Hokuetsu AIRMAN SDG220S-8E1 User manual

AIRMAN
INSTRUCTION MANUAL
ENGINE GENERATOR
j SDG220S- 8E1 j
[ENVIRONMENTAL CONTAINMENT
BASE TANK TYPE]
Please be sure to read this manual
before using this machine.
HOKUETSU INDUSTRIES CO., LTD.

Preface/Table of Contents
Thank you for choosing "Al RMAN"
♦ Keep this manual at hand and refer to it as necessary.
♦ If this manual is missing or damaged, order a new copy from our office or your nearest dealer.
Make sure that the manual is included with the machine when it is handed over to another user.
♦ The contents of this manual may differ from the machine as a result of design changes. If anything
is unclear please contact our office or your nearest dealer for clarification.
♦ Refer to the Engine Operation Manual for engine handling, maintenance, and safety information.
-Table of Contents -
1. Major Components------------------------------------------------------------------------------ 1-1
1.1 Internal Components------------------------- 1- 1
2. Transportation and Installation------------------------------------------------------------- 2-1
2.1 Transporting Machine------------------------- 2-1
2.2 Conditions of Installation 2- 2
2.3 Grounding 2- 4
2.4 Selecting Cable 2- 6
2.5 Fuel Pipe Selector Valve 2- 7
3. 0 peration-------------------------------------------------------------------------------------------- 3-1
3.1 Operation Panel--------------------------- 3- 1
3.2 Connecting Loads 3- 3
3.3 Engine Oil·Coolant· Fuel · DEF 3- 7
3.4 Before Starting the Unit 3- 9
3.5 Operating Procedure 3-15
3.6 Emergency Stop 3-22
3. 7 SCR Cleaning 3-23
3.8 SCR Inducement 3-25
4. Fa iIures and Troubleshooting--------------------------------------------------------------- 4-1
4.1 Protection device-------------------------- 4- 1
4.2 Troubleshooting--------------------------- 4- 4
5. Periodic Inspection ----------------------------------------------------------------------------- 5-1
5.1 Important Items at Periodic Inspection and Maintenance------------- 5- 1
5.2 Periodic Inspection and Maintenance Schedule---------------- 5- 2
5.3 Periodic Replacement Parts----------------------- 5- 3
5.4 Maintenance Items-------------------------- 5- 4
6. Storage and Disposal -------------------------------------------------------------------------- 6-1
6.1 Preparation for Long-term Storage -------------------- 6- 1
6.2 Disposal of Product------------------------- 6- 1
7. Specifications------------------------------------------------------------------------------------- 7-1
7.1 Specifications--------------------------- 7- 1
7.2 Outline drawing--------------------------- 7- 2
7.3 Generator Wiring Diagram----------------------- 7- 4
7.4 Engine Wiring Diagram------------------------ 7- 5
7.5 Piping Diagram-------------------------- 7- 6

Safety
This section explains safety precautions for operation, inspection, maintenance, installation,
movement and transportation. Read these safety requirements carefully and fully understand the
contents before starting the machine.
For better understanding of the precautions in this manual and on this machine, safety precautions
are classified into "DANGER", "WARNING" and "CAUTION" messages with a warning symbol ffi
marked, according to the degree of hazard.
When one of these messages is found, please take preventive measures for safety and carry out "SAFE
OPERATION AND PROPER MAINTENANCE OF THE MACHINE".
IA DANGER I DANGER indicates
an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
IAwARNINGI
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
IA CAUTION I 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.
IIMPORTANTI
IMPORTANT indicates important caution messages for the performance
or durability of the machine, which has no concern to injury or accident of
or to a human body.
This 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.
PROPOSITION 65 WARNING
!ii ~ WARNING I
Breathing engine exhaust exposes you to chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust system.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary
For more information, go towww.P65warnings.ca.gov/diesel
S-1

Safety
♦ If you have any questions about the machine, please contact our office or your nearest dealer. Be
sure to have your machine's serial number to assist in providing the correct information for you.
A plate stamped with the model and serial number is attached to side of the machine.
/'
0
ENGINE GENERATOR
MOD EL
I
SER. NO.
I
GEN.OUTPUT
I
VOLTAGE I
FREQUENCY
I
POWER FACTOR
80 X PHASE
RULE J EM 1398
NET DRY MASS I
OPERATING MASSI
0
AIRMAN USA CORPORATION
ASSEMBLED IN USA
"
0
kVA
V
Hz
3
kg
kg
0
~
A180077
S-2
* Each illustrated figure (Fig.) has a number
(for instance, A180077) at the right bottom.
This number is not a part number, it is an
internal reference number.

