SDG25S-100S 3A Series Service Manual PDF
SDG25S-100S 3A Series Service Manual PDF
SDG25S-100S 3A Series Service Manual PDF
MOBILE GENERATORS
SDG25S-3A3, SDG45S-3A4,
SDG60S-3A2, SDG75S-3A2,
SDG100S-3A2
TOC-1
1. Safety
1. Safety
This operation manual explains and illustrates general requirements for safety and cautions for
safety.
Read these safety requirements carefully and fully understand the contents before starting the
machine.
For better understanding, 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.”
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
Ventilation
1-2
1.Safety
Handling battery
handling a battery.
If battery electrolyte contacts your clothes or skin,
rinse with large amounts of water immediately.
If the battery electrolyte gets into your eyes, rinse
immediately with plenty of water and see a doctor at
once, because eyesight could be damaged.
Dispose of battery, observing local regulations.
TR0093
Do not operate the machine if you are tired, impaired or under the influence of drugs.
Otherwise, careless handling may cause an unexpected injury or accident. Manage your
physical and mental health and be cautious in handling the machine.
1-3
1.Safety
Transportation
Use the lifting bail in the center of bonnet for hoisting the machine.
When towing or transporting the machine from a job site, securely fix it with tie-downs.
Only qualified personnel should operate a crane.
If machine is towed with trailer, reduce travelling speed to a safe level.
When transporting the machine, be sure to set it on a truck bed and fix the machine in place,
so it can not shift.
Select an appropriate crane and truck by referring to the mass and dimensions shown in
“Specifications” in Chapter 9.
Do not hoist the machine while it is running. Otherwise, a fatal or serious accident may occur.
Installation
1-4
1.Safety
Such things as unnecessary equipment, tools, cables, hoods, covers and wood pieces which
are a hindrance to the job, must be cleared and removed. Operators and/or personnel nearby
may stumble on them and could be injured.
Safety outfit
Safety equipment
TR0085
Safety aids
1-5
1.Safety
TR0304
Never put your hand near the engine cooling fan during
operation. It could cause serious injury if a hand should
be caught.
W009
1-6
1.Safety
W005
Fire prevention
1-7
1.Safety
PK0028
Reduce the load if the circuit breaker actuates frequently during operation.
When a single-load is used, check the current of each phase, and adjust the load so that
each load value remains balanced.
If the above procedure is neglected during operation, the generator could be damaged or
cause a fire. If the machine is operated with the frequency lower than the rated frequency, it
could cause the generator or load to be damaged.
1-8
1.Safety
TR0304
M003
1-9
1.Safety
Lighting apparatus
blow off the cap when turned. Steam jetting out of the
radiator could result in scalding. Follow these procedures
under all circumstances.
1-10
1.Safety
When washing the machine, cover the control panel, generator and its electric parts to prevent
them from being exposed to splashing water. This will avoid decrease in electrical insulation or
other problems to the machine.
Waste liquid from the machine contains harmful material. Do not discharge onto the ground,
river, lake or sea. Such material will contaminate the environment.
Use a container to hold the waste liquid taken from the machine.
Follow designated regulations when disposing of oil, fuel, coolant (antifreeze), battery or other
harmful materials.
1-11
1.Safety
PREVENT
Keep your hands AWAY from fan PREVENT BURNI NG ACCI DENT
BURNING ACCIDENT
during operation. Entanglement in
Do not open radiator cap while W h e n wo r k i s r e q u i r e d
the fan can cause serious injury.
it is still hot. n e a r h o t p a r t s , wa i t
for the parts to cool
d o wn f u l l y b e f o r e
39176 52600 (39176 37900) 39176 35300 s t a r t i n g wo r k .
39176 56400
WARNING CAUTION
Read and understand this operation book before starting operation.
To avoid electric shock and fire, never connect the generator outlets to an
installation which is also connected to the public mains and in-house lines.
To avoid electric shock or injury, cut off the circuit breaker before starting
operation.
To avoid electric shock, keep the terminal cover locked during operation.
B E W AR E O F E X H AUS T G AS E S To avoid electric shock, this product shall be surely grounded.
