Multiquip KD1800, KD6 User Manual

PARTS AND OPERATION MANUAL

Model KD1800/KD6

A.C. GENERATOR

USED WITH MLT SERIES

MODULAR LIGHT TOWERS

© COPYRIGHT 2002, MULTIQUIP INC.

Revision #1 (06/16/05)

MULTIQUIP INC

18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: [phone]
310-537-3700
800-421-1244 800-478-1244
FAX: [phone] FAX: [phone]

E-mail:[e-mail] • www:multiquip.com

Atlanta • Boise • Dallas • Houston • Newark
Montreal, Canada • Manchester, UK
Rio De Janiero, Brazil • Guadalajara, Mexico

..

. PARTS DEPARTMENT:

..

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE:

P/N 29309

PAGE 2 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING

PARTS DEPARTMENT

800-427-1244 or 310-537-3700
FAX: [phone] or 310-637-3284

SERVICE DEPARTMENT/TECHNICAL ASSISTANCE

800-478-1244 or 310-537-3700
FAX: [phone]

WARRANTY DEPARTMENT

888-661-4279, or 310-661-4279
FAX: [phone]

MAIN

800-421-1244 or 310-537-3700
FAX: [phone]

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 3

TABLE OF CONTENTS

Here's How To Get Help ............................................ 3

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Safety Alert Message Symbols .............................. 6-7

Rules For Safe Operation ...................................... 8-9

Operation and Safety Decals ............................. 10-11

Generator Specifications ........................................ 12

Engine Specifications .............................................. 13

General Information ................................................ 14

Multiquip KD1800/KD6
AC Generator

Dimension ............................................................... 15

Controls and Indicators ...................................... 16-17

Installation ............................................................... 18

Pre-Setup (Generator) ....................................... 19-20

Pre-Setup (Engine) ............................................ 21-22

Instrumentation ....................................................... 23

Load Application ..................................................... 24

Engine Operating Instructions ................................ 25

Maintenance (Engine)........................................ 26-27

Maintenance (Generator) ....................................... 30

Preparation For Long Term Storage ....................... 31

Troubleshooting (Generator) .................................. 32

Troubleshooting (Engine) ................................... 33-34

Explanation Of Codes In Remarks Column ............ 36

Suggested Spare Parts ........................................... 37

Nameplate and Decals....................................... 38-39

Enclosure Assy. .................................................. 40-41

Control Box Assy. ............................................... 42-43

Engine Mounting Hardware Assy. ...................... 44-45

Radiator Assy. .................................................... 46-47

Air Cleaner and Muffler Assy. ............................ 48-49

Battery Assy. ...................................................... 50-51

Drain Plug Assy. ................................................. 52-53

Fuel Assy. ........................................................... 54-55

Generator Assy. ................................................. 56-57

Control Box Wiring Diagram.................................... 58

Generator Wiring Diagram ...................................... 59

Engine Wiring Diagram ........................................... 60

Kubota D905EBG-2 Engine

Crankcase Assembly .........................................62-63

Oil Pan Assembly ............................................... 64-65

Cylinder Head Assembly .................................... 66-67

Gear Case Assembly .........................................68-69

Head Cover Assembly ....................................... 70-71

Oil Filter Assembly .............................................72-73

Dipstick and Guide Assembly ............................74-75

Main Bearing Case Assembly ............................ 76-77

Camshaft and Idle Gear Shaft Assembly ........... 78-79

Piston and Crankshaft Assembly .......................80-81

Flywheel Assembly ............................................82-83

Fuel Camshaft and Governor Shaft Assembly ..84-85

Engine Stop Lever Assembly ............................. 86-87

Stop Solenoid Assembly .................................... 88-89

Injection Pump Assembly ................................... 90-91

Injection Pump (Component Parts) Assembly ... 92-93

Governor ............................................................ 94-95

Speed Control Plate Assembly .......................... 96-97

Nozzle Holder and Glow Plug Assembly ............ 98-99

Nozzle Holder (Component Parts) Assy. ...... 100-101

Fuel Pump Assembly (Mechanical) .............. 102-103

Alternator and Pulley Assembly .................... 104-105

Alternator (Component Parts) Assembly ...... 106-107

Starter Assembly .......................................... 108-109

Starter (Component Parts) Assembly .......... 110-111

Oil Switch/Thermometer and Plug Assembly 112-113

Water Flange and Thermostat Assembly...... 114-115

Water Pump Assembly .................................. 116-117

Water Pipe Assembly .................................... 118-119

Fan Assembly................................................ 120-121

Valve and Rocker Arm Assembly .................. 122-123

Inlet Manifold Assembly ................................ 124-125

Exhaust Manifold Assembly .......................... 126-127

Accessories and Service Parts Assembly ..... 128-129

Label and Operator's Manual ....................... 130-131

Terms and Conditions Of Sale — Parts ................ 132

NOTE

Specification and part
number are subject to
change without notice.

