Hokuetsu AIRMAN SDG45S-8E2 User manual

AIRMAN
INSTRUCTION MANUAL
ENGINE GENERATOR
j SDG45S- 8E2 j .
[ENVIRONMENTAL CONTAINMENT
BASE TANK TYPE]
Please be sure to read this manual
before using this machine.
HOKUETSU INDUSTRIES CO., LTD.

Preface
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 because ofdesign 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 Internal Components
2. Transportation and Installation
2.1 Transporting Machine
2.2 Conditions of Installation
2.3 Grounding
2.4 Selecting Cable
2.5 Fuel Pipe Selector Valve
1-1
1-1
2-1
2-1
2-2
2-4
2-7
2-8
3. Operation --------------------------------------------------------------------------------------------- 3-1
3.1 Control Panel -------------------------
3.2 Connecting Loads ------------------------
3.3 Engine Oil • Coolant · Fuel
3.4 Before Starting the Unit ----------------------
3.5 Operating Procedure
3.6 Emergency Stop -------------------------
4. Failure and Troubleshooting ---------------~-------------------------------------------
4.1 Protection devices
4.2 Troubleshooting
3-1
3-3
3-7
3-9
3-15
3-22
4-1
4-1
4-3
5. Periodic Inspection ----------------------------------------------------------------------- 5-1
5.1 Important Items at Periodic Inspection and Maintenance ------------ 5-1
5.2 Maintenance Schedule ---------------------- 5-2
5.3 Replacement Parts Schedule -------------------- 5-3
5.4 Maintenance Items ------------------------
6. Storage and DisposaI -------------------------------------------------------------------
6. 1 Preparation for Long-term Storage
6.2 Disposal of Product ------------------------
7. Specifications -------------------------------------------------------------------------
7. 1 Specifications
7.2 Exterior drawing
7.3 Generator Wiring Diagram
7.4 Engine Wiring Diagram
7.5 Piping Diagram
5-4
6-1
6-1
6-1
7-1
7-1
7-2
7-4
7-5
7-7

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 & 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.
IA WARNING I 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.
I IMPORTANT I 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
WARNING
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 to www.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.
o ENGINE GENERATOR
0
MODEL I
F===========l
SER. NO. I
'-------;==========l
GEN.OUTPUT I k~
~-==========:
VOLTAGE I Y
'------;::=========:
FREQUENCY I Hz
PO WE R FA CT OR BOX PHASE 3
RULE JEM1398
~-------,
NET DRYM AS S kg
0 PER AT ING IIAS S ._____ ___ ___, kg
00 HOKUETSU INDUSTRIES CO., LTD.
MADE IN JAPAN
A040491
S-2
* Each illustrated figure (Fig.) has a number
(for instance, A040491) 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.
Always keep these labels clean . 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
LIFTING BAIL
39176 69300
2
ACAUTION
rL
PREVENT
BURNING ACCIDENT
Do not open
radiator cap while
it is still hot.
39176 69600
5
3
ACAUTION
rL
PREVENT
BURNING ACCIDENT
When work is required
near hot parts , wait
for the parts to coo I
down fu 11 y before
starting work.
3917669500
4
® I
Ji) DIESEL FUEL
I
EPA REGULA TIDN
ULTRA LOW SULFOR FUEL ONLY.
DIESEL A TRES FAIBLE TENEUR EN SOUFRE
FLAMMABLES
UNIQUEM ENT,
39178 22031
6 7
rn
A WARNING
A DANGER
&. WARNING
Breathing diesel engine exhaust exposes you to
chemicals known to the State ofCalifornia to cause
cancer and birth defects or other reproductive harm.
Do rot tcu:h live electrical ports.
Always wear dry insulotirg gloves.
Do not operate the unit \n the roin,Clf'OU1d stcming water or wren wet.
Maintain oil electrical cords and conections in§.ooer ccnditior.
[AJw~§_gf.ounalfii .9en!rol_or fo eprtflieJor§~OlLffii 391?6 62900
DO NOT OPEN PANEL WHILE
UNIT IS RUNNING
· ~~~1iT!t!ba:r:~~ operate the engine in a well-
If in an enclosed area, vent the exhaust to the
outside.
• Do not modify ortamper with the exhaust system.
• Do not idle the engine except as necessary.
HIGH VOLTAGE
391766240{ For more information go
www. P65warnings.ca.gov/diesel
8
&DANGER
Using a generator indoors CAN KILL YOU IN MINUTES,
Generator exhaust contains carbon monoxide.This is
a poison you cannot see or smell.
Jil ~~_y.
NEVER use inside a home Only use OUTSIDE and
or ga~ge,EVEN IF doors far away from windows,
ana windows are open, doors,and vents.
Avoid other generator hazards.
READ MANUAL BEFORE USE.
39176 09310
12
9
A WARNING
BEWARE OF EXHAUST
GASES
When you operate machine
INDOORS or in TUNNEL,
provide good ventilation.
Poor ventilation can cause
fatal accident.
39176 73300
13
AWARNING
DANGEREXPLOSIVE GASES
fit.'::- !:ft:,o;:.a~:;'t:.i:teC:~~!,/~x~~ A:~
or adjust PQ1t connections without pruper Instruction and training.
~tJ
~~
~\,
BEWARE OF
ENTANGLEMENT
Keep your hands AWAY from
fan during opration.
Entanglement in the fan
can cause serious injury.
39176 73500
KEEP VENT CAPS TIGHTAND LEVEL
POISON CAUSES SEVERE BURNS
ConUlns 1dluric acid. Avoid contact with tkln, eyes or clolhlng. In
event ol accident flush with water and cal I phYlician ~.
KEEP OUT OF REACH OF CHILDREN
39176 50000
S-3
10
A CAUTION
DO NOT SWITCH WHILE
UN IT IS RUNN I NG
39178 50820
39178 67840
11
A WARNING
;/JJ.
BEWARE OF
ENTANGLEMENT
Keep your hands AWAY from
moving parts such as
V-belts, pilleys etc ..
Entanglement in them
can cause serious injury.
39176 73800

