DGK150D Owners Manual - kWiet Power Generators
Contents
1. 38 Procedure 38 11 5 Draining Water From the Internal Fuel Tank 38 Frequency 38 Procedure 38 11 6 Changing Engine Coolant 38 Frequency 38 Procedure 38 12 LONG TERM STORAGE PROCEDURES 0 20 0 20 00 39 13 TROUBLESHOOTING 7 7 40 Shindaiwa Construction Products 2 1 Introduction Thank you for purchasing a Shindaiwa Kwiet Power Sound Attenuated Diesel Generator e This user s manual was created to help ensure the safe operation of this equipment The manufacturer of this equipment strongly recommends that the user follow all of the instructions contained within this manual to avoid unnecessary2. 33 10 6 Connecting to an External Fuel Tank 34 11 MAINTENANCE 2 222 222 202 2022 222022002 35 11 1 Oil Change 37 FreQUENCY 37 Procedure 37 11 2 Oil Filter Change 37 Frequency 37 Procedure 37 11 3 Cleaning Changing the Air Filter Element 37 FreqUenCy 37 Procedure 37 11 4 Cleaning Changing the Fuel Filter 38 Frequency
3. 17 Glow Lamp 17 Pilot Lamp 17 Panel Light 17 6 4 Switches 18 Start Switch 18 Voltmeter Selector Switch 18 Ammeter Selector Switch 18 Voltage Selector Switch 19 Panel Light Toggle Switch 19 Emergency Stop Switch 19 6 5 Output Circuit Breaker 19 6 6 Voltage Adjustment Rheostat 19 6 7 Fuel
4. 29 9 3 2 Checking the Coolant Reservoir Tank Level Adding Coolant 29 9 4 Checking the Fan Belt 29 9 4 1 TENSION 30 9 4 2 Condition 30 9 5 Checking the Fuel Level 30 9 6 Checking for LeakS 30 9 7 Checking the Batteries 31 10 OPERATION 222c2enennnncnnnnnnnennnnnnnnncnennnnnnnnennnnennnnnnnnnnnnnen 31 10 1 Starting 31 10 2 Loading the Generator 32 10 3 Operating the Generator 32 10 4 Stopping the Generator 32 10 5 Automatic Shutdowns and Alarms
5. 14 Battery Charge Monitoring Lamp 14 Diagnosis Lamp 15 Boost Temperature Lamp 15 Over Speed Lamp 16 6 2 Meters and Gauges 16 Hour Meter 16 Volt Meter 16 Amimeter 16 Frequency Meter 16 Coolant Temperature Gauge 17 Oil Pressure Gauge 17 Fuel Gauge Optional 17 6 3 Lamps and Lights
6. 19407 00073 19402 00210 19402 00306 kWiet Power Label 19406 00109 14 Oil Drain 19401 00154 Shindaiwa Label 19420 00096 15 Fuel Drain 19401 00155 150 kVA Label 50980 00880 16 Cooling Water Drain 19401 00242 19401 00243 19401 00244 19401 00372 19401 00251 14131211 10 9 8 ed WI Wali C 1 Generator Name Plate 50980 00870 12 Pilot Lamp 19401 00210 2 Voltage Adjust Rheostat 19401 00214 13 Auto Start Optional 19407 00055 3 Off L1 L2 L3 Off 19401 00259 14 Main Circuit Breaker 19401 00235 4 Emergency Stop 19401 00210 15 Engine Control 19401 00375 5 Stop Run Start 19401 00216 16 EPA Label 50980 00660 6 Glow Lamp 19401 00373 17 Electric Shock 19402 00215 7 Internal Fuel Tank Only 19401 00371 18 Output Position 19401 00308 8 Monitor Lamps Label 19401 00374 19 GM Spec 6277M 19402 00295 9 Ammeter Switch Inst 19401 00323 20 Voltage Selector 10 Off L1 L2 L2 L3 Switch Caution 19402 00288 L3 L1 Off 19401 00258 11 Panel Light 19401 00212 Shindaiwa Construction Products 7 4 Specification Generator Type Revolving Field Brushless AC kVA 150 Rated Output kW 120 Voltage Three phase V 208 220 240 416 440 480 Voltage Single phase V 120 127 139 240 254 277 Single phase 120V A 361 x 2 zigzag Single phase 240V A 361 zigzag Amps Three phase 208 V A
7. e Do not leave the switch in this position while the engine is stopped It may drain the battery START This position allows the user to start the engine When the operator releases the key while in this position the switch will automatically return to the Operating Preheating position Voltmeter Selector Switch The voltmeter selector switch is a 5 position switch located on the generator control panel next to the voltmeter This switch selects which phase voltage the voltmeter will be displaying There are two off positions for this switch one at the far left position and one at the far right position In the off positions the voltmeter will not be displaying any voltage In the L1 L2 position the voltmeter will display the phase voltage between phase L1 and phase L2 In the L2 L3 position the voltmeter will display the phase voltage between phase L2 and phase L3 In the L3 L1 position the voltmeter will display the phase voltage between phase L3 and phase L1 This switch must be in the L1 L3 position to read single phase voltage Ammeter Selector Switch The ammeter selector switch is a 5 position switch located on the generator control panel next to the ammeter This switch selects which phase current the ammeter will be displaying There are two off positions for this switch one at the far left position and one at the far right position In the off positions the ammeter will not be displaying any amperage In the L1 position the amme
8. kwiet Shindaiwa Generators DGK150D 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 Construction Products 8 22 06 Part No 81583 Table of Contents 1 INTRODUCTION 2 00 0 0ne omen enn ene n nnn en enn enennenennenenn ene nnnnenes 3 2 SAFETY GUIDELINES 0 00 n cnecnencnncnencnncnnnnnnnnnncnnnennnnnacencnnnnnnnnnne 4 al BY Eee aw Rec SST SOS COE oN RE SDC AA 6 A SPECIFICATION ai aa 8 5 OUTLINE DRAWINGS 2 2 22 2 22 22 2 02 2202 222 22 9 5 1 Control Panel 10 5 2 Main Terminal Board 11 5 3 Receptacle Panel 12 6 EGUIPMENT ca ee 13 6 1 Monitor Displays 13 Coolant Temperature Monitoring Lamp 13 Engine Oil Monitoring Lamp
9. 416 Three phase 240V A 361 Anarnator Three phase 480V A 180 Frequency Hz 50 60 Rated speed rpm 1800 3 phase 4 wire Winding Star with neutral Zig zag Power factor 8 Insulation class F Excitation Static brushless No of poles 4 Vertical Water cooled 4 cycle Type Diesel Engine Model Manufacturer 6HK1TC ISUZU EPA 3 No of Cylinders bore x stroke in mm 6 4 53X4 92 115x125 Continuous rated output hp 190 Rated speed rpm 1800 Displacement cu 475 4 7 790 in liters Combustion system Direct Injection Turbo Inter cooler Engine Cooling method Radiator Lubricating method Forced lubrication Starting method Electric Fuel Diesel Lubricant oil CD class or higher Fuel tank capacity gal liters 74 280 Lubricant volume gal liters 9 9 38 Cooling water volume gal liters 6 2 23 8 Battery capacity V AH 12V 2 100AH Meters Voltage Frequency Amperage Hour Voltage Automatic Voltage Regulator Readiation Adjustable 4696 to 15 HUG e loo Speed 5 Regulation tree Shutdowns Oil pressure Water temperature Lamp indication with shutdown Warning Battery Charge Lamp indication Unit Dimensions L x W x H in mm 135 8x48 8x72 81 3450x1240x1850 Dry weight Ibs kg 6834 3100 Sound Level No Load 59dBA Full Load 60dBA Shindaiwa Construction Products 8 5 Outline Drawings Exhaust Outlet Control Panel Access Terminal Board and Fuel Fill Voltage Selector Switch Access Receptacle Access Shindaiwa Cons
