AirMan SDG60S-7A6 Instruction Manual
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AirMan SDG60S-7A6 Instruction Manual

Engine generator
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Summary of Contents for AirMan SDG60S-7A6

  • Page 2 Preface Thank you for having selected our “AIRMAN” product. ◆ This manual explains about the proper operation and daily inspection and maintenance of this machine. ◆ In order to use a machine safely, people with sufficient knowledge and sufficient technology need to deal with it.

  • Page 3: Table Of Contents

    Table of Contents Safety ..............................1-1 Caution before Operation ......................1-2 Caution during Operation ......................1-4 Caution during Inspection and Maintenance ................1-6 Safety Warning Labels ........................1-8 Part Names ............................. 2-1 Internal Components........................2-1 Installation .............................. 3-1 Transporting Unit ........................... 3-1 Conditions of Unit Installation ......................

  • Page 4: Safety

    1.Safety This 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...

  • Page 5: Caution Before Operation

    1.Safety Caution before Operation 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.
  • Page 6 1.Safety 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.

  • Page 7: Caution During Operation

    1.Safety 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.
  • Page 8 1.Safety 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.

  • Page 9: Caution During Inspection And Maintenance

    1.Safety 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.
  • Page 10 1.Safety 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.

  • Page 11: Safety Warning Labels

    1.Safety 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.

  • Page 12: Part Names

    2. Part Names 2.1 Internal Components A070010-1...
  • Page 13 2. Part Names Description Function Control panel Panel fitted with various meters and controllers. Air filter Filtering device for filtering dust floating in intake air. Engine oil level gauge Scale for measuring engine oil level. Engine oil filter For filtering engine oil. Engine For driving the generator main unit.

  • Page 14: Installation

    3. Installation 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“2”to secure it with rope.

  • Page 15: Conditions Of Unit Installation

    3. Installation Conditions of Unit Installation Ventilation Exhaust gas from the engine is poisonous, and it could cause casualties when it is inhaled. 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.
  • Page 16 3. Installation How to locate the unit Never locate the unit with the exhaust muffler facing any private house: As the exhaust fume (gas) from the engine is poisonous, never direct it to any other persons passing by. ○ × Private house A050505 Installation...
  • Page 17 3. Installation Preparation of safety fences 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 Safety fences around the unit: A050507...

  • Page 18: Leakage Protection Device And Grounding Method

    3. Installation Leakage Protection Device and Grounding Method Caution on Grounding Make sure to perform grounding connection of the external body of load. If such grounding connection is neglected or fails, it can cause electric shock to human body by leaked current, leading to serious accident as death.
  • Page 19 3. Installation Independent grounding method Leakage relay ground terminal (E) Machine grounding Load equipment terminal Grounding rod Grounding rod A050314-1 Common grounding method Leakage relay ground terminal (E) Machine grounding Load equipment terminal Grounding rod Grounding rod A050315-1...

  • Page 20: Selecting Cable

    3. Installation Selecting Cable Select a cable with sufficient diameter by considering the permissible current on the cable and the distance from the machine to the load. If the current flowing to the load exceeds the permissible current of the cable, resultant overheating may burn the cable.

  • Page 21: Operation

    4. Operation 4.1 Instrument panel A070001E 1. Output indicator lamp 10. Monitor lamp (for details, see 4.2.1) 2. Voltmeter 11. Leakage relay 3. Ammeter 12. Starter switch 4. Panel light switch 13. Current selection switch 5. Frequency meter 14. Voltage regulator 6.

  • Page 22: Protection Device

    4. Operation 4.2 Protection device For prevention of troubles during operation, this machine is provided with various protection devices. When the engine stops due to function of the protection devices and circuit breaker trips, get rid of the causes of trouble, referring to the trouble shooting clause and then restart operation. List of protection devices 4.2.1 This machine is equipped with the following devices in the table.
  • Page 23 4. Operation 4.2.2 Leakage Relay When residual current flows to machine and load, the residual current indicator lamp goes on to trip the circuit-breaker and circuit breaker (dedicated to single phase). (Set value at which it starts to function: 30mA) Pressing the reset button of leakage relay, and returning the lever of the circuit-breaker to OFF position once, then it is possible to switch ON...

