AirMan SDG25S-6A7 User manual

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AIRMAN
INSTRUCTION MANUAL
ENGINE GENERATOR
SDG 25S-6A7
SDG 45S-6A6
SDG 65S-6A6
SDG1 00S-6A6
HOKUETSU INDUSTRIES CO., LTD.
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Preface
◆This manual explains and illustrates proper handling of the unit, method of daily inspection and
maintenance to enhance the performance of AIRMAN’s generators.
◆In order to use a machine safely, people with sufficient knowledge and sufficient technology need to deal
with it.
◆Before operating the unit, read the manual carefully, fully understand its operation and maintenance
requirement. Maintain “SAFETY OPERATION AND PROPER MAINTENANCE OF THE UNIT”.
Be sure to follow safety warnings and cautions given in the manual. Unsafe operation
could cause serious injury or death.
◆For details of handling, maintenance and safety of the 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 machine. Ask your dealer if you have any questions or problems.
◆If you have any questions about the unit, please inform us the model and serial number. A plate
stamped with the model and serial number is attached to side of the unit.
A
040491
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Table of Contents
1. Safety ....................................................................................................................................................... 1-1
1.1 Caution before Operation ................................................................................................................ 1-2
1.2 Caution during Operation ................................................................................................................
1-4
1.3 Caution during Inspection and Maintenance ...................................................................................
1-6
1.4 Safety Warning Labels ....................................................................................................................
1-8
2. Part Names .............................................................................................................................................. 2-1
2.1 Unit Appearance and Part Names ................................................................................................... 2-1
2.2
Internal Components ....................................................................................................................... 2-2
3. Installation ............................................................................................................................................... 3-1
3.1 Transporting Unit ........................................................................................................................... 3-1
3.2
Place and Conditions of Unit Installation ................................................................................... 3-2
3.3 Selecting Cable ...............................................................................................................................
3-3
3.4 Connecting load................................................................................................................................
3-4
3.5 Grounding Method ............................................................................................................................
3-8
3.6
Selector Valve of Fuel Pipe .......................................................................................................... 3-9
4. Operation ................................................................................................................................................. 4-1
4.1 Instrument panel ............................................................................................................................ 4-1
4.2
Protection device ........................................................................................................................... 4-2
4.3
Check before Starting the Unit .................................................................................................... 4-6
4.4
Unit Operation ................................................................................................................................ 4-8
4.5
Stopping Procedures ..................................................................................................................... 4-12
4.6
Adjustment of frequency ................................................................................................................. 4-12
4.7
Emergency Stop .............................................................................................................................. 4-13
4.8
Air Bleeding ...................................................................................................................................... 4-13
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 Inspection List ...................................................................................................................
5-3
5.4 Periodic Replacement of Parts .........................................................................................................
5-4
5.5 Maintenance .....................................................................................................................................
5-5
6. Maintenance/Adjustment ....................................................................................................................... 6-1
6.1 Maintenance of Battery..................................................................................................................... 6-1
6.2 Troubleshooting ................................................................................................................................
6-3
7. Storage of the Unit ................................................................................................................................. 7-1
7.1 Preparation for Long-term Storage ................................................................................................. 7-1
8. Specifications .........................................................................................................................................
8-1
8.1 Specifications.................................................................................................................................... 8-1
8.2 Outline drawing .............................................................................................................................. 8-5
9. Wiring Diagram .......................................................................................................................................
1 9-1
9.1 Generator Wiring Diagram................................................................................................................ . 9-1
9.2 Engine Wiring Diagram.....................................................................................................................
. 9-4
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1.Safety
1-1
This operation 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 − attached to each message.
When one of these messages is found, please take preventive measures for safety to carry out “SAFETY
OPERATION AND PROPER MAINTENANCE OF THE UNIT ”.
DANGER indicates an imminently hazardous situation 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 practices.
IMPORTANT indicates important caution messages for the performance or
durability of the unit, which has no concern to injury or accident of or to a
human body.
Follow warnings mentioned in this manual. This instruction manual does not describe all safety items.
We, therefore, advise you to pay special attention to all items (even though they may not be described in
