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kWiet Power DGK25E Owner's Manual

Sound attenuated diesel generator sets
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DGK25E Owners Manual
Sound Attenuated Diesel
Generator Sets
WARNING!
CALIFORNIA – Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects, and
other reproductive harm.
6/30/08

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  • Page 1 DGK25E Owners Manual Sound Attenuated Diesel Generator Sets WARNING! CALIFORNIA – Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 6/30/08...

  • Page 3: Table Of Contents

    CONTENTS 1. INTRODUCTION ………..…………………………….………………………..…..1 2. SAFETY INSTRUCTIONS………………………………………………………... 2 3. LABELS….……………..……………………………………………..…………..7 3.1 Locations ………………………………………………………….…..………… …7 3.2 Part Numbers……………………………………………………………………….8 4. SPECIFICATION ………………………………………………………………...…9 5. DESCRIPTION.…………………………………………………………….….…..10 5.1 Outside View……………………………... ………………….……………………10 5.2 Control Panel……………………… ………………………………………………12 5.3 Layout……………………… ………………………………………………………14 5.4 Generator ….. ………………………………………………………………...…...15 5.5 Receptacles and Main Terminals…………………….………………………….18 5.6 Drain Plugs and External Fuel Ports…….…………………………..……..19 6.
  • Page 4 CONTENTS 12. OPERATION…. ………..…………………………….…………………………..40 12.1 Starting…………………..……………………………………………………..40 12.2 Loading the Generator….…………………………………………..…………...40 12.3 Operating the Generator……………………………………….…..……………41 12.4 Resetting the Main Breaker after Overload……………………………………41 12.5 Stopping the Generator………………………………………………………….41 13. GENERAL MAINTENANCE ………………………………………………….…42 13.1 Engine Maintenance and Periodic Maintenance Table.…...………….……..42 13.2 Oil Change………………………..………………….……………………..…..44 13.3 Oil Filter Replacing………………………………………………………….…...45 13.4 Cleaning/Replacing the Air Filter Element………………………………...…..46 13.5 Cleaning/Replacing the Fuel Filters…………………………....…….47...

  • Page 5: Introduction

    1. INTRODUCTION Thank you for purchasing a Shindaiwa KWiet Power Sound Attenuated Diesel Generator. This manual contains important information for maintenance and safe operation of the Shindaiwa diesel generator DGK25E. Please read and understand this manual before operating to avoid accidents or unnecessary repairs.

  • Page 6: Safety Instructions

    2. SAFETY INSTRUCTIONS WARNING SYMBOLS USED IN THE MANUAL In this manual, safety and caution items are classified as [WARNING] and [CAUTION]. WARNING Indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury and property damage.
  • Page 7 SAFETY INSTRUCTIONS WARNING DANGER OF ELECTRIC SHOCK DO NOT TOUCH OUTPUT TERMINALS DURING EQUIPMENT OPERATION! Do not touch the output terminal while the generator unit is operating since it can cause an electric shock. When it is necessary to touch the output terminals such as for load connections, make sure that the engine is not operating.
  • Page 8 SAFETY INSTRUCTIONS CAUTION [TRANSPORTATION] DANGER OF EQUIPMENT DROPPING HANDLE SUSPENDING EQUIPMENTS CAREFULLY! (1) Do not use twisted or frayed wire cable to lift up the unit, as it can be break easily. (2) Do not twist chains, since twisted chains can break easily. HANDLING EQUIPMENT AT DESIGNATED LOCATION! The generator unit is designed with a single lifting hook on the top section.
  • Page 9 SAFETY INSTRUCTIONS [MAINTENANCE AND INSPECTION] DANGER OF BURNS AND FIRE DISCONNECT THE BATTERY BEFORE INSPECTION AND MAINTENANCE! Before inspecting electrical parts, disconnect the negative (-) cable from the terminal of the battery. If the maintenance is conducted with the battery cables connected, the electric current flowing from the positive (+) terminal of the battery can cause a short-circuit resulting in burns or fire.
  • Page 10 SAFETY INSTRUCTIONS BE CAREFULL OF ELECTROLYTE! Electrolyte contains dilute sulfuric acid. Careless handling of the battery can cause the electrolyte to spill resulting in loss of sight or burns. (1)Any work that requires the handling of electrolyte must be conducted under the supervision of a battery expert or a person experienced in handling batteries.

