Shindaiwa DGK45F Owner's And Operator's Manual
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Shindaiwa DGK45F Owner's And Operator's Manual

Diesel engine generator
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'
OWNER
S AND OPERATOR
Vertical, Water-Cooled 4-Cycle Diesel Engine
WARNING
CALIFORNIA – Proposition 65 Warning
 Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
 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 use and keep near for ready use.
'
S MANUAL
X750-026 37 0
X750801-580 0
DGK45F

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  • Page 1 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 use and keep near for ready use. DGK45F X750-026 37 0 X750801-580 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 Safety Instructions ................2 Specifications .................. 6 2-1. Specifications ................6 2-2. Ambient Conditions ..............7 Applications ..................7 Part Names ..................7 4-1. External View/Part Names ............7 4-2. Operation Panel Configuration ..........9 Equipment ..................10 5-1.

  • 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 : EXPLOSION  Never use or recharge the battery if the fluid level is below the minimum level.  Do not create sparks or bring flame near the battery as it generates flammable gas. 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.
  • Page 7 CAUTION : INJURY  Always be sure to use lifting hooks when lifting up the generator, and slowly lift it straight up.  Personnel performing lifting work must wear protective gear such as helmets, safety shoes and gloves.  Remove the wood ties if using anchors to secure the generator ...
  • 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 (Part no. : X505-004620) ②...

  • Page 9: Specifications

    Specifications 2-1. Specifications Model Unit DGK45F Revolving Field Brushless Generator Type Rated Frequency Three phase Rated Output(Prime) 27 [13.5] *1 Single phase 27 [13.5] *1 Three phase Standby Output 30 [15] *1 Single phase 30 [15] *1 Three phase 208/240/ [480] *1...

  • 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 Fuel Filter Electromagnetic Fuel Pump (Main) Fan Guard Alternater Check Door Radiator Intercooler Engin Check Door Intercooler Drain Plug External Fuel Inlet External Fuel Return Fuel Filter 3way Fuel Valve (Pre) Coolant Sub-Tank Air Cleaner Oil Filler Oil Level Indicator Engine Check Door Alternator Check Door Oil Filter...

  • Page 12: Operation Panel Configuration

    4-2. Operation Panel Configuration ⑳ ⑮ ⑪ ⑨ ⑩ ⑬ ② ⑤ ③ ④ ① ⑫ ⑯ ⑥ ⑦ ⑧ ⑱ ⑰ ⑲ ⑭ ○  Circuit Breaker(3-Phase & 1-Phase) Engine Monitor ○ Oil Pressure/Water Temperature/Speed  Voltmeter Selector Switch ○...

  • Page 13: Equipment

    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 14: Warning Indicators

    CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the engine as they are still extremely hot. The bed of this generator is equipped with a spill containment (structure for preventing leakage of liquid) so that any spilled liquid will not leak to outside of the generator when oil or fuel is spilled or leak.
  • Page 15 This generator is equipped with the following warning indicators: BATTERY (battery charge), OIL PRESS (engine oil pressure), WATER TEMP (coolant temperature), OVER SPEED (engine overspeed), AIR FILTER (air cleaner clogging), SPILL CONTAINMENT (spill containment amount), and ENGINE (engine malfunction). When the engine starts, all the lamps will be lights off.

  • Page 16: Spill Containment Overflow Warning Indicator

    (4) OVER SPEED (Engine Overspeed) Warning Indicator This generator is equipped with a function such that the engine is automatically stopped if an engine fault occurs causing the engine speed to increase excessively. If the engine speed rose above 2,070rpm during operation, the OVER SPEED warning indicators and ENGINE warning indicators illuminates, and the engine will be automatically stopped.

  • Page 17: Meters And Gauges

    If the liquid stored in the spill containment exceeds approximately about 25gal ( 94.6 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 18 Generator Meters and Gauges (1) Voltmeter The voltmeter displays the three-phase output voltage (voltage between L1-L3). Check that 240 V is displayed during operation. Output voltage for single-phase three-wire (voltage between U-W) is the same voltage as the three-phase output voltage (voltage between L1-L3).
  • Page 19 Switches Breaker Trip (1) Starter Switch Selector Switch  STOP The engine is stopped and all power is shut off with this position. The key can be inserted and removed only in this position.  RUN/PREHEAT 3-Phase 1-Phase Breaker Breaker Position for operating the generator.

