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.
◆ Before operating the unit, read the manual carefully, fully understand its operation and
maintenance requirement. Maintain “SAFETY OPERATION AND PROPER MAINTENANCE OF
THE UNIT”.
Be sure to follow safety warnings and cautions given in the manual.
Unsafe operation could cause serious injury 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 the manual and the actual machine due to
improvements of the machine. Ask your dealer if you have any questions or problems.
◆ If you have any questions about the unit, please inform us the model and serial number. A plate
stamped with the model and serial number is attached to side of the unit.
◆ Each illustrated figure (Fig.) has a number of 7
digits (for instance, A040491) at the right
bottom. This number is not a part number, but
it is used only for our reference number.
A040491
Table of Contents
1.
Safety ----------------------------------------------------------------------------------------------
1.1
1.2
1.3
1.4
Caution before Operation ......................................................................................................................1-2
Caution during Operation ......................................................................................................................1-4
Caution during Inspection and Maintenance ........................................................................................1-6
Safety Warning Labels ...........................................................................................................................1-8
1-1
2.
Part Names --------------------------------------------------------------------------------------
2-1
2.1 Internal Components ...............................................................................................................................2-1
3.
Installation---------------------------------------------------------------------------------------
3-1
3.1
3.2
3.3
3.4
3.5
Transporting Unit ....................................................................................................................................3-1
Conditions of Unit Installation ..............................................................................................................3-2
Grounding Method..................................................................................................................................3-4
Selecting Cable ........................................................................................................................................3-7
Selector Valve of Fuel Pipe ..................................................................................................................3-8
4.
Operation-----------------------------------------------------------------------------------------
4-1
4.1 Instrument panel.....................................................................................................................................4-1
4.2 Protection device....................................................................................................................................4-2
4.3 Connecting Load ....................................................................................................................................4-5
4.4 Engine Oil・Coolant・Fuel...................................................................................................................4-8
4.5 Check before Starting the Machine .....................................................................................................4-10
4.6 Unit Operation.........................................................................................................................................4-13
4.7 Stopping Procedures .............................................................................................................................4-17
4.8 Adjustment of frequency .......................................................................................................................4-17
4.9 Emergency Stop .....................................................................................................................................4-18
4.10 Air Bleeding .............................................................................................................................................4-18
5.
Periodic Inspection/Maintenance --------------------------------------------------------
5.1
5.2
5.3
5.4
5.5
Important items at Periodic inspection and Maintenance or after Maintenance ................................5-1
Daily Inspection and keeping Operation Log .......................................................................................5-2
Periodic Replacement of Parts.............................................................................................................5-2
Periodic Inspection List .........................................................................................................................5-3
Maintenance.............................................................................................................................................5-4
5-1
6.
Maintenance/Adjustment -------------------------------------------------------------------
6-1
6.1 Maintenance of Battery............................................................................................................................6-1
6.2 Troubleshooting .......................................................................................................................................6-3
7.
Storage of the Unit ----------------------------------------------------------------------------
7-1
7.1 Preparation for Long-term Storage .............................................................................................................7-1
8.
Specifications ----------------------------------------------------------------------------------
8-1
8.1 Specifications ...........................................................................................................................................8-1
8.2 Outline drawing .....................................................................................................................................8-2
9.
Wiring Diagram----------------------------------------------------------------------------------
9-1
9.1 Generator Wiring Diagram ......................................................................................................................9-1
9.2 Engine Wiring Diagram ...........................................................................................................................9-2
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 -attached to each message.
When one of these messages is found, please take preventive measures for safety to carry out “SAFETY
OPERATION AND PROPER MAINTENANCE OF THE UNIT ”.
DANGER indicates an imminently hazardous situation which, if
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.
IMPORTANT indicates important caution messages for the performance or durability of the unit, which has no concern to injury
or accident of or to a human body.
Follow warnings mentioned in this manual. This instruction 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.
1-1
1.Safety
1.1
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.
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
Ventilation
Exhaust gas from the engine is poisonous, and could cause
casualties when it is inhaled.
Avoid using the machine in an insufficiently ventilated
building or a tunnel.
PC002
Handling battery
Keep flames away from battery.
Battery may generate hydrogen gas and may explode.
Battery electrolyte is dilute sulfuric acid.
In case of mishandling, it could cause skin burning.
Wear protective gloves and safety glasses when handling a
battery.
Dispose of battery, observing local regulations.
D004
TR0093
1-2
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.
TR0084
Maintain both physical and mental health
Do not operate the machine when you are tired or drunk or under the influence of drugs. Otherwise,
a hasty conclusion or careless handling may cause unexpected injury or accident. Manage your
physical and mental health and be cautious in handling the machine.
Protection equipments
Please 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.
TR0085
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 department available in case of
emergency.
TR0096
Safety around the machine
Such things as unnecessary equipment and tools, cables, hoods, canvas sheets and pieces of wood
which are a hindrance to the job, have to be cleared and removed. This is because operators and
personnel nearby may stumble on them and may be injured.
1-3
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. The
operator must keep the key during operation.
Neglecting the cautions mentioned above, and a third
party starting the machine during operation may cause
serious accidents such as electric shock.
H990208
Hands off from rotating parts and belts
Keep hands off from the rotating portion or belts while running.
It could cause serious injuries if hands should be caught in.
TR0304
Do not remove radiator cap during operation
Do not, under any circumstance, open the radiator cap while
running or immediately after stopping operation. Otherwise
high temperature steam jets out and this could cause
scalding.
H990432
1-4
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.
Coolant water and engine oil are also very hot and dangerous
to touch. Avoid checking or refilling them while the unit is
running.
H990432
Fire prevention
Do not, under any circumstance, bring lit cigarettes or matches
near such oils as diesel fuel oil, and engine oil, etc.
They are extremely flammable and dangerous, so be careful
when handling.
Refilling oils should be done in an outdoor well-ventilated
place.
Refuel after stopping the engine, and never leave the fuel
nearby the machine. Do not spill. It may cause a fire. When it
is spilt, wipe it up completely.
D004
Do not supply fuel up to the fuel cap. And then the fuel may
get spilt when the unit is moved, transported and it is vibrating.
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.
H990433
1-5
1.Safety
1.3
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. The checker must keep the key
during checking and maintenance.
Remove the negative (–) side cable from the battery.
If the above procedure is neglected, and another person starts
operating the machine during check or maintenance, it could
cause serious injury.
SY001
Adjusting tension of fan belt
Be sure to stop the engine and remove the starter key
whenever the tension of the fan belt is to be adjusted.
If the machine is running, it might catch the operator’s hand
into the fan belts, and this could cause a serious injury.
TR0304
Hands off from cooling fan
Be sure to stop the engine and remove the starter key
whenever the tension of the fan belt is to be adjusted.
If the machine is running, it might catch the operator’s hand
into the fan belts, and this could cause a serious injury.
W009
Cleaning by air-blow
When cleaning dust accumulated in such devices as the
air-filter, etc., by blowing compressed air, wear safety glasses,
etc. to protect your eyes.