10. Tank Level Adding Coolant Also please refer to the accompanying Instruction Manual for the engine 1 Ensure the coolant level is between the MIN and the MAX line 2 If the coolant level is low add the same mixture of coolant used in the radiator to fill the reservoir tank to the MAX line CAUTION e Always use potable water when mixing coolant e Do not spill antifreeze or engine coolant on the exhaust system or hot engine parts Under some conditions the long life coolant is combustible 9 4 Checking the Fan Belt Also please refer to the accompanying Instruction Manual for the engine A DANGER Injuries e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the equipment check or maintenance should always keep the key To avoid injuries by unintentional contact with the cooling fan or fan belt close and lock all doors while operating this equipment ACAUTION Burns Due to extremely high temperatures do not touch the engine or muffler while operating or immediately after stopping the equipment Shindaiwa Construction Products 29 9 4 1 Tension The fan belt should have to V2 inch slack when applying finger pressure at the midpoint between the fan pulley and the alternator pulley 9 4 2 Condition Check the fan belt for any damage and replace if necessary CAUTION e Refer to the Instruction Manual for the engine to adjust or replace the fa
11. This meter should be used to schedule preventive maintenance Note The hour meter will continue to operate as long as the start switch is in the ON position regardless of whether the engine is actually running or not Volt Meter The volt meter displays the voltage output from the generator The voltage displayed will be dependent on the position of the voltage selector switch For single phase operation it will display L1 or L3 voltage only Ammeter The amp meter displays the electrical current output from the generator The amperage displayed will be dependent on the position of the amp meter selector switch For single phase operation it will display L1 or L3 phase amperage only Frequency Meter The frequency meter will display the frequency of the generated power Shindaiwa Construction Products 16 Coolant Temperature Gauge This gauge indicates the temperature of the engine coolant in degrees Fahrenheit Under normal operating conditions this gauge should read approximately 180 F to 200 F Oil Pressure Gauge This gauge indicates the oil pressure of the engine in pounds per square inch Under normal operating conditions this gauge should read approximately 40 to 60 pounds per square inch Fuel Gauge Optional This gauge indicates the fuel level in the internal fuel tank only If there is an external fuel tank being used to supply fuel to the generator this gauge will not indicate the fuel level of that tank 6 3 Lamps
12. and Lights Glow Lamp When the start switch is turned to the Run Preheat position the Glow Lamp will light to indicate that the glow plugs are energized and preheating the engine cylinders When the preheating is completed the lamp will go off indicating that the engine is ready to be started CAUTION e Preheating time may vary from 1 to 5 seconds depending on the coolant temperature Pilot Lamp The pilot lamp is located on the generator control panel and indicates whether or not the engine is running When the lamp is lit the engine is running When the lamp is not lit the engine is not running Panel Light The panel light is located on the generator control panel and is used to illuminate the generator and engine control panels This light is turned on and off with the panel light toggle switch which is also located on the generator control panel next to the panel light This light can only be energized when the engine is running Shindaiwa Construction Products 17 6 4 Switches Start Switch The Start Switch is a three position switch that is used for starting stopping and preheating the engine POSITIONS STOP When the switch is set to this position all power will be off The switch must be set to this position to remove the key Run Preheat The switch must be set to this position during operation This position is also used to preheat the glow plugs and for removing air from the fuel lines CAUTION
13. shutdown will be activated This will cause the engine to shut down Insufficient battery charging will cause the light to flash only The diagnosis lamp flashes but does not shut the engine down if the electronic control module detects a fault that could affect engine operation The boost temperature lamp flashes but does not shut the engine down if there is an excessive temperature at the inlet to the intake manifold The over speed light flashes and shuts the engine down on an over speed condition If an automatic shutdown is activated check for and correct the cause of the shutdown prior to trying to restart the generator set Coolant Temperature Monitoring Lamp ACAUTION Injuries To avoid injuries by unintentional contact with the cooling fan and or fan belts close and lock all doors while operating this equipment Burns e To avoid sustaining burns from hot vapor do not open the radiator cap while operating or immediately after stopping this equipment Due to extremely high temperatures do not come in contact with the engine and or muffler while operating or immediately after stopping this equipment If the coolant temperature reaches 212 Fahrenheit increasing during operation the coolant temperature monitoring lamp will flash and the automatic shutdown will activate If this occurs check the coolant reservoir tank and replenish coolant if needed refer to 9 3 Checking Engine Coolant If the coolant level is normal
