OPERATION AND INSTALLATION GUIDE FOR DIESEL FUEL MODELS: SPJD-250 THRU SPJD-2100 (JOHN DEERE DRIVEN, DIESEL GEN-SETS) AND SPMD-2500 THRU SPMD-4000 (MTU DRIVEN, DIESEL GEN-SETS) GILLETTE GENERATORS AUTOMATIC POWER SYSTEMS OGU07-OWN796-20120824
DIESEL GENERATOR-TABLE OF CONTENTS Page Introduction, General Cautions, Warnings, Danger & Danger Points -------3-10 Receiving, Un-packing and Installation of your Generator Set ---------------10-13 Diesel Generator Dimensional Chart ----------------------------------------------13 Muffler and Generator Installation on Open (No Housing) Gen-Sets --------14-15 Engine Muffler and Radiator Systems ----------------------------------------------16-17 Diesel Starting, and Battery Requirements --------------------
PRODUCT SAFETY INFORMATION SECTION 1 SAFETY RESPONSIBILITY Be sure that you are completely familiar with the safe operation of this equipment. Improper use can cause serious or fatal injury. GILLETTE Generator installation and repair procedures require specialized skills. Contact GILLETTE service department for repairs or any questions you may have about the safe installation and operation of this system. The precaution statements are general guidelines for the safe use and operation of this generator.
use by non-qualified operator can cause serious or fatal injury. clothing or extremities and cause serious of fatal injury. DANGER: Disconnect all electrical wires and load devices from generator power outlets before servicing the generator. Electrical shock can cause serious or fatal injury. DANGER: Do not put hands, feet, tools, clothing, or other objects near rotating parts such as cooling fan, drive shaft, pulley, belt, etc.
death. Symptoms of carbon monoxide poising include: dizziness, nausea, headaches, sleepiness, vomiting, or incoherence. If anyone experiences these symptoms, get out into fresh air immediately. Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or generator may need an increase in cooling air input and hot air output. DANGER: Never operate the generator set indoors in a poorly or non-ventilated area.
WARNING: Parts of this generator are extremely hot during and after operation. To prevent severe burns, do not touch any part of the generator until you have first determined it has cooled down to a safe point to touch. CAUTION: Do not operate generator in tropical ambient conditions without a special protected insulating varnish on generator windings and insulation system. Copper windings absorb moisture and soon cause a generator malfunction.
GILLETTE GENERATORS has made every effort to present a modern, safe generator set that will give you a safe, clean supply of an alternative electricsource. However, because each installation is different, it is impossible for this manual and GILLETTE to know and advise against all possible hazards. The listings of dangers, warnings, cautions, and notices in this manual and on tags and decals affixed to the generator set, are therefore, NOT ALL INCLUSIVE.
● Generator should not be exposed to excessive and constant moisture, dust, dirt, or corrosive environments. ● If connected loads cause over heating or excessive vibration, an overload condition exists. Remove loads until condition stabilizes. ● Do not sit, step, or load heavy items on generator roof. Added stress can cause breakage. ● Do not start generator with air cleaner, air cleaner cover, or oil dipstick removed, nor with oil drain hose in open drain position.
generator. Jewelry will conduct electricity, causing electric shock. Contact with exhaust muffler and exhaust pipe can result in serious burns. ● If generator must be serviced while it is running, stand on a dry, insulated surface from ground to reduce shock hazard. Never service a generator in the rain or snow. Exhaust heat may ignite combustibles such as leaves or other such debris that is allowed to accumulate around base or interior of generator where exhaust exits.
can be ignited. Leaks in fuel system can be ignited. Both are conditions that can cause fire and/or explosion, leading to possible death. make sure that different procedure, work method, or operating method is totally safe, against harm and hazards to operators, buildings or environments. ● Do not operate generator if smell of fuel is detected. UNPACKING AND INSPECTION ● Wipe up any oil spills immediately. Remove any debris that has accumulated inside or around generator base and housing.
● Starting battery is not included. See page 17 for battery supply information. inspector or city hall to insure you are aware of all codes and regulations. ● All gen-sets have the required vibration isolators between generator and steel mounting skid base. No further vibration isolation is required. GENERATOR LOCATION GUIDELINES ● Fuel input pipe is supplied for fuel connection.
moved, use (2) steel pipes thru the lift point, to lift gen-set. This mounting location of gen-set is important. It must be installed in an area that is protected from harmful gases, liquids, dust, metallic particles, shock, or vibrations. It should be installed in an outdoor location, so that exhaust fumes are vented to the atmosphere. The factory installed weather and sound protected enclosure is designed to keep out undesirable weather elements.
WARNING: An open bottom, stationary gen-set must be installed over a non-combustible material, such as a cement slab, and must be positioned to prevent combustible materials, rain, pooling water, sprinklers from entering into, and accumulating under gen-set. A) Installation should place gen-set as close as possible to the fuel supply, the transfer switch, and distribution/ circuit breaker panel. B) Service access must be provided to allow generator housing doors to fully open.
TYPICAL EMERGENCY GENERATOR INSTALLATION PRACTICES FOR “OPEN” (NON-SELF ENCLOSED) GENERATOR A standby emergency power systems will give years of dependable service when installed properly. Incorrect installations can cause continuing service problems and may result in harm to humans. It is the responsibility of the owner or operator to know and understand the correct installation methods. It is of particular importance to know safe methods especially, when installing an open generator inside a building.