PAGE 4 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

PARTS ORDERING PROCEDURES

■■

■ Dealer account number

■■

■■

■ Dealer name and address

■■

■■

■ Shipping address (if different than billing address)

■■

■■

■ Return fax number

■■

■■

■ Applicable model number

■■

■■

■ Quantity, part number and description of each part

■■

■■

■ Specify preferred method of shipment:

■■

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

•

Express account number)*

Airborne Express*

•

Truck or parcel post

•

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers
and are received by fax qualify for the following extra
discounts:

Number of
line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Get special freight allowances
when you order 10 or more
line items via FAX!**

■■

■

UPS Ground Service at no charge for freight

■■

■■

■

UPS Third Day Service at one-half of actual freight cost

■■

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.

Extra Fax DiscountExtra Fax Discount

Extra Fax Discount

Extra Fax DiscountExtra Fax Discount

for Domestic USAfor Domestic USA

for Domestic USA

for Domestic USAfor Domestic USA

Dealers OnlyDealers Only

Dealers Only

Dealers OnlyDealers Only

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 5

800/6-PARTS-7 • 800-672-7877

KD1800/KD6 — SAFETY MESSAGE ALERT SYMBOLS

FOR YOUR SAFETY AND THE SAFETY OF OTHERS!

Safety precautions should be followed at all times when
operating this equipment. Failure to read and understand the
Safety Messages and Operating Instructions could result in
injury to yourself and others.

HAZARD SYMBOLS

NOTE

This Owner's Manual has been developed to provide
complete instructions for the safe and efficient operation
of the MQ Whiteman Model KD1800/KD6 6KW
Generator. Please refer to the engine manufacturers
instructions for data relative to its safe operation.

Before using this Generator, ensure that the
operating individual has read and understands all
instructions in this manual.

SAFETY MESSAGE ALERT SYMBOLS

The three (3) Safety Messages shown below will inform you
about potential hazards that could injure you or others. The
Safety Messages specifically address the level of exposure to
the operator, and are preceded by one of three words: DANGER,

WARNING, or CAUTION.

Lethal Exhaust Gases

Engine exhaust gases contain poisonous
carbon monoxide. This gas is colorless and

odorless, and can cause death if inhaled.
NEVER operate this equipment in a confined

area or enclosed structure that does not
provide ample free flow air.

Explosive Fuel

Diesel fuel

vapors can cause an explosion if ignited. DO
NOT start the engine near spilled fuel or

combustible fluids. DO NOT fill the fuel tank
while the engine is running or hot. DO NOT
overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or
sparks from the ignition system. Store fuel in
approved containers, in well-ventilated areas
and away from sparks and flames. NEVER
use diesel fuel as a cleaning agent.

is extremely flammable, and its

DANGER: You WILL be KILLED or

SERIOUSLY injured if you DO NOT follow
directions.

WARNING: You CAN be KILLED or

SERIOUSLY injured if you DO NOT follow
directions.

CAUTION: You CAN be injured if you

DO NOT follow directions.

Potential hazards associated with KD-1800/KD-6 Generator
operation will be referenced with Hazard Symbols which appear
throughout this manual, and will be referenced in conjunction
with Safety Message Alert Symbols.

Burn Hazards

Engine components can generate extreme heat.
To prevent burns, DO NOT touch these areas
while the engine is running or immediately after
operations. NEVER operate the engine with
heat shields or heat guards removed.

Rotating Parts

NEVER operate equipment with covers, or

guards removed. Keep fingers, hands, hair and
clothing away from all moving parts to prevent
injury.

PAGE 6 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — SAFETY MESSAGE ALERT SYMBOLS

Accidental Starting

ALWAYS place the ignition switch in the OFF

position, remove key when the equipment is
not in use. Store key in a safe place.

Over Speed Conditions

NEVER tamper with the factory settings of the

engine governor or settings. Personal injury
and damage to the engine or equipment can
result if operating in speed ranges above
maximum allowable.

Sight and Hearing hazard

ALWAYS wear approved eye and hearing

protection.

Equipment Damage Messages

Other important messages are provided throughout this manual
to help prevent damage to your generator, other property, or the
surrounding environment.

NOTE

This generator, other property, or the
surrounding environment could be damaged
if you DO NOT follow instructions.

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 7

KD1800/KD6 — RULES FOR SAFE OPERATION

■

CAUTION:

Failure to follow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and

qualified personnel only! This equipment is
for industrial use only.

The following safety guidelines should always be used when
operating the KD1800/KD6 6 KW AC
Generator:

GENERAL SAFETY

■

DO NOT operate or service this equipment
before reading this entire manual.

■

This equipment should not be operated by persons under 18
years of age.

■

NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.

NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or generator.

■

High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact

hot

with

■

The engine of this generator requires an adequate free flow
of cooling air. NEVER operate the generator in any enclosed

components can cause serious burns.

or narrow area where free
flow of the air is restricted.
If the air flow is restricted it
will cause serious damage
to the generator engine
and may cause injury to
people. Remember the
generator's engine gives

DEADLY

off
monoxide gas.

carbon

■

■

NEVER operate this equipment when not
feeling well due to fatigue, illness or taking
medicine.

■

NEVER operate this equipment under the
influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not
recommended by Multiquip for this equipment. Damage to
the equipment and/or injury to user may result.

■

Manufacture does not assume responsibility for any accident
due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.

■

ALWAYS check the machine for loosened threads or bolts
before starting.

■

■

■

■

ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.

ALWAYS use extreme caution when
working with flammable liquids. When
refueling, stop the engine and allow it
to cool.