the manual) for your safety.
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1.Safety
1-2
1.1 Caution before Operation
Ventilation
 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.
PC002
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.
 Do not modify the machine without prior approval. The safety
may be compromised, functions may be deteriorated, or
machine life may be shortened.
 Never use the machine for the other purposes than power
supply. Otherwise, serious accidents may occur.
TR0086
Handling battery
 Keep flames away from battery.
Battery may generate hydrogen gas and may explode.
 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.
 Dispose of battery, observing local regulations.
D004
TR0093
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1.Safety
1-3
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.
Maintain both physical and mental health
 Do not operate the machine when you are tired or drunk or under the influence of drugs. Otherwise,
a hasty conclusion or careless handling may cause unexpected injury or accident. Manage your
physical and mental health and be cautious in handling the machine.
Protection equipments
 Please wear protection implements, such as a helmet,
protection glasses, earplugs, safety shoes, a glove, and a
protection-against-dust mask, according to the contents of
work for safety.
Safety fittings
 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.
Safety around the machine
 Such things as unnecessary equipment and tools, cables, hoods, canvas sheets and pieces of wood
which are a hindrance to the job, have to be cleared and removed. This is because operators and
personnel nearby may stumble on them and may be injured.
TR0084
TR0085
TR0096
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1.Safety
1-4
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. The
operator must keep the key during operation.
Neglecting the cautions mentioned above, and a third party
starting the machine during operation may cause serious
accidents such as electric shock.
 Never touch the interior of the control panel during operation.
Notice that the voltage of several hundreds volt is applied to
the interior of the control board.
 When checking or operating the interior of control panel, be
sure to stop the machine, remove the starter key from the
starter switch, then carry out a work. The operator must keep
the key during operation.
H990208
Hands off from rotating parts and belts
 Keep hands off from the rotating portion or belts while running.
It could cause serious injuries if hands should be caught in.
TR0304
Do not remove radiator cap during operation
 Do not, under any circumstance, open the radiator cap while
running or immediately after stopping operation. Otherwise
high temperature steam jets out and this could cause scalding.
H990432
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1.Safety
1-5
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.
 Coolant water and engine oil are also very hot and dangerous
to touch. Avoid checking or refilling them while the unit is
running. H990432
Fire prevention
 Do not, under any circumstance, bring lit cigarettes or matches
near such oils as diesel fuel oil, and engine oil, etc.
They are extremely flammable and dangerous, so be careful
when 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.
 Such parts as muffler and exhaust pipe can be extremely hot.
Remove twigs, dried leaves, dried grass and waste paper, etc.
from the exhaust outlet of the muffler.
 Keep a fire extinguisher available by the machine in case of
unexpected fire.
D004
Draining during operation prohibited
 Do not, under any circumstance, open the portions below
during operation.
Coolant drain valve and plug
Engine oil drain plug
Unbalance of overload and load
 Reduce the load when the circuit breaker actuates frequently during operation.
 When a single-load is used, check the current of each phase, and adjust the load so that each load
value should be balanced.
 If the above procedure is neglected during operation, the generator could be burned or it could cause
a fire. If the machine is operated with the frequency lower than the rated frequency, it could cause the
generator or load motor to be burned.
H990433
PK0028
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1.Safety
1-6
1.3 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. The checker must keep the key
during checking and maintenance.
 Remove the negative (–) side cable from the battery.
If the above procedure is neglected, and another person starts
operating the machine during check or maintenance, it could
cause serious injury.
 Be sure to stop the engine and remove the starter key
whenever the tension of the fan belt is to be adjusted.
 If the machine is running, it might catch the operator’s hand
into the fan belts, and this could cause a serious injury.
Hands off from cooling fan
 Be sure to stop the engine and remove the starter key
whenever check or maintenance work is carried out near the
cooling fan.
 If the cooling fan is rotating, it may catch the operator or part of
his body into the fan, and it could cause a serious injury.
Cleaning by air-blow
 When cleaning dust accumulated in such devices as the air-filter,
etc., by blowing compressed air, wear safety glasses, etc. to
protect your eyes.
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.
W009
TR0206
W003
TR0304
SY001
A
djusting tension of fan belt
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1.Safety
1-7
Taking off the radiator cap
 Be sure to stop the machine first and then loosen the radiator
cap slowly, after the coolant water is sufficiently cooled and the
inner pressure is released.
If this procedure is neglected, its inner pressure can blow off the
cap，and steam jetting out of the radiator could result in causing
scalding. Follow these procedures under all circumstances.
Opening coolant water drain valve
 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 cooled
enough, hot water could jet out, and it could cause scalding.
Refilling or draining of engine oil
 After stopping the engine, wait 10 to 20 minutes until the engine
oil cools off. Then check the level of the engine oil, or refill or
drain the oil.
 During operation or immediately after the engine stops, its oil is
extremely hot and pressurized, so it may jet out when the cap
is loosened. Be careful not to scald yourself from it.
Cleaning the unit
 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.
Disposal of waste liquid, etc.
 Waste liquid from the machine contains harmful material. Do not discharge it onto the ground or into
the river, lake or sea. Such material will pollute the environment.
 Be sure to use a container to hold the waste liquid from the machine.
 Be sure to follow the designated regulations when disposing of oil, fuel, coolant (antifreeze), filter,
battery or other harmful materials.
H990432
H990432
H990432
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1.Safety
1-8
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.
1 2 3 4
5 6 7 8
9
39178 50820
SDG45S-6A6,SDG65S-6A6,SDG100S-6A6
39178 58320
SDG25S-6A7
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1.Safety
1-9
●The pasting position of safe warning label is as follows.
SDG25S-6A7
6
2
3
5
4
7
8
1
A
040571
DETAIL OF INSTRUMENT PANEL
9
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1.Safety
1-10
SDG45S-6A6,SDG65S-6A6
6
2
3 5
4
7
8
1
DETAIL OF INSTRUMENT PANEL
9
A
040572
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1.Safety
SDG1 00S-6A6
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DETAIL OF INSTRUMENT PANEL
1-11
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2. Part Names
2.1 Unit Appearance and Part Names

