AirMan SG Series Instruction Manual
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AirMan SG Series Instruction Manual

Engine generator environmental containment base tank type
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  • Page 2 Preface Thank you for choosing “AIRMAN”  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.

  • Page 3: Table Of Contents

    Table of Contents 1. Major Components ----------------------------------------------------------------------------- 1-1 Internal Components --------------------------------------------------------------------------------------------- 1- 1 2. Transportation and Installation ------------------------------------------------------------- 2-1 Transporting Machine -------------------------------------------------------------------------------------------- 2- 1 Conditions of Installation ---------------------------------------------------------------------------------------- 2- 2 Grounding ----------------------------------------------------------------------------------------------------------- 2- 5 Selecting Cable ---------------------------------------------------------------------------------------------------- 2- 8 Fuel Pipe Selector Valve ---------------------------------------------------------------------------------------- 2- 9 3.
  • Page 4 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”...
  • Page 5 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. ※...
  • Page 6 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.
  • Page 7 Safety  The locations of the safety warning labels are as follows. Radiator Battery 10 9 VIEW A A190013...
  • Page 8 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.
  • Page 9 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 water could jet out, causing burns or scalding. H990432 ...

  • Page 10: Major Components

    1. Major Components 1.1 Internal Components A190058 Description Function SCR(Selective Catalytic Reduction) Selective reduction-type catalyst that uses DEF as a reducing agent. Radiator Cooling the coolant for engine in the system. Reserve Tank Checking coolant level and supplying it. Air Filter Filtering dust from intake air.
  • Page 11 1. Major Components A190059 Description Function Control Panel Controlling device; various meters and controls. Engine Driving the generator. Intercooler Cooling the air compressed by engine supercharger. DEF Tank Container for DEF DOC(Diesel Oxidation Catalyst) Catalyst for oxidizing exhaust gas. Fuel Tank Storing fuel.

  • Page 12: Transportation And Installation

    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 <Procedure> 1. Before lifting the unit up, make sure to check the lifting bail [A] for any cracks or loosened bolts.

  • Page 13: Conditions Of Installation

    2. Transportation and Installation 2.2 Conditions of Installation The machine has to be installed on a dry, firm, and level area.  The machine should be operated in the following conditions: Ambient temp: -5°F to 104°F (-15°C to 40°C)  Humidity: Less than 85% ...
  • Page 14 2. Transportation and Installation  Never locate the unit with the exhaust muffler facing ○ any private house.  As the exhaust gas from the engine is poisonous, never direct it to any other persons passing by. × Private house A050505 In case that the machine is installed indoors ...
  • Page 15 2. Transportation and Installation  The unit should be installed within 5 ﾟ degree inclination.  If installation site is not flat, put square bar under the unit so as to install it horizontally.  Avoid installing the unit in a damp place or a place where water collects.

  • Page 16: Grounding

    Load Switch Load Grounding Rod Grounding Rod A180934 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 is connected to the system ground.
  • Page 17 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.
  • Page 18 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.

  • Page 19: Selecting Cable

    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.

  • Page 20: Fuel Pipe Selector Valve

    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 <Procedure> 1. Machine is delivered from factory with fuel line piping and selector valves built in as shown in the following Fig.1.
  • Page 21 2. Transportation and Installation  Always keep watching the fuel feeding conditions while feeding fuel from the external fuel storage tank.  When using an external fuel tank, take care to ensure that the DEF tank is also refilled as needed. ...

  • Page 22: Operation

    3. Operation 3.1 Control Panel A180918 1. Panel Light 4. Panel Light Switch 2. Control Panel 5. Voltage Adjuster 3. Circuit Breaker 6. Control Power Switch...
  • Page 23 3. Operation Control Panel Navigation button Display Monitor lamp Stop/Reset button Auto Mode button Start button Manual Mode button Alarm mute button A180097E [How to switch monitor] 1. Items shown below can be selected by pressing◄ or ► button. Status Engine Generator Alarms...

  • Page 24: Connecting Loads

    3. Operation 3.2 Connecting Loads Select a cable with sufficient diameter by considering the load capacity and the distance from the generator to the load. Use terminals for connection and securely fasten them. (See 2.4)  After checking phase number and voltage of the load, 3 Phase output terminal make sure to connect them correctly.
  • Page 25 3. Operation 3.2.1 How To Switch Voltages  Open the operation panel and connect the terminal bars as shown in the diagrams below to achieve desired voltage.  For the 480/277V configuration, stack 2 bars for each connection. Voltage Selector Plate Three phase 480/277V A040153-1 A040154-1...
  • Page 26 3. Operation 3.2.2 Auxiliary AC Power GFCI RECEPTACLES BREAKER AUX. RECEPTACLES BREAKER GFCI receptacles can be used Aux. receptacles can be used independent of the position of independent of the position the short-circuit plate behind of the short-circuit plate the control panel. behind the control panel.
  • Page 27 3. Operation 3.2.3 The Maximum Combined Simultaneous Power Consumption Refer to the table below for maximum load capacity of the GFCI receptacles at different voltages. (GFCI amperage values are per receptacle.) [Allowable load capacity of GFCI at three phase] Three Phase GFCI (240/480V) Receptacle...