14. vapor 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 muffler while operating or immediately after stopping this equipment When checking or changing engine oil always stop the engine and wait until the engine cools down Opening either the line to the oil gauge or the oil filler cap during operation may cause injury due to hot oil Fire e Always immediately wipe up any diesel fuel or engine oil that is spilled Do not use this equipment if there are any leaks Repair the equipment before further use To maximize the useful life of this generator follow the recommended periodic equipment and maintenance checks according to the following table The hour meter should be used as a guide for actual operating time CAUTION With the exception of the pre startup and operating checks only qualified technicians should perform the equipment and maintenance checks Maintenance items marked with XX should be referred to the nearest authorized dealer This chart covers only basic checks and maintenance for the engine For more detailed maintenance information for the engine refer to the Instruction Manual for the engine For maximum performance and useful life always use genuine replacement parts Shindaiwa Construction Products 35 Startup Every Every Every Every Every Description Check 200 h
15. www kwietpower com 7 25 07 Part No 80350 Manufactured by Shindaiwa Corporation Hiroshima Japan
16. 4OW _ gt SAE 15W 40 20W 40 W ____ __ CAUTION e Use API class CD grade or higher engine oil 9 3 Checking Engine Coolant Also please refer to the accompanying Instruction Manual for the engine A DANGER Injuries e Prior to performing any equipment check or maintenance stop the engine and remove the engine key The person performing the equipment check or maintenance should always keep the key ACAUTION Burns e To avoid sustaining burns from hot vapor 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 muffler while operating or immediately after operation of this equipment Shindaiwa Construction Products 28 9 3 1 Checking Radiator Level Adding Coolant Also please refer to the accompanying Instruction Manual for the engine 1 Remove the radiator cap and check the level of the coolant by observing the level in the radiator filler port The coolant level should be up to the filler port neck If not add coolant The coolant should be a 50 50 mix of GM SPEC 6277M or equivalent long life Coolant Water 2 Fill the radiator with coolant until it reaches the filler port neck Fill slowly to prevent air entry 3 Reinstall the radiator cap and tighten 4 Recheck the level after a few minutes of running the engine and add additional coolant if necessary 9 3 2 Checking the Coolant Reservoir
17. Directional Valve Optional 20 6 7 1 Using Fuel From The Internal Tank 20 6 7 2 Using Fuel From The External Fuel Tank 21 6 7 3 Fuel Directional Valve Location 22 Shindaiwa Construction Products 1 7 LIFTING TRANSPORTING AND INSTALLING 22 7 1 Lifting 22 7 2 Transporting 23 7 3 Installing 23 hs CONNECTING CA ii 24 9 INITIAL STARTUP AND PRE CHECKS 27 9 1 Checking Engine Oil 27 9 2 Selecting the Proper Engine Oil 28 9 3 Checking Engine Coolant 28 9 3 1 Checking Radiator Level Adding Coolant
18. Due to extremely high temperatures do not come in contact with the engine and or muffler while operating or immediately after stopping this equipment When checking or changing engine oil always stop the engine and wait until the engine cools down Opening either the line to the oil gauge or the oil filler cap during operation may cause injury due to hot oil If the inlet temperature to the inlet manifold exceeds 185 F the boost temperature lamp will flash but will not shut the engine down Investigate and correct the reason for the excessive temperature Shindaiwa Construction Products 15 Over Speed Lamp A DANGER Injuries e To avoid injuries by unintentional contact with the cooling fan and or fan belts close and lock all doors while operating this equipment ACAUTION Burns e Due to extremely high temperatures do not come in contact with the engine and or muffler while operating or immediately after stopping this equipment When checking or changing engine oil always stop the engine and wait until the engine cools down Opening either the line to the oil gauge or the oil filler cap during operation may cause injury due to hot oil If the electronic control module detects that engine speed has exceeded 2070 rpm it will flash the over speed lamp and will shut the engine down Investigate the cause and correct before trying to restart the engine 6 2 Meters and Gauges Hour Meter The hour meter keeps track of run time
19. Every 500 hours Procedure 1 Drain the engine oil completely as described in section 11 1 2 Using an oil filter wrench loosen and remove the oil filter 3 4 Screw the new filter into place and hand tighten it until the gasket just contacts the filter seat Then using an oil filter wrench give it additional 3 4 turn to seat the filter 5 Add oil and reinstall the filler cap 11 3 Cleaning Changing the Air Filter Element Frequency Every 200 hours Replace Every 500 hours Procedure 1 Unscrew the wing nut and remove the filter element 2 Clean or replace the filter element and reinstall it CAUTION e In dusty or other high particulate environments increase the frequency of cleaning e To clean the filter element e f the element has dried contaminants it may be cleaned by blowing compressed air through it from the inside If the element has any carbon or grease buildup it should be replaced with a new element Shindaiwa Construction Products 37 11 4 Cleaning Changing the Fuel Filter Freguency Clean Every 500 hours Replace Every 500 hours Procedure 1 Remove the outer case of the filter using the filter wrench Isuzu part No 8 9801 3170 0 2 Remove the fuel filter element 3 Install the new fuel filter element 4 Fill the case with clean diesel to help facilitate bleeding the fuel system upon completion 5 Tighten the case by hand ensuring that the diesel does