It is, however, available as an option purchase. GILLETTE does not offer the “Industrial” grade muffler as it is very loud and is seldom satisfactory to the end user. Muffler selections are: Residential grade (reasonable quietness), “Critical” grade (very quiet) or “Hospital” grade for ultimate silencing. NOTE: The gen-set drawings on page 14 shows a horizontal Hospital grade muffler.
F) The exhaust piping system is subject to engine vibration, so it must be solidly installed to reduce potential for pipe cracks or breakage. G) It is very important to discharge exhaust gasses away from the engine and out of the generator building. If these gasses remain in the engine cylinders, poor engine performance and eventual engine damage may result.
A) Engine driven blower fan. B) Circulating coolant pump C) Cooling radiator. D) Thermostat. STARTING BATTERY The blower fan pulls cooling air across the radiator coils. The coolant pump circulates coolant through the engine until it reaches operating temperature. The engine thermostat open and allows coolant to circulate into the radiator core. Thermostat can also close, restricting the coolant flow, as necessary to prevent over cooling.
bles (from frame ground) to the battery negative post. NOTE: Both positive and negative battery cables have protective “boots” that enclose the cable connections to battery posts. Also, positive battery cable is secured, so that, if cut or disconnected in any way, positive cable won’t touch metal door or cable restraint or boots, as both are required safety measurements.
● Disconnect the battery charger and positive battery cable before working on battery terminals, or replacing battery. DANGER: Never remove protective battery connection boots, or positive battery cord restraint, as dangerous shock conditions may exist. BATTERIES CAN CAUSE DANGEROUS CHEMICAL BURNS A battery can cause a chemical burn.
each KW generator size, paying close design attention to the required amount of cooling air entering the housing, and to ensure adequate hot air discharge is ample, sound deadening is maximum, without degrading normal operation of generator set. The generator housing is all metal, with air openings and air baffles, strategically located to maximize hot air discharge and minimize vibrations and sound. Sound deadening foam is used thru-out the interior of the metal enclosure.
RECOMMENDED ENGINE OIL Engine power rating after “break-in” is usually within 3% of engine published rating. OIL CAPACITY WITH FILTER QT (L) GENERATOR MODEL OIL CAPACITY WITH FILTER QT (L) SPJD-250 SPJD-300 5 (4.7) 9.0 (8.5) SPJD-1800 SPJD-2100 35.3 (33.4) SPJD-420 SPJD-520 8.7 (8.2) SPJD-600 11.9 (8.2) SPJD-800 SPJD-1000 SPJD-1250 14 (13.2) 18 (17.0) 23 (21.5) SPJD-1550 26(24.6) GENERATOR MODEL Temperature and altitude directly derate generator power.
NOTE: It is important for Buyer to know, that all ATS operating methods, parts supplied, operational services, warranties, etc. are the responsibilities of chosen ATS supplier. However, GILLETTE’S responsibilities are to ensure all such requirements are carried out, by the selected ATS vendor. A) When all connections, adjustments, and tests are completed, and the automatic transfer switch is installed and wired, the standby generator system is ready to be placed on standby duty.
OIL DRAIN: Remove oil drain hose from the holding clip. Remove the end cap from end of oil drain hose, and let oil drain into a separate container. Remove dipstick and oil fill cap to facilitate complete draining process. When oil is drained, replace dip stick, oil fill cap, oil hose drain cap and place hose in holding clip. OIL FILL: Replace oil with premium grade API SJ/10W-30 oil when ambient temperature is above 32º F (0º C).
8) Double wall heavy duty, 7 gauge steel, “LeakProof” construction. specifics on fuel information. OPTIONAL DIESEL TANK CONSIDERATIONS 9) Fuel drain with 1/2” NPT plug. 1) A flexible fuel line must be used at connection point on the diesel engine (option) 10) Powder coat finish with oil fog interior. AREAS REQUIRING SPECIAL DIESEL TANKS 2) Five (5) gallon spill/fill container. 3) A 2” overfill valve. Many states and Regions have specific requirements, for fuel tanks.
TIGHTENING TORQUE FOR PRESSURE WIRE CONNECTORS WITH INTERNALDRIVE SOCKET-HEAD SCREWS TERMINAL CONNECTOR TORQUE Use the torque values shown for terminal connectors. Refer to UL-486A, UL-486B, and UL0486E for information on terminal connectors for aluminum and/or copper conductors. Comply with applicable national and local codes when installing a wiring system. SOCKET SIZE ACROSS FLATS, TIGHTENING TORQUE, mm (in.) Nm (in. lb.
FORMULAS THAT MAY BE OF USE TEMPERATURE ºC = (ºF – 32) x 0.55555 ºF = (ºC X 1.8) + 32 VELOCITY ft/sec x 0.3048 = m/sec miles/hr x 1.6093 = km/hr miles/hr x 0.44704 = m/sec m/sec x 3.2808 = ft/sec km/hr x 0.6214 = miles/hr m/sec x 3.2808 = ft/sec VOLUME inches3 x 16.388 = mm3 feet3 x 0.0283 = m3 gallons x 3.785 = liter gallons x 0.13337 = ft3 cc3 x 0.06102 = inches3 m3 x 35.315 = feet3 liter x 0.2642 = gallon PRESSURE pounds/ft2 x 0.006944 = pounds/in2 psi x 6.8948 = kPa psi = 0.
Gillette Generators, Inc. 1340 Wade Drive Elkhart, IN 46514 Phone: 574-264-9639 Fax: 574-262-1840 E-mail: sales@gillettegenerators.com www.gillettegenerators.com Call for Tech Support: 1-866-537-4388 Email: service@gillettegenerators.