  • Page 28: Engine Oil･Coolant･Fuel・Def

    3. Operation 3.3 Engine Oil・Coolant・Fuel・DEF 3.3.1 Engine Oil Use engine oil recommended below. Be sure to use CJ-4 class or higher engine oil or superior class. (Using engine oil with poor quality may shorten the life of the engine). Classification API service classification CJ-4 class or higher Viscosity SAE10W-40 (as ex-factory)
  • Page 29 3. Operation 3.3.2 Coolant Coolant freezing could cause cracks of cylinder and radiator. Be sure to always use mixture of LLC (antifreeze) and soft water (like tap water) of good quality.  When water with dirt, sand, or dust, or hard water such as well water (ground water) is used, deposits can form inside the radiator or on the cylinder head and resulting in engine overheat from poor coolant flow.
  • Page 30 3. Operation 3.3.4 DEF DEF (AdBlue or equivalent) is a transparent, colorless, and non-hazardous. In some circumstances, DEF will put off odor, but this is normal and not indicative of any problems.  Only use DEF which conforms to API standards. ...

  • Page 31: Before Starting The Unit

    3. Operation 3.4 Before Starting the Unit Be sure to check the unit before operation. When any abnormality is found, be sure to repair it before starting. Be sure to make daily check before operation. If the unit is operated without prior check and without noticing its abnormality, such operation could cause seizure of components or may even cause fire.
  • Page 32 3. Operation 3.4.2 Check Coolant Level  Check the coolant level in the surge tank. If it is lower than the limit, open the cap and refill the coolant. (Level must be kept above LOW.)  If the coolant in the surge tank is exceedingly low or empty, remove the radiator cap and check the amount of coolant in the radiator.
  • Page 33 3. Operation 3.4.3 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.  Refilling fuel tank should be done in an outdoor well-ventilated place. ...
  • Page 34 3. Operation 3.4.5 Check DEF Level  If DEF tank level is below 10%, warning lamps will DEF TANK LEVEL illuminate and symbols will be displayed as shown below.  If DEF tank level is at 0% and the engine is operated with no DEF, the engine will shut down.

  • Page 35: Clean Instruments In Control Panel

    3. Operation 3.4.7 Clean Instruments In Control Panel  Before starting operation, open control panel and check each Air blow breaker, terminal plate and each controller for any dust, sand and dirt accumulated.  If the machine is operated with dust, sand, or dirt in the instrumentation, it could cause malfunction or damage.
  • Page 36 3. Operation 3.4.9 Check Thermo Label of Alternator Thermo-label on the stator irreversibly changes its color from white to brown by reaching or exceeding 212°F ( 100℃), that signalize overload during operation. Do not overload the generator.  Remove the trash and dust from the generator inside by Stator thermo-label 212°...

  • Page 37: Operating Procedure

    3. Operation 3.5 Operating Procedure Make sure that all enclosure doors are closed before starting. 3.5.1 Operating Procedure To start, please follow the procedure below. Manual Start Procedure <Procedure> 1. Set the circuit breaker [A] on the instrument panel to [OFF] position. 2.
  • Page 38 3. Operation Check frequency and voltage <Procedure> 1. After warming up, display Generator monitor and press ▲▼ to show [Generator Frequency] . Check that the frequency of the generator is at 60Hz after warm up. (See 3-2) Monitor Screen 2. Press ▲▼ to show [Generator Voltage] and adjust to rated voltage with a voltage adjuster [F]. Display Voltage Adjuster Operation with Load...
  • Page 39 3. Operation Auto Start 1. Cable connection method of remote control switch. The remote control terminal [J] 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 cable terminal.
  • Page 40 3. Operation 2. Function  When the start signal activates in stand-by mode, it starts the unit. (This includes preheating.) When the stop signal activates, the unit will continue to operate for 10 seconds to cool down, then the unit stops and is placed again in stand-by mode. A190108 3.
  • Page 41 3. Operation 3.5.2 Meters and indicator lights during operation During normal operation, each indication of instruments is shown in the table below. Refer to the table for daily checks. Note: The values marked ＊ vary with location of the voltage selector switch. Monitor Lamp Voltage Frequency...
  • Page 42 3. Operation  Do not under any circumstance, open the portions below during operation. Coolant drain valve  Engine oil drain valve  PK0028  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.
  • Page 43 3. Operation 3.5.5 Fuel line air bleeding device If the machine runs out of fuel, bleed the air, according to the following procedures. <Procedure> 1. Loosen air bleeding plug [A] of fuel filter. 2. Loosen it till the head of priming pump [B] comes out.