When you operate machine INDOORS To avoid injury, keep the side-door locked during operation.
or in TUNNEL, provide good ventilation. To avoid a fire, never operate this product near a location where flammables
Poor ventilation can cause fatal are present.
accident. To avoid a fire, refill fuel oil after stopping the engine.
To avoid injury, never move the product during operation.
39176 52701
5 6 7
※ Models SDG25S and 45S,60S,75S,100S are provided with different sizes of warning
labels.
The number in parentheses( )indicates part number of warning lable attached to Model
1-12
1.Safety
9 10 11
CAUTION CAUTION
LIFTING BAIL DO NOT SWITCH WHILE
UNIT IS RUNNING.
39176 35500
39176 62700
12 FLAMMABLES
39176 35600
DANGER
Authorized service personnel
only to open panel.
39176 65501
1-13
1.Safety
SDG45S/60S
1-14
2. Specifications
2. Specifications
SDG25S
Generator
Operating mass lb(kg) 1,520(690) Rated output kVA 25
Fuel tank capacity gal.(L) 17.2(65) Rated output kW 20
Voltage V 240/480
Current A 60/30
Number of poles 4P
General Specifications
Insulation H class
2-1
2. Specifications
SDG45S
Generator
Operating mass lb(kg) 2,670(1,210) Rated output kVA 45
Fuel tank capacity gal.(L) 29(110) Rated output kW 36
Voltage V 240/480
Current A 108/54
Number of poles 4P
General Specifications
Insulation F class
2-2
3. Cautions for Overhauling
3-1
3. Cautions for Overhauling
(1) Wash dirt, dust and grime off vinyl tube and fuel hose before removing it, and take
necessary steps to cover or tape the openings of vinyl tubes or fuel hoses to prevent any
dirt from entering them.
(3) When disassembling parts, wash their outer surface and place them on a clean sheet of
paper or cloth, taking care not to contaminate or damage them.
(4) Wash disassembled parts with diesel oil (cleaning solvent) after checking for
contamination or discoloration. However, do not wash rubber parts with diesel oil.
(5) Be careful not to damage disassembled parts, they are precision built.
(6) Replace consumables such as oil seals, O-rings, filters, oil, etc. with new items when
reassembling parts.
(7) Apply a coating of clean grease to O-rings when installing them in the machine.
(8) When reassembling parts, place each part in the order of assembly and take care that no
parts are missing or misassembled.
(9) When reassembling an assembled part (set part), be sure to replace it as an assembly.
(10) Contamination or rusting may occur due to dust or humidity if parts are left in
disassembled or partly disassembled condition for a long time. Therefore, be careful to
prevent dust or rust from affecting parts if you have to leave the repair incomplete for a
long period of time.
(12) Check the direction of rotation, speed, and oil leakage after assembly.
(13) Before starting the machine after disassembly, run it at low idle to check for unusual
noises, etc. to prevent engine or generator damage.
3-2
3. Cautions for Overhauling
Type Low or medium carbon steel bolt High strength steel bolt
(SS400B, etc.) (SCM435, etc.)
Strength,
classification, 4.6−6.8 (4T−6T) 8.8−12.9 (7T−12T)
and indication Indication does
example not appear in
some cases.
Torque
10 18 245 35 485
12 31 425 61 845
14 49 675 98 1350
Each clamping torque listed in the above-mentioned table applies to bolts being
used for generators.
The list shows normal clamping torque. In some sections, special specified torque
is required. In such a case, use the specified torque only.
Make sure to remove rust and dust before tightening.
3-3
3. Cautions for Overhauling
Terminal Plate
① ② ③
3-4-1
3-4-2
3-4
4. Electrical Parts
4 Electrical Parts
4.1 Electrical Parts of Generator
4.1.1 AS (Ammeter change-over switch)
4-1-1
4-1-2
4-1-3
4-1
4. Electrical Parts
SDG25S/60S
4-2-1
SDG45S
4-2-2
SDG75S/100S
4-2-3
4-2
4. Electrical Parts
Avoid excessive adjustments, except in a case where the characteristics are changed due to a
change in parts.