W003
1-6
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.
TR0206
Opening coolant water drain valve
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 cooled
enough, hot water could jet out, and it could cause scalding.
H990432
Refilling or draining of engine oil
After stopping the engine, wait 10 to 20 minutes until the engine
oil cools off. Then check 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.
H990432
Caution of the cleaning
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
trouble of the instruments. Clean them by blowing compressed air.
Disposal of waste liquid, etc.
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 the 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.
1-7
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.
1
5
2
3
6
4
7
8
9
39178 88820
1-8
1.Safety
The pasting position of safe warning label is as follows.
1
2
6 7
5
4
3
8
A080467
9
DETAIL OF INSTRUMENT PANEL
1-9
2. Part Names
2.1
Internal Components
1
2
3
4
5
6
7
8
16
15
No.
14
13
12
11
Description
10
9
A070138
Function
1
Control panel
Panel fitted with various meters and controllers.
2
Fuel filter
Filtering device for filtering dust mixed in fuel oil.
3
Engine oil filter
For filtering engine oil.
4
Air filter
Filtering device for filtering dust floating in intake air.
5
Engine
For driving the generator main unit.
6
Engine oil filler port
For supplying and replenishing engine oil to engine.
7
Reserve tank
For feeding cooling water.
8
Radiator
For cooling engine.
9
Exhaust muffler
Equipment which muffles an engine exhaust sound.
10
Fuel tank
Fuel oil container.
11
Battery
For electrically starting engine.
12
Engine oil level gauge
Scale for measuring engine oil level.
13
Selector valve of fuel pipe
For supplying fuel oil from the tank provided outside.
14
Sedimentor
For separating water mixed in fuel oil.
15
Generator main unit
16
Output terminals
For generating AC power to be supplied.
Equipped with three phase and single phase terminal and
receptacle for single phase.
2-1
3. Installation
3.1
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 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
1
A040151
1
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
crane.
A040151
3-1
3. Installation
3.2
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.
PC002
In case that the unit is installed indoors
In case that the unit is installed indoors for
operation, suction air port and exhaust fume outlet
port should be provided for better air ventilation.
Make sure to secure enough space in front of air
suction port and also to secure it after exhaust
fume outlet port so that the engine may not get
overheated.
Exhaust fume pipe extension should be provided
to send exhaust fume out of the installation place.
Exhaust fume
outlet port
Exhaust fume
(or gas)
Suction air
inlet port
Exhaust fume
extension pipe
A050511
Installing the unit st such poorly-ventilated place
In case that 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. In case that the unit is
operated under exhaust air pressure, make
sure to install the exhaust pipe to be
supported.
Exhaust fume
extension pipe
Suction air is fed
by air blower.
Exhaust fume
(or gas)
Exhaust
○
×
3-2
A050506-1
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
The machine has to be installed on dry, firm, and level
area.
The machine should be installed within 5゚degree inclination.
Avoid installing the machine in a place such as a damp
place or a place where puddles are apt to be formed
after rain. Such installation could cause electric shock.
When 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.
In case that the unit has to be installed inevitably on any
rough and uneven ground; it is necessary to insert
square wooden bars under the unit for levelling it.
SG0103-1
1000 or more
1000 or more
The machine should be operated in following conditions:
Ambient temperature
-15℃ to +40℃
Humidity
Less than 85%
Altitude
Lower than 500 m above sea level
If more than two machines are placed parallel in
operation, keep enough distance so that exhaust air
from one machine does not effect the other one.
Keep enough space around the unit for inspection and
maintenance access.
1000 or more
Unit : mm
SG0110
3-3
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
around the unit:
Safety fences
A050507
3.3
Grounding Method
3.3.1
Ground Terminal
The generator ground terminal“1”is connected to the
frame of the generator, metal non-current-carrying
generator parts and the ground terminals of each
receptacle.
1
3.3.2
A040172-1
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 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 utility power is restored, the generator
may explode, burn, or cause a fire in the building’s electrical system.
3.3.3
Ground 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.
3-4
3. Installation
3.3.4
GFCI (Ground-fault circuit interrupter) Receptacles
Using the generator in rain, snow or near water can lead to death from electric shock. Keep the
generator dry.
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 off)
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
Reset button
A040270
3-5
3. Installation
Grounding method
Machine grounding
terminal
Load equipment
Grounding rod
Grounding rod
A080433
3-6
3. Installation
3.4
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.
Working
Current I (A)
Cable Thickness A (mm2)
Cable Length L(m)
A080434
Simplified three-phase three-wire formula to seek voltage drop from cable length and working
current. Select such a cable length and thickness so that the voltage drop will remain less
than 5%.
Output system
Voltage drop
Three-phase 3-wire Type
e =
30.8×L×I
1,000×A
Three-phase 4-wire Type
e’=
17.8×L×I
1,000×A
e :Voltage drop(V)
e’:Voltage drop between an outside
line or one line of each phase,
and a neutral line (V)
A :Cable thickness (mm2)
L :Cable length (m)
I :Working current (A)
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
Length
Unit:mm2
50m
75m
100m
125m
150m
200m
50A
8
14
22
22
30
38
100A
22
30
38
50
50
60
Current
Three-Conductor Cabtyre Cable
Length
Unit:mm2
50m
75m
100m
125m
150m
200m
50A
14
14
22
22
30
38
100A
38
38
38
50
50
60
Current
3-7
3. Installation
3.5
Selector Valve of Fuel Pipe
Always keep watching the fuel feeding conditions while feeding fuel from a separate fuel storage tank
separately installed.
In order to use a separator fuel storage tank, be sure to change the handles of the selector valves to a
predetermined position. 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.
If excessive force is loaded to the selection handle, it will not move smoothly and it could cause fuel
leakage. Be careful about the handle.
3.5.1
Selector valve
This valve is designed to feed fuel directly to the engine of the unit, not from the tank integrated
in the unit, but from a fuel tank installed separately.
3.5.2
Operation method
① Unit is delivered from factory with fuel line piping and selector valves built in as shown in the
following Fig.1. When operating a unit, using installed fuel tank, run the machine with the fuel
line piping and the handles of selector valves factory-arranged.
② When using a separate storage tank, remove the plug fitted at the connections to the separator
tank and make piping as shown in Fig.2. And then turn the handles of the selector valve as shown
in Fig.2.
③ When removing the piping connections, make sure to return the handles to the original positions
shown in Fig.1 and install the plugs.
3.5.3
Installation of Separate Storage Fuel tank and piping method
① Use oil resistant hoses of inside diameter of 8mm to 10mm.
② Install the fuel tank so that the fuel level of the tank may be kept at the level from zero to 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 at the 15mm to 20mm higher level 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 refilling fuel in the tank, take much care not mix water and sediment.
