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AirMan SDG1 00S-6A6, Instruction 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. 

BTW Equipment Supply • www.btwequipmentsupply.com • ORDER PARTS ONLINE

Summary of Contents for SDG1 00S-6A6

Page 1: ...G II U1 C G i J a C G a U1 l a 1 C e 0 0 t a AIRMAN INSTRUCTION MANUAL ENGINE GENERATOR SDG 25S 6A7 SDG 45S 6A6 SDG 65S 6A6 SDG100S 6A6 HOKUETSU INDUSTRIES CO LTD BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 2: ...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 ...

Page 3: ...nit 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 Mainte...

Page 4: ... 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 IMPO...

Page 5: ...d 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 di...

Page 6: ...lease 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 depart...

Page 7: ...e 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...

Page 8: ... 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 ...

Page 9: ...he 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 ...

Page 10: ...ck 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 avoi...

Page 11: ...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 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 12: ...1 Safety 1 9 The pasting position of safe warning label is as follows SDG25S 6A7 6 2 3 5 4 7 8 1 A040571 DETAIL OF INSTRUMENT PANEL 9 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 13: ...1 Safety 1 10 SDG45S 6A6 SDG65S 6A6 6 2 3 5 4 7 8 1 DETAIL OF INSTRUMENT PANEL 9 A040572 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 14: ...1 Safety SDG1 00S 6A6 1 2 7 5 C J CJ Jr i 3 CJ m A 8 o o 6 I I A050011 DETAIL OF INSTRUMENT PANEL 1 11 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 15: ... 2 1 Unit Appearance and Part Names EJ 4 3 I I 1 2 IE c J I Lifting bail 2 Exhaust outlet m I B SDG45S 6A6 2 1 n 3 Door 4 Instrument panel A040573 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 16: ... 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 A040574 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 17: ...r 7 Fuel tank 8 Sedimentor 2 Part Names 13 2 3 12 11 10 9 4 8 5 6 7 A040575 9 Filter for electromagnetic pump 10 Fuel air bleeding electromagnetic pump 11 Battery 12 Fuel filter 13 Engine oil level gauge 14 Output terminals 15 Generator 2 3 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 18: ...ator 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 BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 19: ...ort 6 Reserve tank 7 Radiator 4 2 5 11 5 6 7 9 8 A050016 8 Fuel tank 9 Intercooler 10 Fuel filter 11 Sedimentor 12 Engine oil filter 13 Battery 14 Output terminals 15 Generator Instrument 4 5 7 13 marked are provided on the other side opposite side of maintenance BTW Equipment Supply www btwequipmentsupply com ORDER PARTS ONLINE ...

Page 20: ...ut 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 cr...

Page 21: ...n 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 in the air or into the machine The machine should be operated in following conditions Ambient temperature 15 C to 40 C Humidity Less than 85 Altitude...

Page 22: ...ree 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 50A 8 14 22 2...

Page 23: ...on 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 SG0101 A CAUTION When using a single phase load 277Vor 139V see to it that the loads on the different p...

Page 24: ...ltage 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 Voltage selector sw Three phase 480 277V Output terminals Three phase 480V Output terminals Single phase 480V Output terminals Single phase 277V A040250 A040153 1 A040154 1 A040155 1 Voltage selec...

Page 25: ...independently of the position of voltage selector switch on the control panel Procedure CDStart the generator unit and turn the main breaker ON on the control panel Turn the receptacle breaker of output terminal ON 3 6 r12ov 7 rw O xl IT y2J A040271 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 CD...

Page 26: ... simultaneous current consumption from the main terminals SDG25S SDG45S SDG60S Single Phase 120V 20A GFCI Rcept Three Phase 240 480V Single Phase 240 120V Three Phase 240 480V Single Phase 240 120V Three Phase 240 480V Single Phase 240 120V kW kVA kW kVA kW kVA kW 0 0 25 0 14 4 45 0 26 0 63 0 36 5 1 2 20 8 13 2 40 9 24 8 59 0 35 3 2 4 16 7 12 0 36 7 23 6 54 9 34 1 3 6 12 5 10 8 32 6 22 4 50 7 32 9...