SDG25S
4-3-1
4-3
4. Electrical Parts
Adjusting AVR (SDG25S) (Set voltage selector switch to middle position 240/139V)
1. Connect the wiring to the AVR. (See generator wiring diagram.)
2. Make sure pin No.60 and C of FREQUENCY SELECTION (8) are short-circuit.
3. Rotate the VOLTS (1) knob fully counterclockwise.
4. After connecting the HAND TRIMMER (15) wiring, set the voltage regulator knob to the
maximum position.
5. Set the STABILITY SELECTOR switch (10) to the position 1.
6. Start the engine. (Make sure that the engine revolution is not only normal but also stable
in unload operation.)
7. Adjust the frequency to 62.5 Hz. Gradually rotate the VOLTS (1) clockwise to set it to
250V. Make sure that the voltage stays in the specified range of 208-250 V at the time of
60 Hz operation.
8. In the normal condition it is not necessary to adjust the STABILITY (11). (Mid-position
setting is normal.) If the voltage is unstable, following adjustment is required:
9. Rotate the STABILITY (11) fully clockwise once, gradually rotate it counterclockwise
until the voltage becomes unstable. Slightly rotate it clockwise to set for the best position.
A digital multi-meter should be used for measuring voltage.
10. In the initial start-up stage, when the VOLTS and STABLE knobs are completely
adjusted, no adjustment of the UFRO knob is required. However, should the voltage
regulation function be faulty or the voltage disappear, adjust the UFRO knob as described
below.
Knee-point
%V
100
95
Typical setting curve
90
85
80
75 80 85 90 95 100
%Rotating speed (frequency)
4-4
4. Electrical Parts
(4) (2)
9 Pin(female) 6 Pin(female)
1:Brown 4:Yellow 7:Purple 1:Brown 4:Yellow
2:Red 5:Green 8:Gray 2:Red 5:Green
3:Orange 6: / 9: / 3:Orange 6: /
4-5-1
Name Function
(1) VOLT. ADJ Voltage setting variable resistor
(2) V. F. ADJ V/Hz adjust variable resistor
(3) STAB. ADJ Stability adjust variable resistor
(4) CPR Over-excitation protection circuit protector
AVR CONNECTOR
Line color Connection Remarks
1 Brown Hand trimmer
Variable resistor 2kΩ 5W
2 Red Hand trimmer
3 Orange NIL
6 pins
(female) 4 Yellow No.5 of connector 6P To get corner frequency 57Hz, No.5
connector 6P and No.4 connector 6P short
5 Green No.4 of connector 6P circuited
6 NIL
1 Brown Generator cable No.3
AVR power supply (Generator cable 3 &
2 Red Generator cable No.4
4)
Detect generator output voltage between
3 Orange Generator cable E3
(4) and (5)
9 pins
4 Yellow Generator cable J Field winding of exciter
(female)
5 Green Generator cable K Field winding of exciter
6 NIL
7 Generator cable U Auxiliary winding
8 Generator cable V Auxiliary winding
9 NIL
4-5
4. Electrical Parts
Corner Frequency
100
80
Output Voltage
60
60Hz
40
20
0
20 40 60 80
Routing Speed (frequency)
a. The above frequency compensation characteristic graph is used to improve the load
characteristics by controlling voltage rise which occurs until steady frequency begins.
・ Regarding the unit having 60Hz specifications, in order to obtain corner frequency of
57Hz connector terminal (6 pins) (green) by jumper line.
b. The "corner frequency" of the units of 60Hz can be adjusted by V/Hz adjustment knob of
AVR (V. F. ADJ). The frequency can be increased by turning the knob clockwise.
(1) Before starting generator, fully turn V/Hz adjustment knob (V. F. ADJ) clockwise.
(2) After starting generator, set the voltage to the rated one by inside voltage adjustment
knob (VOLT. ADJ).
(3) Set the frequency of generator to the required corner frequency.
(4) Turn V. F. ADJ knob counter-clockwise slowly till output voltage begins to drop, and
then set the corner frequency.
