Shindaiwa DGK7F Service Manual
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Shindaiwa DGK7F Service Manual

Shindaiwa DGK7F Service Manual

Diesel engine generator
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SERVICE MANUAL
Disassembly & Assembly
File №DGO-630_DGK7F & DGK7FU

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Summary of Contents for Shindaiwa DGK7F

  • Page 1 SERVICE MANUAL Disassembly & Assembly File №DGO-630_DGK7F & DGK7FU...

  • Page 2: Table Of Contents

    Table of Contents Attention Statement ····································································· 1 General Safety Instruction ································································ 2 Disassembly & Assembly ······························································ 4 Disassembly ··············································································· 4 1. Remove the battery ································································· 4 2. Remove the bonnet·································································· 5 3. Remove the fuel tank ······························································ 10 4. Disconnect wiring from the alternator to the front panel ···················· 14 5.

  • Page 3: Attention Statement

    Attention Statement ・Only technicians with enough knowledge and experience should perform maintenance and operational checks after maintenance. ・Before maintenance, always read this service manual as well as the owner’s manual and be familiar with the contents thoroughly before starting the service and maintenance of the equipment.

  • Page 4: General Safety Instruction

    General Safety Instruction WARNING! ELECTRIC SHOCK Entangled Injuries under By Moving Componen NEVER touch the output terminals during operation NEVER touch the output terminal during NEVER reach or touch moving operation even though the breaker on the components during operation! load is being set at “OFF”...
  • Page 5 CAUTION! Work Safely! Generators and welders operate at very high STOP the equipment immediately when speeds and can do serious damage or abnormal circumstances are noticed! injury if they are misused or abused. Never STOP the equipment immediately whenever allow a person without training or instruction abnormal circumstances are noticed such as to operate or service this equipment! unusual noise, smell vibration and etc.

  • Page 6: Disassembly & Assembly

    Disassembly & Assembly WARNING! Before start servicing, prepare; 1. Stop engine and make sure it stopped. 2. Allow the engine and other moving component to cool before servicing. 3. Work on a flat open area. Do not serve the equipment on the tilted ground. 4.

  • Page 7: Remove The Bonnet

    2. Remove the bonnet Bonnet 1) Open the right door Stopper Pin...
  • Page 8 2) Remove the bolt (M8 x 20) and separate the collar and stopper pin from the right door. Bolt (M8 x 20) Collar Stopper Pin WARNING Hold the door when removing the bolt to avoid serious injury. 1. Shut and lock the door until it sounds “click”.
  • Page 9 3) Unfasten the four (4) bolts (M6 x 16) and remove the left door. WARNING Remove the bolts in order as per the numbers that are indicated above for your own safety. Incorrect removal may lead failing the door and serious injury. 4) Loosen the screw in the metal band and remove the intake hose.
  • Page 10 5) Remove the bolt (M6 x 16) from the bonnet. Right Side (4 bolts) Left Side (4 bolts) Rear (3 bolts) Inside of Front Cover (2 bolts) Note: Open the front panel to access the bolt in the front cover. Top Cover (1 pc) Top Cover (2 pcs)（M10×25）...
  • Page 11 6) Remove the tank cap and bushing. Tank Cap Bushing 7) Cut the cable ties that hold the drain tube with the nippers and pull the tube out. Unit after the bonnet was removed. Note: Note: Mount the tank cap to prevent the Plug the intake inlet to prevent the invasion of the dust.

  • Page 12: Remove The Fuel Tank

    2. Remove the fuel tank WARNING Before removing the fuel tank, drain fuel from the tank. How to drain fuel from the tank. Place the drip pan underneath the drain plug of the fuel Turn the drain plug to counter-clockwise with a wrench and remove the plug. Wait for a while until dripping of the fuel stops.
  • Page 13 1) Remove the cable, fuel level sensor and air drain hose Air Drain Hose Tie Band Connector Circlip Fuel Return Hose Right side of the generator 1. Cut the tie band by the nippers. Pull the connector from the fuel level sensor. 2.
  • Page 14 3) Remove the plate. Remove the plate by removing the two (2) bolts (M8 x 20). The plate is mounted behind the frame with the bolts. Bolt (M8 x 20) Plate 4) Remove the fuel filter comp. Air Drain Hose Fuel Supply Hose 1.
  • Page 15 6) Plug the end of the fuel hose. 1. Plug the end of the fuel hose with the bolt. (M8 x 20). Note：The bolt is used to fasten the Plate. 2. Hold the clip and slide the clip up with the pliers. 3.

