Shindaiwa DGK180F Owner's And Operator's Manual
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Shindaiwa DGK180F Owner's And Operator's Manual

Diesel engine generator
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OWNER'S AND OPERATOR'S MANUAL
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
 Always start and operate the engine in a well ventilated area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING
Cancer and reproductive Harm-
www.P65Warnings.ca.gov
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and
other chemicals known to the State of California to cause cancer and birth defects or 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 use and keep near for ready use.
Vertical, Water-Cooled 4-Cycle Diesel Engine
California Proposition 65
DGK180F
X753-007 87 0
X753801-300 0

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  • Page 1 State of California to cause cancer and birth defects or 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 use and keep near for ready use. DGK180F X753-007 87 0 X753801-300 0...
  • Page 3 Introduction Thank you for purchasing this Shindaiwa soundproof diesel engine generator.  This manual has been created to ensure safe usage of this generator. Be sure to read this manual before operation. Improper operation/handling of this generator will result in an accident or malfunction.

  • Page 4: Table Of Contents

    Table of Contents 1. Safety Instructions ······························································ 2 2. Specifications ····································································· 6 2-1. Specifications ·································································· 6 2-2. Ambient Conditions ·························································· 7 3. Applications ········································································ 7 4. Part Names ········································································· 7 4-1. External View/Part Names ················································· 7 4-2. Operation Panel Configuration ········································· 10 5.

  • Page 5: Safety Instructions

    1. Safety Instructions WARNING : EXHAUST GAS POISONING  Do not operate the generator in poorly ventilated areas such as indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health.  Do not direct exhaust fumes at bystanders or buildings. WARNING : ELECTRIC SHOCK ...
  • Page 6 CAUTION : FIRE  Do not carry flammable items (such as fuel, gas and paint) or items that are highly combustible near the generator as the muffler, exhaust gas and other parts become extremely hot.  Position this generator 3 ft. (1 m) or more from walls or other hindrances, and on a level surface.
  • Page 7 CAUTION : INJURY  Always be sure to use lifting hooks when lifting up the generator, and slowly lift it straight  Personnel performing lifting work must wear protective gear such as helmets, safety shoes and gloves.  Position the generator on a level stable surface so that it cannot slide or move in any manner.
  • Page 8 ■ Warning /Caution Label Locations If warning or caution labels become damaged and difficult to read, replace with new labels in the indicated locations. Order labels using part number indicated in the parenthesis. ① Caution: Do not change voltage Part no. :X505-004620 ②...

  • Page 9: Specifications

    2. Specifications 2-1. Specifications Model Unit DGK180F Generator Type Revolving Field Brushless Rated Frequency Three phase Rated Output(Prime) 108 [54] *1 Single phase 108 [54] *1 Three phase Standby Output 118.8 [59.4] *1 Single phase 118.8 [59.4] *1 Three phase...

  • Page 10: Ambient Conditions

    2-2. Ambient Conditions Use this generator in ambient conditions as described below. Failure to provide these conditions can result in problems such as malfunction, insufficient output and reduced durability. ■ Ambient temperature: 5 to 104 °F (-15 to 40 °C) ■...
  • Page 11 Inspection / Cleaning Panel SCR Check Panel Tie hole Tie hole DEF Tank Fuel Inlet Cover Check Panel Tie hole Radiator Engine Alternater Fan Guard Check Door Intercooler Check Door Intercooler Drain Plug...
  • Page 12 Coolant Sub-Tank Engine Oil Level Gauge Oil Filter Air Cleaner Oil Filler Check Door Fan Guard Alternater Check Door Fuel Filter Coolant Drain Plug 3way Fuel Valve Oil Drain Plug Battery (Main) External Fuel Inlet Fuel Filter Electromagnetic Fuel Tank External Fuel Return (Pre) Fuel Pump...

  • Page 13: Operation Panel Configuration

    4-2. Operation Panel Configuration ① ⑬ Circuit Breaker(3-Phase & 1-Phase) Available Output Monitor ② ⑭ Voltmeter Fuel Level ③ ⑮ Ammeter Fuel Leak Detected Lamp ④ ⑯ Frequency Meter DEF Level ⑤ ⑰ Pilot Lamp Hour Meter ⑥ ⑱ Voltage Regulator Glow Lamp ⑦...

  • Page 14: Equipment

    5. Equipment 5-1. Three-phase and Single-phase simultaneous Output This generator is capable of generating three-phase and single-phase three-wire output simultaneously. (Three-phase output terminal and single-phase three-wire output terminal are equipped individually.) Neither switching operation of output nor switching operation of wiring is needed. Three-Phase and Single-Phase Three-Wire Output Terminal GROUND <...