In case an air tank separately
provided is used
In case the mounted air tank is used
Selector handle
return side
Inside
outside
Inside
outside
A
Separator
storage tank
suction side
Plug
Fig 2
Fig 1
15~20mm
A070019
3-8
4. Operation
4.1
Instrument panel
1
2
3
4
5
6
7
8
9
17
16
15
14
13
12
11
10
A080439
1. Panel light switch
10. Engine oil pressure gauge
2. Frequency meter
11. Ammeter for battery charge
3. Voltmeter
12. Manual-automatic change-over switch
4. Panel light
13. Ammeter change-over switch
5. Ammeter
14. Starter switch
6. Coolant temperature gauge
15. Voltage regulator
7. Fuel gauge
16. Voltage selector switch
8. Tachometer with hourmeter
17. Three-phase circuit breaker
9. Monitor lamp (for details, see 4.2.1)
4-1
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.
4.2.1
List of protection devices
This machine is equipped with the following devices in the table. Repair and make necessary
treatment in accordance with the item ○.
Item
Engine oil
pressure drop
Engine water
temperature
Engine
stops
○
Three-phase
Lamp discircuit
play
breaker trips.
○
○
tion
Fuel residual
level
Clogging of air
filter
*
Oil Fence
Discharged
battery
Overcurrent or
short circuit
Functions
When engine oil pressure drops, it
functions.
Operating pressure:
lower than 15psi (0.1MPa)
In case of abnormal rise of engine
water temperature, it functions.
temperature reaches:
more than230°F (110℃)
○
○
○
○
○
○
When engine rotates excessively, it
begins to function.
Function rotation: 2,070min-1 (69Hz)
―
―
○
When fuel level of fuel tank becomes
lower, the lamp goes on.
―
―
○
When air filter is clogged and it becomes necessary to clean it, it functions.
rises.
Excessive rota-
Monitor
―
―
○
When more condensate (fuel, engine
oil and coolant) than 1/3 of capacity
in the oil fence is accumulated
monitor lamp lights.
―
―
○
It functions in case of faulty battery.
―
○
○
In case of overload or short circuit
accident, it functions.
*When the monitor lamp lights in the oil fence, immediately drain it.
(For the capacity of the oil fence, refer to 8.1 Specifications). To protect environment, do not drain it directly into rivers. (For details, see 4.4)
4-2
4. Operation
4.2.2
Three-phase circuit-breaker
In case overload and short-circuited wire connection should occur, the circuit-breaker trips.
When this is tripped, stop the unit immediately
and reset the circuit breaker after getting rid of
the causes of trouble.
<How to reset>
In order to reset the lever of circuit-breaker, press
hard the lever downward till the lever sounds “click”.
A080441
A030403E
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.
Reset button
Thermal relay
A080440
4-3
4. Operation
4.2.4
Circuit protector (CP) for AVR protection
AVR is equipped with circuit-protector (CP) for protection against overcurrent. Under the following
cases, it happens to function.
In case the machine gets overloaded while engine
speed is still lower.
In case the output voltage of generator is increased
higher than 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.
Reset
A080442
4-4
4. Operation
4.3 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. It may cause an electric shock, machine
troubles and even a fire.
Make sure to ground the machine and the load. It could
cause an electric shock when the machine is installed at a
damp place or on a steel frame or a steel plate.
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. The operator must keep the key during operation.
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
H9902081
When using a single-phase load [277Vor 139V], see to it that the loads on the different phases will be
evenly balanced. Unbalanced loads may cause the generator burning.
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.
After checking phase number and voltage of the load,
make sure to connect them correctly.
―Terminal size―
Three-phase output
(L1,L2,L3,N)
Leakage relay
ground terminal(G)
M8
Three-phase
output terminals
M8
A040169-1
Install a switch between the output terminal and the
load to switch on/off the load. Do not switch the load
on/off directly by the circuit-breaker of the generator. It
could cause damage to the circuit-breaker.
Connect the connecting cable to the load so that the
output terminals should not touch each other.
Switch panel for
switching on/off load
A080443
4-5
4. Operation
4.3.1 Proper Connection of Three-phase Four-wire Type Terminal
Never use voltage selector switch during operation
During operation, do not operate voltage selector switch. Voltage
selection during operation may cause abnormal voltage on the load
side to damage the load and may cause a fire.
In addition it could cause damage to generator and automatic
voltage 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.
A040250
H990181
A040251
A040161
A040153-1
A040156-1
A040159-11
A040141
A040154-1
A040157-1
A040155-1
A040158-1
A040160-1
NOTE;
When the voltage selector switch is in the single-phase 240/120V position, place the ammeter
change-over switch to the L1 or L3 position to read the output.
4-6
4. Operation
4.3.2
Auxiliary AC Power
Auxiliary AC Power will be
available independently of the
position of voltage selector
switch.
GFCI RECEPTACLES
BREAKER
AUX. RECEPTACLES
BREAKER
Auxiliary AC Power
will be available only
when the voltage selector
switch
is
turned to 240/120V.
A080445
GFCI RECEPTACLES
120V 20AMPS
AUX.RECECTACLES
240/120V 50AMPS
120V
H
G
120V
W
W
120V
X
240V
Y
A040270
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>
①Turn the voltage selector switch to
240/120V on the control panel when the
generator unit stops.
②Start the generator unit and turn the main
breaker “ON” on the control panel.
③Turn the receptacle breaker of output terminal “ON”.
<How to use GFCI Receptacles>
It is available to get 1 phase/120V from
GFCI receptacles independently of the position of voltage selector switch on the control
panel.
<Procedure>
①Start the generator unit and turn the main
breaker “ON” on the control panel.
②Turn the receptacle breaker of output terminal “ON”.
4-7
4. Operation
4.3.3
The Maximum Combined Simultaneous Power Consumption
Never exceed the maximum combined simultaneous power consumption.
The following chart shows the maximum power available from the 120V-20A GFCI receptacles during
simultaneous consumption (main terminals and receptacles) for both single or three phase settings.
Values shown in the left column give the maximum current available at the 120V-20A GFCI receptacles compared to the value of the simultaneous current consumption from the main terminals.
Single Phase
120V-20A
GFCI Rcept.
SDG25S
Three Phase
240/480V
Single Phase
240/120V
kVA
25.0
20.8
16.7
12.5
8.4
kW
14.4
13.2
12.0
10.8
9.6
kW
0.0
1.2
2.4
3.6
4.8
4.4
Engine Oil・Coolant・Fuel
4.4.1
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
-22°Fto 50°F
10W
(-30℃ to 10℃)
30
14°Fto 104°F (-10℃ to 40℃)
40
32°Fto 122°F (0℃ to 50℃)
-4°Fto 104°F (-20℃ to 40℃)
15W/40
Be sure to use CD class engine oil or superior class. (Using engine oil with poor quality may shorten the
life of the engine).
When two or more different brands of oil are mixed, its performance can be deteriorated. Do not mix oils.
Follow the designated regulations to dispose of engine oil.
4-8
4. Operation
4.4.2
Coolant
Quality of coolant and antifreeze
Use soft water of good quality such as tap water for coolant.