20. accidents or repairs e Operate this equipment only after thoroughly reviewing and understanding the contents of this manual e This manual should always be kept on or near the generator e The battery or batteries supplied with the generator are dry when shipped Dilute sulfuric acid must be added The following convention will be used throughout this manual to indicate various degrees of cautions ADANGER May cause severe injuries or death ACAUTION May cause minor injuries or damage to the equipment or other property CAUTION Other types of caution e Even some of the items noted in ACAUTION may lead to severe injuries Read and carefully follow all items and safety guidelines Shindaiwa Construction Products 3 2 Safety Guidelines A DANGER Suffocation from exhaust fumes Exhaust fumes from the engine on this diesel generating set contain many elements that have been proven to be harmful to humans Do not operate this equipment in poorly ventilated areas such as inside a room or in a tunnel Do not direct exhaust fumes toward people or buildings Electrical Shock Do not come in contact with or allow anything else to come in contact with the output terminals during operation Be sure to place the protective covers over the output terminals and fasten them securely while operating this equipment Do not insert metal objects such as pins or wires into plug in receptacles Do not touch the wirin
21. ames or spark producing devices 10 Operation ADANGER Suffocation from exhaust fumes e Exhaust fumes from the engine on this diesel generating set contain many elements that have been proven to be harmful to humans Do not operate this equipment in poorly ventilated areas such as inside a room or in a tunnel e Do not direct exhaust fumes toward pedestrians or buildings ACAUTION Fire e Temperatures around the muffler and exhaust piping can get extremely high Keep any flammable items such as fuel gas paint etc away from these areas e This equipment must be operated only on flat surfaces and at least 3 feet away from any obstructions such as walls that could hinder airflow Injuries e Always place the equipment on a flat and stable surface to keep it from sliding e Before starting the engine turn off the connected equipment and turn the generator output circuit breaker to the OFF position 10 1 Starting 1 Turn the output circuit breaker on the control panel to the OFF position 2 Turn the starter switch to the Start position 3 As soon as the engine starts release the starter switch 4 In cold temperatures turn the starter switch to the Operating Preheat position until the preheat lamp turns on and then turn it to the Start position CAUTION e Preheating time may vary from 1 to 5 seconds e Do not crank the starter motor for more than 10 seconds at a time e If the engine does not start wait at lea
22. as fuel gas paint etc away from these areas Follow the guidelines below when performing any troubleshooting If you cannot resolve the problem s by using this troubleshooting guide contact the nearest authorized service center Symptoms Possible cause Corrective Actions 1 Dead battery 1 Replace the battery Starter motor will not turn over 2 Weak battery 2 Recharge the battery 1 Low fuel 1 Refill the fuel tank Starter motor turns over but the 2 Water or contaminants in 2 Drain water or clean the fuel tank and engine will not start the fuel fuel filter 1 Low oil pressure 1 Check the oil level and fill if necessary Engine starts but stalls 2 High coolant temperature 2 Check coolant level and fill if necessary immediately 3 Airin the fuel system 3 Bleed out the air 1 Circuit breaker has not 1 Turn the circuit breaker to the OFF Cannot turn the circuit breaker been completely turned to position and then back to on to the ON position the OFF position 2 Overload 2 Check the load side reset the thermal 3 Terminal cover is open overload relay inside the control panel 3 Close and latch the terminal cover l _ Black or white smoke is coming Reduce the load out of the exhaust line Overloading Shindaiwa Construction Products 40 Construction Products Shindaiwa Incorporated 11975 SW Herman Road Tualatin OR 97062 Phone 503 692 3070 Fax 503 692 6696
23. aust piping can get extremely high Keep any flammable items such as fuel gas paint etc away from these areas e Always immediately wipe up any diesel fuel or engine oil that is spilled Do not use this equipment if there are any leaks Repair the equipment before further use If the generator will not be used for more than two months perform the following maintenance and storage procedures RIOD m Remove the battery Change the engine oil Drain the fuel from the fuel tank and fuel filter Clean all parts cover the generator and store it away from dust and humidity CAUTION e Recharge the removed battery at least once a month e Refer to the engine instruction manual for detailed care procedures for the engine Shindaiwa Construction Products 39 13 Troubleshooting A DANGER Electrical Shock e Donotoperate this generator if it is wet e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the check or maintenance should always keep the key ACAUTION Injuries e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the check or maintenance should always keep the key Fire e The battery may emit highly explosive gases Never expose it to flames or spark producing devices Temperatures around the muffler and exhaust piping can get extremely high Keep any flammable items such
24. ce the equipment on a flat and stable surface to keep it from sliding When starting the engine disconnect the supplied load and set the output circuit breaker to the OFF position Do not move the equipment during operation When performing equipment checks and or maintenance always stop the engine Do not operate this equipment if it is being modified or if any parts have been removed WARNING KEEP TERMINAL BLOCK FREE OF DUST AND MOISTURE AT ALL TIMES Always keep environmental contaminants such as dust and moisture from building up on the terminal block and generator control box or arcing from the terminals to the generator control box or terminal block mounting screws may result Shindaiwa Construction Products 5 3 Labels Caution Danger Warning and Operation Information Labels Make sure all information labels are undamaged and readable Immediately replace damaged or missing information labels New labels are available from your local authorized Shindaiwa distributor or dealer Serial Number Plate kWiet Power Label kWiet Power Label Striping Label Striping Label Striping Label O ON OA FW N 0 Striping Label 50980 00890 19406 00089 19406 00108 19407 00066 19407 00072 19407 00073 19407 00074 Striping Label Danger Lifting Hook General Safety Fuel Inlet Optional Fuel Return Optional 3 Way Valves Optional Diesel Fuel Only Shindaiwa Construction Products 6