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
A040573
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2. Part Names
2-2
2.2 Internal Components
SDG25S-6A7
1 2 3 4 5 6
12 11 10 9 8 7
13
1. Control panel
2. Engine
3. Air filter
4. Engine oil filler port
5. Reserve
tank
6. Radiator
7. Fuel
tank
8. Battery
9. Engine oil level gauge
10. Sedimentor
11. Fuel filter
12. Generator
13. Output terminals
A
040574
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SDG45S-6A6
1
 
 
 
 

 
 
 
 
2. Part Names

2 3
   
4
8
5 6
7
A040575
 
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 
2·3
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2. Part Names
2-4
SDG65S-6A6
1. Control panel
2. Air filter
3. Engine oil level gauge
4.Reserve tank
5.Engine
6. Sedimentor
7. Fuel filter
8. Radiator
9. Fuel tank
10. Engine oil filler port
11. Fuel air-bleeding electromagnetic pump
12. Engine oil filter
13. Battery ※
14. Output terminals
15. Generator
A040576
1 2 3 4 5 6 7 8
15 14 13 12 11 10 9
Instrument 12 marked “ ※” are
provided on the other side (opposite
side of maintenance).
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2. Part Names
SDG1 00S-6A6
1
 
 
 
 
2 
 
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  
 
  
4

11
5 6 
9 8
A050016
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 
 
 
 
  
 
 

 

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3. Installation
3-1
3.1 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. Otherwise, a
fatal trouble or serious accident may occur.
3.1.1 Lifting
 Use the lifting bail1fitted on center of bonnet.
 Select an appropriate crane or truck by referring to the
mass and dimensions mentioned in “Specifications”.
 Only a qualified crane operator is allowed to operate a
crane.
1
A
040151
A
040151
1
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