When water with dirt, sand, and/or dust contained, or hard water such as well water (ground water) is
used, this will cause deposits inside radiator or on cylinder head, and will cause engine overheat due to
poor flow of coolant.
When the unit is used in a cold region and possible freezing is expected, it is recommended to use LLC
(Antifreeze) for the coolant.
Adjust mixing ratio of LLC with water according to the temperature.
Use LLC within the range of its mixing ratio between 35 and 60%.
If LLC in the water exceeds more than 60%, it may decrease its antifreezing effect.
Reference of LLC mixing ratio
Temperature
Mixing ratio
-4°F (-20℃)
35%
-104°F (-40℃)
55%
Follow the designated regulations to dispose of LLC (Antifreeze).
4.4.3
Fuel
Choose appropriate fuel
The following specific advantages are required for the diesel fuel.
Must be free from minute dust particles.
Must have adequate viscosity.
Must have high cetane value.
Must have high fluidity at low temperature.
*Low sulfur or ultra low sulfur diesel fuel only.
Must have little residual carbon.
*EPA regulations
4-9
4. Operation
4.5
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 noticing its abnormality, such operation could cause seizure of components or may even cause fire.
4.5.1
Check Engine Oil Level
The machine should be on level before checking oil level.
MAX
When you check oil level after you have once started operation,
wait 10 to 20 minutes after stopping engine, before checking the
oil level.
MIN
<Procedures>
① Pull out the engine oil level dipstick, and wipe it with a clean
cloth.
② Then, re-insert the dipstick fully and pull it out again. If the
gauge shows the oil level between MAX and MIN limits, it is
A000063
normal.
③ 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.
4.5.2
Check Coolant Level
Taking off the radiator cap
Be sure to stop the machine first and then loosen the radiator
cap slowly, after the coolant water is sufficiently cooled and the
inner pressure is released.
If this procedure is neglected, its inner pressure can blow off the
cap, and steam jetting out of the radiator could cause scalding.
H990432
Check the coolant level in the reserve tank. If it is lower
than the limit, open the cap and replenish the coolant.
(Level must be kept above LOW mark)
If little coolant is left in the reserve tank, replenish the tank
and radiator also. (See 5.5.16.)
LOW
TR314
4-10
4. Operation
4.5.3
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.
The fuel is extremely flammable and dangerous. Be careful of fire
because it is very likely to catch fire.
Refuel only after stopping the engine, and never leave open fuel can
near the machine. Do not spill. It could cause a fire. When it is spilt,
wipe it up completely.
Refilling fuel tank should be done in an outdoor well-ventilated place.
Do not supply fuel up to the fuel cap. And then the fuel may get spilt
when the unit is moved, transported and it is vibrating.
4.5.4
D004
Check Fan-belt tension
If Fan-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 Fan-belt by the
following procedure:
<Procedures>
① Unfasten the mounting bolts of the alternator to
adjust the alternator.
② Visually check the belt for any crack, wear, and
other defect.
③ Loosen the mounting bolt of alternator once. Then
adjust it so that the belt deflection will be 8 to 10
mm [100N (9.8kgf)] when pressing with a finger.
④ Be careful not to leave any grease and LLC on the
belt. If any of such material is left, wipe it off
completely.
4.5.5
Depress the middle of
the belt with a finger.
Then check the
deflection of the
belt and make
sure that it shall
be 8 to 10mm.
A010181
Check condensate in the oil fence
A drain outlet is provided at the side of the oil fence. Remove
the drain plug “1” and drain the condensate accumulated inside
the oil fence.
After making sure that the condensate is drained, install the
drain plug “1”.
Drain the condensate in container, and then dispose of condensate according to the designated regulations.
1
A080446
4-11
4. Operation
4.5.6
Cleaning the instruments inside control panel
Before starting operation, open control panel and
check each breaker, terminal plate and each
controller for any dust, sand and dirt accumulated.
If the machine is operated with such dust, sand and
dirt sticking, it could cause malfunction and trouble
of instrumentation. If any, stop the machine, and
clean them by blowing compressed air. when doing
cleaning job, wear protection glasses.
Control panel
A080139-1
4-12
4. Operation
4.6
Unit Operation
Keep the door shut and locked when machine is in operation.
If opening the door is necessary, be careful not to touch rotating or hot parts. Burns or serious injury
could result.
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 engine 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.
Also, make sure that the alarm lamps are off.
Be sure to operate the generator at a rated frequency, irrespective of the load capacity.
If the machine is operated with a frequency lower than the rated frequency, it could cause the generator
or to be burned.
4.6.1
Procedure to Start the Unit
Follow the starting procedure below.
<Manual operation>
① Switch "OFF" the circuit breaker on the instrument
panel.
② Set the selector switch “1” to “MANUAL” operation position.
③ Turning the starter switch to the “RUN” position, the engine starts preheating automatically.
④ When the preheating lamp goes off, turn the starter
switch to “START” position and start the engine.
⑤ Once engine has started, let it warm up about five min1
A070126
utes at no-load condition.
⑥ Make sure that engine speed at no-load meets
62.5Hz(1.875min-1)
⑦ Adjust the voltage to the rated voltage by turning the voltage regulator knob, watching the
voltmeter.
⑧ Switch the three-phase breaker “ON” to supply generator power. To use auxiliary AC power receptacles, switch the single-phase and three-phase breakers to “ON” for power.
4-13
4. Operation
<Automatic operation>
Inspection and maintenance prohibited during automatic operation
Never put your hands close to the interior of the machine, because the generator can be started when start signal functions
even while the machine is in stop position.
Before starting inspection and maintenance job, make sure to
place the selector switch of automatic starting panel to “MAN”
position and to hang the tag “Under inspection and maintenance”.
Remove the battery cathode cable terminal.
Pull out the starter key of the generator and the inspector himPK0028
self should keep it during inspection and maintenance job. neglect and/or ignoring the above items could cause a serious accident 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
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 cable terminal.
1
A070125-1
Install the battery charger
While the machine is in stand-by conditions during automatic operation, battery discharge occurs.
Make sure to charge battery, operating the battery charger.
4-14
4. Operation
2.
Operating procedure
① Start the generator unit under the procedure of manual operation and adjust the frequency and
voltage.
② Turn the starter switch to “STOP” position and stop the engine.
③ Turn the circuit breaker of output terminal “ON” after the generator unit stopped when you use
the circuit breaker and single phase receptacle on the control panel.
④ Turn the operating selector switch to “AUTO” position on the control panel.
⑤ The unit will be under stand by and start once the start signal is sensed.
3.
Function
When start signal activates in stand-by conditions, it starts the generator engine after preheating.
When stop signal activates, it continues 5 seconds cooling down operation to stop engine and the
machine is placed again in stand-by conditions.
5
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 even after cranking operation is repeated three times, trouble signal goes on showing difficulty in starting.
Perform periodical inspection and maintenance of the generator
For maintenance of the generator, try operation 5 to 10 minutes once a week.