Safety
[Safety Warning Labels]
Following labels are attached to the machine.
Keep them clean at all times. If they are damaged or missing, immediately place an order with your
nearest dealer for replacement. Part numbers are indicated on the lower right corner of the label.
Adhere a new one to the original location.
1 2 3 4 5
ACAUTION
sf A
WARNING
;/f).
A WARNING
~~J
2~
"\.,
0
ACAUTION
sf
PREVENT
BURNING ACCIDENT BEWARE OF
ENTANGLEMENT BEWARE OF
ENTANGLEMENT LIFTING BAIL PREVENT
BURNING ACCIDENT
When work is required Keep your handsAWAY from Keep your handsAWAY from
near hot parts , wait
for the parts to coo I
down fu 11 y before
starting work.
moving parts such as
V-belts, pilleys etc ..
Entanglement in them
can cause serious injury.
fan during opration.
Entanglement in the fan
can cause serious injury.
3917669500
39176 73800
39176 73500
6
DANGER EXPLOSIVE GASES
~~-:~:·~~r1:1°fr:a~~~~:.
1
t~~tect:~~ir'~~~:;,/~:1:
oradjustponcoooectionswithoutproporinstructionandtraining,
KEEP VENT CAPS TIGHT AND LEVEL
POISON CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with tkin, eyas 01 clothing. In
event of accident flush with water and cal a phY1ldan immediately.
KEEP OUT OF REACH OF CHILDREN
39176 50000
9
7
&DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide.This is
a poison you cannot see or smell.
fl:E=l>
NEVER use inside a home Only use OUTSIDE and
or garage,EVEN IF doors far away from windows,
ana windows are open. doors,and vents.
Avoid other generator hazards.
READ MANUAL BEFORE USE.
39176 09310
10
A WARNING
A DANGER
~
DO NOT OPEN PANEL WHILE
UNIT IS RUNNING
HIGH VOLTAQ,~,
BEWARE OF EXHAUST
GASES
When you operate machine
INDOORS or in TUNNEL,
provide good ventilation.
Poor ventilation can cause
fatal accident.
39176 73300
12
Please refill DEF when
refilling diesel fuel
®
FLAMMABLES
13
I
Ji) DIESEL FUEL
EPA REGULA TIDN
ULTRA LOW SULFOR FUEL ONLY.
DIESEL A TRES FAIBLE TENEUR EN SOUFRE
UN!QUEMENT.
39176 69300
Do not open
radiator cap while
it is still hot.
39176 69600
8
f-------,··'&. WARNI NG
Breathing diesel engine exhaust exposes you to
chemicals known to the State of California to cause
cancer and birth dC?feGts or other reproductive harm.
· Always start and operate the engine in awell-
ventilated area.
· Ifin an enclosed area, vent the exhaust to the
outside,
· Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For mare information go www. P65warnings.ca.gov/diesel
39178 67840
11
A
WARNING
Do not t"uch live electrical parts.
Always wear dry insulattng gloves.
Do not operate the unit ln the rain,araund standing water ar when wet.
Maintain all electrical cords and conecttans inJFooer condition.
~lway~auncfHie .9en~rator to eartb berore_gi_?raftn9.:: 39175 52900
I
39178 70940
39178 22031
S-3

Safety
• The locations of the safety warning labels are as follows.
A
1 2 3
VIEW A VIEWB
. .
. I I [II!] .
[G
c-----fft-------,
Ill
[II!]
.
(!I
~
-
0 0
0 0
II
0
S-4
6
~
~
Battery
12 13
~
VIEWC
A210278

A_ DANGER
W013
TR0086
TR0304
M003
Safety
• Never touch the control panel during operation. Be aware that a voltage of
several hundred volts is applied to the control panel.
• Be sure to stop the engine and turn control power switch OFF whenever the
control panel has to be checked or operated. Disconnect the negative
battery terminal during checking and maintenance.
• Read each instruction plate which is displayed in the manual or on the
machine carefully, understand its content and follow the indications thereof.
• 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.
• Keep hands away from the rotating machinery or belts during operation.
These pose the risk of serious injuries to hands if touched.
• When cleaning dust accumulated in devices such as filters, etc., with
compressed air, wear safety glasses, etc. to protect your eyes
S-5