  • Page 16: Disconnect Wiring From The Alternator To The Front Panel

    4. Disconnect wiring from the alternator to the front panel 1) Remove the front door. Front Door WARNING! Before start servicing; 1. Turn the starting key to OFF position and remove the key. 2. Allow the engine and other moving component to cool before servicing.
  • Page 17 3. Unscrew the screw (M5 x 12) and disconnect the wires (N：black). Note: Refer to the wiring drawing in the service manual of the DGK7F for the details. Top View from the front panel Cut the tie band. Right side of the generator.
  • Page 18 4) Cut the eleven (11) tie bands. Right side of the generator Upper view of the generator 5) Disconnect the wiring that locates near the engine. 1. Remove the connector of the motor comp. 2. Unfasten the bolt (M10 x 15) for grounding with the hex. wrench. Left side of the generator 3.
  • Page 19 1. Cut the tie band with the nippers. 2. Disconnect the connector A in the starting motor but remain the Connector A connector B connected. 3. Loosen the oil pressure switch bolt (M4 x 8) and disconnect the terminal. Connector B Terminal Upper Engine 1.

  • Page 20: Remove The Alternator

    Unfasten the four (4) bolts (M8 x 20) and remove the Bonnet. Left View Right View 5. Remove the Alternator 1) Unfasten the six (6) flange nuts and remove the flexible tube. Flange Nut (M8) Note: Plug the opening with the masking tape after the flexible tube was removal.
  • Page 21 2) Remove the two (2) nuts (M10) that fit the alternator and bed. Left View Right View 3) Fasten the stay (black) with the two (2) nuts (M10) and the bolts (M10 x 80) on both left and right side. Nut (M10) &...
  • Page 22 4) Hook a nylon sling to the M10 bolt (both side) and lift the alternator. WARNING! Always wear a safety helmet and shoes for your own safety. IMPORTANT! The fan should position to form as “V-shaped” so there would be enough space between the fan and alternator cover.
  • Page 23 IMPORTANT! The fan shall not contact the radiator when lifting the alternator. CAUTION! 1. Contact of the fan and alternator cover may lead the fan damage. 2. Inspect the fan tips if it is wounded or broken when the fan contacted. 3.
  • Page 24 8) Turn the center bolt to clockwise and pull the stator out with a puller. Puller Center Bolt 9) Remove the stator. Pull 10) After the stator was removed...
  • Page 25 11) Remove the six (6) bolts with the wrench to release the fan. (M8 x 25) WARNING! 1. Support and hold the rotor with a nylon sling before starting the removal of the bolt for your own safety. Always tighten the sling! 2.
  • Page 26 15) Remove the stay by loosening the eight (8) bolts. (M10 x 30). Left View Right View M10 x 30 16) Remove the rear bracket by loosening the four (4) bolts. (M12 x 220) Bolt (M12×200) Remove the four (4) pcs. of the bolt (M5 x 40) and remove the exciter stator from the rear bracket.

  • Page 27: Assembly

    Assembly 1. Stator and Rotor 1) Tighten the exciter stator to the rear bracket with the four (4) pcs. of the bolt. (M5 x 40) Rear Bracket Exciter Stator Refer to Note below. [Fastening Torque] Lead Wire Note:Fasten the bolts in a crisscross pattern. 3.0～4.9 N･m {31～49kgf･cm} 2) Place the stator case on the “heavy duty”...
  • Page 28 3) Mount the stay to the stator with the four (4) bolts. (M10 x 30) Left View Right View [Fastening Torque] 19.7～24.5 N･m {201～249 kgf･cm} 4) Mount the rotor with the four (4) bolts. (M10 x 30) [Fastening Torque] 40.7～49.5 N･m {416～504 kgf･cm} Open the “check window”...
  • Page 29 5) Mount the fan to the stator with the six (6) bolts. (M8 x 25) [Fastening Torque] 9.9～14.7 N･m {101～149 kgf･cm} Nylon Sling 6) Assemble the stator with the eight (8) bolts. (M10 x 25) Tie Mount Alternator [Fastening Torque] IMPORTANT! The stay shall be mounted with the 19.7～24.5 N・m {201～249kgf・cm}...
  • Page 30 8) Fasten the stator with the stator and bed by the two (2) nuts. (M10) [Fastening Torque] 21.0～31.0 N・m {214～316kgf・cm} 1. Loosen the two (2) nuts with the spanner. 2. Remove the bolt. Note: Each nut and bolt locate at Bolt both left and right side.
  • Page 31 10) Mount the bonnet with four (4) bolts. (M8 x 20) [Fastening Torque] 11.0～16.0 N・m {112～163kgf・cm} Left View Right View 11) Mount the front panel with the five (5) bolts. (M6 x 16) [Fastening Torque] 4.3～6.4 N・m {44～65kgf・cm}...