Page 27: ...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 28: ... 6A7 Selector valve SDG45S 6A6 SDG65S 6A6 SDG100S 6A6 A040583 3 6 2 Operation method 1 Select the valve position as Fig 1 when only the internal fuel tank of generator is used 2 Select the valve position as Fig 2 when both the internal fuel tank and trailer tank are used together 0 Fig 1 suction side return side IIInternal fuel tank Trailer fuel tank 3 9 Fig 2 suction side return side 11Internal 1...

Page 29: ...r crank warning lamp 11 Charging lamp 5 4 1 6 7 8 10 11 12 13 14 15 19 18 17 16 A040162 12 Glow lamp 13 Air filter clogging flickers warning lamp 14 Selector switch 15 Starter switch 16 Engine oil pressure gauge 17 Coolant temperature gauge 18 Ammeter for battery charge 19 Ammeter change over switch 20 Voltage regulator 21 Voltage selector switch 22 Three phase circuit breaker BTW Equipment Supply...

Page 30: ...0 lMPa pressure SDG45S lower than 22psi 0 15MPa SDG65S lower than 15psi 0 lMPa SDGlO0S lower than 15psi 0 lMPa Lamp glows when coolant temperature reaches and then engine stops Coolant SDG25S more than230 F llO C temperature SDG45S more than230 F llO C SDG65S more than221 F l 05 C SDGlO0S more than221 F l 05 C This lamp goes on when operator fails to Overcrank start engine during automatic operati...

Page 31: ...aker 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 4 3 ON J TRIP RESET A030403E Rese...

Page 32: ... 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 BUTTON To restore po...

Page 33: ...han 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 things as a screwdriver ball point pens etc A040188 Mac...

Page 34: ...s the oil level between MAX and MIN limits it is normal When the oil level is below its MIN 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 3 2 Check Coolant Level Taking off the radiator cap Be sure to stop the machine first and then loosen the radi...

Page 35: ...wear and other defect Loosen the mounting bolt of alternator once Then adjust it so that the belt deflection will be 8 12 mm 98 1N 10kgf when pressing with a finger Be careful not to leave any grease and LLC on the belt If any of such material is left wipe it off completely Fire prevention Do not under any circumstance bring lit cigarettes and or matches to the fuel The fuel is extremely flammable...

Page 36: ...ed with a frequency lower than the rated frequency it could cause the generator or to be burned 4 4 1 Procedure to Start the Unit Follow the starting procedure below Manual operation Switch OFF the circuit breaker on the instrument panel Set the selector switch 1 to MANUAL operation position Turning the starter switch to the RUN position the engine starts preheating automatically When the preheati...

Page 37: ...t 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 PK0028 The remote control terminal 1 is provided inside the output terminal Perform cable connection as shown below for remote control operation of the machine For this cable connection job make sure to remove the battery cathode c...

Page 38: ...2seconds 2seconds 5seconds cti O Cf O O O C C t cti cti 0 C1J C1J E 0 Cl Cl E 0 C C u5 Cf Cf en Olm Cl Cl O E Cf c 8 u5 u5 C t 0 C S C1J Q 1 C1J C1J a t Q t5 l 0 0 en en Ol 0 0 t C e en en Jg C1J w c5 c3 en 0 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 ev...

Page 39: ... up preheating 0 0 0 Off Off Off On Off On During Operation Full load 240 480 60 During Operation Unload 240 480 62 5 Less than rated current Off 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 opera...

Page 40: ... frequency during operation take the following steps Procedure CD Loosen the locknut of the engine governor adjusting bolt Watching the frequency meter adjust the frequency to the value mentioned in 4 4 1 by turning the adjusting bolt Turning screwing in the adjusting bolt to right increases frequency On the other hand loosening to the left lowers frequency After this adjustment is finished be sur...

Page 41: ... 4 8 Air Bleeding Emergency stop Emergency stop button Push button A040192 Reset H980179 Should the machine stop due to the shortage of fuel perform the air bleeding operation according to the following procedures Procedure CD Replenish fuel Place the operation selector switch to the MANUAL position Turning the starter switch to RUN position the electromagnet pump functions to bleed the air in fue...

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