25. check for a loose fan belt or possible water leak in the cooling system Always allow the engine to cool down prior to making these checks Shindaiwa Construction Products 13 CAUTION e f the coolant level is too low the temperature sensor cannot detect the coolant temperature Always check the water level in the radiator and the coolant reservoir tank prior to operating this equipment Engine Oil Monitoring Lamp A DANGER Injuries e To avoid injuries by unintentional contact with the cooling fan and or fan belts close and lock all doors while operating this equipment ACAUTION Burns e Due to extremely high temperatures do not come in contact with the engine and or muffler while operating or immediately after stopping this equipment When checking or changing engine oil always stop the engine and wait until the engine cools down Opening either the line to the oil gauge or the oil filler cap during operation may cause injury due to hot oil If the engine oil pressure drops below 10 psi during operation the oil pressure monitoring lamp will flash and the automatic shutdown will activate If this occurs check the engine oil level and fill to the maximum level if needed CAUTION e The oil pressure sensor cannot detect engine oil degradation due to extended use Oil change intervals listed under section 11 must be strictly adhered to Battery Charge Monitoring Lamp Insufficient battery charge during operation wil
26. e control panel Itis a red momentary contact type switch that must be held in until the engine completely stops 6 5 Output Circuit Breaker The Output Circuit Breaker is located on the control panel and is used for connecting and disconnecting the load from the output of the generator Turning the circuit breaker to the ON position will allow power to be supplied to the load Turning the circuit breaker to the OFF position will remove all power from the load The breaker will also trip and remove power from the load in the event that there is an overload condition on the generator or if the terminal board cover is opened while the generator is running 6 6 Voltage Adjustment Rheostat The Voltage Adjustment rheostat is used to adjust the generated output voltage of the generator Turning the voltage adjust knob clockwise will increase the generated voltage Turning the voltage adjust knob counter clockwise will decrease the generated voltage The adjustment range available with this knob is plus 6 5 and minus 15 Shindaiwa Construction Products 19 6 7 Fuel Directional Valve Optional ACAUTION Burns e Always stop the engine prior to performing any work on fuel lines e Immediately wipe up any fuel leakage The fuel directional valve provides a quick and convenient method of using an external fuel tank as a fuel supply for the engine If an external fuel supply is being used the internal fuel tank is not available as a supply of f
27. engine cools down before refueling Always immediately wipe up any diesel fuel or engine oil that is spilled Do not use this equipment if there are any leaks Repair the equipment before further use Temperatures around the muffler and exhaust piping can get extremely high Keep any flammable items such as fuel gas paint etc away from these areas Shindaiwa Construction Products 4 ACAUTION The battery may emit highly explosive gases Never expose it to flames or spark producing devices This equipment must be operated only on flat surfaces and at least 3 feet away from any obstructions such as walls that could hinder airflow Do not connect the AC output to any indoor wiring without an approved disconnecting device between the generator and the building s electrical service Burns To avoid sustaining burns from hot vapor 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 muffler while operating or immediately after stopping the equipment When checking or changing engine oil always stop the engine and wait until the engine cools down Opening either the line to the oil gauge or the oil filler cap during operation may cause severe burns due to hot oil Injuries Do not use the tie downs for lifting They are not designed to hold the weight of the equipment and using them for lifting may cause the equipment to fall Always pla
28. g or any electrical or electronic parts inside the equipment during operation There is always a danger of being electrocuted by a short circuit to ground Be sure to test the generator s insulation resistance to ground periodically Before connecting or disconnecting load cables from the output terminals always turn the output circuit breaker to the OFF position stop the engine and remove the engine key The person performing the cable disconnect should always keep the key Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the check or maintenance should always keep the key Injuries To avoid injuries by unintentional contact with the cooling fan or fan belt close and lock all doors while operating this equipment When lifting the equipment always use the installed lifting hook The lifting hook is designed to lift only the generator Do not lift any additional added weight such as fuel tanks and or trailers ACAUTION Injuries to eyes and skin Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or clothing If contact with the acid does occur especially with the eyes flush immediately with large volumes of water and contact a physician Fire This equipment uses diesel a flammable liquid as a fuel When refueling always stop the engine and maintain an adequate distance from flames or spark producing devices Always wait until the