  • Page 15: Spill Containment

    5-3. Spill Containment WARNING : INJURY  Do not open the check door when the starter switch is in the AUTO or START position. It will cause injury by rotating parts such as cooling fans and fan belt.  Always turn the starter switch to the STOP position and stop the engine, then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment.

  • Page 16: Warning Indicators

    5-4. Warning Indicators WARNING : INJURY  Do not open the check door when the starter switch is in the AUTO or START position. It will cause injury by rotating parts such as cooling fans and fan belt.  Always turn the starter switch to the STOP position and stop the engine, then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment.
  • Page 17 (3) WATER TEMP (Coolant Temperature) Warning Indicator (High Water Temp.) CAUTION: BURNS  Do not open the radiator cap immediately after stopping the engine.Do so will result in hot steam gushing out.  Hot steam gushes out from the coolant sub-tank if the generator overheats. Do not touch the coolant sub-tank.

  • Page 18: Scr (Selective Catalytic Reduction) System And Indicators

    (7) SPILL CONTAINMENT (Spill Containment Amount) Overflow Warning Indicator If the liquid stored in the spill containment exceeds approximately about 55gal (208 liters) during operation, the SPILL CONTAINMENT overflow warning indicator illuminates, and the engine automatically stops. If this occurs, flush the liquid stored in the spill containment. (Refer to section “10.
  • Page 19 Ⓡ  DEF, or other similar urea fluids, may be called AdBlue depending on region. Ⓡ  AdBlue is a registered trademark of Verband der Automobilindustrie (VDA). This generator is equipped with the SCR SYSTEM MONITER. The indicator lights up according to the control operation of the SCR system. (1) DEF LEVEL It shows the amount of DEF in the tank.
  • Page 20  FORCE PURGE Purge forcibly runs in case that PERIODIC PURGE fails twice. FORCE PURGE is lit during operation. < Note >  During purging, electrical output capacity decreases to 80% of the rated output. Available output capacity can be confirmed by Available Output Monitor. ...

  • Page 21: Meters And Gauges

    ■ DEF Indicator Lamp Action LAMP EXH. NO POWER ESCAPE ENGINE （SHUTDOWN） State SYSTEM MODE ○ ○ ○ Stage-Ⅰ － － Warning (Turn ON) (Turn ON) (Turn ON) ○ ○ ○ Stage-Ⅱ － － Early Inducement (Slow Blinking) (Turn ON) (Turn ON) Stage-Ⅲ...
  • Page 22 (2) Oil Pressure / Water Temp / Speed Monitor Displays the engine speed, water temperature and oil pressure. Switching the selector switch changes the display in the following order: Speed  Water temp  Oil press. Engine speed is displayed first when the engine is started. Oil Press ...
  • Page 23 * Check that 208 V is displayed during operation if using at the three-phase 208 V setting. Check that 480 V is displayed during operation if using at the three-phase 480 V setting. The voltage of single-phase three-wire output of “U-W Voltage” is a value that is one half of the displayed voltage meter value.
  • Page 24 < Note >  Set the STARTER SWITCH selector to STOP to activate this function.  Do not leave the ACCESSORY switch at ON position. This is causing battery from drain out. (3) Breaker This switch is for transmitting electrical power to the load side. Turn to ON position to output voltage to the output terminals.

  • Page 25: Fuel Piping Switch (3Way Fuel Valve)

    5-7. Fuel Piping Switch (3Way Fuel Valve) CAUTION : FIRE  Always make sure that the engine is stopped when working on piping.  Always be sure to wipe up any spilled fuel.  After working on the piping, check that there is no fuel leakage. Change the three-way fuel valve to switch to supply fuel from the external tank.

  • Page 26: Transport/Installation

    6. Transport/Installation 6-1. Transport Procedures WARNING : INJURY  Always be sure to use lifting hooks when lifting up the generator. The other thing could result in the generator falling.  No persons should ever be under a lifted generator. CAUTION : INJURY ...

  • Page 27: Load Connections

     Position this generator on a hard, flat and leveled surface.  Position this generator 3 ft. (1 m) or more from walls or other hindrances so that the operation panel door and left/right check doors are accessible for internal inspection/maintenance. <...
  • Page 28 (Ex.) If used voltage is 208 V and voltage drops by 10.4 V. Three-phase: Cabtyre cables (Unit: AWG) Length 100 ft (30 m) 200 ft 300 ft 400 ft 500 ft 600 ft or less (61 m) (91 m) (122 m) (152 m) (183 m) Current...