NEVER
machine. Fire or explosion could result from
fuel vapors, or if fuel is spilled on a hot
engine.

NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe

Topping-off to filler port is dangerous, as it tends to spill fuel.

smoke

around or near the

bodily harm or even death.

PAGE 8 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — RULES FOR SAFE OPERATION

■

DO NOT operate or service this equipment before reading
this entire manual.

■

This equipment should not be operated by persons under 18
years of age.

■

NEVER operate this equipment without proper protective
clothing, shatterproof glasses, steel-toed boots and other
protective devices required by the job.

■

This generator is a source of providing LETHAL high voltages.
NEVER permit unqualified personnel-especially children to

operate the generator.

■

ALWAYS refuel in a well-ventilated area, away from sparks
and open flames.

■

ALWAYS use extreme caution when working with flammable
liquids. When refueling, stop the engine and allow it to cool.

DO NOT

could result from flames or sparks, or if fuel is spilled on a hot
engine.

■

This generator is equipped with a
protection. ALWAYS complete the grounding path from the
generator to an external grounding source.

■

NEVER operate this generator, or handle any electrical
equipment while standing in

smoke around or near the machine. Fire or explosion

ground terminal

for your

water, while bare foot, while

hands are wet, or in the rain. Dangerous electrical shock

could occur causing severe bodily harm or even death.

■

Keep electrical cords in good condition. Worn, bare or frayed
wiring can cause electrical shock, thus causing

bodily harm

or even death.

■

This generator requires an adequate free flow of cooling air.
NEVER operate the generator in any enclosed or narrow area
where free flow of the air is restricted. If the air flow is restricted
it will cause serious damage to the generator and may cause
injury to people.

■

NEVER touch the hot exhaust manifold, muffler or cylinder.
Allow these parts to cool before servicing generator.

■

■

■

■

CAUTION:

the phone numbers of the nearest

department

an emergency.

Maintenance Safety

■

■

■

■

■

Provide adequate ventilation when operating the generator.
DO NOT operate the generator in any enclosed or narrow
space. The gasoline engine that provides power to the
generator gives off DEADLY monoxide gas.

NEVER operate the generator in an explosive atmosphere or
near combustible materials. An explosion or fire could result
causing severe

ALWAYS make sure that the generator is secure on level
ground so that it cannot slide or shift around, endangering
workers. Also keep the immediate area free of bystanders.

High Temperatures – Allow the machine and engine to cool
before adding fuel or performing service and maintenance
functions. Contact with
burns.

NEVER lubricate components or attempt service on a running
machine.

ALWAYS allow the machine a proper amount of time to cool
before servicing.

Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace

broken parts.
Dispose of hazardous waste properly. Examples of potentially

hazardous waste are used motor oil, fuel and fuel filters.

bodily harm or even death.

hot

components can cause serious

Emergencies

■

ALWAYS know the location of the nearest

fire extinguisher

location of the nearest telephone. Also know

. This information will be invaluable in the case of

and

first aid kit

. Know the

ambulance, doctor

and

fire

■

DO NOT use plastic containers to dispose of hazardous
waste.

■

DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 9

KD1800/KD6 — OPERATION AND SAFETY DECALS

Machine Safety Decals

The KD1800/KD6 generator is equipped with a number of safety decals. These decals are provided for operator safety and
maintenance information. The illustration below shows these decals as they appear on the machine. Should any of these decals
become unreadable, replacements can be obtained from your dealer. For a complete decal sheet order P/N 29345.

PAGE 10 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — OPERATION AND SAFETY DECALS

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 11

KD1800/KD6 — GENERATOR SPECIFICATIONS

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tuptuOmumixaMsttaW000,6

SNOITACIFICEPSROTARENEG.1ELBAT

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042/021taspmAspmA52/05

ycneuqerF.zH06

deepSmpr008,1

1

thgieWyrD

2

thgieWyrD

1. This weight is for the generator

only

. It DOES NOT

include the cabinet.

2. This weight is for a complete generator, which includes
the engine, radiator and cabinet enclosure.

ylnOrotareneG).gK05(.sbl011

etelpmoC).gK503(sbl207

PAGE 12 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — GENERATOR SPECIFICATIONS

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s'mpr008,1@PH7.31

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thgieW).gk39(.sbl502

.reliart)TLM(rewoTthgiLraludoMfotrapsiknatleuF*

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient
conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric
reading of 29.92 inches and a temperature of 60 degrees Fahrenheit.

°°

°

°°

Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10

°°

°

Fahrenheit above the standard temperature of 60

°°

F

F

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 13

KD1800/KD6 — GENERAL INFORMATION

KD1800/KD6 FAMILIARIZATION
Generator

Housed within the KD1800/KD6 generator package is a

Marathon Model 332, 6,000 watt (6-KW) generator. This
generator can provide up to 50 amps of current. In addition
two voltage output receptacles have been provided on the
generator's

control box

. One receptacle has an output of

120/250 VAC and the other is a 120 VAC, GFCI protected

Control Panel

The

generator's control box

components:

z

One Duplex GFCI 120 VAC Receptacle, 15 Amps

z

One 120/250 VAC receptacle, 30 Amps

z

Main Circuit Breaker 240 V @30 Amps

z

GFCI Circuit Breaker 120 V @15 Amps

receptacle.

z

Pre-Heat Lamp Indicator

The Marathon Model 332 generator should only be operated

z

at a frequency of 60 hertz. The speed should be 1,850 rpm's
(no load) and 1,800 rpm's (full load). A single capacitor is

Ignition Switch

Engine

used to regulate the voltage to within 5% of the rated load.