4-6
4. Electrical Parts
It is possible to adjust the response speed of generator output voltage in case of sudden
change of load, using the inside stability adjustment knob (STAB. ADJ).
a. Turning stability adjustment knob clockwise, the response speed drops and voltage
overshoot value becomes smaller (stabilized).
b. Turning it counter-clockwise, the response speed rises and voltage overshoot value
becomes larger (not stabilized).
<OVER-EXCITATION PROTECTION>
Considering possibilities of incorrect cable connection, cable disconnection and improper cable
contact, a circuit protector (CPR)is installed inside AVR power input to prevent AVR from
being damaged by over-excitation current.
This protector works to push up the white push button fitted on the top of CPR and it is kept
pushed up.
First remove the cause of over-excitation current occurrence, and then release it by depressing
the white button on the top of CPR.
4-7
4. Electrical Parts
4-8-1
Calculation formula
1
Set value = Rated current at 60 Hz × CT ratio × 1.1 ×
1.2
4-8
4. Electrical Parts
4-9-1
Performance
1) In the case of normal oil pressure and water temperature
• At the time of engine starting, voltage appears at terminal (3) to energize the solenoid
relay coil, allowing the solenoid to activate.
• Once the engine has started, for six seconds after the terminal (4) receives the alternator
output voltage, no emergency stop signals can be detected at the oil pressure switch
terminal (2) or the temperature switch terminal (6).
2) In the case of abnormal oil pressure and water temperature
• Input voltage applied to the terminal (4) cannot appear at the terminal (3). Therefore, the
solenoid relay coil cannot be energized, preventing the solenoid from activating.
4-9
4. Electrical Parts
SDG45S/60S/75S/100S
4-10-1
Performance
1) In the case of normal oil pressure and water temperature
• At the time of engine starting, the input voltage applied to the terminal (1) appears at the
terminal (2) to energize the solenoid relay coil, allowing the solenoid to activate.
• After the engine has started, the alternator output voltage is received at the terminal (3)
and the input voltage applied to the terminal (1) appears at the terminal (6) five seconds
after the start to energize the solenoid relay coil, allowing the solenoid to activate.
2) In case of abnormal oil pressure and water temperature
• Input voltage applied to the terminal (4) cannot appear at the terminal (2) or (6). Therefore, the
solenoid relay coil cannot be energized, preventing the solenoid from activating.
4-10
4. Electrical Parts
4-11-1
Specifications
Performance
1) Starting operation at the time of stopping condition
• When the voltage is applied from the starter switch to the terminal S, the input voltage
from the terminal B appears at the terminal C to rotate the starter motor, causing the
engine to start.
• After the engine has started, when the A.C.G. output of 21.5 VDC is received at the
terminal R, the input voltage applied to the terminal B disappears at terminal C to cause
the starter motor rotation to stop.
2) Starting operation at the time of running condition
• When the A.C.G. output of 22.5 VDC is received at the terminal R while the engine is
running, even the input voltage applied to terminal S from the starter switch cannot
appear at the terminal C, preventing the starter motor from rotating.
4-11
4. Electrical Parts
AS-006
AS-017
SDG45S/60S
AS-011
AS-018
4-12
4. Electrical Parts
SDG75S/100S
4-13-1
4-13-2
4-13
4. Electrical Parts
4-14-1
4-14-2
SDG45S/60S/75S/100S
4-14-3
4-14-4
4-14
4. Electrical Parts
4-15
5. Periodic Inspection/Maintenance
5 Periodic Inspection/Maintenance
5.1 Periodic Inspection List
● means change △ means check/clean
Every Every Every Every Every Every
Maintenance Daily 50 hrs
250 hrs 300 hrs 500 hrs 600 hrs 1,000 hrs 2,000 hrs
Check external chassis
△
Generator
ground.
Check each meter and
△
warning lamp.
Check insulation resistance. △
Check battery. △
Clean or change air-filter
△・●
element.
● ●
Change fuel filter.