  • Page 24: Check Frequency Selection Switch For Avr

    4. Operation 4.2.5 Circuit protector (CP) for AVR protection AVR is equipped with circuit-protector (CP) for protection against overcurrent. Under following cases, it happens to function. In case the machine gets overloaded while engine speed is still lower. In case the output voltage of machine is increased higher than the specified voltage.

  • Page 25: How To Switch Voltages

    4. Operation 4.4 How To Switch Voltages It is possible to select 3 phase 4 wire 200 volt or 3 phase 4 wire 400 volt. But before starting operation, make sure to confirm the voltage set for the machine without fail. If any load is connected to the machine with the wrong voltage set, it can cause damage or burning accident to the load.

  • Page 26: Connecting Load

    4. Operation 4.5 Connecting Load Electric shock and electric leak Make sure not to connect the output terminal of the machine with the commercial power source from electric power company. This is not only prohibited by the regulations, but it may cause an electric shock, machine troubles and even a fire.
  • Page 27 4. Operation Install a switch between the output terminal and the load to switch on/off the load. Do not switch the Switch panel for load on/off directly by the circuit-breaker of the switching on/off load machine. It could cause damage to the Connect the connect- ing cable to the load so that the output terminals should not touch each other.
  • Page 28 4. Operation 4.5.2 How to connect single phase load The method of connection of 3 phase 4 wire single phase load is as follows. The allowable current limit shall not exceed the values in the following table. Conditions of Load Allowable Current Limit Conditions Allowable current limit up to...
  • Page 29 4. Operation 4.5.3 Single Phase Output (100/110V 50/60Hz) In the output terminal portion the single phase output terminal (U ) (W ) two set and the auxiliary receptacle are provided. When the AC ammeter indicates 200/220V and 400/440V, the single phase output voltage is 100/110V.

  • Page 30: Engine Oil・Coolant・Fuel

    4. Operation 4.6 Engine Oil・Coolant・Fuel 4.6.1 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. Relation between viscosity (SAE) and temperature SAE Viscosity number Temperature...

  • Page 31: Check Before Starting The Machine

    4. Operation 4.7 Check before Starting the Machine Check before starting the unit Be sure to check the machine before operation. When any abnormality is found, be sure to repair it before starting the unit. Be sure to make daily check before operation. If the unit is operated without prior check and without no- ticing its abnormality, such operation could cause seizure of components or may even cause fire.
  • Page 32 4. Operation 4.7.3 Check Fuel Before starting operation, make sure to check the level of residual fuel so that fuel shortage during operation can be avoided. If necessary, drain condensate accumulated at the bottom of the fuel tank. Fire prevention Do not, under any circumstance, bring lit cigarettes and/or matches to the fuel.
  • Page 33 4. Operation 4.7.6 Check V-belt Tension If V-belt tension too tight, it can cause shaft breakage or shorten the life of a bearing. If too loose, the belt may slip and will cause early breakage or damage to the belt. Adjust the fan belt and alternator V-belt by the following procedure: Depress the middle of...

  • Page 34: Operation And Stopping

    4. Operation 4.8 Operation and Stopping Never touch the interior of output terminals ,control board Keep the output terminal cover shut and locked whenever the machine is running. Notice that the voltage of several hundreds volt is applied to the output terminal and control board. When opening the door unavoidably, be careful not to touch the rotating parts and hot parts.
  • Page 35 4. Operation After the engine starts up, warm up it under unload for approx. five minutes. Warming up after starting up is necessary for smooth operation of the engine. Do not operate the en- gine at full load immediately after it starts up. This will shorten the equipment life. During the warm-up operation, examine the different parts of the equipment for any looseness, leakage of water, oil, fuel, and other irregularities.
  • Page 36 4. Operation 4.8.2 Gauge Indication while Operating During normal operation, each indication of instruments is shown in the table below. Refer to the table for daily checks. Indicator Monitor lamp lamp Voltmeter Frequency Ammeter meter Engine Water Excessive (Hz) Charge Leak temp.
  • Page 37 4. Operation 4.8.5 Operating Procedures when Engine Fails to Start up on First Attempt When the engine fails to start up even following the start-up procedures, do not keep the starter running, but set the starter switch back to “STOP” and wait about 30 seconds. Then, repeat the start-up procedure once again.