29. ilure to do so may result in damages to and or malfunction of the equipment 7 3 Installing A DANGER Suffocation from exhaust fumes Exhaust fumes from the engine on this equipment contain many elements that have been proven to be harmful to humans Do not operate this equipment in poorly ventilated areas such as inside a room or in a tunnel Do not direct exhaust fumes toward pedestrians or buildings ACAUTION This equipment must be operated only on flat surfaces and at least 3 feet away from any obstructions Such as walls that could hinder airflow Temperatures around the muffler and exhaust piping can get extremely high Keep any flammable items such as fuel gas paint etc away from these areas CAUTION This equipment must be operated on a hard and flat surface Operating under any other conditions may result in damage to or malfunctions of the equipment Do not block the airflow from the radiator output or muffler exhaust This may result in reduced engine performance overheating or other significant damage Operating in abnormally dusty salty or high particulate environments may result in fouling of the radiator or air cleaner The frequency of maintenance and operating checks should be increased when operating this equipment in these types of environments Shindaiwa Construction Products 23 8 Connecting Cables A DANGER Electrical Shock e Before connecting or disconnecting load cables from the output
30. l cause the battery charge monitoring lamp to flash If this occurs check the condition and tightness of the fan belt and replace or tighten if necessary CAUTION e For changing the belt refer to the engine Workshop Manual e The Battery Charge Monitor cannot detect the degradation of battery life or the battery fluid level refer to 9 7 Checking the Battery Shindaiwa Construction Products 14 Diagnosis Lamp A DANGER Injuries e To avoid injuries by unintentional contact with the cooling fan and or fan belts close and lock all doors while operating this equipment ACAUTION Burns e Due to extremely high temperatures do not come in contact with the engine and or muffler while operating or immediately after stopping this equipment When checking or changing engine oil always stop the engine and wait until the engine cools down Opening either the line to the oil gauge or the oil filler cap during operation may cause injury due to hot oil If the electronic control module detects a fault that could affect engine operation it will flash the diagnosis lamp to indicate that further diagnosis as to the source of fault is necessary This will not shut the engine down Investigate and correct the cause of the diagnosis lamp Boost Temperature Lamp A DANGER Injuries e To avoid injuries by unintentional contact with the cooling fan and or fan belts close and lock all doors while operating this equipment ACAUTION Burns e
31. n belt 9 5 Checking the Fuel Level ACAUTION Fire e Always immediately wipe up any diesel fuel or engine oil that is spilled Do not use this equipment if there are any leaks Repair the equipment before further use Prior to starting the engine check the level of the fuel in the tank that is currently supplying fuel The fuel gauge on the control panel shows only the level of the fuel in the internal tank If an external fuel tank is connected and being used as the fuel source the fuel level in this tank is monitored and read separately from the gauge on the control panel CAUTION e Ensure the fuel strainer is installed in the neck of the fill spout e Fill the tank to slightly less than the FULL mark 9 6 Checking for Leaks ACAUTION Fire e Do not use this equipment if there are any leaks Repair the equipment before further use e Check all hose connections for leakage Prior to starting the engine make a complete and thorough inspection of the engine to ensure there are no fuel leaks Shindaiwa Construction Products 30 9 7 Checking the Batteries ACAUTION Injuries to eyes and skin e Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or clothing If contact with the acid does occur especially with the eyes immediately flush with large volumes of water and contact a physician Fire e The battery may emit highly explosive gases Never expose it or the surrounding area to fl
32. nal fuel tank For detailed instructions refer to Section 10 6 Connecting to an External Fuel Tank Fuel Directional Valve in the External Tank Position Using External Fuel Tank Engine Internal Fuel Tank External Fuel Tank Shindaiwa Construction Products 21 Engine 6 7 3 Fuel Directional Valve Location The Fuel Directional Valve is located directly behind the radiator and is mounted to the bottom of the enclosure 7 Lifting Transporting and Installing A DANGER e The lifting hook is designed to lift only the generator Do not lift any additional added weight such as fuel tanks and or trailers with the lifting hook ACAUTION Injuries e Use only the installed lifting hook for lifting this equipment e Do not use the tie down posts for lifting They are not designed to hold the weight of this equipment 7 1 Lifting Always use the installed lifting hook whenever lifting this equipment This lifting hook is designed to lift only the generator Do not lift any additional added weight such as fuel tanks and or trailers with this lifting hook Do not lift with the tie downs Lifting ie Tie Down Top View Tie Down Shindaiwa Construction Products 22 7 2 Transporting When transporting this eguipment make sure that the eguipment is properly secured using the tie down posts CAUTION Always use extreme care when loading unloading and transporting this equipment Fa
33. ngine oil that is spilled Do not use this equipment if there are any leaks Repair the equipment before further use 1 Turn the Fuel Directional valve to the internal tank position see Page 19 Disconnect the 3 8 inch pipe plugs from both the external fuel intake and the external fuel return lines and connect the hoses from the external fuel tank ensuring that the suction and return are connected to the proper plugs 3 Turn the Fuel Directional valve to the external tank position see Page 19 4 Remove the air from the connected hoses by positioning the starter switch to the Operating Preheat position and holding it there for approximately 10 to 15 seconds This will allow the use of the fuel from the external fuel tank CAUTION To avoid leaks from the external fuel intake or the external fuel return ports always turn the 3 way valve to the internal tank position while connecting or disconnecting the external fuel tank lines Use extreme caution when connecting the external fuel tank lines If the 3 way valve is not set properly fuel may leak from either the internal fuel tank or the external fuel tank Shindaiwa Construction Products 34 11 Maintenance A DANGER Electrical Shock e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the equipment check or maintenance should always keep the key ACAUTION Burns To avoid sustaining burns from hot