4-15
4. Operation
1
This machine is so designed for safety that operator may not touch the output terminal during operation. If you open the output terminal cover during operation with three-phase breaker switched “ON” ,
the three-phase breaker will be “OFF” to cut power supply to the output terminal.
When starting operation , make sure that the output terminal cover is closed.
4.6.2
Meter and Indicator Lights while Operating
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.
Before
Starting up
Voltmeter Frequency Ammeter
meter
Engine
Water Over
(V)
(Hz)
(A)
oil
temp. speed
press.
Starter
switch
(RUN)
0
0
During
Operation
(Full load)
※
240
480
60
During
Operation
(Unload)
※
240
480
62.5
0
Indicator
lamp
Monitor lamp
Fuel
Engine Contain
Over
-ment Charge
Air
crank
level
filter
●
●
●
●
●
●
Off
Off
Off
Off
Off
Off
Less
than
rated
current
On
Glow
●
●
Off
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 operation, check the current of L1, L2, and L3 phase with the ammeter, by
turning the ammeter change-over switch.
Each current should be balanced if unbalanced. Change
load connections so the current of L1, L2, and L3 is
equally balanced. Make sure that the current of each
phase does not exceed the rated one.
When the voltage selector switch is in the single-phase
240/120V position, place the ammeter change-over switch
to the L1 or L3 position to read the output.
A040164
Ammeter change-over switch
4-16
4. Operation
4.7
Stopping Procedures
<Procedure>
① Switch “OFF” the breaker on the operation panel of the generator.
② After performing cooling down operation about 5 minutes, place the starter switch to the “STOP”
position to stop the engine.
③ While the machine is kept unused, keep the operation selector switch placed to the “OFF” position.
4.8
Adjustment of frequency
When it is necessary to adjust frequency during operation, take the following steps.
<Procedure>
① Loosen the locknut of the engine governor
adjusting bolt.
② Watching the frequency meter, adjust the
frequency to the value mentioned in 4.6.1
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.
③ After this adjustment is finished, be sure
to tighten the lock-nut securely so that
the nut can be fixed not to get loose during operation.
Adjusting
bolt
Lock nut
A080468
4-17
4. Operation
4.9
Emergency Stop
The Emergency Stop button should be used only for emergency stop.
Regularly check the operating performance.
If it is necessary to stop the generator for emergency,
press the Emergency Stop button.
A040192
To reset the button, turn the button head in the
direction of the arrow. If it is not reset, the machine
cannot restart to operate.
H980179
4.10
Air Bleeding
Should the machine stop due to the shortage of fuel, perform the air bleeding operation according to
the following procedures.
<Procedure>
① Replenish fuel.
② Place the operation selector switch to the “MANUAL” position.
③ Turning the starter switch to “RUN” position, the electromagnet pump functions to bleed the air in
fuel pipe system automatically.
④ The air bleeding operation can be finished within 20 to 30 seconds.
4-18
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 operating conditions. Inspection and maintenance should be performed more often under extremely
harsh conditions.
Hang a“Now Checking and under Maintenance”tag
Remove the starter key from the starter switch before
starting inspection, and hang up a “Now Checking and
under Maintenance” tag where it can be easily seen. The
checker must keep the key during checking and
maintenance.
Remove the negative (-) side cable from the battery. If the
above procedure is neglected, and should another person
start operating the machine during check or maintenance, it
could cause serious injury.
Be sure to use appropriate tools for inspection and
maintenance work. Inappropriate tools could cause
unexpected injury.
SY001
Precaution for check and maintenance
Be sure to use recommended fuel, oil, grease, or antifreeze.
Do not disassemble or adjust engine, compressor or part(s) for which inspection or maintenance is not
referred to in this manual.
Use genuine parts for replacement.
Any breakdown, caused by using unapproved parts or by wrong handling, will be out of the scope of
“WARRANTY”.
Do not pour water or steam on electrical components.
Place a container or a pan underneath the oil port to receiver waste liquid so that such liquid cannot be
spilt out on the floor or inside the machine.
Be sure that no waste liquid is disposed of on the ground. Such waste on the ground, river or lake will
cause serious environmental contamination. Be sure to follow the local regulations. If harmful material
such as oil, antifreeze solution or filters are disposed of incorrectly, the responsible person should be
punished by the authority.
Observe local regulations when disposing of such toxic materials as oil, fuel, coolant (anti-freeze), filters,
and battery etc.
5-1
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. If any trouble or abnormality is found, immediately investigate its cause and
make repairs. If the cause is unknown or not traceable, or if the trouble involves a part or component not described in the manual, ask your nearest dealer for information.
(a) Controls and instruments function properly.
(b) Quantity and any leak of water, fuel, and oil or
any contamination should be checked.
(c) Appearance, abnormal noise or excessive heat
should be checked.
(d) Loose bolt or nut should be checked.
(e) Any damage, wear or shortage of machine
components and parts should be checked.
(f) Performance of each part or component should
TR0049
be proper.
Keep the operation log to record constant inspection of
each component, so that trouble of the machine can be easily discovered and preventive measures
can be taken.
It is very useful to record information such as frequency, temperature, current, maintenance items
and replenishment of lubricant on a daily maintenance log.
5.3
Periodic Replacement of Parts
Use our genuine elements
Air filter is a crucial component for the performance and the life of a unit.
Use genuine part for replacement.
Part number changes upon modification. For replacement of parts, make sure whether the part
number is correct or applicable.
Part Name
Part Number
Quantity
Engine oil filter
37438 07500
1
Air filter element
32143 11500
1
Fuel filter element
43541 00200
1
ISUZU 892224 9990
1
V-belt
5-2
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 require expert technical knowledge on them.
The following table shows the intervals of inspection and maintenance under normal operation conditions.
Inspection and maintenance should be done at either of the hour or the period mentioned in the remarks
column, whichever comes earlier.
*Refer to engine operation manual for inspection and maintenance of an engine.
Generator
Maintenance
Cleaning instruments in control
panel
Check each instrument and
monitor lamp
Check insulation resistance
Every
Every
Every
Daily Every
Page
50 hours 250 hours 500 hours 1,000 hours
○
4-12
○
4-16
5-5 Every 4 months
Check GFCI receptacles
○
5-6 Every monthiy
How to check thermal relay
○
5-6
Check fuel
○
4-11
Check engine oil level
○
4-10
Check coolant level
○
4-10
Check Fan-belt tension
○
the case of NG, it
4-11 In
exchanges.
○
Change engine oil
(First time)
○
5-7
○
5-7
5-8
○
5-4
○
Change engine oil filter
Engine
Cleaning should
be done when needed.
○
Check and Clean clogging of air
filter element
Drain fuel tank.
(Including sedimenter)
Check battery electrolyte.
Perform cleaning when
themonitor lamp glows.
5-4
○
(First time)
5-7
○
Check Specific gravity of battery
electrolyte.