  • Page 29: Connecting Load Cables

    7-2. Connecting Load Cables WARNING : ELECTRIC SHOCK  Always turn all the breakers OFF, place the starter switch in the STOP position and stop the engine before connecting / disconnecting the load cable to the output terminal or receptacle. ...
  • Page 30  For single-phase load:  Terminal voltage is 208/240/480 V. GROUND Load Load Load (2) Single-Phase Three-Wire Output Terminal and Receptacle  For single-phase three-wire type load:  U-W terminal voltage is 240 V.  U-N terminal voltage is 120 V. ...
  • Page 31  Power available for use by each output terminal and receptacle are as show below. GROUND CON5,CON6,CON7 120V （U-N） U-N / W-N / U-W 120V 240V (W-N) （U-W） CON1 CON3 CON5 CON6 CON7 Load Load CON2 CON4 Load Load Load Load Load ...

  • Page 32: Pre-Operation Inspection

    8. Pre-Operation Inspection WARNING : INJURY  Do not open the check door when the starter switch is in the AUTO or START position. It will cause injury by rotating parts such as cooling fans and fan belt.  Always turn the starter switch to the STOP position and stop the engine, then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment.

  • Page 33: Checking Coolant

     Relation of Viscosity/Temperature Temp. (°F) SAE 10W-30 SAE 10W-40 SAE 15W-40 (3) Engine Oil Replacement Amount Total Lubrication Oil Amount 10.5 gal． Value in parenthesis is the filter capacity 8-2. Checking Coolant CAUTION: BURNS  Do not open the radiator cap immediately after stopping the engine.Do so will result in hot steam gushing out.

  • Page 34: Checking The Fan Belt

     Change the LLC every 1,000 hours or every year.  LLC is a toxic substance. Wear rubber gloves and other protective wear when handling.  If someone mistakenly ingests LLC, induce vomiting immediately and seek medical care.  If LLC gets on skin or clothing, wash with water immediately. ...

  • Page 35: Checking The Fuel

    8-4. Checking the Fuel CAUTION : FIRE  This generator uses diesel fuel. Always be sure to stop the engine and not bring flames close when inspecting fuel or refueling. Wait until the engine has cooled before performing such procedures. ...

  • Page 36: Checking The Spill Containment

     Always be sure to wipe up any spilled DEF.  DEF is a clear, colorless, and harmless aqueous solution. it is normal for DEF to emit an odor in some circumstances.  DEF may cause inflammation in rare circumstances depending on its constitution. In such cases, take the following actions.
  • Page 37 Check the fluid level, and add distilled water until it reaches the upper level when the fluid level is near the lower level. Check the terminals for looseness and tighten properly. < Note >  It is necessary to recharge the battery when the specific gravity of the battery fluid is 1.23 or less.

  • Page 38: Operating Procedures

    9. Operating Procedures 9-1. Initial Startup/Pre-Check WARNING : EXHAUST GAS POISONING  Do not operate the generator in poorly ventilated areas such as indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health. ...
  • Page 39 (1) Manual Start Accessory 3-Phase 1-Phase Turn off the three-phase and single-phase Switch Breaker Breaker breakers on the operation panel of this machine. Turn the Throttle switch to IDLING. Set the ACCESSORY switch to OFF, and Voltage use the safety cap to cover it. Regulator Set the STARTER SWITCH selector to Starter...

  • Page 40: 208/240/480V Switching Selection

    9-2. 208/240/480V Switching Selection WARNING : ELECTRIC SHOCK  If performing any electric voltage switching, turn all breakers to OFF and stop operation.  Lock the generator using a padlock so that no one except for designated operators can operate switches. CAUTION : PROPERTY DAMAGE ...

  • Page 41: Procedures During Operation

    9-3. Procedures during Operation (1) Checks after Startup  Make sure that all meters and indicators are in normal status. (Refer to section “5. Equipment”.)  Check that there is no abnormal vibration or noise.  Check that the exhaust gas color is normal. When operation is normal, the exhaust gas should be colorless or slightly bluish.

  • Page 42: Stopping Operation

    9-4. Stopping Operation CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the engine as they are still extremely hot. (1) Manual Start Turn the switches and breakers on the load side to OFF. Turn the three-phase and single-phase breakers on the operation panel to OFF.

  • Page 43: Protective Functions

    9-5. Protective Functions WARNING : INJURY  Do not open the check door when the starter switch is in the AUTO or START position. It will cause injury by rotating parts such as cooling fans and fan belt.  Always turn the starter switch to the STOP position and stop the engine, then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment.

  • Page 44: Connecting With External Fuel Tank

    9-6. Connecting with External Fuel Tank CAUTION : FIRE  Always make sure that the engine is stopped when working on piping.  Always be sure to wipe up any spilled fuel.  After working on the piping, check that there is no fuel leakage. ■Capacity of the external tank should be less than 400 gal (1515 liters).