A CAUTION
dH990432
Safety
• Be sure to stop the engine and let the coolant water sufficiently cool down
before draining it.
• If the drain valve is opened before the coolant water is cool enough, hot
scalding water could jet out, causing burns.
• 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 issues with the
instrumentation. Clean them using compressed air.
A100285
• 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 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.
• The engine of this machine contains many electrical and electronic parts.
Before welding, be sure to disconnect all electronic control equipment (specifically the ECM).
Failure to do so could result in equipment malfunction due to excessive current.
S-6

1. Major Components
1.1 Internal Components
1 2 3 4
9 7 8 7 6 5
A210282
No.
Part Name
Function
1 DOC (Diesel
Oxidation Catalyst) Catalyst for oxidizing exhaust gas
2 Intercooler
Cools the air compressed by the engine supercharger
3
Engine
Drives the generator
4
Control Panel (Operation Panel)
Controlling device; various meters and controls
5
Battery
Power source to start the engine
6
Alternator
Generates the electricity supplied to the load
7
Fuel Tank
Vessel for storing fuel
8
Fuel Pipe Selector Valve
Switches to external fuel tank supply
9
SCR (Selective Catalytic Reduction) Selective
reduction-type catalyst that uses DEF as a
reducing agent
1-1

1. Major Components
10 11
12
13 14 15 16
22 21 20 19
18
17
A210283
No. Part Name
Function
10 Air Filter Filters dust from intake air.
11
Fuel air- bleeding electromagnetic
Device that automatically bleeds air from the fuel lines
pump
12
Engine Oil Filter Filters engine oil
13
Breather/ OCV (Open Crankcase
Vents gas from engine crankcase
Ventilation)
14
Engine Oil Filler Port Port for supplying / replenishing engine oil
(Oil Level Gauge)
Wso for checking the engine oil level and contamination)
15
Surge Tank For checking & replenishing coolant
16 Radiator Cools the engine coolant
17
DEF Tank
Container for DEF
18 DEF Filter
Filters foreign matter & particulate mixed in DEF
19 Supply Module Pump to move DEF fluid within the system
20
Fuel Pre- Filter
Removes dust and water mixed in fuel
21
Fuel Filter
Filters foreign matter & particulate mixed in fuel
22 Output Terminal Board Outlet ports for AC power
1-2

2. Transportation and Installation
2.1 Transporting Machine
• When loading and unloading the machine, be sure to use the lifting bail [A] provided on the center
of the machine top.
2.1.1 Lifting
A180080-1
<Procedures>
1. Before lifting the unit up, make sure to check the
lifting bail [A] for any cracks or loosened bolts.
2. Connect the hook of the crane or shackle with the
lifting bail fitted at the top center of the unit, and
make sure that there is no person standing near the
unit. Then perform hoisting operation.
• 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.
2.1.2 Fastening to a truck bed
J A
C B
AwARNING
A CAUTION
• When moving or removing the machine from the
work site, load it onto a truck and secure it to the
truck with ropes [B] using the supplied tie points [A]
on both sides of the cover, and be sure to install a
chocking block [ C] on the bed of the truck as well.
A030104-1
A180079-1
A210376
• Never step underneath the unit when it is suspended. It is
very dangerous.
• When moving or removing the unit from the work site, load it
onto a truck and use the supplied rope tie points [A] to secure
it firmly to the truck bed.
• Do not lift the unit while it is running. Otherwise, a fatal or
serious accident may occur.
• Before transporting, check if there is condensate (fuel, oil and
coolant) inside the oil fence, and if so drain it.
(See 3.4.10)
• When transporting with condensate (fuel, oil and coolant)
accumulated inside the oil fence, the condensate may flow
out of the machine.
2-1

2. Transportation and Installation
2.2 Conditions of Installation
• The machine should be operated in the following
conditions:
Using the machine outside the above conditions
may cause serious failure.
• Ambient temp: 5°F to 104°F (-15°C to 40°C)
• Humidity: Less than 85%
• Altitude: Lower than 1,000m above sea level
• The machine has to be installed on a dry, firm, and
level area.
• If more than two units are placed parallel in
operation, keep enough distance so that exhaust air
from the one does not affect the other one.
1,500 or more
Unit: mm • Keep enough space around the unit for inspection
SG0110 and maintenance access.
-------------------
gas
0
~
Private house
PC002
Using a blower
G-- fan for air intake
A050506-1
A050505
• Exhaust gas from the engine is poisonous. Exhaust
gas can cause death or serious injury upon
inhalation.
Avoid using the machine in an insufficiently ventilated
building or a tunnel.
• Do not position the exhaust gas outlet in the direction
of a person or a house.
• If the unit is installed inside a tunnel, make sure to
provide fresh air and ventilate it.
• In this case, make sure to extend the exhaust fume
pipe outdoors, and also make sure to prevent any
leak from any connecting pipes.
• Never position the unit with the exhaust muffler facing
any private house.
• As the exhaust gas from the engine is poisonous,
never direct it at people passing by ..
2-2