  • Page 38: Periodic Inspection/Maintenance

    5. Periodic Inspection/Maintenance 5.1 Important Items at Periodic Inspection and Maintenance or after Maintenance The manual shows proper interval for periodic inspection and maintenance under normally oper- ating conditions. Inspection and maintenance should be performed more often under extremely harsh conditions . Hang a “...

  • Page 39: Daily Inspection And Keeping Operation Log

    5. Periodic Inspection/Maintenance 5.2 Daily Inspection and Keeping Operation Log Be sure to carry out daily inspection every morning before operation. See Chapter 4 “OPERATION” of the manual for the details of inspection. Pay attention to and carefully observe the following points during daily operation or inspection and maintenance work.

  • Page 40: Periodic Inspection List

    5. Periodic Inspection/Maintenance 5.4 Periodic Inspection List Such items marked shall be carried out by customers. ○ For the following items or clauses marked ●, contact us directly or our distributors because they re- quire expert technical knowledge on them. ◎Refer to engine operation manual for inspection and maintenance of an engine.

  • Page 41: Maintenance

    5. Periodic Inspection/Maintenance 5.5 Maintenance 5.5.1 Change Engine Oil [At 50 hours for the first change and every 500 hours thereafter] Caution in filling or draining engine oil When checking, replenishing, and draining the engine oil, be sure to wait 10 to 20 minutes after engine stops until it cools down. Engine oil is very hot and highly pressurized during or just after the operation.
  • Page 42 5. Periodic Inspection/Maintenance 5.5.2 Change Engine Oil Filter [At 50 hours for the first change and every 500 hours thereafter] ＜Procedure＞ ① When installing a new oil filter“1”, spread oil over the packing“2”, and then screw it in. When the packing touches the sealing surface, further tighten the filter by approximately two-thirds turn with a filter wrench.
  • Page 43 5. Periodic Inspection/Maintenance 5.5.4 Check Leakage Relay Operation [Every 2 months or every 250 hours] Never attempt to test the leakage relay by way of human body. In case the leakage relay has tripped due to leakage, always investigate the cause to remove it. Regularly check the relay operation for safety.
  • Page 44 5. Periodic Inspection/Maintenance 5.5.6 Check and Clean Clogging of Air Filter Element [Every 250 hours] Be sure to properly clean air filter element When an element that is clogged or has holes or cracks is used, dust or foreign material will get in the engine.
  • Page 45 5. Periodic Inspection/Maintenance 5.5.8 Check Battery electrolyte and specific gravity of battery electrolyte [Battery electrolyte : every 250 hours] [Specific gravity of battery electrolyte : every 500 hours] If there to be a problem in starting an engine due to a flat battery, carry out the checks by following the procedures below: (1) Ordinary type battery: Measure specific gravity of battery electrolyte, and if it shows below 1.24, recharge the battery...
  • Page 46 5. Periodic Inspection/Maintenance 5.5.12 Change Filter inside the fuel air-bleeding electromagnetic pump [Every 1,000 hours] Turn the cap “1” counterclockwise to remove it, change the filter “2” inside. (See 5.3.) As the fuel inside spills out when it is removed, prepare a fuel receiver.
  • Page 47 5. Periodic Inspection/Maintenance 5.5.15 Change Air Filter Element [Every 1,000 hours] Be sure to properly clean air filter element When an element that is clogged or has holes or cracks is used, dust or foreign material will get in the engine.
  • Page 48 5. Periodic Inspection/Maintenance 5.5.16 Clean inside of the oil fence and check it for any rust [Every 1 years] <Procedure> ① Remove the oil filler cap cover, fuel pipes and electric wire connected to the fuel tank. ② Remove 6 pieces of the bolts connecting oil fence and the machine with the lifting eye hooked with the crane.
  • Page 49 5. Periodic Inspection/Maintenance 5.5.17 Change Coolant [Every 2 years] Upon changing coolant Be sure to stop the machine and loosen the radiator cap slowly, after the coolant water is sufficiently cooled and the inner pressure is released, then take the cap off. If the following procedures are neglected, the radiator cap could be blown by the internal pressure or hot moisture air be blown out to cause burning.