Safety
• The locations of the safety warning labels are as follows.
1 2
Battery
B
11 12 10 3
A
D D
'lo
Fuel Tank
0~4
~
VIEW A A200207
S-4

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 rotating components during operation.
• When cleaning dust accumulated in devices such as filters, etc., with
compressed air, wear safety glasses, etc. to protect your eyes
S-5

A CAUT
H990432
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 the 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 5
8 7 6 A200205
No.
Description Function
1 Intercooler
Device that cools the air compressed by the engine
supercharger.
2
Air Filter
Filtering dust from intake air.
3
Engine
Device that drives the alternator.
4 Voltage
Selector Switch Switching output voltage.
5
Control Panel (Operation Panel) Controlling device; various meters and controls.
6
Alternator
Device that generates electricity supplied to a load.
7
Battery
Power source to start the engine.
8
Fuel Tank
Vessel for storing fuel.
1-1

1. Major Components
9 10
11 12 13
00
6 6 6 6 6
liliiiW -
17 16
15 14
A200206
No.
Description Function
9
Terminal Board Outlet ports for AC power.
10
DOC (Diesel Oxidation Catalyst) Catalyst for oxidizing exhaust gas.
11 Engine Oil Filler Port Port
for supplying / replenishing engine oil.
12 Reserve tank
Tank for checking & replenishing coolant
13 Radiator
Device that cools the engine coolant.
14
Fuel Pipe Selector Valve Device to switch to external fuel tank supply.
15
Engine Oil Filter Device that filters engine oil.
16
Fuel air- bleeding electromagnetic
Device that automatically bleeds air from the fuel
pump
lines.
17 Fuel Filter
Device that filters foreign matter & particulate mixed
in fuel.
1-2

2. Transportation and Installation
2.1 Transporting Machine
• When loading and unloading machine, be sure to use the lifting bail provided on the center of the
machine top.
2.1.1 Lifting
A
A180553
AwARNING
<Procedure>
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
lifting bail fitted at the top center of the unit,
and make sure that there is no person standing
around 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.
• Never go underneath the unit when suspended because it is very dangerous.
• Do not lift the unit while it is running. Otherwise, a fatal or serious accident may occur.
2-1

