fence is accumulated monitor lamp lights Discharged battery It functions in case of faulty battery GL...

Page 25: ...reset the lever of circuit breaker press hard the lever downward till the lever sounds click 4 2 3 Thermal relay In case overload or short circuit should occur to load or load connection cable this relay functions to trip the circuit breaker It is not necessary to push the reset button even after the three phase main breaker is tripped since the thermal relay is set automatic return at factory A03...

Page 26: ...the output voltage of generator is increased higher than the specified voltage Symptom When circuit protector functions and load is applied to the machine such trouble as larger variance of voltage and or delayed voltage recovery follow How to reset Press the white colored AVR button inside the control panel for resetting the circuit breaker Note Do not hold the button with such sharply pointed th...

Page 27: ...ion For a connecting cable to load do not use a cable with damaged sheath nor an inappropriate insulation cable to the voltage Secure connections between each cable terminal and input output terminal Otherwise it may be slackened during operation and may cause a fire or an electric shock accident When using a single phase load 277Vor 139V see to it that the loads on the different phases will be ev...

Page 28: ...e load and may cause a fire In addition it could cause damage to generator and automatic voltage regulator AVR Be sure to shut off generator before using voltage selector switch When voltage selection is completed lock the voltage selector switch in position to prevent anyone from operating it NOTE When the voltage selector switch is in the single phase 240 120V position place the ammeter change o...

Page 29: ... switch on the control panel Procedure Start the generator unit and turn the main breaker ON on the control panel Turn the receptacle breaker of output terminal ON How to use aux receptacles Aux receptacles are available only when the voltage selector switch is turned to 240 120V on the control panel Procedure Turn the voltage selector switch to 240 120V on the control panel when the generator uni...

Page 30: ...A kVA 0 0 38 0 22 0 45 0 26 0 1 2 33 8 20 8 40 9 24 8 2 4 29 7 19 6 36 7 23 6 3 6 25 5 18 4 32 6 22 4 4 8 21 4 17 2 28 4 21 2 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 Use eng...

Page 31: ...ng to the temperature Use LLC within the range of its mixing ratio between 35 and 60 If LLC in the water exceeds more than 60 it may decrease its antifreezing effect Upon delivery from the works LLC density is 55 Follow the designated regulations to dispose of LLC Antifreeze 4 4 3 Fuel The following specific advantages are required for the diesel fuel Must be free from minute dust particles Must h...

Page 32: ... shows the oil level between HIGH and LOW limits it is normal When the oil level is below its LOW add engine oil See 5 5 1 While checking oil level check also for contamination If the oil is found dirty contaminated or should be changed according to the periodic inspection list change the oil 4 5 2 Check coolant level Be sure to stop the machine first and then loosen the radiator cap slowly after ...

Page 33: ...tation of machine 4 5 4 Check drain water sedimenter Check if the red float 1 in the water sedimenter rises up to the water drain level 2 then drain water if it is near the drain level Draining procedure Place the lever 2 provided on the top of sedimenter to Close position Loosen the ring nut 3 and remove the cup 4 In this case carefully remove the cup because it is filled with diesel oil so that ...

Page 34: ...he side of the oil fence Remove the drain plug 1 and drain the condensate accumulated inside the oil fence After making sure that the condensate is drained install the drain plug 1 Drain the condensate in container and then dispose of condensate according to the designated regulations 4 5 8 Cleaning the instruments inside control panel Before starting operation open control panel and check each br...

Page 35: ...ne is operated with a frequency lower than the rated frequency it could cause the generator or to be burned 4 6 1 Procedure to Start the Unit Follow the starting procedure below Manual operation Check and confirm that the circuit breaker 1 on the operation panel and the circuit breaker for auxiliary receptacle at output terminal portion are both OFF Set the selector switch 2 to MANUAL operation po...

Page 36: ...elf should keep it during inspection and maintenance job neglect and or ignoring the above items could cause a serious accident to other personss standing close by the machine when any other person than the inspector himself starts the machine 1 Cable connection method of remote control switch The remote control terminal 1 is provided inside the output terminal Perform cable connection as shown be...

Page 37: ...e after preheating When stop signal activates it continues 5 seconds cooling down operation to stop engine and the machine is placed again in stand by conditions 4 Starting action Even when the engine will not start even after cranking operation for 10 seconds stop it 8 seconds and then try cranking operation again In case the engine will not start even after cranking operation is repeated three t...

Page 38: ...nt Off Be sure to frequently check meters and indicators for proper operation or any machine water oil fuel leaks etc The above table gives standard values They may vary slightly depending on operating conditions and other factors In single phase load operation check the current of L1 L2 and L3 phase with the ammeter by turning the ammeter change over switch Each current should be balanced if unba...