  • Page 50: Maintenance/Adjustment

    6. Maintenance/Adjustment 6.1 Maintenance of Battery Handling battery Keep flames away from battery. Battery may generate hydrogen gas and may explode. Therefore, recharging should be done at a well-ventilated place. Do not spark near the battery nor light a match, nor bring lit cigarette and match close to the battery.
  • Page 51 6. Maintenance/Adjustment 6.1.1 Charge Battery Disconnect the cable between battery and the unit, and charge the battery with a 12 V battery charger. Do not charge two batteries at the same time. Be sure not to connect (+) and (–) terminals backwards. Be sure to read the operation manual of the battery charger to know if it is applicable, before using it.

  • Page 52: Troubleshooting

    6. Maintenance/Adjustment 6.2 Troubleshooting Should any trouble occur during operation, do not leave it. Investigate the cause and take appropriate measures. Read the manual carefully and fully understand what to do in case of trouble. The better you understand the construction and function of the unit, the faster you can find a problem and solution.
  • Page 53 6. Maintenance/Adjustment Symptom Cause Counter measures Even when (1) Faulty voltmeter Check/change operated at a rated (2) Poor tightening of terminals Check/repair speed, no voltage or (3) Broken or short-circuited winding of Check/repair too low voltage generator main unit generated. (4) Faulty AVR Check/change (5) Faulty silicon rectifier (mounted on...

  • Page 54: Storage Of The Unit

    7. Storage of the Unit 7.1 Preparation for Long-term Storage When the unit is left unused or not operated longer than half a year (6 months), store it at the dry place where no dust exists after the following treatments have been done to it. Put the unit in a temporary cabin if it is stored outside.
  • Page 55 8. Specifications Specifications Model SDG60S-7A6 Specifications Dual Voltage Type (With oil fence) Brushless Exciting system Three-phase, four-wire system Phase number Power factor Frequency Rated output Rated output Voltage 380/400/415 Current 76.0/72.2/69.6 78.7 Voltage 7.5×2 8.25×2 Exclusive terminal 1.5×2 1.65×2 Outlet...

  • Page 56: Specifications

    8. Specifications Outline drawing...

  • Page 57: Wiring Diagram

    9. Wiring Diagram 9.1 Generator Wiring Diagram A050635E...

  • Page 58: Engine Wiring Diagram

    9. Wiring Diagram 9.2 Engine Wiring Diagram A070003E...

  • Page 59: Piping Diagram

    10. Piping Diagram 10.1 Fuel piping A070103E-1 10-1...
  • Page 60 北 越 工 業 株 式 会 社    発行 本社工場 新潟県燕市下粟生津3074 TEL ０２５６−９３−５５７１ FAX ０２５６−９４−７５６７ (無断複写・転載を禁ず) ＨＯＫＵＥＴＳＵ ＩＮＤＵＳＴＲＩＥＳ ＣＯ., ＬＴＤ. 8TH FLOOR SHINJUKU SAN-EI BLDG, 22-2 NISHI-SHINJUKU 1-CHOME,SHINJUKU-KU TOKYO 160-0023 JAPAN TEL:81-3-3348-7281 FAX:81-3-3348-7289 URL:http//www.airman.co.jp 39600 85821 PRINTED IN JAPAN 2007. 9...

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