2. Transportation and Installation
2.2 Conditions of Installation
1, 000mm or more
Exhausted gas
Private house
~
Ji
0
0
, .... f
]~
s
0
0
0
, .... f
SG0110
PC002
t;--Using Blower
A050506-1
A050505
This machine should be installed only on a dry, level
surface and operated in an appropriate environment as
below:
• Ambient temp: 5°F to 104°F (-15°C to 40°C)
• Humidity: Less than 85%
• Altitude: Lower than 1,000m above sea level.
*Using the machine outside the above conditions may
cause serious failure.
• 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.
• Keep enough space around the unit for inspection and
maintenance access.
• 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 any 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 connection pipes.
• Never locate 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
Extended exhaust pipe
Exhaust gas
ouUetport ___ _
cJ'l\-~ c==-=:'.;"I
-.::..:
Exhausted
gas
A CAUTION
Safety Fence
V/,,,J V/,,,J
Air Inlet
¢=:J
A090641-1
SG0103-1
A050507-1
• When installing indoors, both an intake port and
an exhaust port must be used to improve air
ventilation.
• Make sure to secure enough space in front of air
suction 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 to send exhaust fumes
outdoors.
• The cooling air outlet port of radiator should have
access to the outdoors through a duct or the like
for air ventilation.
• The unit should be installed within 5° degree
inclination.
• If installation site is not flat, put square bar under
the unit 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.
• When installing the unit at the seashore, make
sure that it is not exposed directly to sea water
because there is a risk of the change to the
insulation resistance of the generator assembly
or control panel inside. To request a model with
measures against salt damage, please consult
the nearest sales office.
• When installing the unit at a sandy place, make
sure that exhaust from the generator or radiator
does not blow the sand up in the air or into the
machine.
• To prevent unauthorized personnel on the job
site from using or interacting with
2-3
the machine, please take precautions such as
safety fencing around the unit.

2. Transportation and Installation
2.3 Grounding
2.3.1 Ground Terminal
6 o O 6
Grounding method
A180816
• The ground terminal [A] on the AC output terminal
board is connected to ground of this unit and to the
ground terminals of each outlet.
Grounding Terminal [A]
Load Switch
Load
Grounding Rod
Grounding Rod
A180554
2.3.2 Grounding 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 (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: To test, depress the "TEST" button. (Power is turned oft)
RESET BUTTON: 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 ~
A040270
A CAUTIO
• Using the generator in rain, snow or near water can lead to death from electric shock.
2-5

2. Transportation and Installation
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.
• 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. For more information please consult with the
utility company or a qualified electrician.
2-6

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 melt 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 may be diminished.
Cable Thickness A (mm2) Working
Current I (A)
Load Switch
A180885
• 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 area of Cable
e: Voltage drop (V)
e': Voltage drop between
30.8 XLXI
A=
30.SXLXI
outside line or one line of
3 Phase, 3 Wire
e=
1,000XA
l,QQQX e
each phase and neutral
line.
17.SXLXI 17.SXLXI
A: Cable thickness (mm
2)
3 Phase, 4 Wire
e'=
1,000XA
A=
l,000X e'
L: Cable length (m)
r: 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.)
Single-Conductor Cable (Unit:
mm
2)
~
t 165ft (50m) 246ft (75m) 328ft (100m) 410ft (125m) 492ft (150m)
656ft (200m)
50A 8 14 22 22 30 38
100A 22 30 38 50 50 60
150A 38 38 50 60 80 100
Three-Conductor Cable (Unit:
mm
2)
Length
165ft (50m) 246ft (75m) 328ft (100m) 410ft (125m) 492ft (150m)
656ft (200m)
Current
50A 14 14 22 22 30 38
lO0A 38 38 38 50 50 60
150A 22x2 22x2
38X2 38X2
38X2 50X2
2-7

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. Machine is delivered from the factory with fuel line piping and selector valves set as shown in the
following Fig.1. When operating the machine, with the installed fuel tank, run the machine with
the fuel line piping and the handles ofselector 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.1 and install the plugs.
2.5.3 Installation of External 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. 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.
When using the
internal fuel tank
Inlet
When using an external fuel tank.
Selector handle
Suction side
Outlet ==rs.~~~=-
~
Selector handle
1-·-------------·--
! Return side
i
Outside
! r--·---·
I'~
!
i
1 t
Inlet ,
L___ _ ________ J
L ____ _
External fuel
tank
s
11:J
C'-1
---~ ~
~ ~
(External fuel
connection port) 15 to
20mm z
1--1
Fig 1
Fig 2
Generator grounding plan;E
A130861
2-8

2. Transportation and Installation
A CAUTIO
• Always watch the fuel supply conditions when supplying fuel from an external fuel tank. Make sure to
change the handles of the selector valves to the predetermined positions.
If you make a mistake in turning the handles, it can burst the fuel pipe and cause overflowing. It could
lead to a serious accident.
• Take great care not to use excessive force on the selector valve handle. It may cause damage or fuel
leakage.
2-9