kWiet Power DGK25E User manual

6/30/08
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.

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. EQUIPMENT……………………………………………………………………….20
6.1 Engine Control Circuit ………………………………………………………... .…20
6.2 Monitors and Displays ……………………………………....… ……… …… ….21
6.3 Meters and Gauges………... ………………………………………………..... ...23
6.4 Lamps and Lights……………… …………………………………………………24
6.5 Switches……………... …………………………………………….…………...…25
6.6 3 Way Valve. ………………………………………………………………………27
7. LIFTING, TRANSPORTING and INSTALLING…………………………….....28
7.1 Lifting ………………………………………………………………...…………….28
7.2 Transporting…………… …………………………………………………....…....29
7.3 Installing……………………………………………………………….……....…..29
8. SIMULTANEOUS OUTPUT…………………………………………………......30
9. CONNECTING CABLES… …………………………………………….....….... 31
9.1 Main Terminal Connection 480/277V Position…………………………......... 31
9.2 Main Terminal Connection 240/139V Position….…………………................32
10. GENERATOR….…………………………………......................................... 33
11. INITIAL STARTUP and PRE-CHECK…………..…………….…..…........... 34
11.1 Checking Engine Oil………………………………………………………...... 35
11.2 Selecting the Proper Engine Oil………………………..……………………..36
11.3 Check for Leaks …………………………………….………………………….36
11.4 Checking Engine Coolant………………………..…………………………….37
11.5 Procedure for Checking Fan Belt and Tension ……………………….........38
11.6 Checking the Fuel Level ……………………….……………………………...39
11.7 Battery Check ………………..…………………………………………………39
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
13.6 Replacing Electric Fuel Pump Filter…………………………………………….48
13.7 Draining Water from the Internal Fuel Tank…….…………………………......48
13.8 Replacing LLC Antifreeze………………………………………………………..49
14. TROUBLESHOOTING.…………………………………….……………………50
14.1 Generator ………………………………………………………………...…….…50
14.2 Engine…………..……….…………………………………………………....…...51
15. LONG TERM STORAGE………………………………………………………..52
CONTENTS

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.
This manual should always be kept on or near the generator at all times
Always keep the generator properly maintained.
For periodic maintenance and repair of the engine, please contact
KWiet Power dealer or authorized ISUZU service center.
1. INTRODUCTION
ENGINE MODEL ：BV-4LE1 (ISUZU)
US EPA Interim Tier 4 Compliant
1

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.
Note that CAUTION item can also lead to major accidents under some circumstances if
not correctly followed.
All items listed in this manual are important for safe operation of the generator unit. Be sure to
observe them closely.
2. SAFETY INSTRUCTIONS
2

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.
DANGER OF EXHAUST GAS POISONING
DO NOT OPERATE GENERATOR UNIT IN AN ENCLOSED AREA!
The exhaust gas of the engine contains substances that are harmful to human health. Operate the unit
in a well ventilated area. Using the generator unit indoor or in enclosed place can cause exhaust gas
poisoning.
DANGER OF INJURY CAUSED BY ROTATING PARTS
DO NOT TOUCH ROTATING PARTS DURING EQUIPMENT OPERATION!
Stay clear of rotating parts such as the belt, pulleys and the fan while the generator unit is running.
Your hands or other parts of your body can be caught by rotating parts, or strike your body with great force,
thus causing injury. Turn off the engine before inspecting the unit or conducting maintenance work.
DANGER OF ELECTRIC SHOCK, INJURIES AND BURNS
PRECAUTIONS FOR MAINTENANCE AND INSPECTIONS!
Before conducting an inspection or maintenance work, remove the key from the starter switch, and place
a [DO NOT OPERATE EQUIPMENT] sign or similar warning over the starter switch.
An accidental operation of the engine during an inspection or maintenance work can cause
a serious accident.
SAFETY INSTRUCTIONS
3

