Shindaiwa DGK60D Owner's Manual
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Shindaiwa DGK60D Owner's Manual

Shindaiwa DGK60D Owner's Manual

Diesel engine generator
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OWNER
S AND OPERATOR
S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
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.
DGK60D
X753-006 80 0
X753801-030 0

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  • Page 1 S MANUAL Vertical, Water-Cooled 4-Cycle Diesel Engine 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. DGK60D X753-006 80 0 X753801-030 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 .................. 5 2-1. Specifications ................5 2-2. Ambient Conditions ..............6 Applications ..................6 Part Names ..................6 4-1. External View/Part Names ............6 4-2. Operation Panel Part Names ............ 8 Equipment ..................9 5-1.

  • Page 5: Safety Instructions

    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 bring 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  Cable burnout can occur due to generated heat if the load 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.

  • Page 8: Specifications

    Specifications 2-1. Specifications Model Unit DGK60D Revolving Field Brushless AC Generator Type Simultaneous 3 Phase-120V/240V 1 Phase Rated Frequency Three phase Rated Output 36/ [18] *1 Single phase 36/ [18] *1 Three phase 208/240/ [480] *1 Rated Voltage Single phase...

  • Page 9: 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 10 Radiator Plate Engine Check Door Alternator Check Door Safety Guard Radiator Oil Separator External Tank Fuel Inlet plug External Tank Fuel Return plug Air Cleaner Coolant Sub-Tank Alternator Check Door Oil Level Indicator Battery Engine Check Door Fuel Tank Oil Filter Fuel Filter Fuel Pre-Filter Oil Filler...

  • Page 11: Operation Panel Part Names

    4-2. Operation Panel Part Names ○  3-Phase Circuit Breaker Engine Monitor ○ Oil pressure/Water Temperature/Speed  1-Phase Circuit Breaker Selector Switch ○  Voltmeter Display Selector Switch ○  Ammeter Available Output Monitor ○  Frequency Meter Fuel Meter ○...

  • Page 12: Equipment

    Equipment 5-1. Three-phase and single-phase simultaneously 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 13 CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the engine as they are still hot. 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).

  • Page 14: Meters And Gauges

    (3) 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 rises above 2070 rpm during operation, the OVER SPEED and ENGINE warning indicators light up, and the engine automatically stops.
  • Page 15 Be careful as the hour meter operates when the starter switch is at RUN regardless of whether the engine is running. (2) Engine 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 first displayed when the engine is started.
  • Page 16 < 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”. (3) Frequency Meter Displays the frequency of the power source. Check that 60 Hz is displayed during operation. Indicators (1) Pre-heating Indicator Pilot Lamp...

  • Page 17: Spill Containment

    (3) Breaker Trip Selector Switch This switch is for selecting the tripping order of the three-phase and single-phase breaker when there is a short circuit or overload on the load side. If the three-phase or single-phase breaker is selected for precedence in tripping, the selected breaker will trip first when the total generator output exceeds the rated capacity.

  • Page 18: Fuel Piping Switch (3Way Fuel Valve)

    Refer to section “10. Inspection/Maintenance (8) Flushing Liquid in Spill Containment” for flushing procedures. The generator is equipped with the following in order to prevent liquid from spilling in case you forget to flush the liquid: The operation panel is equipped with an indicator that lights up when its sensor is triggered as the spill containment capacity accumulated enough liquid to reach the 1/4 full (approx.

  • Page 19: Transporting/Installing

    Transporting/Installing 6-1. Transport Procedures WARNING : INJURY  Do not lift up the unit using tie downs. Use of such could result in the generator falling.  No persons should be under a lifted generator. CAUTION : INJURY  Always be sure to use lifting hooks when lifting up the generator, and raise it slowly at a completely vertical angle.

  • Page 20: Installation Procedures

    6-2. Installation Procedures 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. CAUTION : FIRE ...

  • Page 21: Load Connections

    Load Connections 7-1. Load Cable Selection CAUTION : PROPERTY DAMAGE  Cable burnout can occur due to generated heat if the load 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.

  • Page 22: Connecting Load Cables

    7-2. Connecting Load Cables WARNING : ELECTRIC SHOCK  Before connecting or disconnecting the load cables to/from the output terminal, always turn the output circuit breakers to the OFF position, stop the engine, and remove the ignition key.  Close the output terminal cover before operating. ...
  • Page 23  For single-phase load:  Terminal voltage is 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 24  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 Use is possible up to the kVA as shown below.

  • Page 25: Pre-Operation Inspection

    Pre-Operation Inspection WARNING : INJURY  Always be sure to stop the engine and remove the engine key when performing inspection or maintenance.  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. CAUTION : BURNS ...