○
5-7
Change fuel filter
○
5-8
Clean outside of radiator
○
condition
5-8 Dirt
cleans.
○
5-9 Every 4 months
Check for crack and leak on the
exhaust flexible pipe
Change air filter element
○
5-11
Change coolant (LLC)
○
5-11 Every 2 years
Check engine valve clearance
●
Adjust fuel injection nozzle
●
Check fuel injection timing
●
Check condensate in the oil fence
Others
Remarks
4-11
○
Check the terminal portion of
electrical circuits and cable connections
Clean inside of the oil fence and
check it for any rust
Check vibration isolator rubbers
5-9 Every 4 months
○
Check each rubber hose
○
5-10 Yearly
○
5-12 Yearly
○
5-12 Yearly
Note:The above intervals of inspection and maintenance are respectively based on the operation time of 125
hours of used per month and of 1,500 hours of use per year.
5-3
5. Periodic Inspection/Maintenance
5.5
Maintenance
5.5.1
Change engine oil
[At 50 hours for the first change and every 250 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. Hot oil could blow out and can cause injury.
H990432
<Procedure>
① Remove the drain plug “1”provided outside the machine. Open the drain valve “2” inside the machine to
drain the engine oil condensate.
② After having drained the condensate, install the drain
plug “1” and close the drain valve “2”. Replenish engine oil by removing the cap of the engine oil filler
port.
③ After finishing the oil supply, tighten the cap of oil
filter port“3”firmly.
④ Before starting operation, make sure to check the engine oil level whether it is proper.
3
2 1
A080448
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.
② After the oil filter“1”is assembled, check if there are
any oil leaks during operation. (See 5.3)
2
1
H000049
5-4
5. Periodic Inspection/Maintenance
5.5.3
Check Insulation resistance
[Every 4 months or every 500 hours]
When the generator has not been operated for a long time or moisture has entered inside the machine, be sure to measure the insulation resistance. If resistance is lower than 1MΩ, i t could cause
an electrical leakage or fire. Dry the generator with compressed air until the resistance exceeds 1MΩ
pr io r to operating.
Since the generator insulation may drop when moisture, oil vapor, and dust are stuck, always keep
the machine clean.
<Procedure> <Megger tester required>
① Remove the load side cable from the output terminal
board.
② Remove the cable between the terminal “N” and terminal
“Ground” which are connected on the back of the output
terminal plate.
③ Remove the AVR connector inside the generator control
panel.
④ Switch ON the three-phase breaker, measure each insulation resistance between the terminals L1,L2,L3 terminal and bonnet.
⑤ Insulation resistance when measured with a 500 V megger tester must be above 1 MΩ.
⑥ After finishing the measurement of insulation resistance,
re-connect the cable between the terminal "N" and terminal "Ground".
Bonnet
A040180-1
A080449
AVR Connector
After making sure that the insulation resistance of the
generator is higher than 1 MΩ, be sure to re-connect
the cable between the terminal "N" and terminal
"Ground" just as it was originally connected.
If it is left disconnected, the grounding becomes imperfect so that it could cause electric shock.
A080449
5-5
5. Periodic Inspection/Maintenance
5.5.4 Check GFCI receptacles
[Monthly or 250 hours operation, whichever comes first.]
If the generator is stored outdoors, unprotected from the weather, test the GFCI receptacle before
each use.
In case the GFCI has tripped due to the hazard of ground fault currents, investigate the cause and
correct it.
Regularly check the GFCI operation for safety.
<Procedure>
① Unplug all appliances from the generator.
② Start the engine.
③ Turn each single-phase and three-phase breaker ON.
④ Press the TEST BUTTON
The RESET BUTTON should extend with a click.
If the RESET BUTTON does not extend, contact your
nearest dealer.
⑤ Press the RESET BUTTON
⑥ When the RESET BUTTON extends during peration.
Unplug all appliances from the GFCI protected
receptacle.
Press the RESET BUTTON:
Test button
Reset button
A040270
IF THE GFCI CANNOT BE RESET: The GFCI is faulty. Contact your nearest dealer.
IF THE GFCI RESETS PROPERLY: Check the appliance or the power cord.
5.5.5
How to check thermal relay
[Every 250 hours]
Test lever
<Procedure>
① Turn the starter switch to ON.
② Set the main breaker to ON.
③ The three phase main breaker will trip if you push
the test lever of the thermal relay in the arrow direction.
④ Note that once the three phase main breaker trips
to the off position, the single phase breaker that
supplies power to the GFCI outlets can still be ON.
Push
Thermal relay
A060468
5-6
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. This causes accelerated wear in each sliding part of the engine. Be sure to make daily check
and cleaning so that the life of the engine will not be shortened.
When the air filter monitor lamp glows, clean the air filter.
<Procedure>
① After removing the cap “1”by loosening its latch“2”, clean
its interior properly.
② Remove the element “3”, and clean it.
③ When installing the cap “1”after finishing the cleaning
job, push the element into the case “4”surely by hand,
and then make sure that the latch“2”fixing the cap
surely hooks the case “4”. Finally tighten it.
④ If the element is found heavily dusty, replace it with a
new one. (See 5.3)
2
1
3
4
H000051-1
5.5.7
Drain fuel tank
[Every 250 hours]
Drain the condensate accumulated in the fuel tank “1” by
removing the drain plug “2”.
After making sure that the condensate is completely
drained, install the drain plug “2” firmly.
Drain the condensate in container, and then dispose of
condensate according to the designated regulations.
2
5.5.8
1
A080447
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
immediately. (See 6.1)
2.Enclosed type battery:
Check the indicator on top surface of the battery.
If the indicator shows that charge is needed, recharge the battery immediately.
5-7
5. Periodic Inspection/Maintenance
5.5.9 Check Condensate in water sedimentor
[Every 250 hours]
Check if the red float“1”in the water sedimentor rises up to the water drain level, then drain water
if it is near the drain level“2”.
<Procedure>
① Place the lever“3”on the top of sedimenter to “CLOSE”
position.
② Loosen the ring nut“4”and remove the cup“5”. Carefully
handle the cup because it is filled with fuel, and never spill
the fuel inside the machine.
③ After draining the water collected inside, clean the cup“5”
and then install it.
④ Turn the lever“3”to “OPEN” position and fill the cup“5”
with fuel. Then bleed air (See 4.8).
Drain the condensate in container, and then dispose of
condensate according to the designated regulations.
3
IN
4
1
2
5
H000040
5.5.10 Change fuel filter
[Every 500 hours]
<Procedure>
① Take out the cartridge by using a filter wrench
② After coating fuel on the new cartridge“1”packing“2”,
screw it in. (See 5.3)
③ When the packing“2”touches the seal face, tighten it by
approximately two-thirds turn using a filter wrench.
④ Bleed the air of fuel. (See 4.10)
⑤ After installing a fuel filter, check for fuel leakage during
operation.