  • Page 45: Inspection/Maintenance

    10. Inspection/Maintenance California Proposition 65 WARNING Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING. WARNING : ELECTRIC SHOCK / INJURY ...
  • Page 46 < Note >  All procedures except for pre-operation inspection should be performed by specialized technicians.  Request authorized distributor where the generator was purchased to perform the procedures in the table with a “”.  Always be sure to use genuine parts or those indicated specifically for replacement parts. ...
  • Page 47 Every Every Every Every Every Every Description Daily Remarks 250 hrs 500 hrs 750 hrs 1000 hrs 2000 hrs 4500 hrs  Fuel/Coolant/Oil Hoses and Anti-Vibration Every Rubber (Replace) 2 years  Air Hose(Engine/ Intercooler/Air Creaner) Every SCR system LLC hose 2 years...
  • Page 48 (1) Engine Oil Replacement Oil Level Gauge Replace Every 500 hours Oil Filler Set a container to catch spilled engine oil. Remove the oil filler cap. After removing the oil drain plug and o-ring, open the oil drain valve and drain the engine oil. After the oil has been drained,close the oil drain valve and reinsert the oil drain plug with o-ring.
  • Page 49 (3) Replacing the PCV (Oil Separator) Filter Replace Every 500 hours Remove the PCV filter bands and PCV filter cover. Wipe clean around the PCV filter cap taking care so that no foreign particles entry. Remove the PCV filter cap. Remove the PCV filter element.
  • Page 50  The mass air flow (MAF) sensor is installed to the air cleaner inlet duct. Refrain from using commercially available cleaning agent to remove dust clinging to the sensor; otherwise the engine output will be reduced.  Outer Element part no.: P812363 (Isuzu part no.) ...
  • Page 51 < Note >  When attaching the Element, check that there is no foreign material adhering to the gasket.  Be careful not to over-tighten the air bleeder plug.  After attaching, be sure to always start the engine and check that there is no fuel leakage. ...
  • Page 52 (8) Electromagnetic Fuel Pump Filter Cleaning/Replacement Clean/Replace Every 500 hours Place a container under Fuel Pump to catch spilled fuel. Turn the cover, located at the bottom of pump, Electromagnetic Fuel Pump counter-clockwise and remove cover. Remove the filter and gasket. Clean the filter with the compressed air and rinse it in the Gasket fuel before installing the filter and gasket.
  • Page 53 (10) Supply Module Filter Replacement Supply Module Replace Every 2000 hours Filter Element Place a container under Supply Module to catch spilled DEF. Remove the filter cover using the socket wrench. Pull out the Filter element and Equalizing element together. Install the new Filter element and Equalizing element.
  • Page 54 (12) Coolant Replacement Replace Every 1000 hours or every 1 year Set a container to catch spilled coolant. Radiator Plate Remove the radiator plate. Remove the radiator cap. Remove the radiator coolant drain plug. Loosen the engine coolant drain plug. Apply sealant coating to the radiator coolant drain Radiator Cap plug or wrap it in seal tape.
  • Page 55 (13) Bleeding air from EGR cooler Bleeding air Every after coolant change Loosen the air bleeder plug of the EGR cooler Air Bleeder Plug in order to bleed air from within the EGR and improve cooling performance. When coolant flows out from the air bleeder plug, tighten the air bleeder plug.
  • Page 56 (16) Elimination of excessive carbon in the exhaust system by extensive light load WARNING : EXHAUST GAS POISONING  Do not operate the generator in poorly ventilated areas such as indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health. ...
  • Page 57 (17) Cleaning the Rear Cover CAUTION : BURNS  Do not touch the SCR system and surrounding components immediately after stopping the engine as they are still extremely hot. CAUTION : INJURY  Position the generator on a level stable surface so that it cannot slide or move in any manner.

  • Page 58: Long-Term Storage

    11. Long-Term Storage WARNING : INJURY  Always turn the starter switch to the STOP position and stop the engine, then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment. CAUTION : FIRE  Always be sure to wipe up any spilled fuel or oil. ...

  • Page 59: Troubleshooting

    (2) Double-Stacking Storage Procedures WARNING : INJURY Always be sure to observe the following items when double stacking this generator in a warehouse or similar location.  Check that the hood of this generator is not dented, and that bolts are not loose or missing. ...
  • Page 60 Problem Suspected cause Action Starter motor 1. Battery output is weak 1. Check battery fluid or charge does not drive 2. Battery is deteriorated 2. Replace Battery or speed is low 3. Battery terminal is OFF or loose 3. Fix/Tighten terminal 4.
  • Page 61 Problem Suspected cause Action White smoke 1. Too much or too little oil to cylinder 1. Contact distributor or dealer for repair comes out from 2. Water is interfused in fuel line 2. Drain water in fuel filter or fuel tank Muffler 3.

  • Page 62: Generator Circuit Diagram

    13. Generator Circuit Diagram...

  • Page 63: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 66 ©2019...

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