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.
Do not lift the unit at any other sections. If wire cables are attached to the other parts,
the unit can become unbalanced or drop when it is lifted.
[INSTALLATION]
DANGER OF INJURIES
DO NOT OPERATE EQUIPMENT IN SLOPED/UNEVEN LOCATION!
Do not operate the generator on unleveled or soft ground surfaces, the generator unit can move or tilt and could
cause personal injuries.
[OPERATION]
DANGER OF FIRE
USE EXTRA CAUTION WHEN ADDING FUEL OR OIL!
Before adding fuel or oil, stop the engine and make sure there is no open flame in the area. If fuel is spilled
or leaks onto hot parts or electric components, a fire could occur. If fuel or oil is spilt, clean the area immediately.
Close the cap securely after supplying fuel or oil.
SAFETY INSTRUCTIONS
4

[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.
DO NOT SPLASH WATER ON ELECTRICAL PARTS WHEN CLEANING!
When cleaning the generator unit with water, close all doors of the generator unit. If water is splashed
on the control panel, it could cause a malfunctions and a short-circuit, and result in a fire. If water is
accidentally splashed on electrical components or the control panel, use compressed air to dry out completely.
PRECAUTIONS IN HANDLING BATTERY
HANDLING BATTERY CAREFULLY!
The battery generates hydrogen gas and oxygen, which are flammable. A flame when brought near
the battery can cause an explosion. Handle the battery with extra caution.
(1)Wear protective grasses and rubber gloves when conducting maintenance work or inspecting the
battery.
(2)Do not smoke or generate a spark near the battery.
(3)Stop the engine before conducting an inspection or maintenance of the battery.
(4)Do not touch both terminals of the battery with a tool or metal object.
(5)When removing the battery cables, disconnect the cable at the negative (-) terminal first.
When connecting the cables, install the positive (+) terminal first.
(6)Change the battery in a well-ventilated area only.
(7)Connect the cables securely to each terminal posts. Loose cables could be causing faulty contact,
which can generate a spark and causing an explosion.
(8)Before conducting maintenance work on the electrical system or conducting electric welding,
remove the negative (-) cable from the battery to cut-off the electric current flow to the circuits.
SAFETY INSTRUCTIONS
5

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.
(2)Do not use the battery with the electrolyte surface below the minimum level, as it can
cause an explosion.
(3)If electrolyte spills on the skin or clothing, wash immediately with plenty of water, then clean
thoroughly with soap.
(4)If electrolyte accidentally enters the eye, wash immediately with plenty of clean water and consult
a doctor immediately. Electrolyte can cause the loss of eye sight.
(5)If electrolyte is accidentally swallowed, rinse mouth repeatedly with plenty of water, drink large
amounts
of water, and consult a doctor immediately.
SAFETY INSTRUCTIONS
6
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.

3. LABELS
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
7
3.1 Locations

LABEL
8
3.2 Part Numbers

4. SPECIFICATION
Standard Specification condition:
Altitude: 3280 ft (1000m) or lower, Temperature: 5 to 104°Ｆ( -15 to ＋40℃),
Humidity: 85% or lower (no condensation) *Reference data only*
GENERAL SPECIFICATION
9
Revolving Field Brushiess Ac
Simultaneous 3 Phase-120/240V 1 Phase
kVA 25
kW 20
V 208,240,480
V 120,139,240,277
Single phase-120V A 62.5 x 2
Single phase-240V A 62.5
Three phase-208V A 69
Three phase-240V A 60
Three phase-480V A 30
Hz 60/50 ± less than 5%
rpm 1800/1500
Star with Neutral
.8
F
Self excitation (brushiess)
4
Vertical Water-cooled 4-cycle Diesel
4LE1 (ISUZU)
(in./mm) 4 (3.35 x 3.78/85 x 96)
hp 31
rpm 1800/1500
Cu.in./liters 133/2.179
Swirl Chambered
Radiator
Forced lubrication
Electric
ASTEM No. 2 Diesel
gal./liters 1.76/6.68 per hour @ full load
CD class or higher
gal./liters 20.6/78
gal./liters 2.2/8.5
gal./liters 2.2/8.2
V-kW 12V-2.0kW
V-A 12V-20A
V-AH 12V-80AH
Meters
3 Phase ±1.0%
1 Phase ±5.0%
Shutdowns Lamp indication with shutdown
Warning Lamp indication
in./mm 57 x 31 x 45/1440 x 780 x 1140
lbs./kg 1543/700
dB(A) 53
dB(A) 56
Specifications are subject to change without notice.
Shindaiwa Construction Products 11975 SW Herman Road Tualatin, OR 97062
Voice 503-692-3070 Fax [phone] www.kwietpower.com
*US emission certified at 1800 rpm only*
Engine
Dry weight
Unit
Oil pressure, Water temperature
Battery charge
Dimensions (L x W x H)
Voltage/Frequency/Amperage/Hour
Fuel Consumption
Displacement
No Load
Rated speed,60/50Hz
Voltage Regulation
Generator Type
Rated Output
Automatic Voltage Regulator
Charging altemator capacity
Battery capacity
Starting motor capacity
Amps
Sound Level
Full Load
Lubricating oil
Fuel tank capacity
Lubricant volume
Cooling water volume
Lubricating method
Starting method
Fuel
No. of poles
Combustion system
Cooling method
Type
Model (Manufacturer)
No. of Cylinders (bore x stroke)
Continuous rated output
DGK25E Specifications
Alternator
Voltage-Three phase
Voltage-Single phase
Frequency-regulation
Rated speed
Winding
Power factor
Insulation class
Excitation