  • Page 26: Checking Coolant

    (3) Engine Oil Replacement Amount Total Lubrication Oil Amount 3.5 (0.1) 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 steam gushing out. ...

  • Page 27: Checking The Fan Belt

     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 the coolant sub-tank. (3) Coolant Amount Total Coolant Amount 3.3 (0.4) gal...

  • Page 28: Checking The Spill Containment

    < NOTE >  The fuel injector pump, injectors and other parts of the fuel system and engine can be damaged if any fuel or fuel additives are used other than those specifically recommended by the engine manufacturer.  Refer to the Engine Instruction Manual for the recommended Fuel Strainer Fuel Inlet fuels.

  • Page 29: Operating Procedures

    Check the fluid level, and add distilled water when it is near the lower level until it reaches the upper level. Check the terminals for looseness and tighten if loose. < NOTE >  It is necessary to recharge the battery when the specific gravity of the battery fluid is 1.23 or less. Request the authorized distributor where the generator was purchased to recharge the battery.
  • Page 30 CAUTION : FIRE  Do not bring 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 31: 240/480-V Switching Function

    After starting the engine, remove your hand from the starter switch. The engine idles for approximately five minutes. Turn the Throttle switch to RUN. Adjust the voltage regulator dial to the specified voltage. Turn the breakers to ON to start power transmission. 9-2.

  • Page 32: 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 33: 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 engine key when performing inspection or maintenance.

  • Page 34: 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 to the Position A “A”...

  • Page 35: 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 36 Every Every Every Every Every Every Every Every Description Daily 100 hrs 200 hrs 400 hrs 500 hrs 800 hrs 1000 hrs 1500 hrs 3000 hrs Each parts  (Clean/Tightening) Engine oil  (Check/Add)  Engine oil time  (Replace) 50 hrs ...
  • Page 37 (1) Engine Oil Replacement First Time 50 hours Oil Level Thereafter Every 200 hours Indicator Oil Filler Cap Set a container to catch spilled engine oil. Oil Filler Remove the oil filler cap. After removing the oil drain plug and packing(a rubber seal is attached),open the oil drain valve and drain the engine oil.
  • Page 38 (3) Air Filter Element Cleaning/Replacement Clean 100 hours Replace Every 400 hours Remove the air cleaner clips and cleaner cap. Remove the outer element. Clean or remove the outer element. Replace by performing the above procedures in reverse order. < NOTE > ...
  • Page 39 After water has been drained, tighten the valve and air bleeder plug. If foreign material is adhering to the gauze filter in the cup, remove the cup, float and gauze filter, and clean by blowing compressed air from the inside of the gauze filter. Reassemble the gauze filter, cup and float to their original location.
  • Page 40 (7) Coolant Replacement Radiator Plate Replace Every 1000 hours Remove the radiator plate. Filler Neck Remove the radiator cap. Remove the coolant drain plug and packing. After the coolant has been drained, reinsert the coolant drain plug with new packing. Remove the subtank and flush the coolant from the Radiator Cap subtank.
  • Page 41 (9) Electric Fuel Pump Filter Replacement Replace Every 1000 hours Turn the bottom cover of the pump counter-clockwise to disassemble the pump body. Remove the filter element and seals. Electric Fuel Pump Install the new filter element and seals in the reverse order.
  • Page 42 Inlet port Return port Position A Position B < NOTE >  Always be sure to connect properly in between supply and return route of fuel hose(s).  After reassembling, bleed air from the fuel system. (Refer to section “9-3. Procedures during Operation”.) ...
  • Page 43 Lifting Hook Wire Connector Bolt Bolt Inlet Port Return Port Fuel Tank Wire Connector Fuel Line (Inlet Side) Spill Containment Fuel Line (Return Side) (11) Oil Separator Filter Replacement Replace Every 1000 hours Remove the cover, and remove the O-ring and oil separator filter. Assemble a new O-ring to the cover and spread a thin layer of oil on the O-ring.

  • Page 44: Long-Term Storage

    (12) 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 an indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health.
  • Page 45 CAUTION : FIRE  Always be sure to wipe up any spilled fuel or oil.  Allow the generator to cool before covering with the protective cover. CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the engine as they are still hot.

  • Page 46: 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 47 Engine starts but 1. Fuel filter is clogged 1. Clean/Replace fuel filter stalls immediately 2. Gauze filter is clogged 2. Clean/Replace gauze filter 3. Water is interfused in fuel line 3. Drain water in water separator, fuel filter or fuel tank 4.
  • Page 48 The voltage drops 1. AVR is defective 1. Ask our distributor to 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 49: Generator Circuit Diagram

    13. Generator Circuit Diagram...

  • Page 50: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 52 ©2017...

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