Shindaiwa DGK150D, Owner'S And Operator'S Manual

Page 1: ...e of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and leads compounds chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling CAUTION Do not operate the Generator or any other appliance before you have read and understood the instructions for u...

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Page 3: ...eration Store this manual in a specified location where it will be secure and available for consulting at any time Order another copy from the authorized distributor where this generator was purchased if this manual becomes dusty grimy or torn Consult with the authorized distributor where this generator was purchased if you have any inquiries regarding any points related to this generator and manu...

Page 4: ...cedures 22 7 Load Connections 23 7 1 Load Cable Selection 23 7 2 Connecting Load Cables 24 8 Pre Operation Inspection 26 8 1 Checking Engine Oil 26 8 2 Checking Coolant 27 8 3 Checking the Fan Belt 28 8 4 Checking the Fuel 29 8 5 Checking for Fuel Oil and Coolant Leaks 30 8 6 Checking the Battery 30 9 Operating Procedures 32 9 1 Initial Startup Pre Check 32 9 2 Voltage Switching Function 34 9 3 Pr...

Page 5: ...l the earth terminals of the loads have been grounded to the earth the bonnet grounding terminal should be grounded to the earth There is always a danger of being electrocuted by short circuit Be sure to test generator s insulation resistance periodically Grounding should be made after the engine is stopped WARNING INJURY Close all doors and lock them during operation Close all doors and place loc...

Page 6: ...o wipe up any spilled fuel or oil Allow the generator to cool before covering with the protective cover Never allow flame to come close to the generator 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 CAUTION BURNS ...

Page 7: ...d current exceeds the allowable current of the cable The voltage drop between cables is large if the cable is excessively long or thin resulting in decreased input voltage to equipment using the generator thereby causing decreased performance faulty operation and malfunction Warning Caution Label Locations If warning or caution labels become damaged and difficult to read replace with new labels in...

Page 8: ...esel Engine Model Manufacturer 6HK1 ISUZU No of Cylinders bore x stroke in mm 6 4 53x4 92 115x125 Continuous rated output kW 142 HP 190 Rated speed rpm 1800 Displacement cu in liters 475 4 7 790 Combustion system Direct Fuel Injection with Turbo Charger Cooling method Radiator Lubricating method Forced lubrication Starting method Electric start Fuel Diesel Lubricant oil CD class Fuel tank capacity...

Page 9: ...less 3 Applications Power source for submerged pumps and similar civil engineering equipment Power source for lighting and similar equipment Power source for electrical tools and household appliances 4 Part Names 4 1 External View Part Names CAUTION PROPERTY SECONDARY DAMAGE Do not use for any application other than those listed above If using this generator for medical equipment check before use ...

Page 10: ...IDE RIGHT SIDE Fuel Inlet Fuel Tank Coolant Sub Tank Engine Check Door Alternator Check Door Oil Filler Cap Oil Level Indicator Oil Drain Fuel Drain Water Sedimenter Fuel Filter Oil Filter Air Cleaner Receptacle Panel Cover Terminal Cover Electromagnetic Pump PCV Filter Receptacle Panel Voltage Selector Switch Accessories Owners Manual Engine Key 2 pieces Engine Warranty ...

Page 11: ...14 Hour Meter 4 Voltmeter 15 Water Temperature Gauge 5 Ammeter 16 Oil Pressure Gauge 6 Frequency Meter 17 Fuel Gauge 7 Auto start Panel Optional 18 Glow Lamp 8 Auto start Switch Optional 19 Emergency Stop Button 9 Panel Light Switch 20 Starter Switch 10 Voltmeter Selector Switch 21 Throttle Switch 11 Ammeter Selector Switch ...

Page 12: ...9 4 3 Main Terminal Board 4 4 Receptacle Panel NOTE All duplex receptacles are GFCI protected and are rated at 20 amps All twist loc receptacles are rated at 50 amps Plexiglass Cover Main Terminals ...

Page 13: ...erating conditions these monitoring lamps will come on momentarily when the engine is first started but will go off very shortly thereafter WARNING INJURY Close all doors and place locks during operation to avoid injuries by unintentionally contact with moving parts such as the cooling fan and fan belt Before performing any equipment check or maintenance stop the engine and remove the engine key A...

Page 14: ... 2 OIL PRESS engine oil pressure Warning Indicator Low Oil Press CAUTION BURNS Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil gauge or oil filler cap during operation will result in hot oil cause personal injury When the engine oil pressure drops below 14 5 psi 100 kPa during operation the oil pressure monitor ...