The KD1800/KD6 is powered by vertical, water-cooled, 4-

The engine-generator set must be installed in a protected
environment, with a minimal exposure to fumes, moisture,

cycle

diesel

performance requirement for the generator.

dust and dirt.

NOTE

When operating the generator, remember the
outside air temperature must not exceed

40

°°

°

°°

C (104

°°

°

°°

F).

ALWAYS

check list before starting the engine.

is provided with the following

engine. This engine is designed to meet every

perform a maintenance

Remember the following when using the generator:

z

DO NOT obstruct the generator's intake and outlet
passages.

z

ALWAYS provide sufficient air circulation around the
generator to remove engine heat and to provide ample
generator cooling.

z

HOT AIR from the radiator must not enter into the
generator.

z

Use extreme caution when handling capacitors. A
potential shock condition exist even when the engine
has been shut-off. See maintenance section of this
manual for the proper handling of capacitors.

z

For operation at

high altitudes

, ratings must be derated

2% for each 1000 feet above sea level.

z

Frame temperatures above 60

°°

°

C (104

°°

°°

°

F) are too high,

°°

indicating a temperature rise in the copper windings of

°°

105

°

°°

z

After running the generator for 30 minutes at full load

C (122

°°

°

F) or more.

°°

check the temperature rise. If the temperature is
excessive, examine the generator for the following:

A. Obstructed air-flow
B. Hot air feeding into the inlet of the generator.
C. By-passed air (air not pulled through

generator)

Reference Tables 1 and 2 for generator and engine
specifications.

Refer to the engine maintenance
section for more information about
the engine.

Figure 2 (page 16) shows the basic components and
indicators for the KD1800/KD6 generator.

NOTE

In keeping with Multiquip's policy of
constantly improving its products, the
specifications quoted herein are subject to

change without prior notice.

PAGE 14 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — DIMENSIONS

Figure 1. KD1800/KD6 Dimensions

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 15

KD1800/KD6 — CONTROLS AND INDICATORS

Figure 2. KD1800/KD6 Components

PAGE 16 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — CONTROLS AND INDICATORS

Figure 2 shows the location of the controls and indicators of the
KD1800/KD6 generator. The functions of each control or indicator
is described below:

1. Radiator Filler Port – Remove this plate to add coolant

(anti-freeze) to the radiator. NEVER add coolant to the
radiator when the radiator is HOT!. Allow the radiator to
cool before adding coolant. Use a water coolant mixture as
recommended in the maintenance section of this manual.

2. Air Outlet Exhaust Pipe – Allows engine exhaust to exit

the generator into the open air. NEVER block this opening.

3. Muffler– Used to reduce noise and emissions.

4. Lifting Hook – Use this hook to lift the generator.

use a lifting device of adequate lifting capacity to lift the
generator.

5. Oil Drain Plug – Remove this plug to drain oil from the

engine crankcase. Fill with recommended type oil as
specified in the maintenance section of this manual.

6. Engine Air Cleaner – Prevents dirt and other debris from

entering the fuel system. Lift locking latch on air filter cannister
to gain access to filter element.

7. Marathon Generator – Provides single-phase AC power

for external equipment. See specification table (Table 1)
within this manual.

8. Generator Output Box – Contains the excitation

electronics for the generator.

9. Generator Mounting Hardware – Use this hardware to

install or remove the generator from the trailer frame.

10. Receptacle G.F.C.I. – Provides 120 volts output at 15

amps.

11. Circuit Protector Circuit Breaker – This single pole circuit

breaker provides circuit protection (120V @15 amps) for
the G.F.C.I receptacle.

12. Main Circuit Breaker – This 2-pole circuit breaker provides

circuit protection (120/240V @30 amps) for the load side of
the generator.

13. Hour Meter – Indicates number of hours machine has

been in use or hours engine was run.

14. Ignition Switch – With key inserted turn clockwise to start

engine.

15. Pre-Heat Indicator Light – Lights blue during engine

start-up. Indicates that engine glow plugs are being pre­heated. Light will go off after approximately 10 seconds.

ALWAYS

16. Battery Terminals – Connect these terminals to the battery.

Always pay close attention to the polarity of the terminals
when connecting to the battery, RED (positive), and BLACK
(negative).

17. Fuel Filter – Prevents dirt and foreign debris from entering
the fuel system. Replace this filter as recommended in the
maintenance section of this manual.

18. Engine Oil Filler Port – Remove this cap to add engine
oil. Use only recommended type oil. See table 3.

19. Battery – Provides +12 VDC power for the generator. When
replacing battery (12V 40 AH) use only recommended type
battery.

20. Air Inlet vent – Allows outside air to enter the generator.
NEVER block this opening.

21. Engine Oil Dipstick – Remove this dipstick to determine

the level of the oil in the engine crankcase. For safe engine
operation always maintain the oil between the two notches
on the dipstick. Add recommended type engine oil as
specified in Table 4.