  • Page 44: Emergency Stop

    3. Operation 3.6 Emergency Stop 3.6.1 Emergency stopping procedures  If it is necessary to stop the generator for emergency, press the Emergency Stop button located under the control panel. When shutting down with the emergency stop button, the machine will stop immediately.

  • Page 45: Scr Cleaning

    3. Operation 3.7 SCR Cleaning  SCR (Selective Catalytic Reduction) is a cleaning device to reduce nitrogen oxide (NOx) in exhaust gas by converting it into harmless water (H O) and nitrogen (N  In order to maintain the function of the system, cleaning (purge) is performed automatically for each fixed operating time.

  • Page 46: Scr Inducement

    3. Operation 3.8 SCR Inducement  The warnings below will be indicated before the situation become critical when sensing problems such as no DEF supply, use of poor quality DEF, DEF injection issues, or disconnection of sensors etc.  If no action is performed, the engine will shutdown 3.5 hours later. ...

  • Page 47: How To Activate Escape Mode

    3. Operation 3.9 How to activate Escape Mode  When the engine is stopped due to final Inducement, the unit can only be run for 30 minutes by performing Escape mode. <Procedure> 1. Press and hold the tick ✔ button on the control panel to access the Running Editor. 2.

  • Page 48: Failure And Troubleshooting

    4. Failure and Troubleshooting 4.1 Protection device To prevent issues during operation, this machine is equipped with various protection devices. 4.1.1 List of protective devices, warning lamps, and monitor alarms This machine is equipped with protective devices, and indicates the type of issue with lamps and messages on the monitor display as shown in the table below.
  • Page 49 4. Failure and Troubleshooting 4.1.2 Circuit Breaker  In case of an overload or short-circuited wire connection, the circuit-breaker trips.  When the breaker is tripped, stop the machine immediately and reset the circuit breaker after resolving the cause of the trouble. <How to reset>...

  • Page 50: Troubleshooting

    4. Failure and Troubleshooting 4.2 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 machine, the faster you can find a problem and solution.
  • Page 51 4. Failure and Troubleshooting Symptom Cause Counter measures Circuit breaker (1) Overloaded Reduce the load trips. (2) Short-circuit occurred at the load side. Get rid of cause of short-circuiting. Even when operated (1) Poor tightening of terminals Check/tightening at a rated speed, no (2) Broken or short-circuited circuit to Repair voltage or too low...

  • Page 52: Periodic Inspection

    5. Periodic Inspection 5.1 Important Items at Periodic Inspection and Maintenance The following table shows the inspection and maintenance intervals under normal operation conditions. When used or operated under hard environmental conditions, it is impossible to warrant the machine even if the above conditions are performed according to the intervals listed in the above table.

  • Page 53: Maintenance Schedule

    5. Periodic Inspection 5.2 Maintenance Schedule Such items marked ○ shall be carried out by customers. For the following items or clauses marked ●, contact your nearest dealer because they require expert technical knowledge on them. The following table shows the intervals of inspection and maintenance under normal operation conditions.

  • Page 54: Periodic Replacement Parts

    5. Periodic Inspection Every Every Every Maintenance Daily 1,000 Ref. Remarks hours hours hours Check interior 3-13 ○ Check oil fence drain 3-15 ○ Check terminal and wirings 5-13 Every 4 months ○ Check engine/generator mount 5-14 Every 1 year ○...

  • Page 55: Maintenance Items

    5. Periodic Inspection 5.4 Maintenance Items 5.4.1 Change Engine Oil (Change the engine oil filter at the same time) Every 500 Hours When checking, replenishing, and draining the engine oil, be sure to wait more than 10 minutes after engine stops to allow it to cool down. When draining oil, prepare a small length of hose (300mm), hose joint (R3/4), and a container for drained oil.

  • Page 56: Change Engine Oil Filter Element (Main / By-Pass)

    5. Periodic Inspection 5.4.2 Change Engine Oil Filter Element (Main / By-pass) Every 500 Hours <Procedure> Main filter By-pass filter 1. Loosen the drain plugs [A] on the main filter and by-pass filter and drain. 2. Loosen the center bolt [B] and [C] of each filter. 3.
  • Page 57 5. Periodic Inspection 5.4.4 Maintenance of Battery Battery may generate hydrogen gas and may explode. Therefore, recharging should be done at a well-ventilated place.  Do not check the battery by short-circuiting the positive and negative terminals with a metallic piece.

  • Page 58: Check And Clean Air Filter Elements

    5. Periodic Inspection [How to use booster cable] <Procedure> To engine block 1. Stop the engine. 2. Connect one end of the (+) booster cable to the (+) Internal battery terminal of the machine battery. 3. Connect the other end of the (+) booster cable to the Booster cable (+) (+) terminal of the external battery.