2
1
H000049
5.5.11
Clean outside of radiator
[Every 500 hours]
When the fin tubes“1”of radiator are clogged by dust or
other foreign materials, the heat exchange efficiency
drops and this will raise coolant temperature. These
tubes and fins should be cleaned depending on the state
of dirt inside the tubes even before maintenance
schedule.
Do not use high pressure washer for washing to prevent
fin tubes“1”from being damaged.
When the unit is used, installed near seaside and on boat
board, clean the radiator using fresh water more times
than once a month.
5-8
1
A010184
5. Periodic Inspection/Maintenance
5.5.12 Check for crack and leak on the exhaust flexible pipe
[Every 4 months or every 500 hours]
Check for any crack and gas leak on the flexible pipe
and exhaust between flexible pipe between engine
exhaust outlet and the flexible pipe.
If any leak is found, avoid getting burned by the
exhaust gas.
Crack
Exhaust
ble pipe
flexi-
A080451
Gas leak
5.5.13
Check the terminal portion of electrical circuits and cable connections
[Every 4 months or every 500 hours]
Check for any looseness on the cables and any damages on insulated covers and disconnection,
disconnected cables, or short-circuit etc.
[Checking points of electrical circuits on the generator side]
Terminal connection of three-phase output
terminal plate.
Main circuit of circuit breaker.
Terminal connection on control box.
Each terminal connection of each
instrument.
Looseness
Looseness
[Checking points of electrical circuits on
the engine side]
Circuit breaker
Output terminal board
Portion of connectors to the engine.
Check for looseness of terminal connections.
Looseness
Disconnection
Looseness・Disconnection
A070437
5-9
5. Periodic Inspection/Maintenance
5.5.14
Clean inside of the oil fence and check it for any rust
[Every 1 years or every 1,000 hours ]
<Procedure>
① Remove the oil filler cap cover, fuel pipes and electric wire connected to the fuel tank.
② Remove 4 pieces of the bolts connecting oil fence and the machine with the lifting eye hooked with
the crane.
③ Lift up the machine to separate the oil fence from the machine.
④ Check and clean the inside of the oil fence.
Check the inside of the oil fence for dust, fur and other foreign matter and check it for any rust.
When the oil fence is found rusted, remove the rust outside and inside and paint it again.
Should any leakage be found, contact your dealer or us directly.
⑤ Check whether the seal rubber attached on the top of oil fence is slanted or curved.
⑥ Combining this machine and the oil fence, tighten the nuts 4 pieces.
⑦ Install oil filler cap cover, fuel pipes and also electric wires.
A
B
Combining this machine
and oil fence with the
nuts 4 pieces
[This machine]
Connecting to the
electric wire
Connecting to the
fuel pipes
Seal rubber
Fuel Tank
Oil filler
cap cover
Seal rubber
Oil fence
A080450
5-10
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. This causes accelerated wear in each sliding part of the engine. Be sure to make daily check
and cleaning so that the life of the engine will not be shortened.
<Procedure>
① After removing the cap“1”by loosening its latch“2”, clean
its interior properly.
② Remove the element “3”and then replace it with a new
one. (See 5.3)
③ When installing the cap“1”after replacing it, properly
push the element into the case“4”by hand and then
make sure that the hooks for fixing the cap are surely set.
Finally tighten it.
2
1
3
4
5.5.16 Change Coolant
H000051-1
[ Every 2 years or every 1,000 hours ]
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. Therefore, make sure to carry out
them without fail.
LLC (Antifreeze) is a toxic material.
H990432
When a person has drunk LLC (Antifreeze) by accident, make
him vomit and make him see a doctor immediately.
When a person gets LLC (Antifreeze) in his eyes, wash the eyes with clean running water and make him
see a doctor immediately.
When LLC (Antifreeze) is stored, put it in a container with an indication saying "LLC (Antifreeze) inside"
and seal it up, then Keep it in a place away from children.
Beware of flames.
<Procedure>
① To drain coolant, remove the radiator cap“1”, then
loosen the drain valve“2”.
② Be sure to also unfasten the drain plug“3”on the
engine cylinder block for drainage.
③ When the coolant is completely drained out, close
each drain valve“2”and drain plug“3”, and supply
new coolant from the filler port of radiator“4”.
④ After changing the coolant, run the engine under
unload operation for 2 to 3 minutes, then stop it.
Check the coolant level again and replenish it if
necessary.
5-11
1
4
3
2
A030145
5. Periodic Inspection/Maintenance
5.5.17
Check vibration isolator rubbers
[Every 1 year or every 1,000 hours]
The vibration isolation rubber “1” is used for the
support of generator and engine. Check the rubber
for any damage or deterioration due to oil sticking.
1
A080452
5.5.18
Check each rubber hose
[Every 1 year or every 1,000 hours]
Check all the rubber hoses for being hardened, crack and fissure.
If any hardening, crack or fissures are found on each hose (air filter, radiator, fuel and drain)
replace it by a new one.
Check each clip fixing the hoses and if any loosened hose is found, retighten it.
Even before the periodical internal comes, replace it if any hardening, any cracks are found.
When replacing it, please contact our branch office or your distributor.
5-12
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.
Do not check the battery by short-circuiting the positive and
negative terminals with a metallic piece.
Never operate the machine nor charge the batteries with the
battery liquid level being kept lower than the “LOWER” level.
Continuing operation at this lower level will cause deterioration of
such parts as pole plates etc., and also it may cause explosion
as well as reduction of battery life.
Add distilled water so that the liquid level may reach the middle
level between the “UPPER” and “LOWER” level without any
delay.
Do not charge the frozen battery. Otherwise it may explode. If
the battery is frozen, warm it up until the battery temperature
becomes 16°C to 30°C.
Battery electrolyte is dilute sulfuric acid.
In case of mishandling, it could cause skin burning.
Wear protective gloves and safety glasses when handling a
battery.
When such battery electrolyte contacts your clothes or skin,
wash it away with large amount of water immediately.
If the battery electrolyte gets into your eyes, wash it away
immediately with plenty of water and see a doctor at once,
because it is feared that eyesight might be lost.
Dispose of battery, observing local regulations.
6-1
D004
W010
TR0093
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.
Battery
Battery charger
(12V)
H000060
6.1.2
How to Use Booster Cable
Do not reverse the cable connection
When a booster cable has to be used or when cables are connected again after an battery is
replaced, be careful not to connect (+) and (–) terminals backwards. Such wrong-connection will
cause spark and damage to each component.
<Procedure for using a booster cable>
① Stop the engine.
② Connect one end of the (+) cable to the (+) terminal of
Connect to the engine block
of the unit
the machine battery.
③ Connect the other end of the (+) cable to the (+)
terminal of the external battery.
④ Connect one end of the (–) cable to the (–) terminal of
the external battery.
⑤ Connect the other end of the (–) cable to the engine
Machine battery
block of the machine.
⑥ Start up the engine.
⑦ Disconnect
the
booster cable
External battery (12V)
by
following
procedure back in the reverse order.
6-2
the
TR0345E
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.