Page 15: ...oil gauge or oil filler cap during operation will result in hot oil cause personal injury If the intake temperature to the intake manifold exceeds 185 F 85 C the boost temperature lamp will flash but will not shut the engine down If this occurs contact the authorized distributor where the generator was purchased 6 Over Speed Indicator CAUTION BURNS Always be sure to stop the engine and allow the e...

Page 16: ... water temperature meter exceeds the standard value immediately stop the equipment being used allow the generator to cool by idling the engine and wait until the water temperature decreases 3 Oil Pressure Gauge Oil Pressure Gauge displays the pressure of engine oil Normal pressure may vary depending on the environment but it should display 43 5 87 0 psi 3 0 6 0 x 100kPa However under cold weather ...

Page 17: ...selector switch position Only L1 or L3 phase amperage will be displayed for single phase operation 3 Frequency Meter Frequency meter will display the frequency of the generator Please check it showing 60Hz during operation Lamps 1 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 cy...

Page 18: ...anel next to the panel light This light can only be energized when the engine is running Switches 1 Starter Switch 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 in this position during operation This position also is used to begin the engine preheat cycle and to remove air from the fuel sy...

Page 19: ...o ON Power will be transferred to the output receptacles and to the load side The breaker trips to OFF when overload or short circuit occur 4 Thermal Relay This relay sends the signal to the circuit breaker to trip off when over current flows in the circuits When the breaker trips off it is set at the middle in between ON and OFF position Reset the breaker to the ON position according to the follo...

Page 20: ...e L3 L1 position the voltmeter will display the phase voltage between L3 and L1 6 Ammeter Selector Switch The ammeter selector switch is a 5 position switch located on the control panel to the left of the ammeter The ammeter selector switch selects which phase current is displayed on the ammeter Positions Off There are two off positions on the ammeter selector switch One at the full clockwise posi...

Page 21: ...djusts generator output voltage Turn the dial clockwise to increase or counter clockwise to decrease the voltage 2 Engine Speed Switch Throttle Switch Set the toggle switch to START position for warm up or cool down the engine and set to RUN position during rated operation ...

Page 22: ...ree Phase 480 277V position gives an output from the generator of 480 volts three phase or 277 volts single phase 3 PHASE 208 120V The Three Phase 208 120V 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 resister on the contr...

Page 23: ...A when the equipment is shipped In addition both the external fuel inlet and the external fuel return are safeguarded with R1 2 plugs Do not remove the plugs when using the built in fuel tank NOTE Always set the lever for 3 way valve back to A position and cover the external fuel inlet and return port with the supplied plugs after the hoses are removed 2 Using fuel from external fuel tank Connect ...

Page 24: ...generator CAUTION INJURY Always be sure to use lifting hooks when lifting up the generator and raise it slowly at vertical angle completely Personnel performing lifting work must wear protective gear such as helmets safety shoes and gloves Do not move the generator during operation Lifting Procedures Always be sure to use lifting hooks when lifting up the generator and raise it slowly at vertical ...

Page 25: ...etely around the boundary line of the construction area and take measures to prevent persons not involved in the construction from entering the area Always set the generator on a hard flat and leveled surface that serves as the foundation Keep the generator 3ft 1m or more from walls or other hindrances so that the operation panel door and left right check doors are accessible for internal inspecti...

Page 26: ...equipment using the generator NOTE Select cable with a thickness that ensures that the voltage drop across the cable will be within 5 of the rated voltage Load Cable Selection Tables Ex If used voltage is 240 V and voltage drops by 12 V Three phase Cabtyre cables Unit AWG Length 100 ft 30 m or less 200 ft 61 m 300 ft 91 m 400 ft 122 m 500 ft 152 m 600 ft 183 m Current 50 A 10 8 6 4 4 2 100 A 8 4 2...

Page 27: ...inal connection position and load power source are all matching If using the N terminal be careful that the currents of each phase are uniformed If using three phase output simultaneously with a single phase three wire type output use in a range where the total current does not exceed the rated current If using three phase output simultaneously with a single phase three wire type output be careful...

Page 28: ... Position 240 Volt Single Phase and 120 Volt Single Phase Switch Position NOTE Select the voltmeter selector switch for L3 L1 position and the ammeter selector switch for L1 or L3 position when the Voltage Selector Switch is set for 1 Phase 240 120V position ...

Page 29: ...nual CAUTION BURNS Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil Opening the oil level indicator or oil filler cap during operation will result in hot oil cause personal injury To check the engine oil keep the equipment leveled remove oil level indicator to be wiped and then re insert the dipstick fully Prior to start the eng...