22. Oil Filter – Provides oil filtering for the engine. Replace
with only recommended type oil filter.

23. Primer Bulb – Removes air from the fuel system in the
event the engine has run out of gas.

24. Overflow Bottle – Supplies coolant to the radiator when
radiator coolant level is low. Fill to indicated level as shown
on bottle

25. Cabinet Latch – Use this latch to keep cabinet door open.

26. Documentation Box – Operation, parts and service

manuals are kept in this box.

27. Cabinet Handle – Turn handle clockwise to release locking
mechanism, then pull cabinet door upward to gain access
to engine compartment.

28. Output Receptacle – Remove cover plate to gain access
to receptacle. To receive power from the generator, plug
external power cable into this receptacle.

29. Frame Ground Lug – Connect a ground strap between
this lug and a ground rod. Make sure that the ground rod is
inserted deep into the ground to provide a good earth
ground. Consult with local Electrical and Safety Codes for
proper connection.

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 17

KD1800/KD6 — INSTALLATION

Outdoor Installation

Install the generator in a location where it will not be exposed
to rain or sunshine. Make sure that the welder/generator is
on secure level ground so that it cannot slide or shift around.
Also install the generator in a manner so that the exhaust
will not be discharged in the direction of nearby homes.

The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and grounding.

Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear, not
only to the engine parts, but also to the alternator parts.

Indoor Installation

Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure which will cause the engine to heat
excessively and possibly burn the valves.

Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any gasoline engine
are very poisonous if discharged in a closed room, but
harmless if allowed to mix with the outside air. If the generator
is installed indoors, you must make provisions for venting
the engine exhaust to the outside of the building.

CAUTION :

Pay close attention to ventilation when
operating the generator inside tunnels and
caves. The engine exhaust contains
noxious elements.

PAGE 18 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — PRE-SETUP (GENERATOR)

General Inspection Prior to Operation

The KD1800/KD6 utilizes a generator that has been
thoroughly inspected and accepted prior to shipment from
the factory. However, be sure to check for damaged parts or
components, or loose nuts and bolts, which could have

NEC articles 250-91a and 250-95 sets the following
grounding requirements:

1. Use one of the following wire types to connect the

generator to earth ground.
a. Copper - 10 AWG (5.3 mm2) or larger.

occurred in transit.

b. Aluminum - 8 AWG (8.4 mm2) or larger.

Generator Grounding

To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.

Article 250 (Grounding) of the National Electrical Code (NEC)
provides guide lines for proper grounding and specifies that
the cable ground shall be connected to the grounding system
of the building as close to the point of cable entry as practical.
If a building is not accessible, then the use of a ground rod
is sufficient.

2. The ground terminal on the generator should always be

used to connect the generator to a suitable ground. The
ground ring on the generator (Figure 3) should be able to
accommodate #8 size copper or aluminum wire.

3. Crimp the ground wire to the ground lug on the generator.

Connect the other end of the ground wire to a suitable
building ground or ground rod.

4. NEC article 250-83c specifies that the earth ground rod

should be buried a minimum of 8 ft. into the ground.

NOTE

Check local city codes for proper
grounding requirements.

NOTE

When connecting the generator to
any buildings electrical system
ALWAYS consult with a licensed
electrician.

Figure 3. Generator Grounding

Configuration

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 19

KD1800/KD6 — PRE-SETUP (GENERATOR)

Circuit Breakers

To protect the generator from an overload, a 2-pole, 30 amp,

main

circuit breaker is provided. In addition a single pole,
15 amp breaker is provided for the G.F.C.I. receptacle. Make
sure to switch both circuit breakers to the "OFF" position
prior to starting the engine.

Extension Cable

When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to a
minimum. Use the cable selection chart (Table 3 ) as a guide
for selecting proper cable size.

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PAGE 20 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — PRE-SETUP (ENGINE)

Lubrication Oil (Engine)

Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the generator is level.
With the dipstick inserted all the way into its holder. Verify
that the oil level is maintained between the two notches
(Figure 4) on the dipstick. See Table 4 for proper selection of
engine oil.

Fuel

Fill the fuel tank with No. 2
beyond capacity. Use a strainer when pouring the fuel into
the tank. This will prevent dirt and debris from entering the
fuel system.

Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 13, Engine
Specification Table 2.

The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel.

CAUTION :

diesel fuel

NEVER fill the fuel tank while the engine

is running or in the dark.
spillage on a hot engine can cause a fire
or explosion. If diesel fuel spillage occurs,
wipe up the spilled gasoline completely to
prevent fire hazards.

. DO NOT fill the tank

Diesel fuel

Figure 4. Engine Oil Dipstick

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Coolant

Check coolant level as described in the maintenance section of
this manual.

Use distilled water mixed with coolant. If hard water or water
with many impurities is used, the inside of the engine and
radiator may become coated with deposits and cooling
efficiency will be reduced.

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KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 21

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KD1800/KD6 — PRE-SETUP (ENGINE)

CAUTION :

When adding coolant or anti-freeze to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled.

Radiator

Day-to-day addition of coolant or anti-freeze is done via the
reserve tank. See maintenance section (radiator) of this
manual for filling requirements.