This chapter describes the state, cause and countermeasures of important troubles in detail:
Symptom
Cause
Counter measures
Starter does not
rotate. Low starter
revolution speed
even when starting.
(1)Battery malfunction
Check Battery →Charge/Change
Starter rotates but
engine does not start
up.
(1)Fuel filter clogging
(2)Filter of fuel air-bleeding electric pump
clogging
(3)Fuel shut-off solenoid malfunction
Disassemble, clean, and change
Change filter
Engine oil pressure
drop monitor lamp
glows.
Coolant temperature
rise monitor lamp
glows.
(4)No diesel fuel oil
(5)Air mixing in fuel pipings
(1)Engine oil shortage
(2)Engine oil filter clogging
(3)Oil pressure switch malfunction
(4)Loosened or disconnected wiring, or
connector
(1)Radiator clogging
(2)Faulty thermostat
(3)Faulty coolant temperature switch
(4)Shortage of coolant
(5)Slip of fan belt
(6)Looseness, disconnection of wiring or
connectors
Check fuse
Change solenoid
Check connector
Replenish fuel
Bleed air
Replenish fuel
Change
Change
Check/repair
Clean
Change
Change
Replenish
Adjust tension
Check/repair
Excessive rotation
monitor lamp glows.
(1)Trouble of engine governor
Repair
Fuel residual level
monitor lamp glows.
(1) Fuel runs short
(2) Malfunction of sending unit for fuel oil
level drop
(1) Leakage on generator side
(2)Leakage on load side
(3)Leakage on connecting cable
(4)Defective leakage relay
Add fuel oil
Inspect/replace
Recharging monitor
lamp glows.
(1) Alternator problem
(2) Loseness, disconnection of wiring or
connector
Check/change
Check/repair
The monitor lamp
for air filter clogging
flickers.
(1)Air filter clogging
Clean
Oil fence monitor
lamp glows.
(1)The condensate (fuel, engine oil and
coolant) is accumulated in the oil fence.
(2)The liquid surface level detecting switch
does not function good.
Drain the condensate.
Leakage relay lamp
glows.
6-3
Check/repair
Check/repair
Check/repair
Check/repair
Check/change
6. Maintenance/Adjustment
Symptom
Even when operated
at a rated speed, no
voltage or too low
voltage generated.
Too high voltage
generated when set
at the rated
frequency
(50Hz/60Hz),
Voltage will not drop
even when the
voltage regulator
controlling knob is
turned.
Unstable voltage
generation
Cause
Counter measures
(1) Faulty voltmeter
(2) Poor tightening of terminals
(3) Broken or short-circuited winding of
generator main unit
(4) Faulty AVR
(5) Faulty silicon rectifier (Module type)
(6) Faulty exciter
(7) Broken or short-circuited circuit to
exciter field winding
(8) AVR frequency selection switch is not
set to meet the frequency to be
operated.
(9) Function circuit protector (CP) for
AVR protection
(1) Loosened or disconnected wiring, or
connector to AVR
(2) Faulty AVR
(3) Broken wire or poor contact of AVR
variable resistor
(1) Poor tightening of each terminal
(2) Faulty AVR
(3) Function circuit protector (CP) for
AVR protection
Check/change
Check/repair
Check/repair
Check/change
Check/change
Check/repair
Check/repair
Check/select
Reset
Check/repair
Check/change
Repair or change
Check/repair
Check/change
Reset
Please contact your nearest dealer if you find it difficult to repair by yourselves.
Please refer to the engine operation manual for troubles concerning the engine.
6-4
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. Avoid leaving the unit outside with a
sheet cover directly on the paint for a long time, or this will cause rust to the unit.
Perform the following treatments at least once every three months.
<Procedure>
① Discharge existing lubricant from the engine oil pan. Pour new lubricant in the engine to clean
its inside. After running it for a while, drain it again.
② Spread lubricant on each moving part.
③ Completely charge the battery and disconnect grounding wires. Remove the battery from the
unit, if possible, and store it in a dry place. (Charge the battery at least once every month.)
④ Discharge coolant and fuel from the unit.
⑤ Seal air-intake port of engine and other openings like the muffler with a vinyl sheet, packing
tape, etc., to prevent moisture and dust from getting in the unit.
⑥ Measure the insulation resistance of the generator, and make sure that it is more than 1MΩ.
(See 5.5.3)
⑦ Be sure to repair any trouble and maintain the unit so that it will be ready for the next
operation.
Stacking up box type machines
When stacking up the machines for storage, only two
units stacking is acceptable. The mass of the lower
machine should be larger than that of the upper one.
Select a leveled floor with sufficient strength.
Before stacking the machines up, check the machine for
deformation of bonnet, looseness or missing of bolts,
and other parts.
When stacking them, be sure to securely fix them as
shown in the figure so that the balanced weight is applied
to each squared lumber for preventing a sideslip or a
collapse.
Never operate the machines with stacking conditions.
It is very dangerous.
Machines stacked could fall down due to sideslip or
collaspse when an earthquake occurs. Therefore, safety
should be sufficiently considered for surroundings of
storage places.
7-1
H000028
8. Specifications
8.1
Specifications
Model
SDG25S-8B1
Brushless
Exciting system
Armature connection
Star with Neutral
ZigZag
Three
Single
80
100
Generator
Phase number
Power factor
%
Frequency
Hz
60
Rated output
kVA
25
14.4
Rated output
kW
20
14.4
Voltage
V
240
480
240/120
Current
A
60
30
60
Model
ISUZU BV-4LE1
Type
4-cycle, water-cooled, swirl chamber type
Number of cylinders
Engine
Total displacement
Rated output
Revolution per minute
Lubricating oil capacity
Coolant capacity
(including radiator)
4
cu. in. (L)
133 (2.179)
hp (kW)
31.5 (23.5)
rpm (min-1)
1,800 (1,800)
gal. (L)
2.1 (8)
gal. (L)
1.6 (6)
Battery
Others
General Specifications
Fuel tank capacity
80D26R (12V)
gal. (L)
50 (190)
Overall length
in. (mm)
67 (1,690)
Overall width
in. (mm)
28 (700)
Overall height
in. (mm)
50 (1,280)
Net dry mas(weight)
lbs (kg)
1,587 (720)
Operating mass(weight)
lbs (kg)
1,962 (890)
The capacity of oil fence
gal. (L)
24 (90)
8-1
8. Specifications
8.2
Outline drawing
Unit : in.
A070148
SDG25S-8B1
8-2
8. Specifications
Unit : mm
A070149
SDG25S-8B1
8-3
9. Wiring Diagram
9.1
Generator Wiring Diagram
A070160
9-1
9. Wiring Diagram
9.2
Engine Wiring Diagram
A040580-1
9-2
2006年 2月 27日 初版
2003年 4月 20日 改訂
発行 北
越工業株式会社
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
Copyright(C)2008 HOKUETSU INDUSTRIES CO., LTD. All Rights Reserved 39600 91520
PRINTED IN JAPAN 2008.11
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