  • Page 32: Installation Of The Flexible Tube

    2. Installation of the Flexible Tube Fasten the flexible tube with 6 pcs of the flange nut.（M8） [Fastening Torque] 17.7～21.5 N・m {181～219kgf・cm} 3. Connect the lead wire of the stator 1) Connect the main harness to the engine. Upper view of the engine 1.
  • Page 33 Left side of the engine Starter 1. Connect the connector of the starter. 2. Fasten the terminal with the oil pressure switch bolt. (M4 x 8) 3. Connect the connector of the float switch. 4. Fasten the two (2) grounding wires with the bolt.
  • Page 34 1. Connect the connector of the motor comp. 2. Fasten the two (2) grounding wires with the bolt. (M8 x 15) Note: Numbers in the photo and explanation in the left are co-related. [Fastening Torque] 19.7-24.5 N・m {201～249kgf・cm}...
  • Page 35 2) Connect the lead wires of the stator. [Fastening Torque] 2.6～3.8 N・m {27～39kgf・cm} [Fastening Torque] Fasten the blue wire (WO：blue) in 11.0～16.0 N・m the upper right and red wire { 112～163kgf・cm } (UO：red) in the upper left of the breaker with the screw. (M8 x 14) 2.
  • Page 36 3) Tie the hoses and wires with the tie band. Upper View of the engine Left side of the engine Tie with the hose clamp Left side of the engine Top view in the front panel Right View Stator The tie band that the arrow shows should be tightening in loose as the wires would vibrate during engine run.

  • Page 37: Assembly The Other Component

    4) Mount the front door. Knob 1. Fasten the operational panel with the knobs. 2. Mount the front door. Align the upper and lower vise. Assembly the other component 1) Mount the fuel tank. 1. Mount the fuel tank with the eight (8) bolts. (M6 x 16) 2.
  • Page 38 2) Mount the plate Drain Plug Fasten the bolt (M8 x 20) together with the plate. [Fastening Torque] 11.0～16.0 N・m {112～163kgf・cm } IMPORTANT! The plate shall be mounted in the back of the bed. Plate 3) Mount the fuel filter comp. Fuel Supply Hose Air Drain Hose Clip...
  • Page 39 1. Hold the clip and slide the clip down with the pliers. 2. Remove the bolt (M8 x 20) from the fuel hose. Circlip 4) Insert the fuel hose to the engine. 1. Insert the fuel hose to the engine. 2.
  • Page 40 1. Mount the top cover with the bolt. (M6 x 2. Put the bushing and tank cap back in order to the original position. [Fastening Torque] Tank Cap 4.3～6.4 N・m Bushing {44～65kgf・cm} Right Side (4 bolts) Left Side (4 bolts) Inside of Rear (3 bolts) the Front Cover (2 bolts)
  • Page 41 Top Cover (1 pc) [Fastening Torque] 4.3～6.4 N・m {44～65kgf・cm} Top Cover (2 pcs)（M10×25） [Fastening Torque] 21.0～31.0 N・m {214～316kgf・cm} 7) Tie the drain tube with the tie band. Tie Band Tie Band...
  • Page 42 8) Insert the drain hoses to the spill containment. 8) Fasten the panel with the four (4) bolts with the wrench. (M6 x 16) [Fastening Torque] 4.3～6.4 N・m {44～65kgf・cm} WARNING! Always wear a safety gloves and shoes for your own safety. WARNING Fasten the bolts in order as per the numbers that are indicated above for your own safety.
  • Page 43 10) Mount the right door. WARNING! Always wear a safety shoes and eye protection for your own safety. Groove e-ring 1. Place the door to the original position and lock the door until it sounds “click”. 2. Insert the hinge pin to the vise while lifting the door.

  • Page 44: Mount The Battery

    5．Mount the battery 5.1 Place the battery to the bed. 5.2 Connect the clamp and terminal to positive (+) post to the battery. 5.3 Connect the clamp and terminal to negative (-) post to the battery. 5.4 Fasten the battery firmly with the holder and wing nut. [Fastening Torque] 6.9～8.8 N・m {71～89kgf・cm}...

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