  • Page 11: Labels

    3. LABELS 3.1 Locations Note: Make sure all information labels are undamaged and readable. Immediately replace any damaged or missing label. New labels are available from your local Shindaiwa distributor or dealer...

  • Page 12: Part Numbers

    LABEL 3.2 Part Numbers...

  • Page 13: Specification

    4. SPECIFICATION GENERAL SPECIFICATION DGK25E　Specifications Revolving Field Brushiess Ac Generator Type Simultaneous 3 Phase-120/240V 1 Phase Rated Output Voltage-Three phase 208,240,480 Voltage-Single phase 120,139,240,277 Single phase-120V 62.5 x 2 Single phase-240V 62.5 Amps Three phase-208V Alternator Three phase-240V Three phase-480V Frequency-regulation 60/50 ±...

  • Page 14: Description

    DESCRIPTION 5.1 Outside View Units (mm)
  • Page 15 DESCRIPTION Units (mm)

  • Page 16: Control Panel

    DESCRIPTION 5.2 CONTROL PANEL Detail drawing of warning indicator High water temperature Battery charge fault Low oil pressure...
  • Page 17 DESCRIPTION Control Panel (Continued) Name Description of function 3-phases circuit breaker Connects (On) or disconnects (Off) the load from the output of the generator 1-Phase circuit breaker Connects (On) or disconnects (Off) the load from the output of the generator Voltmeter Indicates voltage Ammeter...

  • Page 18: Layout

    5. DESCRIPTION 5.3 Layout Tie-Down Lifting Hook Engine Check Door Tie-Down Radiator Inspection Door Operation Panel Door Fuel inlet Oil Level Indicator Tie-Down Air Cleaner Coolant Sub-Tank Engine Check Door Oil Filler Alternator Check Door Water Separator 3way fuel valve Oil Filter Fuel Drain plug Fuel Filter...

  • Page 19: Generator

    DESCRIPTION 5.4 GENERATOR The main parts of the generator consist of rigid casting, and it has superior quality and durability with the features of a powerful damper winding to minimize wave distortion. Exploded View Thermo Label Screw End Cover Screw Bracket Exciter stator Screw...
  • Page 20 DESCRIPTION Stator The stator is the external stationary portion of the generator that actually provides the electricity for distribution to the load(s). It is composed of several individual coils of copper wire distributed and wound such that the magnetic field associated with the rotor passes over and around the coils and in turn produces an electric potential (voltage) that is used as the supply voltage to the load(s).
  • Page 21 DESCRIPTION Rotor The rotor is the portion of the generator bolted directly to the crankshaft of the engine so that it rotates at the same speed that the engine crankshaft is rotating. The opposite end of the rotor is supported by the generator end bracket using a single ball bearing.

  • Page 22: Receptacles And Main Terminals

    DESCRIPTION 5.5 Receptacles and Main Terminals Note: All duplex receptacles are GFCI protected and are rated at 20 amp. All twist loc receptacles are rated at 50 amps.

  • Page 23: Drain Plugs And External Fuel Ports

    DESCRIPTION 5.6 Drain Plugs and External Fuel Ports Coolant Drain Hose Side View Internal Fuel *External Tank *External Tank Engine Oil Tank Drain Fuel Inlet* Fuel Return* Drain Plug Plug *External Tank *External Tank Fuel Inlet* Fuel Return* Bottom View *The inlet and outlet for external fuel tank are located on the bottom of the generator bed from the factory but can also be easily relocate to the side of the frame depending on the application.*...

  • Page 24: Equipment

    6. EQUIPMENT 6.1 Engine Control Circuit Automatic pre-heating system When the starter switch is set to [ON] position electricity flows to the glow plug and glow indicator. Pre-heating time is automatically based on coolant temperature. Glow timer [QOS] detects the coolant temperature and if the temperature is above 5°F the pre-heating time is approximately 5 seconds, and if the temperature is above 68°F the pre-heating time is approximately 2 seconds.