Page 30: ...n the radiator cap immediately after stopping the engine to avoid sustaining burns from hot vapor Hot steam gushes out from the coolant sub tank if the generator overheats Do not touch the coolant sub tank Check that the sub tank coolant level is in between FULL and LOW If the sub tank coolant is lower than the LOW level add coolant to the sub tank and radiator 1 Filling the Sub Tank Remove the su...

Page 31: ...ely and seek medical care If LLC gets on skin or clothing wash with water immediately LLC is flammable Store in a location where flame is prohibited and it cannot be accessed by children Engine coolant could leak if the radiator is not completely tightened or there is a gap in the seating face Always be sure to securely tighten the radiator cap Do not add engine coolant past the FULL level line of...

Page 32: ...nal fuel tank NOTE Use Diesel fuel ASTM D975 No 2 D in the event ambient temperature reaches down to 23 F 5 C Always use the Diesel Fuel Strainer Fill the fuel tank slightly less than the FULL tank level Fuel requirements NOTICE The fuel injection pump injector or other parts of the fuel system and engine can be damaged if you use any fuel or fuel additive other than those specifically recommended...

Page 33: ...and check for fuel oil and coolant leakage from fuel piping connections and similar locations 8 6 Checking the Battery CAUTION EYE SKIN INJURY Wear rubber gloves and other protective wear to protect eyes skin and clothing from the battery fluid which contains diluted sulfuric acid If the battery fluid contacts eyes or skin wash out immediately with a large amount of water Be sure to receive medica...

Page 34: ...he battery on the left side Remove the clamp and cable from positive post from the battery on the left side Remove the left side battery from the seat Reinstall the new battery in the reverse order always install the cable to the positive post of the new battery first 2 BATTERY B Remove the clamp and cable from negative post from the battery on the right side always remove negative side first Remo...

Page 35: ... or other hindrances and on a level surface CAUTION INJURY Do not operate the generator if it has been modified or any parts have been removed Position the generator on a level stable surface so that it cannot slide or move in any manner Before starting operation always be sure to turn off all switches of equipment being used and all breakers to OFF Turn every circuit breaker to OFF position Turn ...

Page 36: ...0Hz 480V 208V For single phase load 60Hz 277V 240V 120V Turn the breakers to ON to start power transmission WARNING ELECTRIC SHOCK INJURY Before turning the circuit breaker to ON position ensure that the breaker or the Switch of loads are positioned to OFF Operate the circuit breaker well communicating with the electrician by the load side 4 5 7 8 6 Circuit Breaker Voltage Adjust Regulator Starter...

Page 37: ...tion and load power source are consistent Turn the circuit breakers on the operation panel to OFF and stop operation Turn the lever of the voltage selector switch to the desired output setting Three phase 480 208 V and Single phase 240 120 V power is output to the main terminal board Refer to section 7 2 Connecting Load Cables Start the engine and turn the circuit breakers to ON to transmit power ...

Page 38: ...uel this generator is equipped with an automatic air bleeding mechanism Perform the following procedures when the engine stops to bleed the air automatically Add fuel to the generator Turn the starter switch will be RUN Air bleeding is completed in approximately 30 seconds NOTE Start the engine and check that the air is completely bled from the system If air bleeding is not complete engine rotatio...

Page 39: ... the foult location or any malfunction In event of the automatic shutdown or alarm lamp flashing turn off the engine and investigate the fault location Protection Feature List indicate the automatic feature indicate the function might operate No Symptoms Action Cause Circuit Breaker OFF Automatic Engine Shutoff Alarm Lamp Flash 1 High Coolant temperature Engine coolant temperature is too high defa...

Page 40: ... The fuel level of the external fuel tank being lower than this generator will result in poor engine operation or shut off Turn the 3way fuel valve lever to the A side in order to prevent fuel from flowing out from the external tank fuel inlet return Turn the lever completely as far as possible If the lever is not completely pressed to either side it might not be possible to supply fuel causing th...

Page 41: ... Personnel performing lifting work must wear protective gear such as helmets safety shoes and gloves Always be sure to use lifting hooks when moving the generator and lift it slowly at a completely vertical angle Perform periodic inspection and maintenance according to the following table in order to constantly maintain this generator in good working condition Use the hour meter as a reference for...

Page 42: ... change 1st time at 50 hrs PCV Filter change 1st time at 50 hrs Coolant level check add coolant Exhaust color check Coolant change bleeding EGR or 1 yr Drain excess water and sediments in the fuel filter and water sedimenter Clean Clean or replace fuel filter element and water sedimenter element Clean Replace Drain water from fuel tank Clean gauze filter in engine feed pump Clean Change filter in ...