34. not leak out 6 Use the filter wrench and tighten and additional 1 3 to 2 3 turns 11 5 Draining Water From the Internal Fuel Tank Frequency Drain water Every 200 hours Procedure 1 Unscrew the fuel drain plug 2 After completely draining any water reinstall the drain plug 11 6 Changing Engine Coolant ACAUTION Replace only with GM SPEC 6277M or equivalent long life coolant Frequency Replace Every 2 years or 400 hours Procedure Remove the radiator cap Loosen the engine coolant water drain plug Drain the engine coolant completely Reinstall the drain plug Remove the reservoir tank and empty the engine coolant that is in the tank Reinstall the reservoir tank 7 Fill the radiator with engine coolant a 50 50 mix of GM SPEC 6277M or equivalent long life coolant and water to the top of the filler neck approximately 1 9 gal Fill slowly to prevent air entry Fill the reservoir tank with engine coolant to the Max line Reinstall the radiator cap 10 Recheck the level after a few minutes of running the engine and refill if necessary BOB Go NS o Shindaiwa Construction Products 38 12 Long Term Storage Procedures A DANGER Electrical Shock e Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the check or maintenance should always keep the key ACAUTION Fire e Temperatures around the muffler and exh
35. not use this equipment until the cause of the leak has been determined and remedied Complete repairs to the equipment before further use 9 1 Checking Engine Oil Also please refer to the accompanying Instruction Manual for the engine 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 tube ACAUTION If the equipment is not level you cannot obtain an accurate oil level reading Do not overfill the engine with oil Too much engine oil could damage the engine 1 Remove the dipstick from the crankcase and wipe it clean with a clean cloth 2 Reinsert it fully and then gently remove it again 3 Check the oil level on the dipstick The level must be between the Max level mark and the Min level mark 4 Ifthe level is above the Max mark drain oil until the level is at or below the Max level mark 5 If the level is at or below the Min level mark add oil until the level is above the Min level mark Shindaiwa Construction Products 27 9 2 Selecting the Proper Engine Oil Use engine oil specifically designed for diesel engine use with the proper viscosity based on the anticipated ambient temperature refer to the chart below Oil Viscosity and Temperature Temperature F 22 5 32 60 77 86 SAE10W 30 SAE10W 1 SAE30W SAE20 20W SAE
36. ped with automatic shutdowns and alarms These shutdowns and alarms activate automatically with display in the event of an abnormal situation automatic stop device has activated turn the starter switch to the STOP position Correct the cause s of the automatic shutdown prior to trying to restart the generator If an alarm occurs correct the cause of the alarm If the cause of the alarm cannot be corrected shut the engine down and investigate and correct the cause of the alarm prior to restarting the engine Automatic Shutdown List Action Circuit Automatic Breaker Engine Alarm Lamp No Symptoms OFF Shutoff Flash Cause Monitor Lamp Engine coolant 1 High Coolant X X temperature is too Temperature high activates at 212 F increasing 2 Low Oil Engine oil pressure Pressure X X too low activates at 10 psi decreasing 3 Insufficient When the battery Charge X can no longer hold a charge 4 Diagnosis X Some abnormal condition has occurred that requires special diagnostic software for analysis 5 High Boost xX When turbocharger Temperature air inlet temperature exceeds 185 F increasing 6 Over Speed xX xX When engine speed exceeds 2070 rpm increasing Shindaiwa Construction Products 33 If an 10 6 Connecting to an External Fuel Tank ACAUTION e Stop the engine prior to commencing external fuel tank connections e Always immediately wipe up any diesel fuel or e
37. rs 400hrs 500 hrs 1000 hrs 2000 hrs Engine Engine oil check add oil X Engine oil change X X Oil Filter change X X Coolant level check add coolant X Change PCV Filter Battery fluid level check Exhaust color check X Coolant change X or 1 yr Clean or replace fuel filter X Drain water from fuel tank X Clean inside fuel tank XX Leak check fuel oil and coolant X Replace fuel hose XX or 1 yr X X Clean or replace air cleaner element Clean Replace Fuel injection nozzle check XX Battery hydrometer check X Fan belt check X Flush Radiator XX Check and adjust engine valve clearance XX Compression check XX Fuel injection timing check XX Generator Meters gauges and alarm lamps X Insulation test X or 1 yr Shindaiwa Construction Products 36 11 1 Oil Change Loosen the engine oil drain plug and allow the oil to drain completely Add oil to the Max line on the dipstick approximately 2quarts Do not overfill Frequency First time 500 hours Thereafter Every 500 hours Procedure 1 Remove the oil fill cap 2 3 Reinstall the drain plug 4 5 Reinstall the filler cap hand tight CAUTION Use only engine oil designated API CC grade or higher 11 2 Oil Filter Change Lightly coat the rubber gasket of the new oil filter with some of the new engine oil Frequency First time 500 hours Thereafter