  • Page 25: Monitors And Displays

    EQUIPMENT 6.2 Monitors and Displays The DGK25E diesel generator is equipped with monitoring functions for coolant temperature, oil pressure and battery charge condition. Under normal operating conditions these monitoring lamps will illuminate momentarily when the engine is first started but will go out shortly thereafter.
  • Page 26 EQUIPMENT Engine Oil Monitoring Lamp WARNING Injuries To avoid injuries by unintentional contact with the moving parts such as the cooling fan and/or belts, close and lock all doors while operating this equipment. WARNING Burns Due to extremely high temperatures, do not come in contact with the engine and/or muffler while operating or immediately after stopping this equipment.

  • Page 27: Meters And Gauges

    EQUIPMENT 6.3 Meters and Gauges Hours Meter The hour meter keeps track of the run time. The meter should be used to schedule preventative maintenance. Note: The hour meter will continue to operate as long as the ignition switch is in the on position regardless if the engine is running or not.

  • Page 28: Lamps And Lights

    EQUIPMENT 6.4 Lamps and Lights Glow Lamp When the starter switch is turned to the run/preheat position the glow lamp will illuminate. The glow lamp will stay lit until the preheat cycle is completed and the engine is now ready to start. The preheat cycle time will depend on the ambient and engine temperatures and may vary from 1- 5 seconds.
  • Page 29 EQUIPMENT Voltmeter Selector Switch The voltmeter selector switch is a 5 position switch located on the control panel to the left of the voltmeter. The voltmeter selector switch selects which phase voltage is displayed on the voltmeter. Positions: Off: There are two off positions on the voltmeter selector switch. One at the full clockwise position and one at the full counter-clockwise position of the switch.

  • Page 30: Voltage Adjustment Knob

    EQUIPMENT Output Circuit Breakers The DGK25E has two main output circuit breakers for the main terminals located on the left side of the control panel. The 3 phase circuit breaker is for connecting and disconnecting the load on terminals L1, L2 and L3. The single phase circuit breaker is for connecting and disconnecting the load on the U and W terminals.

  • Page 31: Way Valve

    EQUIPMENT 6.6 3 Way Fuel Valve The 3 way fuel valve is located inside the enclosure on the right side of the engine. The 3 way fuel valve provides a quick and convenient method of attaching an external fuel tank for supplying fuel to the engine.

  • Page 32: Lifting, Transporting And Installing

    7. LIFTING, TRANSPORTING AND INSTALLING 7.1 Lifting WARNING The lifting hook is designed to lift only the weight of the generator. Do not lift any additional added weight such as fuel tanks and/or trailers with the lifting hook. CAUTION Use only the installed lifting hook for lifting the equipment. Do not use the tie down posts for lifting as they are not designed to hold the weight of the equipment.

  • Page 33: Transporting

    LIFTING, TRANSPORTING AND INSTALLING 7.2 Transporting WARNING Always use extreme caution when loading, unloading or transporting this equipment. Failure to do so may result in personal injury or death and/or damage to the equipment resulting in a malfunction. When transporting this equipment, ensure that the equipment is properly secured using the tie down posts.

  • Page 34: Simultaneous Output

    8. SIMULTANEOUS OUTPUT 8.1 Connecting 3 Phase and Simultaneous Dual 1 Phase When using simultaneous 3 phase and simultaneous dual 1 phase the load must be properly balanced so as to not overload the generator. The operator should know the load that is being connected. The charts below show that when the 3 phase load is increased the available 1 phase output is decreased and vice versa.

  • Page 35: Connecting Cables

    9. CONNECTING CABLES 9.1 Main Terminal Connections 480/277V Position WARNING Electric Shock: Before connecting or disconnecting the load cables from the output terminal, always turn the output circuit breakers to the OFF position, stop the engine, and remove the ignition key. The person performing the connection or disconnection should always have possession of the key.