(25S/45S/60S) (75S/100S)
Change filter of fuel
● ●
air-bleeding electromagnetic
(45S/60S) (75S/100S)
pump.
Change coolant. ●
Clean outside the radiator.
△
(as required)
Clean inside the radiator. △
5-1
5. Periodic Inspection/Maintenance
5-2
5. Periodic Inspection/Maintenance
The main unit of the generator is unilaterally mounted and the clearance is small, so it
must be handled with extreme care to avoid the possibility of damage to the rotor or
stator.
Use hoisting equipment of sufficient capacity when it is necessary to lift up the
engine and the main body of the generator.
Lifting weight
① Generator unit
② Engine
③ Bolt (for coupling of the engine
flywheel and the generator)
④ Bolt (for connection of the engine
flywheel housing and the
generator frame)
5-3-1
The mounting holes are not equally spaced along the circumference. Therefore,
position the holes in advance so as to match the coupling counterpart by turning and
adjusting the engine flywheel.
Use guide bolts while centering to mount the assembly.
Tighten the bolts to the specified torque.
5-3
5. Periodic Inspection/Maintenance
5-4-1
Handle the stator with care after fastening the engine flywheel and generator
coupling, to avoid damage to either the rotor or stator.
Tighten the connections to the specified torque.
5-4
5. Periodic Inspection/Maintenance
① Generator unit
② Engine
③ Bracket
④ Bolt
⑤ Shim
⑥ Cushion rubber
⑦ Nut
5-5-1
5-5-2
5-5
5. Periodic Inspection/Maintenance
(2) Check the gap between the cooling fan and fan shroud
5-6-1
Gap size
SDG25S SDG45S SDG60S SDG75S SDG100S
in. 16.9 19.7 21.6
Fan outer diameter (a) ← ←
(mm) (430) (500) (550)
in. 17.7 20.9 22.8
Shroud inner diameter (b) ← ←
(mm) (450) (530) (580)
in. 0.3 0.5
Top gap (c) ← ← ←
(mm) (7) (12)
in. 0.5 0.7
Bottom gap (d) ← ← ←
(mm) (13) (18)
in. 0.4 0.6
Side gap (e) ← ← ←
(mm) (10) (15)
5-6
5. Periodic Inspection/Maintenance
Use guide bolts to avoid the danger of dropping the bearing shield and to prevent the
rotor and stator from rubbing against each other. (Use the guide bolts used to mount
the main body.)
5-7-1
(2) Changing the bearings
Do not hit the bearing outer race when installing or the bearing may be damaged.
There is no need to grease the bearings because they are sealed grease-filled type.
The bearings have an expected life of approximately 10,000 hours.
5-7-2
5-7
5. Periodic Inspection/Maintenance
Care must be taken not to damage the rotary rectifier when mounting it on the
conductive plate.
When a soldering iron must be used on the rotary rectifier, make the contact time as
short as possible.
Apply LOCTITE agent to the portions where tightness is required.
The surge suppressor is integrated with the insulating plate and cannot be replaced
separately.
Tightening torque
lbw・in 18-21 17 35
Tightening torque ← ←
(kgf・cm) (21-24) (20) (40)
Newage No. Three Bond
Screw-lock agent ← ← ←
030-02318 1402-B
insulating plate
lbw・in 43
Tightening torque − ← ← ←
(kgf・cm) (50)
Three Bond
Screw-lock agent − ← ← ←
1402-B
* Rotating rectifier of SDG25S is locked to the rotor shaft of the generator by a key.
5-8
5. Periodic Inspection/Maintenance
SDG25S
③ Varistor
5-9-1
SDG45S/60S/75S/100S
③ Varistor
5-9-2
5-9
6. Troubleshooting
6 Troubleshooting
6.1 Repairing Procedures
Perform the following preparatory checks before disassembling the machine.
① Try to find out the following information on the problem directly from the operator / user.
• How and when the machine problem started?
• Had anything abnormal occurred to the machine before this problem took place?
• Is there any other symptom existing in the machine?
• Had this machine experienced any other trouble before? If Yes, which parts or portion were
repaired before?
• Had any similar trouble occurred to this machine before this one?