2. Transportation and Installation
Exhaust
gas outlet
Exhaust pipe
port -_~_-_-_ --
J) [: _____ :;'\
l-> /('&!
-..:-.:; Air Inlet
Exhaust
gas _ __,__L.-___,_ _____ ----'-_ __,_,___¢:::::::J
• In case that the unit is installed for indoor operation,
an intake air port and exhaust fume outlet port should
be provided for better air ventilation.
• Make sure to secure enough space in front of the air
intake port and to secure it after exhaust fume outlet
port so that the engine will not get overheated.
• An exhaust pipe or the like should be provided at the
exhaust outlet port so as to send exhaust fumes
.,__ ____________ A_o_9_o6_4_1-_1_. outdoors.
A CAUTIO
I/A V/A
SG0103-1
Safety Fence
A050507-1
• The cooling air outlet port of the radiator should have
access to the outside air through a duct or the like for
air ventilation.
• The machine should be installed within 5°degree
inclination.
• If installation site is not flat, put square bar under the
machine in order to install it horizontally.
• Avoid installing the unit in a damp place or a place
where water collects. Such an installation could
cause electric shock.
• If the unit is installed on the coast, do not allow
seawater to come in direct contact with the unit, as
this may degrade the insulation inside the unit and
control panel.
• When installing the unit at a sandy location, make
sure the exhaust from the generator or radiator does
not blow the sand into the air or into the machine.
• In order to prevent any persons other than those
engaged in the job site from using or interacting with
the machine, please prepare safety fences around
the unit as necessary.
2-3

2. Transportation and Installation
2.3 Grounding
2.3.1 Ground Terminal
0 Ll
L2
L3
N
0 0 0 0
Grounding method
Load
Grounding Rod
2.3.2 Grounding System
A
A180093
Circuit Breaker
rn]
• The ground terminal [A] on the AC output
terminal board is connected to the ground of this
unit and to the ground terminals of each outlet.
Grounding Terminal [A]
Grounding Rod
A180091
AIRMAN's generators have a system ground that connects generator frame components to the
ground terminals in the AC output receptacles. The AC neutral wire (N) is connected to the system
ground.
2-4

2. Transportation and Installation
2.3.3 GFCI Receptacles
• All of the 20 ampere 120 volt receptacles on the generator are protected by a GFCI (Ground-fault
circuit interrupter) for protection against the hazards of ground fault currents. An example of
ground-fault current is the current which would flow through a person who is using an appliance
with faulty insulation and, at the same time, is in contact with an electrical ground such as a
plumbing fixture, wet floor, or earth.
• The ground-fault circuit interrupter 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:
RESET BUTTON: To
test, depress the "TEST" button. (Power is turned off)
To restore power, depress the "RESET" button.
• Perform this test monthly or every 250 hours operation, whichever comes first, in order to ensure
proper operation of the GFCI receptacle. If the generator is stored outdoors, unprotected from the
weather, test the GFCI receptacle before each use. Record your test on the GFCI test card provided
on the control panel.
Test Button
0
Reset Button
D ~
A180093
• Using the generator in rain, snow or near water can lead to death from electric shock. Keep the
generator dry.
2.3.4 Connections to a Building's Electrical System
• Connections for standby power to a building's electrical system must be made by a qualified
electrician. The connection must isolate the generator power from utility power and must comply
with all applicable laws and electrical codes.
A CAUTION
• Improper connections to a building's electrical system can allow electrical current from the generator
to backfeed into the utility lines. Such backfeed may electrocute utility company workers or others
who are in contact with the lines during a power outage. For more information please consult with 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 utility power is restored, the generator may explode,
burn, or cause a fire in the building's electrical system.
2-5