  • Page 36: Main Terminal Connection 240/139V Position

    CONNECTING CABLES 9.2 Main Terminal Connections 240/139V Position WARNING Electric Shock: Before connecting or disconnecting the load cables from the output terminal, always turn the output circuit breakers to the OFF position, stop the engine, and remove the ignition key. The person performing the connection or disconnection should always have possession of the key.

  • Page 37: Generator

    10. GENERATOR 10.1 Technical Specifications Items Reference value Notes 3MΩ or more Armature winding DC500V Insulation Mega ohm 3MΩ or more Exciter field Tester Pre-heating time 5 seconds Automatic pre- (Coolant temp. is less than 5°F(-15℃) heating system 2 seconds (Coolant temp.

  • Page 38: Initial Startup And Pre-Check

    11. INITIAL STARTUP and PRE-CHECKS WARNING Electrical Shock Before performing any equipment checks or maintenance, stop the engine, and remove the engine key. The person performing the equipment checks or maintenance should always have possession of the key. CAUTION Burns To avoid sustaining burns from hot vapors, do not open the radiator cap while operating or immediately after stopping this equipment Due to extremely high temperatures, do not touch the engine or exhaust system while operating or...

  • Page 39: Checking Engine Oil

    INITIAL STARTUP and PRE-CHECKS 11.1 Checking Engine Oil (Also refer to the accompanying Engine Instruction Manual) When checking the engine oil, be sure to keep the equipment level and insert the dipstick fully. Prior to starting the engine, make sure to fill the engine oil to the MAX line through the oil filler opening CAUTION If the equipment is not level, you can’t obtain an accurate oil level reading.

  • Page 40: Selecting The Proper Engine Oil

    INITIAL STARTUP and PRE-CHECKS 11.2 Selecting the Proper Engine Oil Use engine oil specifically designed for diesel engines. Use the chart below to determine the proper viscosity of oil to use for the anticipated ambient temperature the equipment will be operated in. Engine Oil Viscosity Grade –...

  • Page 41: Checking Engine Coolant

    INITIAL STARTUP and PRE-CHECKS 11.4 Checking Engine Coolant (Also refer to the accompanying Engine Instruction Manual) WARNING Injuries Before performing any equipment checks or maintenance, stop the engine, and remove the engine key. The person performing the equipment checks or maintenance should always have possession of the key.

  • Page 42: Procedure For Checking Fan Belt And Tension

    INITIAL STARTUP and PRE-CHECKS 11.5 Checking the Fan Belt (Also refer to the accompanying Engine Instruction Manual) WARNING Injuries Before performing any equipment checks or maintenance, stop the engine, and remove the engine key. The person performing the equipment checks or maintenance should always have possession of the key.

  • Page 43: Checking The Fuel Level

    INITIAL STARTUP and PRE-CHECKS 11.6 Checking the Fuel Level Prior to starting the engine, check the fuel level in the tank that is supplying fuel to the engine. The fuel gauge on the control panel will only display the fuel level for the internal fuel tank. Always use the fuel strainer when refueling.

  • Page 44: Operation

    12. OPERATION 12.1 Starting WARNING Suffocation from exhaust gases: Exhaust fumes from the engine contains many elements that are proven to be harmful to humans. Do not operate this equipment in poorly ventilated areas such as inside a building or in tunnels. Do not direct the exhaust fumes towards pedestrians or buildings.

  • Page 45: Operating The Generator

    OPERATION 12.3 Operating the Generator 1. Make sure all monitoring lights remain off. 2. Check and make sure all gauges and meters are working properly. 3. Check for any usual vibrations or noises. 4. Check for any unusual color from the exhaust. 5.