② Next, check and inspect the actual problem on the machine by operating it yourself.
• Judgement of trouble sometimes vary, depending upon the person who assesses it.
So check and confirm it yourself, in accordance with standards for troubleshooting. You may find
sound / noise varies widely, depending upon the person who judges it.
• Before operating the machine which is suspected to have a problem, additional care should
be taken in case the suspected problem can cause new problems.
• Once the machine is disassembled, it is difficult to reproduce the same trouble conditions
when assembled. It is also likely to lose the evidence / cause of the trouble. Therefore, before
actually disassembling, it is important to test and locate the cause.
• In case there are several causes to troubleshoot, it is good practice to examine the simple
problems first.
• Repair and remove the basic cause completely and consider why such a problem happened.
YES (OK)
(2)
6-1
6. Troubleshooting
YES
YES
Check if fuel
filter is
NO clogged. YES
NO (0V)
6-2
6. Troubleshooting
YES
Remove solenoid from engine. Faulty engine.
Remove starter terminal B.
Between Br and E : 12V Check if solenoid pin moves when
Between C and E : 12V starter switch is placed to "start". Faulty solenoid.
NO
YES
Faulty engine.
YES
Faulty solenoid.
Disconnect solenoid connector.
Check if voltage at harness side
NO between terminal #1 and ・Faulty solenoid relay.
terminal #2 is 24V. ・Faulty time relay.
NO ・Faulty water temp. sw.
・Faulty harness.
YES
Faulty fuel filter.
YES
Faulty fuel pump.
6-3
6. Troubleshooting
Voltage at terminal B is
lower than 12V (24V).
NO
Unit: V
Starter switch
OFF ON START
Terminal
B 12 (24) 12 (24) 12 (24)
6-4
6. Troubleshooting
YES
Faulty starter.
Faulty or disconnection
of harness between
battery and starter.
SDG25S:
Faulty starter switch or
faulty harness between
starter switch and
star-ter relay
connection.
SDG25S:
SDG45S/60S/75S/100S:
Voltage at terminal #3 : 0V
SDG45S/60S/75S/100S Faulty starter switch or
Voltage at terminal R : 0V, B : 0V faulty harness between
starter switch and
t t l
SDG25S:
Measure voltage at
terminals #3 and #5 SDG25S:
on starter relay. Faulty starter relay.
SDG45S/60S/ Faulty engine controller.
75S/100S: SDG25S: SDG45S/60S/75S/100S:
Measure voltage at Voltage at terminal #3 : 12V Faulty safety relay.
terminals R, B and Voltage at terminal #5 : 0V
C on safety relay. SDG45S/60S/75S/100S
Voltage at terminal R : 24V
・Starter Switch : START Voltage at terminal C : 0V SDG25S:
Voltage at terminal B : 24V Faulty harness between
terminal #6 on starter
relay and terminal S on
starter.
SDG25S SDG45S/60S/75S/100S:
Voltage at terminal #5 : 24V Faulty harness between
SDG45S/60S/75S/100S terminal C on safety
Voltage at terminal C : 24V relay and terminal C on
starter.
NO
Faulty battery.
6-5
6. Troubleshooting
NO
A
OK
NO
OK
NO OK
OK
6-6
6. Troubleshooting
No-load speed
OK -1
60Hz About 62.5 Hz/1,875 min
None or low
OK
OK
6-7
6. Troubleshooting
0 or lower.
YES
6-8
6. Troubleshooting
YES
A
YES
SDG25S:
Is AC voltage at AVR input
terminal (7-8) proper?
SDG45S/60S/75S/100S:
Broken wire Repair.
Is AC voltage at AVR input
terminal (3-E3) proper?
YES
SDG25S:
Is DC voltage at AVR output
terminal (F1-F2) proper? Fault in AVR.
NO (Very high)
SDG45S/60S/75S/100S:
Is DC voltage at AVR
connector (J-K) proper?
6-9
6. Troubleshooting
NO
YES
NO
YES
YES
Fault in AVR.