Cleaning the Radiator

The radiator may overheat if the fins become overloaded
with dust or debris. Periodically clean the radiator fins with
compressed air.

Fan Belt Tension
A slack fan belt may contribute to overheating, or to

insufficient charging of the battery. Inspect and adjust it in
accordance with the

The fan belt tension is proper if the fan belt (Figure 5) bends
7 to 9 mm (0.28- to 0.35) when depressed with the thumb as
shown in Figure 8 below.

KUBOTA

Figure 5. Fan Belt Tension

engine manual.

PAGE 22 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

KD1800/KD6 — INSTRUMENTATION

CAUTION :

When using a combination of dual
receptacles, total load should not exceed
the rated capacity of the generator set.

Power Outlets

The generator has the following single-phase 60 Hz, 120/
240 volt receptacles.

zz

Single Phase

z

zz

One Duplex NEMA (GFCI) 5-15R (120V, 15 Amp)
One Twist Lock NEMA L14-30R (120/240V, 30 Amp)

Main Circuit Breaker (2-Pole)

This 2-pole, 30 amp
output receptacle from short circuiting or overloading.

GFCI Circuit Breaker (Single-Pole)

This single-pole, 15 amp breaker protects the GFCI
receptacle from short circuiting or overloading.

GFCI Receptacle

Before connecting a load to the generator's GFCI receptacle,

push

the "Test Button" on the front of receptacle before
connecting the load, to confirm that the receptacle is
functioning correctly.

Pre-Heat Lamp

Lights blue during engine start-up. Indicates that engine glow
plugs are being pre-heated. Light will go off after
approximately 10 seconds.

main breaker

protects the 120/240

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 23

KD1800/KD6 — LOAD APPLICATION

Single Phase Load

Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage and
frequency requirements are satisfactorily supplied by the
generator for operating the equipment.

Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
the wattage is influenced by the efficiency, power factor and
starting system of the equipment.

NOTE

If wattage is not given on the
equipment's name plate, approximate
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.

WATTS = VOLTAGE x AMPERAGE

The power factor of this generator is 1.0. See Table 5 below
when connecting loads.

z

When connecting ordinary power tools, a capacity of
up to the generating set’s rated output (kW) multiplied
by 0.8 can be used.

z

When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.

z

When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.

z

When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.

CAUTION:

An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable.

Motors and motor-driven equipment draw
much greater current for starting than
during operation.

CAUTION:

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Before connecting this generator to any
building’s electrical system, a licensed
electrician must install an isolation
(transfer) switch. Serious injury or death
may result without this transfer switch.

PAGE 24 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

WARNING:WARNING:

WARNING:

WARNING:WARNING:

z

Before Starting

KD1800/KD6 — ENGINE OPERATING INSTRUCTIONS

The engine's exhaust contains harmful
emissions.
exhaust when operating inside tunnels,
excavations or buildings. Direct exhaust
away from nearby personnel.

ALWAYS

ventilate the

NOTE

During winter or when the surrounding air
temperature is cold, in situations where a
cold start is required, turn the key to the

"HEAT"

wait until the preheat light goes off before
turning the key to the start position.

position. Remember you must

1. Be sure to disconnect the

the main circuit breaker to the
starting the engine. Also switch the GFCI circuit breaker
to the

"OFF"

position.

2. NEVER start the engine with the main or GFCI circuit

breakers in the

3. Check the lubricating oil level prior to starting the engine.

Make sure the generator is level. The oil level must be
maintained between two notches on the dipstick.

4. When there is not enough lubricating oil, fill the crankcase

with high grade motor oil. Use a high quality detergent
oil classified CC or higher (See Table 4 on page 21).

5. Check the coolant level in the radiator and subtank.

Replenish with anti-freeze as necessary.
maintain the coolant level between the FULL and LOW
markings on the coolant container. Be sure that the
radiator cap is fastened securely.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

“ON”

z

Check the fuel source for low fuel level.
When fuel is low, fill the fuel tank with
clean fresh automotive No. 2

electrical load

"OFF"

position.

and switch

position prior to

ALWAYS

diesel fuel

.

4. If the engine does not start within 10 seconds after the
key is turned to the “START” position, wait for about 30
seconds and repeat the procedure as described in steps
1 through 4.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

5. Let the engine idle for five minutes with no load

6. If any abnormal vibrations, noises or oil leakages occur,
turn the generator OFF immediately and rectify the
problem.

7. If the generator is running smoothly with no problems
connect the load (output power cable) to the generator.

Engine Shut-down Procedure

1. Remove the load from the generator, then place both
the main and GFCI circuit breakers to the OFF position.

z

NEVER turn the key to the “
position while the engine is running.

START

”

z

If diesel fuel spillage occurs, completely
wipe up the spilled diesel fuel.

Engine Starting Procedure (Diesel)

1.

ALWAYS
closed

cause insufficient cooling to the unit, and damage may
result.

2. Insert the key into the ignition switch and turn it counter­clockwise to the "PRE-HEAT" position.

3. When the "PRE-HEAT" lamp goes off, turn the key to
clockwise to the ”START” position. As soon as the
engine starts, release the key.

operate the generator with the doors in the

position. Operation with the doors open may

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 25

2. Listen for the engine speed to drop. Run at low speed
for 3-5 minutes.

3. Stop the engine by turning the key to the “CENTER”
position and remove the key. Store key in a safe place.

KD1800/KD6 — MAINTENANCE (ENGINE)

General Inspection

At least daily or prior to each use, the generator should be
cleaned and inspected for deficiencies. Check for loose,
missing or damaged nuts, bolts or other fasteners. Also check
for fuel or oil leaks.