5.1 Outside View
DESCRIPTION
10
Units (mm)

DESCRIPTION
11
Units (mm)

12
DESCRIPTION
5.2 CONTROL PANEL
Detail drawing of warning indicator
High water temperature Battery charge fault
Low oil pressure

13
DESCRIPTION
Turns on the control panel lightPanel light switch18
Indicates when the generator is runningPilot Lamp19
Selects the phase voltage the voltmeter is displayingVoltmeter Selector Switch6
OFF: Stops engine operation.
ON: Supplies electricity for control operation and starts pre-heating
START: Starts the engine
Ignition switch16
Indicates total operating hours of the generator unitHour meter14
Indicates lubricating oil pressureOil pressure gauge12
Indicates temperature of the engine coolantCoolant temperature gauge11
Lights when an equipment malfunction occursWarning indicators10
Indicates the fuel level in the internal tankFuel gauge13
Selects the phase current the ammeter is displayingAmmeter selector switch9
Selects voltage output at terminalsVoltage selector switch17
The indicator lights when the key switch is set to the
[ON] position, and starts pre-heating.
Turns off when pre-heating is completed.
Pre-heating indicator15
Used to adjust voltageVoltage adjust potentiometer8
Illuminates control panelPanel light7
Indicates electrical frequencyFrequency meter5
Indicates phase currentAmmeter4
Indicates voltageVoltmeter3
Connects (On) or disconnects (Off) the load from the output of the
generator
1-Phase circuit breaker2
Connects (On) or disconnects (Off) the load from the output of the
generator
3-phases circuit breaker1
Description of functionNameNO.
Control Panel (Continued)

5. DESCRIPTION
14
5.3 Layout
Tie-Down
Coolant Sub-Tank
Tie-Down
Coolant Drain
Lifting Hook
Operation Panel Door
Fuel inlet
Engine Check Door Radiator Tie-Down Inspection Door
Air Cleaner Oil Level Indicator
Engine Check Door
Oil Filler
3way fuel valve
Fuel Drain plug
Oil Drain plug
External fuel return plug
External fuel inlet plug
Fuel Filter
Fuel Tank
Battery
Oil Filter
Water Separator
Alternator Check Door

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.
Serial
number
Main Stator
Thermo
Label
Screw
Exciter stator
Bracket
Screw
End Cover
Screw
Thermo
Label
Screw
Fan cover
Main rotor
Assy
Exciter rotor
Bearing
15
Exploded View

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). This stator also
houses the stationary coils used as the exciter stator for the generator field exciter. The stator is bolted
directly to the flywheel housing of the engine. The end bracket and end cover are bolted directly to the
end of the stator opposite to where the stator is bolted to the flywheel housing.
16