  • Page 20: Fuel Piping Switch (3Way Fuel Valve)

    < Note >  If measuring the output current for a single-phase three-wire type, turn the ammeter selector switch to “L1+U” or “L3+W”. The voltage cannot be accurately measured if set to “L2”. Voltage Regulator/Throttle Switch (1) Voltage Regulator This dial is for regulating voltage output by the generator. Turn the dial clockwise to increase the voltage and counterclockwise to decrease it.

  • Page 21: Transport/Installation

    Transport/Installation 6-1. Transport Procedures WARNING : INJURY  Do not lift up the unit using tie down. Use of such could result in the generator falling.  No persons should be under a lifted generator at all time. CAUTION : INJURY ...

  • Page 22: Load Connections

    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. Operate this generator 3 ft. (1 m) or more from walls or other hindrances, and on a level surface.

  • Page 23: Connecting Load Cables

     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) 200 ft 300 ft 400 ft 500 ft 600 ft or less (61 m) (91 m) (122 m)
  • Page 24 (1) Three-Phase Output Terminal  For three-phase load:  Terminal voltage is 240/480 V. GROUND Load  For single-phase load:  Terminal voltage is 139/277 V. GROUND Load Load Load  For single-phase load:  Terminal voltage is 240/480 V. GROUND Load Load...
  • Page 25  Single-phase 120V receptacle, single-phase 240/120V receptacle CON1 CON3 CON5 CON6 CON7 Load Load CON2 CON4 Load Load Load Load Load  Power available for use by each output terminal and receptacle are as show below. GROUND U-N / W-N / U-W CON1 CON3 CON5...

  • Page 26: Pre-Operation Inspection

    < Note >  If using a single-phase 120 V (between output terminals U-N and W-N), connect an equivalent load between U-N and W-N  If using a single-phase three-wire output terminal simultaneously with a receptacle output, make sure that currents passing through each phase is less than the rated current of this generator. ...

  • Page 27: Checking Coolant

    (1) Types of Engine Oil Use only API service-type CJ-4 class. (2) Engine Oil Viscosity Grades Use a diesel engine oil with an appropriate viscosity corresponding to the ambient temperature (refer to the table).  Relation of Viscosity/Temperature Temp. (°F) SAE 10W-30 SAE 10W-40 SAE 15W-40...

  • Page 28: Checking The Fan Belt

    (2) Filling the Radiator Filler Neck Radiator Plate 給水口 Remove the radiator plate. Open the radiator cover. Remove the radiator cap. Radiator Cover （ CLOSE ） Fill with coolant through the filler neck until the radiator is full. Re-attach and tighten the radiator cap.

  • Page 29: Checking The Fuel

    (3) Fan Belt Adjustment Remove the fan guard. Loosen the bolts of the alternator. Pull the alternator out and adjust the fan belt tension. Securely tighten the bolts of the alternator. Bolt Check that the fan belt tension is correct. Attach the fan guard.

  • Page 30: Checking The Spill Containment

    8-5. Checking the Spill Containment CAUTION : FIRE  If fuel or oil is leaking, repair the leaking location before operating. Open the check door and check the inside of the spill containment. Flush out any accumulated liquid. Refer to section “10. Inspection/Maintenance (10) Flushing Liquid in Spill Containment” for flushing procedures.

  • Page 31: Operating Procedures

    (-) Post () Post Hold-Down Clamp Upper Level Lower Level  Replacing the Battery Remove the battery negative (-) cable. (Always be sure to remove the negative (-) side first. ) Remove battery hold-down clamp. Remove the battery positive (+) cable. Remove the battery.

  • Page 32: 240/480 V Switching Selection

    < Note >  Check that the surrounding area is safe before starting the engine.  When there are multiple workers who are working together, they must mutually signal each other before starting the engine.  Do not use in an area with high temperature or humidity, or an area with a large amount of dust. ...

  • Page 33: Procedures During Operation

    CAUTION : PROPERTY DAMAGE  Check that the voltages of the generator output setting, output terminal connection and load power source are consistent. Turn the three-phase and single-phase 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 240/480 V power is output to the three-phase output terminal.

  • Page 34: Stopping Operation

     Bleeding air from the fuel system when the engine stops due to running out of fuel Add fuel to the generator. Turn the starter switch to RUN, activate the electromagunetic pump. Please do not start the engine. Priming Pump Loosen the air bleeder plug of the fuel filter sufficiently, and operate the priming pump until the fuel comes out.