38. st 30 seconds before retrying 5 After the engine starts ensure all the monitor lamps remain off 6 Run the engine at idling speed without load for at least 10 minutes Shindaiwa Construction Products 31 10 2 Loading the Generator 1 2 Set the reguired voltage using the voltage adjusting knob Turn the generator output circuit breaker to the ON position to apply power to the load terminals A DANGER Electrical Shock e Before connecting or disconnecting load cables from the output terminals always turn the output circuit breaker to the OFF position stop the engine and remove the engine key The person performing the cable connection or disconnection should always keep the key 10 3 Operating the Generator In the event the generator output breaker trips OFF make the necessary correction or repair or decrease the load prior to resetting the breaker by first turning it to the OFF position and then back to the ON position When any RED warning monitor lamp turns ON stop operation immediately and correct the fault before resuming operation 10 4 Stopping the Generator Ph Turn the load breaker s to the OFF position Turn the generator output circuit breaker to the OFF position and allow the engine to run at idling speed for about 3 minutes for cooling down Turn the starter switch to the STOP position Shindaiwa Construction Products 32 10 5 Automatic Shutdowns and Alarms This generator is eguip
39. ter will display phase L1 current In the L2 position the ammeter will display phase L2 current In the L3 position the ammeter will display phase L3 current This switch must be in the L1 or L3 position to read single phase current Shindaiwa Construction Products 18 Voltage Selector Switch The voltage selector switch is a lockable 3 position switch located directly above the terminal connection panel This switch provides a guick convenient method of changing the generator output voltage This switch should never be operated while the generator is running The Three Phase 480 277 position gives an output from the generator of 480 volts three phase or 277 volts single phase The Three Phase 208 120 position gives an output from the generator of 208 volts three phase with 120 volts single phase or 240 volts three phase with 139 volts single phase 208 volts or 240 volts three phase are obtained by adjusting the voltage adjust rheostat on the control panel The Single Phase 240 120 volt position gives a single phase output from the generator of 240 volts or 120 volts Panel Light Toggle Switch This switch is located on the generator control panel next to the Panel Light It is used to turn the panel light on and off To prevent leaving this light on and draining the battery this switch can only turn the Panel Light on when the generator is running Emergency Stop Switch This switch is located just to the left of the start stop switch on the engin
40. terminals always turn the output circuit breaker to the OFF position stop the engine and remove the engine key The person performing the connection or disconnection should always keep the key Cable connection Terminal Board 3 phase single phase 480 Volt Three Phase and 277 Volt Single Phase Switch Position 3 Phase 240 139V 3 Phase 1 Phase 480 277V oe 120 240V LAN a Ca NA NS N a y ji Shindaiwa Construction Products 24 208 Volt Three Phase and 120 Volt Single Phase Switch Position Shindaiwa Construction Products 25 240 Volt Single Phase and 120 Volt Single Phase Switch Position Note Place the voltmeter selector switch in the L3 L1 position and the ammeter selector switch in the L1 or L3 position when the Voltage Selector Switch is in the 1 Phase 240 120V position 3 Phase 240 139V 65000 L1 L2 L3 N O O Shindaiwa Construction Products 26 9 Initial Startup and Pre Checks A DANGER Electrical Shock e Prior to performing any equipment check or maintenance stop the engine and remove the engine key The person performing the equipment check or maintenance should always keep the key ACAUTION Burns e Prior to performing any engine checks or adjustments stop the engine Wait until the engine cools down before performing any checks or adjustments Fire e Always immediately wipe up any spilled or dripped fuel or oil If a leak is found do
41. truction Products 9 5 1 Control Panel 1 Main Circuit Breaker 11 Ammeter Selector Switch 2 Pilot Light 12 Voltage Adjust Rheostat 3 Panel Light 13 Monitor Lights 4 Voltmeter 14 Hour meter 5 Ammeter 15 Water Temperature Gauge 6 Frequency Meter 16 Oil Pressure Gauge 7 Auto Start Panel Optional 17 Fuel Meter Optional 8 Auto Start Switch Optional 18 Glow Plug Lamp 9 Panel Light Switch 19 Emergency Stop Switch 10 Voltmeter Selector Switch 20 Ignition Switch Shindaiwa Construction Products 10 5 2 Main Terminal Board Plexiglass Cover Main Terminals Shindaiwa Construction Products 11 5 3 Receptacle Panel Note All duplex receptacles are GFCI protected and are rated at 20 amps All Twist Loc receptacles are rated at 50 amps SINGLE PHASE 120V CIRCUIT BREAKER SINGLE PHASE 240 120V CIRCUIT BREAKER Shindaiwa Construction Products 12 6 Eguipment 6 1 Monitor Displays This diesel generator set is equipped with monitoring functions for coolant temperature oil pressure battery charge condition diagnosis boost temperature and over speed Under normal operating conditions these monitoring lamps will come on momentarily when the engine is first started but will go off very shortly thereafter If an abnormal condition is detected in coolant temperature or oil pressure the corresponding monitor lamp will flash and the automatic
42. uel for the engine 6 7 1 Using Fuel From The Internal Tank The Fuel Directional Valve is set to the Internal Tank position when the equipment is shipped This position allows the fuel from the internal tank to be used as a fuel source for the engine In addition both the external fuel intake and the external fuel return lines are plugged with 3 8 inch pipe plugs Always ensure that the external fuel intake and return are plugged with the supplied plugs or is connected to an external fuel tank while using the internal fuel tank as the fuel source CAUTION Always set the fuel directional valve to the internal tank position and cover the external fuel intake and fuel return ports with the supplied plugs whenever the internal fuel tank is being used as the fuel source Fuel Directional Valve Instruction Label 3 WAY FUEL VALVES FUEL FROM FUEL FROM EXTERNAL TANK INTERNAL TANK of fe Q Shindaiwa Construction Products 20 Fuel Directional Valve in the Internal Tank Position Using Internal Fuel Tank Engine Internal Fuel Tank External Fuel Tank 6 7 2 Using Fuel From The External Fuel Tank Engine Connect hoses from the external fuel tank to the external fuel intake and the external fuel return ports and set the Fuel Directional valve to the external fuel tank position You can now supply fuel from the exter
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