2. Transportation and Installation
2.4 Selecting Cable
• Select a cable with sufficient diameter by considering the permissible current on the cable and the
distance from the generator to the load.
• If the current flowing to the load exceeds the permissible current of the cable, resultant overheating
may burn the cable. Similarly, if the cable is too small in thickness to the length, the input voltage
to the load will fall to cause the load input power to drop, as a result, the performance of the
machine cannot be displayed.
Cable Thickness A (mm
2)
j 0; 0
Cable Length L (m)
A180090
• Simplified formula to seek voltage drop or cross-sectional area of the cable from cable length and
working current. Select such a cable length and thickness so that the voltage drop will remain
within 5%.
Output system Voltage drop Cross-sectional e :Voltage drop
(V)
area of the cable
e': Voltage drop between an outside
30.8XLXI
30.8XLXI
line or one line of each phase,
Three-phase 3-wire Type
e=
1,000XA
A=
l,000X e
and a neutral line (V)
A: Cable thickness (mm2)
Three-phase 4-wire Type
e'=
17.8XLXI
A=
17.8XLXI
L :Cable length (m)
1,000XA l,000X e' I :
Working current (A)
• The following tables show the relations between the 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 lOV.)
s· I C d t C bl
1ng e- on uc or a e
Unit: mm
2
~
t 165ft (50m) 246ft (75m) 328ft (lO0m) 410ft (125m) 492ft (150m) 656ft (200m)
150A 38 38
50
60
80 100
200A 60 60 60
80 100 125
300A 100 100 100
125
150 200
400A 125 150 150 200 200 250
Three-Conductor Cable (Unit:
mm
2)
~
t 165ft
(50m)
246ft (75m) 328ft (lO0m) 410ft (125m) 492ft (150m) 656ft (200m)
150A 22x2 22x2
38X2 38X2
50X2
50X2
200A
38X2 38X2
38X2
50X2 50X2 60X2
300A
60X2 60X2 60X2
60X2 80X2
10ox2
400A
60X2
60X2 60X2
80X2
10ox2
125X2
2-6

2. Transportation and Installation
2.5 Fuel Pipe Selector Valve
2.5.1 Overview
This valve is designed to feed fuel directly from an external fuel tank or from the installed fuel tank
as described below.
2.5.2 Operation method
<Procedures>
1. The machine is delivered from the factory with fuel line piping and selector valves set as shown in
the following Fig.I. When operating the machine with the installed fuel tank, run the machine with
the fuel line piping and the handles of selector valves as set from the factory.
2. When using an external fuel tank, remove the plug fitted at the connections to the external tank
and set the piping as shown in Fig.2. And then turn the handles of the selector valve as shown in
Fig.2.
3. When removing the external tank piping connection, make sure to return the handles to the
original positions shown in Fig.I and install the plugs.
2.5.3 Installation of Separate Storage Fuel tank and piping method
<Procedures>
1. Use oil resistant hoses with an inside diameter of 8mm to 10mm.
2. Install the fuel tank so that the fuel level of the tank is between O and 2.5m high from the machine
installation level.
3. In order to avoid suction of water and sediment together, install the suction pipe so that the inlet
port of suction pipe may be kept between 15mm and 20mm higher than the bottom line of the tank.
Also install the outlet port of the return pipe inside the tank. (See Fig.2 ·A)
4. When refueling the tank, take caution to prevent water and particulate ingress.
Fig 1
A180092
2-7

2. Transportation and Installation
A CAUTIO
• Always watch the fuel supply conditions when supplying fuel from an external fuel tank.
• When using an external fuel tank, take care to ensure that the DEF tank is also refilled as needed.
• Make sure to return the handles of the selector valves to the predetermined positions. If you make a
mistake in turning the handles, it may cause fuel pipe rupture and cause overflowing from the fuel
tanks.
• Take great care not to use excessive force on the selector valve handle. It may cause damage or fuel
leakage.
• When using the external fuel tank, the Fuel Level displayed on the monitor will not provide an accurate
measurement.
2-8

3.1 Operation Panel
0
0
1. Panel Light
2. Control Panel
3. Circuit Breaker
4. Circuit Breaker Handle
3. Operation
1 2
0 0
0 0
7 6 5
5. Panel Light Switch
6. Voltage Adjuster
7. Control Power Switch
3-1
4
0
3
A210284E

3. Operation
Control Panel
Navigation buttons Display Monitor lamps
e
0
A180097E
Manual Mode button Alarm mute button
[How to switch between display screens]
1. Items show below can be selected by pressing the Left or Right arrow buttons @) ©.
Status
l++I
Engine
l++I
Generator
l++I
Alarms
l++IEGU Current DTGsl
t i
t I Aoout
l++I
Serial Port
l++I
Event log l++I ECU Prev.DTCsl
2. Use the Up and Down buttons @ G) to view details and parameters within a category.
3. The panel will return to main screen if no buttoms are pressed for 3 minutes.
DEF Tank Level E 11111 F
Main Screen A210286E
3-2