Page 43: ...es After reinserting the oil drain plug and shortly after starting the engine be sure to always check that there is no oil leakage 2 Replacing the Oil Filter First Time 50 hours Thereafter Every 500 hours Drain the engine oil Refer to section 1 Engine Oil Replacement Remove the oil filter using a filter wrench Spread a thin layer of oil on a new oil filter gasket Screw the new filter into place an...

Page 44: ...n around the PCV filter cap taking care so that no foreign particles entry Remove the PCV filter cap Remove the PCV filter element Install the new PCV filter element Install the PCV filter cap NOTE PCV filter element ISUZU Part No 898030 5320 4 Air Filter Element Cleaning Replacement Clean Every 250 hours Replace Every 500 hours Loosen the bolt that is holding the air cleaner and remove the cleane...

Page 45: ...t Whenever RED SIGNAL appears in the indicator window clean or change element regardless of operation hour After cleaning or changing finishes push the reset button to release the RED SIGNAL 5 Draining Water from the Fuel Filter and Water Sedimenter Drain water when the float red inside the cup has come up to the bottom part of the filter element Loosen the air bleeding plug Loosen the drain plug ...

Page 46: ...Replace the O ring of the outer case Fill the case with clean fuel so that it is easy to bleed air from the fuel lines Tighten the outer case using the specified filter wrench Drain plug tightening torque 1 5 to 2 5 N m 0 15 to 0 25 kgf m 1 1 to 1 8 lbf ft Outer case tightening torque 29 4 N m 3 0 kgf m 21 7 lbf ft Air bleeding plug tightening torque 7 9 to 11 7 N m 0 8 to 1 2 kgf m 5 8 to 8 6 lbf...

Page 47: ... at the original position and then start the engine If the engine does not Start repeat the procedure Air bleeding plug tightening torque 7 9 to 11 7 N m 0 8 to 1 2 kgf m 5 8 to 8 6 lbf ft 8 Electromagnetic Pump Filter Cleaning Clean Every 500 hours Remove the wirings attached on the pump cover Rotate the cover with a wrench and remove it Turn the cover located at the bottom of pump counter clockw...

Page 48: ...n order to catch spilled fuel when loosing the lever Gaskets are attached to both ends of joint pipe Be careful not to lose and install them in the unit without fail Change both gauze filter and eyebolt when gauze filter is damaged Extract the air in fuel line after gauze filter washing finishes Refer to 9 3 Procedures during Operation Ensure that there is no fuel leakage after reinstallation Engi...

Page 49: ... the draining plug on both the engine and radiator After draining all the water tighten the draining plug on both the engine and radiator Loosen the fastener that holds the sub tank and drain all the water Install the sub tank back and fill the coolant water to the MAX level Fill the radiator with coolant water to the top Reinstall the radiator cap NOTE For the types of engine oil to use refer to ...

Page 50: ...release plug of the EGR cooler in order to bleed air from within the EGR and improve cooling performance When coolant flows out from the air release plug tighten the air release plug Air bleeder plug tightening torque 19 0 to 25 0 N m 1 9 to 2 5 kgf m 14 0 to 18 4 lbf ft 1 2 Air Bleeder Plug ...

Page 51: ...generator if it is not going to be used for two months or more Remove the battery Refer to section 8 6 Checking the Battery Replace the engine oil Refer to section 10 Inspection Maintenance 1 Engine Oil Replacement Drain the fuel from the fuel tank and filter Refer to section 10 Inspection Maintenance 6 Cleaning Changing Fuel Filter and Water Sedimenter Refer to section 10 Inspection Maintenance 1...

Page 52: ... generator when it is double stacked 12 Troubleshooting WARNING ELECTRIC SHOCK INJURY Do not touch output terminals or internal electric parts while the generator is operating Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Before performing any equipment check or maintenance stop the engine and remove the engin...

Page 53: ... zero 1 Fuel is frozen 2 Water in fuel line is frozen 3 Pre heater is defective 1 Use winterized fuel 2 Drain water in fuel line 3 Contact your distributor to repair Engine starts but stalls immediately 1 Fuel filter is clogged 2 Gauze filter is clogged 3 Water is interfused in fuel line 4 Air is interfused in fuel line 5 Poor piping connection to external fuel tank 6 Air filter element is clogged...

Page 54: ...ch set is wrong 1 Contact your distributor to repair 2 Contact your distributor to repair 3 Contact your distributor to repair 4 Contact your distributor to repair 5 Correctly set the connection location to the output terminal 6 Set the Voltage selector switch correct Indicator exceeds the rated voltage 1 Voltage meter is defective 2 AVR is defective 3 Voltage regulator dial is defective 4 Frequen...

Page 55: ...52 13 Generator Circuit Diagram ...

Page 56: ...53 14 Engine Electrical Circuit Diagram ...

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