Engine Side:

For a more detail engine maintenance schedule refer to the

KUBOTA Engine Shop and Operator's Manual

Air Cleaner
Every 50 hours: The air cleaner employed on the KUBOTA

engine Model D905EBG is a dry type, NEVER apply oil to
it.

If the generator will be operating in very dusty and dry grass
conditions, a clogged air cleaner will result in high fuel
consumption, loss of power and excessive carbon buildup
in the combustion chamber. Service air cleaner

1. Open the
ordinary conditions or daily in dusty conditions. This will
eliminate large particles of dust and dirt within the air
cleaner.

evacuator valve

(Figure 6) once a week under

.

daily

.

6. After the element is
element with a light, and check for damage (refer to the
instructions on the label attached to the element).

7. Replace the element once a year or every six cleanings.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

z

DO NOT over service the air cleaner element. Over
servicing may cause dirt to enter the engine causing
premature wear. Use the dust indicator as a guide on
when to service the element.

Oil Change
Every 200 hours: Change the engine oil after the first 50

hours of operation and every 200 hours thereafter.
check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level when checking
the oil level.

fully

dried, inspect the inside of the

z

Make sure the wing nut for the air cleaner
is tight enough. If is loose, dust and dirt
may be sucked in, wearing down the
cylinder liner and piston ring, and thereby
resulting in poor power output.

ALWAYS

1. Remove the oil dipstick from its holder, wipe it clean
and reinstall it.

2. Remove the oil dipstick again from its holder, and check
the oil level.

3. The oil level must be between the two notches on the

Figure 6. Air Cleaner

2. Wipe the inside of the
and remove all dust and debris that may have
accumulated inside air cleaner body.

3. Avoid touching the

4. Use compressed air to clean air filter element. Blow
compressed air from the inside while turning the element.

ALWAYS

99 psi.

5. If

carbon

in detergent for 15 minutes, then wash it several times
in water, rinse with clean water and let dry.

keep the pressure of the compressed air below

or

oil

adheres to the element, soak the element

PAGE 26 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

air cleaner

element

except when cleaning.

with a damp cloth

dipstick as shown in Figure 7.

Figure 7. Engine Oil Dipstick

KD1800/KD6 — MAINTENANCE (ENGINE)

4. If the engine oil level is too low, remove the engine oil
filler cap Figure 9, and fill to the correct operating level.

Figure 9. Engine Oil Filler Hole

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

z

Engine oil should be MIL-L2104C or
have properties of API classification
CD grades or higher.

z

When changing the engine oil, use a oil with a viscosity
appropriate for the atmospheric temperature at the site.
Use SAE-30 oil in the summer, SAE-20 in the winter, or
all season SAE 10W-30 oil which offers stable viscosity
at various ambient temperatures. See Table 4 .

z

When different type oil brands are used, be sure to drain
all the previous oil before adding the new engine oil.

Oil Cartridge
Every 200 hours: Replace the engine oil filter cartridge

(Figure 10) after every 200 hours of operation.

Fuel Lines
Every 50 hours: Check the fuel lines and associated clamp

bands every 50 hours of operation.

1. If the rubber fuel lines and clamp bands become worn,
replace them immediately. Replace all rubber fuel lines
every two years.

Replacing the Fuel Filter
Every 400 hours: Replace the fuel filter (Figure 11) every

400 hours.

Figure 11. Fuel Filter

Fuel Addition

When adding diesel fuel to the fuel tank, the grade may vary
according to season and locations. Typically use

fuel

will filling the fuel tank. Always pour through a mesh

filter, this will prevent sand and dirt from entering the fuel
system.

Removing Water (Condensation) from the Fuel Tank

After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally remove the drain
cock and drain the contents. During cold weather, the more
empty area inside the tank, the easier it is for water to
accumulate. This can be reduced by always keeping the
tank as full as possible.

No. 2 diesel

Figure 10. Oil Filter Cartridge

1. Remove the old oil filter cartridge with a filter wrench.

2. Apply a film of oil to the gasket for the new cartridge.

3. Screw the new cartridge in by hand. DO NOT use the
filter wrench to tighten the new filter.

4. Run the engine for a few minutes, check for leaks. Check
engine oil level, add oil if necessary.

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 27

NOTE

The fuel tank for this generator is contained
within the trailer section of the Modular
Light Tower (MLT).

KD1800/KD6 — MAINTENANCE (ENGINE)

Air Removal

If air enters the fuel system of a diesel engine, starting
becomes impossible. After running out of fuel, or after
disassembling the fuel system, bleed the system according
to the following procedure.

To restart after running out of fuel, turn the key switch to the

“START”

This unit is equipped with an automatic air bleeding system.

Radiator
Check Daily: Coolant will last for one day's work if filled to

the maximum level.

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

z

z

position for 15-30 seconds. Try again, if needed.

NEVER remove the radiator cap while the coolant is

hot!