6-10
6. Troubleshooting
If it cannot be adjusted at
all, please refer to
YES troubleshooting "(1) No
voltage is generated or
voltage too low" on page 6-7.
F
Immediately the
circuit breaks
YES automatically.
NO
YES
NO
6-11
6. Troubleshooting
Drop
OK
NO
6-12
6. Troubleshooting
6-13-1
6-13
6. Troubleshooting
Portions to be connected
F1 and (+) terminal of battery
SDG25S
F2 and (-) terminal of battery
SDG45S/60S/ J and (+) terminal of battery
K
75S/100S K and (-) terminal of battery
6-14-1
6-14
6. Troubleshooting
SDG25S
U1 terminal - U2 terminal , U5 terminal - U6 terminal
V1 terminal - V2 terminal , V5 terminal - V6 terminal
W1 terminal - W2 terminal , W5 terminal - W6 terminal
SDG45S/60S/75S/100S
T1 terminal - T4 terminal , T7 terminal - T10 terminal
T2 terminal - T5 terminal , T8 terminal - T11 terminal
T3 terminal - T6 terminal , T9 terminal - T12 terminal
6-15-2
(3) Exciter armature winding wires
Disconnect the wires leading to the rotary rectifier,
and measure the resistance between the wires.
6-15-3
6-15
6. Troubleshooting
F1 F2
6-16
6. Troubleshooting
SDG45S/60S/75S/100S
6-17
6. Troubleshooting
6-18-1
6-18-2
6-18-3
6-18
6. Troubleshooting
6-19
6. Troubleshooting
6-20-1
The MCB has three lever positions: "ON" "OFF" and "AUTO
OFF".
In manual operation, the lever is shifted between "ON" and
"OFF" only.
If an overload occurs and the automatic-off switch is on, the
lever is automatically shifted to the "AUTO OFF" position
and the lever has range of play around this position.
In order to recover the functioning of the MCB from the
"AUTO OFF" state, shift the lever down to "OFF" once,
then shift it up to "ON" position.
6-20-2
6-20
7. Wiring Diagram
7-1-1
7-1
7. Wiring Diagram
7-2-1
7-2
7. Wiring Diagram
7-3-1
7-3
7. Wiring Diagram
7-4-1
7-4
7. Wiring Diagram
SDG45S/60S
An Example
3 R/W
Wire of Red/White Line
Wire size (mm2)
B Black
Y Yellow
L Blue
G Green
R Red
W White
Br Brown
O Orange
P Pink
Gr Gray
7-6
7. Wiring Diagram
SDG75S/100S
An Example
3 R/W
Wire of Red/White Line
Wire size (mm2)
B Black
Y Yellow
L Blue
G Green
R Red
W White
Br Brown
O Orange
P Pink
Gr Gray
7-7
8. References
8. References
8.1 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.
SG0111
Cable Length L(m)
Simplified three-phase three-wire formula to seek voltage drop from cable length and working
current:
1 Length L(m)
Voltage drop e (V) = × ×Current I(A)×√
3
58 Thickness S(mm2)
Select such a cable length and thickness so that the voltage drop will remain less than 5%.
The table below shows the relationship between cabtire cable length and current and
corresponding cable sectional area (nominal).
The sectional areas in the table are based on the cable (of maximum allowable
insulation: 60℃) in an ambient temperature of 30℃ or lower.
(Based on the condition that working voltage is 400V, with voltage drop of 20V.)
Single-Core Cable (Unit:mm2)
Length
Current 50mor less 75m 100m 125m 150m 200m
20A 2 3.5 3.5 5.5 5.5 8
30A 3.5 5.5 5.5 8 8 14
60A 8 8 14 14 22 22
100A 22 22 22 22 30 38
150A 38 38 38 38 38 50
Three-Core Cable (Unit:mm2)
Length
Current 50mor less 75m 100m 125m 150m 200m
20A 3.5 3.5 3.5 5.5 5.5 8
30A 5.5 5.5 5.5 8 8 14
60A 14 14 14 14 22 22
100A 38 38 38 38 38 38
150A 60 60 60 60 60 60
8-1