Page 39: ...of the arrow If it is not reset the machine cannot restart to operate 4 9 Air Bleeding Should the machine stop due to the shortage of fuel perform the air bleeding operation according to the following procedures Procedure Place the operation selector switch to the MANUAL position Place the starter switch to RUN position to put electromagnetic pump into operating conditions Air bleeding will be com...

Page 40: ...ase or antifreeze Do not disassemble or adjust engine compressor or part s for which inspection or maintenance is not referred to in this manual Use genuine parts for replacement Any breakdown caused by using unapproved parts or by wrong handling will be out of the scope of WARRANTY Check rotor and stator of generator body for any seizure of foreign matter dust or dirt and cable disconnection Do n...

Page 41: ... f Performance of each part or component should be proper Keep the operation log to record constant inspection of each component so that trouble of the machine can be easily discovered and preventive measures can be taken It is very useful to record information such as frequency temperature current maintenance items and replenishment of lubricant on a daily maintenance log 5 3 Periodic Replacement...

Page 42: ...hs Check GFCI receptacles 5 6 Every monthiy Generator How to check thermal relay 5 7 Every 2 months Check drain water sedimentor 4 11 Check fuel 4 11 Check engine oil level 4 10 Check coolant level 4 10 Check belt tension 4 12 In the case of NG it exchanges Check and Clean clogging of air filter element 5 8 Perform cleaning when themonitor lamp glows Drain fuel tank 5 8 Change engine oil First tim...

Page 43: ...l circuits and cable connections 5 10 Every 4 months Clean inside of the oil fence and check it for any rust 5 11 Yearly Check vibration isolator rubbers 5 13 Yearly Others Check each rubber hose 5 13 Yearly Note The above intervals of inspection and maintenance are respectively based on the operation time of 125 hours of used per month and of 1 500 hours of use per year D i s c o u n t E q u i p ...

Page 44: ...ite smoke out of the exhaust and it can cause damage and accident to engine Procedure Remove the drain plug 1 attached outside the plane open a drain valve 2 inside the plane and discharge engine oil drain When the oil is completely drained close a drain valve 2 after attaching a drain plug 1 remove the cap of an engine oil filler port 3 refill new engine oil Oil supply about 3 4gal 13 2 L After f...

Page 45: ...st 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 Regularly check the GFCI operation for safety Procedure Unplug all appliances from the generator Start the engine Turn each single phase and three phase breaker ON Press the TEST BUTTON The RESET BUTTON should extend with a click If the RESET BUTTON do...

Page 46: ...stance between the terminals L1 L2 L3 terminal and bonnet Insulation resistance when measured with a 500 V megger tester must be above 1 MΩ After finishing the measurement of insulation resistance re connect the cable between the terminal N and terminal Ground After making sure that the insulation resistance of the generator is higher than 1 MΩ be sure to re connect the cable between the terminal ...

Page 47: ...e For part number see 5 3 5 5 7 Drain fuel tank Every 250 hours Drain the condensate accumulated in the fuel tank 1 by removing the drain plug 2 After making sure that the condensate is completely drained install the drain plug 2 firmly Drain the condensate in container and then dispose of condensate according to the designated regulations 5 5 8 Check Battery electrolyte and specific gravity of ba...

Page 48: ...ls 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 Do not use high pressure washer for washing to prevent fin tubes 3 from being damaged When the unit is used installed near seaside and on boat board clean the radiator using fresh water more times than ...

Page 49: ...hange air filter element Every 1 000 hours When an element that is clogged or has holes or cracks is used dust or foreign material will get in the engine This causes accelerated wear in each sliding part of the engine Be sure to make daily check and cleaning so that the life of the engine will not be shortened Procedure After removing the cap 1 by loosening its latch 2 clean its interior properly ...

Page 50: ... fur and other foreign matter and check it for any rust When the oil fence is found rusted remove the rust outside and inside and paint it again Should any leakage be found contact your dealer or us directly Check whether the seal rubber attached on the top of oil fence is slanted or curved Combining this machine and the oil fence tighten the nuts 6 pieces Install oil filler cap cover fuel pipes a...

Page 51: ... container with an indication saying LLC Antifreeze inside and seal it up then Keep it in a place away from children Beware of flames Procedure To drain coolant remove the radiator cap 1 then loosen the drain valve 2 Be sure to also open the drain valve 3 on the engine cylinder block for drainage When the coolant is completely drained out close each drain valve 2 and 3 and supply new coolant from ...

Page 52: ...ack or fissures are found on each hose air filter radiator fuel and drain replace it by a new one Check each clip fixing the hoses and if any loosened hose is found retighten it Even before the periodical internal comes replace it if any hardening any cracks are found When replacing it please contact our branch office or your distributor 5 5 19 Check and change engine fuel hose Check every 50 hour...

Page 53: ...d clogging of carbon in the exhaust muffler can degrade engine performance and overheating to the engine resulting in a serious accident In case that such phenomena occur it should be continuously operated with load applied till the exhaust gas color becomes generally gray and also till carbon accumulated in exhaust system can be eliminated being burnt For load current refer to the following table...