  • Page 59: Check Accumulations In Exhaust System

    5. Periodic Inspection 5.4.6 Check Accumulations in Exhaust System Every 250 Hours When a diesel engine driven generator is continuously operated with less than 30% load or no load for a long time, carbon will be stuck inside the exhaust pipes, exhaust muffler, and engine body. Unburned fuel may also come out from connected portions of exhaust pipe and outlet port of the exhaust muffler.
  • Page 60 5. Periodic Inspection 5.4.8 Check Insulation Resistance Every 2 months or 250 Hours <Procedure> 1. Remove the load side cable from the output terminal board. To Bonnet 2. Loose and remove the bolt (M8) securing the ground cable between [N] and [GROUND] on the output terminal board. 3.

  • Page 61: Drain Fuel Tank

    5. Periodic Inspection 5.4.9 Check Thermo Label on the Generator Every 2 months or 250 Hours Thermo-label on the rotor bearing irreversibly changes its color from white to blue by reaching or exceeding 176°F (80°C). Be sure to check the bearing for abnormal noise and vibration if it has changed color.

  • Page 62: Change Fuel Pre-Filter Element

    5. Periodic Inspection 5.4.12 Change Fuel Pre-filter Element Every 500 Hours <Procedure> 1. Loosen the drain plug [A] and air bleeder plug [B] to discharge the fuel inside the filter. After draining completed, tighten the plugs [A] and [B] securely. 2.

  • Page 63: Check And Cleaning Of The Supply Pump Strainer

    5. Periodic Inspection 5.4.14 Check and Cleaning of the Supply pump strainer Every 500 Hours  Loosen the supply pump strainer [A] (joint bolt built-in type) and remove it. After washing it with diesel oil, blow dust and dirt off with high pressure air.

  • Page 64: Check Exhaust Flexible Pipe

    5. Periodic Inspection 5.4.16 Check Exhaust Flexible Pipe Every 4 months or 500 Hours  Check the flexible pipe between the DOC Exhaust flexible pipe and engine exhaust outlet for cracks and exhaust gas leakage. Crack  If any leak is found, take care to avoid getting burned by exhaust gas.
  • Page 65 5. Periodic Inspection 5.4.18 Check Engine/Generator Mount Every year or 1,000 Hours The vibration isolation rubbers [A] are used for the support of generator and engine. Check the rubber for any damage or deterioration due to oil sticking. A180944 5.4.19 Clean the oil fence and check for rust Every year or 1,000 Hours Expert knowledge is required to clean the inside of the oil fence and to check it for rust.
  • Page 66 5. Periodic Inspection 5.4.21 Change DEF Dosing Unit Filter Every 3,000 Hours <Procedure> 1. Set a container under supply module [A], loosen cover [B], and pull it out together with DEF Dosing Unit Filter [C]. 2. Assemble a new DEF Dosing Unit Filter [C]. (For part number, See 5.3) 3.

  • Page 67: Change Coolant (Llc)

    5. Periodic Inspection 5.4.22 Change Coolant Every 2 years When removing the radiator cap, be sure to stop the machine and wait until the coolant cools down. <Procedure> 1. To drain coolant, remove the radiator cap [A], then loosen the drain valve [B]. 2.

  • Page 68: Storage And Disposal

    6. Storage and Disposal 6.1 Preparation for Long-term Storage When the machine is left unused or not operated longer than half a year (6 months), store it in a dry place free of dust after the following treatments have been done to it. ...

  • Page 69: Specifications

    7. Specifications 7.1 Specifications Model SDG400S-8E1 Exciting system Brushless Armature Connection Star with Neutral Phase number 3 Phase – 4 wire Power Factor Frequency Rated Output kVA (kW) 400 (320) Voltage Amps Model ISUZU BQ-6WG1XAGD-02 4 Cycle, water cooled, direct injection, Turbocharged, Type DOC＋SCR Aftertreatment...

  • Page 70: Outline Drawing

    7. Specifications 7.2 Outline drawing [Unit : in.] A190011E...
  • Page 71 7. Specifications [Unit : mm] A190012E...

  • Page 72: Generator Wiring Diagram

    7. Specifications 7.3 Generator Wiring Diagram A180953E...

  • Page 73: Engine Wiring Diagram

    7. Specifications 7.4 Engine Wiring Diagram A190100E-1...
  • Page 74 7. Specifications A180995E...

  • Page 75: Piping Diagram

    7. Specifications 7.5 Piping Diagram [Fuel piping] A190038E [DEF piping] A190039E...
  • Page 76 7. Specifications [Coolant piping] A190040E...
  • Page 78 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 Copyright(C)2019 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved. 39600 05640 Printed OCT.2019...

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