  • Page 46: General Maintenance

    13. GENERAL MAINTENANCE 13.1 Engine Maintenance WARNING Electrical Shock Before performing any equipment checks or maintenance, stop the engine, and remove the engine key. The person performing the equipment checks or maintenance should always have possession of the key. CAUTION Burns To avoid sustaining burns from hot vapors, do not open the radiator cap while operating or immediately after stopping this equipment...
  • Page 47 PERIODIC MAINTENANCE TABLE Daily First Every Every Every Every Description 50 hrs 200 hrs 400 hrs 500 hrs 1000 hrs Engine Engine oil (Check/Add) ○ Engine oil (Replace) ○ ○ time at 50hrs) Oil filter (Replace) (1 time at 50hrs) ○...

  • Page 48: Oil Change

    MAINTENANCE 13.2 Oil Change Frequency First Time 50 Hours Thereafter Every 200 hours Procedure 1. Wipe clean the area around the oil filler cap to prevent entry of foreign material. 2. Remove the oil filler cap. 3. Remove the engine oil drain plug and turn the ball valve inside the enclosure counterclockwise and allow the oil to drain completely.

  • Page 49: Oil Filter Replacing

    MAINTENANCE 13.3 Oil Filter Replacing Frequency First Time 50 Hours Thereafter Every 400 hours Procedure 1. Wipe clean the area around the oil filter and oil filler cap to prevent entry of foreign material. 2. Remove oil filler cap. 3. Remove the engine oil drain plug, turn the ball valve inside enclosure counterclockwise and allow the oil to drain completely.

  • Page 50: Cleaning/Replacing The Air Filter Element

    MAINTENANCE 13.4 Cleaning/Replacing the Air Cleaner Element Frequency Inspect/Clean Daily / 200hours Replace Every 500 hours Procedure 1. Unscrew the retaining ring wing nut for the air filter housing end. 2. Remove the air filter housing end. 3. Remove the wing nut. 4.

  • Page 51: Cleaning/Replacing The Fuel Filters

    MAINTENANCE 13.5 Cleaning/Replacing the Fuel Filters Frequency Pre-Fuel Filter/Clean Daily Pre-Fuel Filter (Drain Water) Every 200 hours Main Fuel Filter Replace Every 500 hours Procedure for Pre-Fuel Filter 1. Turn the fuel shut off valve on the top of the fuel filter to the CLOSED position. 2.

  • Page 52: Replacing Electric Fuel Pump Filter

    MAINTENANCE 13.6 Replacing Electric Fuel Pump Filter Frequency Replace Every 1000 hours Procedure 1. Turn the bottom cover of the pump counterclockwise to remove the end. 2. Remove the electric fuel pump filter and seals 3. Install the new filter and seals in the reverse order. 4.

  • Page 53: Replacing Llc Antifreeze

    MAINTENANCE 13.8 Replacing LLC Antifreeze (Long Life Coolant) Frequency Replace Antifreeze (LLC) Every 1000 hours Procedure 1. Remove the radiator plate located on the top of the enclosure. 2. Remove the radiator cap cover. 3. Remove the radiator cap and check seal (replace if seal is damaged). 4.

  • Page 54: Troubleshooting

    14. TROUBLE SHOOTING Problem and corrective measure 14.1 GENERATOR Problem Suspected cause Inspection Corrective measure No output voltage 1. Faulty voltmeter. 1. Check the voltage at the volt 1. Replace the volt meter. 2. Faulty generator. meter. 2. Replace the 2.

  • Page 55: Engine

    TROUBLE SHOOTING 14.2 ENGINE Problem Suspected cause Inspection Corrective measure Unable to start the 1. Starter does not 1. Check voltage, 1. Check battery fluid level engine. engage. electrolyte level, specific and add if necessary then gravity of the battery. charge battery.

  • Page 56: Long Term Storage

    LONG TERM STORAGE 15.1 Long Term Storage If the generator will not be used for more than 2 months perform the following procedure. Procedure for Long Term Storage 1. Remove the battery. 2. Change the engine oil. 3. Drain the fuel from the fuel tank and filters. 4.
  • Page 58 Shindaiwa Incorporated 11975 SW Herman Road Tualatin, OR 97062 Phone 503 692-3070 Fax 503 692-6696 www.kwietpower.com 7/25/07 Part No. 80355 Manufactured by Shindaiwa Corporation Hiroshima, Japan...

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