  • Page 35: Protective Functions

    9-5. Protective Functions WARNING : INJURY  Do not open the check door during operation. Be careful of pinching or catching of moving parts such as the cooling fan and fan belt.  Always be sure to stop the engine and remove the starter key when performing inspection or maintenance.

  • Page 36: 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. Turn the 3way fuel valve lever 3Way Fuel Valve to the “B”...

  • Page 37: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/INJURY  Do not touch output terminals or internal electric parts while the generator is operating.  Do not open the check door during operation. Be careful of pinching or catching of moving parts such as the cooling fan and fan belt. ...
  • Page 38 Every Every Every Every Every Every Every Description Daily 100 hrs 250 hrs 500 hrs 750 hrs 1000 hrs 1500 hrs 3000 hrs Each parts  (Clean/Tightening) Exhaust color  (Check) Engine oil  (Check/Add)  time  Engine oil (Replace) 50 hrs ...
  • Page 39 (1) Engine Oil Replacement Oil Filler Oil Level First Time 50 hours （Cap） Indicator Thereafter Every 500 hours Remove the oil filler cap. After removing the oil drain plug and o-ring, open the oil drain faucet and drain the engine oil. After the oil has been drained,close the oil drain Oil Drain Faucet...
  • Page 40 (3) Air Filter Element Cleaning/Replacement Clean Every 250 hours Replace Every 500 hours Remove the air cleaner clips and cleaner cap. Remove the element. Clean or replace the element. Attach by performing the above procedures in reverse order. < Note > Air Cleaner ...
  • Page 41 < Note >  After reinserting, be sure to always start the engine and check that there is no fuel leakage.  If water is accumulate in the cup, draining water from the fuel tank.  Be careful not to over-tighten the drain plug and air bleeder plug. ...
  • Page 42 (6) Electromagnetic Fuel Pump Filter Cleaning/Replacement Every500 hours Clean/Replace Electromagnetic Turn the cover, located at the bottom of pump, Fuel Pump counter-clockwise and remove cover. Remove the filter and gasket. Gasket Clean the filter with the compressed air and rinse it in the fuel before installing the filter Filter and gasket.
  • Page 43 Remove the subtank and flush the coolant from the Ari Bieeding Plug （EGR） subtank. Sub-Tank Reattach the subtank to its original position and fill with coolant until it reaches the FULL level. Fill the radiator with coolant until it reaches the filler neck.
  • Page 44 < Note >  When removing or attaching the plug, hold the drain valve fixed using a spanner or similar tool and turn the plug.  If oil or other liquid is mixed in with the flushed liquid, this indicates that there is an oil leak. In such case, check for the leak location.
  • Page 45 < Note >  When removing the fuel hoses, hold the union joint fixed using a spanner or similar tool.  Prepare a container to receive the fuel remaining in the fuel piping that will flow out of the removed fuel piping. Lift the generator, separate the spill containment and set the generator on a flat surface.
  • Page 46 Lifting Hook Wire Connector Bolt Washer Position A Bolt Washer Union Joint Fuel Line (Return Side) Fuel Line (Inlet Side) Spill Containment Wire Connector Fuel Tank (12) Elimination of carbon in the exhaust pipe line and muffler WARNING : EXHAUST GAS POISONING ...

  • Page 47: Long-Term Storage

    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 48 (1) Storage Procedures Perform the following maintenance procedures before storing this generator if it is not going to be used for two months or more. Remove the battery. (Refer to section “8-7. 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.

  • Page 49: Troubleshooting

    12. Troubleshooting WARNING : ELECTRIC SHOCK/INJURY  Do not touch output terminals or internal electric parts while the generator is operating.  Do not open the check door during operation. Be careful of pinching or catching of moving parts such as the cooling fan and fan belt. ...
  • Page 50 Problem Suspected cause Action Engine starts but 1. Fuel filter is clogged 1. Clean/Replace fuel filter stalls immediately 2. Water is interfused in fuel line 2. Drain water in fuel filter or fuel tank 3.Air is interfused in fuel line 3.
  • Page 51 Problem Suspected cause Action The voltage drops 1. AVR is defective 1. Contact distributor or dealer for repair drastically when 2. Unbalanced loads sharing to each 2. Balance the loads sharing to each connecting to load terminal terminal 3. The current of the used equipment 3.

  • Page 52: Generator Circuit Diagram

    13. Generator Circuit Diagram...

  • Page 53: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 54 ©2015...

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