Page 54: ...any delay Do not charge the frozen battery Otherwise it may explode If the battery is frozen warm it up until the battery temperature becomes 16 C to 30 C Battery electrolyte is dilute sulfuric acid In case of mishandling it could cause skin burning Wear protective gloves and safety glasses when handling a battery When such battery electrolyte contacts your clothes or skin wash it away with large ...

Page 55: ...nd terminals backwards Such wrong connection will cause spark and damage to each component Procedure for using a booster cable Stop the engine Connect one end of the cable to the terminal of the machine battery Connect the other end of the cable to the terminal of the external battery Connect one end of the cable to the terminal of the external battery Connect the other end of the cable to the eng...

Page 56: ...ing in fuel pipings Disassemble clean and change Check fuse Check connector Check controller Replenish fuel Bleed air Engine oil pressure drop monitor lamp glows 1 Engine oil shortage 2 Engine oil filter clogging 3 Oil pressure switch malfunction 4 Loosened or disconnected wiring or connector Replenish fuel Change Change Check repair Coolant temperature rise monitor lamp glows 1 Radiator clogging ...

Page 57: ...Check change Check repair Check repair Check change Check change Check repair Check repair Reset Too high voltage generated when set at the rated frequency 50Hz 60Hz Voltage will not drop even when the voltage regulator controlling knob is turned 1 Loosened or disconnected wiring or connector to AVR 2 Faulty AVR 3 Broken wire or poor contact of AVR variable resistor Check repair Check change Repai...

Page 58: ...onger than 12 seconds Malfunction of RPM sensor L 2 and S 1 When RPM sensor is in disorder or cable connection is cut or short circuited Trouble of solenoid sensor L 2 and S 2 When cable of actuator is disconnected or short circuited Disconnection of coolant temperature sensor L 2 and S 4 When cable of coolant thermometer is disconnected Short circuiting of coolant temp sensor L 2 and S 5 When cab...

Page 59: ...other openings like the muffler with a vinyl sheet packing tape etc to prevent moisture and dust from getting in the unit Measure the insulation resistance of the generator and make sure that it is more than 1MΩ See 5 5 4 Be sure to repair any trouble and maintain the unit so that it will be ready for the next operation When stacking up the machines for storage only two units stacking is acceptabl...

Page 60: ...ype Number of cylinders 4 Total displacement cu in L 203 3 318 Rated output hp kW 46 8 34 9 Revolution per minute rpm min 1 1 800 1 800 Lubricating oil capacity gal L 3 4 13 2 Coolant capacity including radiator gal L 2 9 11 0 Battery 95D31R 12V Engine Fuel tank capacity gal L 106 400 Overall length in mm 82 2 080 Overall width in mm 39 1 000 Overall height in mm 61 1 560 Net dry mass weight lbs k...

Page 61: ...f cylinders 4 Total displacement cu in L 230 3 769 Rated output hp kW 61 1 45 6 Revolution per minute rpm min 1 1 800 1 800 Lubricating oil capacity gal L 3 4 13 2 Coolant capacity including radiator gal L 2 9 11 0 Battery 80D26R 12V equivalent Engine Fuel tank capacity gal L 106 400 Overall length in mm 82 2 080 Overall width in mm 39 1 000 Overall height in mm 61 1 560 Net dry mass weight lbs kg...

Page 62: ...8 Specifications 8 3 8 2 Outline drawing Unit in A100399 D i s c o u n t E q u i p m e n t c o m ...

Page 63: ...8 Specifications 8 4 Unit mm A100398 D i s c o u n t E q u i p m e n t c o m ...

Page 64: ...9 Wiring Diagram 9 1 9 1 Generator Wiring Diagram A100400 D i s c o u n t E q u i p m e n t c o m ...

Page 65: ...9 Wiring Diagram 9 2 9 2 Engine Wiring Diagram SDG40S 8B1 A100426 D i s c o u n t E q u i p m e n t c o m ...

Page 66: ...D i s c o u n t E q u i p m e n t c o m ...

Page 67: ...10 Piping Diagram 10 1 10 1 Fuel piping A100427E D i s c o u n t E q u i p m e n t c o m ...

Page 68: ...NCY Hz OPERATION LOG REMARKS INSPECTION PART CHANGE HISTORY ETC OUTPUT CURRNT A ENG OIL REPLACEMENT HOUR h ENG OIL PRESS PSI OPERATION DATE OPERATION TIME COOLANT TEMP F OUTPUT VOLTAGE V TOTAL OPERATION HOURS h D i s c o u n t E q u i p m e n t c o m ...

Page 69: ...nie 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 Tsurumi Husquvarna Target Whiteman Concrete Mortar Stow Concrete Mortar Baldor Wacker Sakai Snorkel Upright Mi T M Sullair Neal Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Blaw Kno...