Let radiator cool before removing cap. Severe burns
and bodily injury could result from removing the radiator
cap when the radiator is hot.

NEVER stop engine suddenly to add coolant, let engine
idle for 3-5 minutes with no load. Then shut-down engine
and let cool.

2. Check the coolant level in the reserve tank, (Figure 13),
make sure it is filled to the "FULL" marking with coolant.
The coolant will last for one days work if filled to the
"FULL" mark. Replenish coolant as coolant approaches
"LOW" marking on reserve tank.

3. DO NOT refill the reserve tank with coolant beyond the
"FULL" marking.

Adding Coolant/Anti-freeze

Day-to-day addition of coolant or antifreeze is done via the
reserve tank. See Table 6 for engine/radiator and reserve
tank coolant capacities and Table 7 for coolant operating
temperatures. Make sure that the coolant level in the reserve
tank is always between the "FULL" and the "LOW" markings.

Figure 13. Reserve Tank

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Checking Coolant Level

1. Remove the radiator cap (Figure 12) only after the engine
has completely
reaches the supply port.

Figure 12. Radiator

PAGE 28 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

cooled

, and check to see that the coolant

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KD1800/KD6 — MAINTENANCE (ENGINE)

Anti-freeze Recommendations

z

Use rubber gloves when handling anti-freeze.

z

When anti-freeze comes in contact with the skin or
clothing, wash it off immediately.

z

DO NOT mix different types of anti-freeze.

z

Keep fire, children and animals away from anti-freeze.

z

Check with local safety codes on the proper disposal
techniques of anti-freeze.

NOTE

When the anti-freeze is mixed with
water, the anti-freeze mixing ratio
must be less than 50%.

Battery

CAUTION:CAUTION:

CAUTION:

CAUTION:CAUTION:

The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.

Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions, always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.

The battery gradually deteriorates over time. The actual life
span will vary according to operating conditions, but generally
a battery two years or older should be replaced.

1. Make sure each
bottom of the
in a well-ventilated area.

electrolyte

vent well

. If necessary add

level (Figure 14) is to the

distilled

water

z

ALWAYS follow safety rules when
handling the battery. NEVER charge the
battery in a flammable environment.
ALWAYS keep open sparks and flames
away from the battery at all the times.

z

NEVER let the battery's electrolyte
contact your body or clothing. ALWAYS
wear gloves when handling the battery.

z

ALWAYS wear eye protection and
rubber gloves when handling the
battery. Remember the diluted
sulfuric acid solution within the
battery burns skin and eats holes
in clothing.

z

If any part of your body comes in contact with the
sulfuric acid of the battery, immediately wash it off with
running water and get medical attention.

This unit is of negative ground. DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.

Direction For Long Term Storage (Battery)

1. Remove the battery from the generator. Adjust the
electrolyte to the correct level, and store in a dry and
dark place.

2. Recharge battery once a month in summer, and every
two months in winter.

Figure 14. Battery Electrolyte

Level

KD1800/KD6 A.C. GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/16/05) — PAGE 29

KD1800/KD6 — MAINTENANCE (GENERATOR)

Generator
Capacitor Regulation

A single capacitor is used to regulate the voltage to within
5% of the rated load.

z

ALWAYS USE EXTREME CAUTION when handling
capacitors. The capacitor will still contain a high voltage
even after the engine has been shut-down.

z

ALWAYS discharge the capacitor before handling. Use
a conductor or a screwdriver (Figure 15) with an insulated
handle. Place screwdriver across both capacitor
terminals while holding onto the handle. This will short
out the voltage and discharge the capacitor.

Flashing Rotor Procedure

1. Disconnect all incoming power leads to the generator.

2. Connect the (+) lead of a 12 volt battery to the "R"
connection (Figure 16).

NOTE

DO NOT run the generator during this

procedure.

Figure 16. Flashing The Rotor Configuration

Figure 15. Discharging Capacitor

Checking the Charge of the Capacitor

1. Use an

discharge

RX-1000 scale.

2. Place the ohmmeter leads on the capacitor terminals
one at a time. A meter deflection should be seen
(charging), followed by a slow return to infinity
(discharging).

3. Reverse the ohmmeter leads and repeat the procedure.
The results should be the same. Replace the capacitor
if no meter deflection or continuity has been indicated
by the ohmmeter.

"OHMMETER"

of the capacitor. Set the ohmmeter to the

to check the

charge

and

3. Connect the (-) lead of the battery to the rotor shaft.

4. Re-connect all incoming power leads to the generator

5. Start the generator as outlined in the

Section"

6. With a voltmeter check the no load voltage at the 120/
240 output connector located on the control box.

7. The no load should be within 10% of the rated load.

8. If residual voltage is normal, the capacitor is defective
and should be replaced.

Diode Check

1. Check the diode individually by removing the (+)

lead stud

the resistance reading is approximately mid -scale on
the lowest ohm scale.

2. Check for leakage in the diode by reversing the polarity.
The diode is good if the resistance reading is

"Operating

of this manual.

rotor

connection (Figure 16). The diode is good if

infinite

.

3. A faulty diode will give a resistance value of

PAGE 30 —KD1800/KD6 A.C. GENERATOR— PARTS & OPERATION MANUAL — REV. #1 (06/16/05)

zero

.