Shindaiwa DGK11F User manual

SERVICE MANUAL
WARNING
This equipment is designed and built with safety in mind. However, your overall
safety can be increased by your full understand followed by the content in this
manual.
Read this manual and familiarize yourself with its contents for your safety.
This equipment should only be operated and maintained by trained and qualified
personnel.
This equipment is designed for generating power source of electric tools, home
appliances and lights.
Do not install, operate or service this equipment without reading this manual and
unless you clearly understand this manual.
Specifications sub ect to change without notice.
File№ DGO-271_DGK11F

This service manual is edited for authorized person to perform repair,
maintenance, and trouble-shooting to Shindaiwa Diesel Engine Generator,
Model Designation DGK11F.
It is inevitabl necessar to maintain and adjust Shindaiwa products
periodicall in order to use full and safel for long time. Therefore,
understand this service manual full enough before use and proper
maintenance.
The information contained in this service manual describes equipment
available at the time of publication. While ever attempt has been made to
give ou the ver latest information about our product, there ma be some
differences between our equipment and the equipment described in this
manual. We reserve the right to make changes to equipments without prior
notice, and without obligation to make alterations to equipments previousl
manufactured.
For service of the engine, refer to Workshop (Service) Manual provided b
the engine manufacturer described below.
MANUFACTURER
MODEL
KUBOTA D1503

Table of Contents
1. Attention Statements ··············································································· 1
2. General Safety Instructions ···································································· 2
3. Specifications ····························································································· 4
4. General ········································································································ 5
4-1 Appearance ······················································································ 5
4-2 Dimension ························································································ 5
5. General Par ts Description ······························································ 7
5-1 Equipment ························································································ 7
5-2 Main Parts and Feature ······································································· 10
5-3 Main Component ················································································ 10
6. Ser vice Data ······························································································· 14
-1 Service Data ····················································································· 14
-2 Generator ························································································· 15
7. ightening orque ······················································································ 22
7-1 Specific Tightening Torque ···································································· 22
7-2 General Tightening Torque ···································································· 23
8. Periodical Check for Engine ··························································· 24
9. rouble Shooting ························································································ 25
10. Wiring Diagram ············································································· 27

1
1. Attention Statements
・Technicians onl who own enough knowledge and experience should work for
maintenance and operational check after maintenance.
・Before maintenance, alwa s read this service manual as well as owner’s manual and
familiarize contents thoroughl before starting the service and maintenance of the
equipment for understanding of the equipment, safet instructions and cautions.
・ Throughout this manual are special attention statements.
A statement preceded b the triangular attention s mbol and the word “WARNING”
contains information that should be acted upon to prevent serious injur .
A statement preceded b the triangular attention s mbol and the word “CAUTION”
contains information that should be acted upon to prevent mechanical damage.
WARNING
CAU ION

2
2. General Safety Instructions
ELECTRIC SHOCK
NEVER touch the output terminals
during operation
NEVER touch the output terminal during
operation even though the breaker on the
load is being set at “OFF” position.
ALWAYS stop engine and make sure it
stopped before ou will connect the loads to
the output terminals.
Suffocation by exhaust gas
NEVER run the engine indoors! Make
sure there is always good ventilation.
Fu es fro engine exhaust cause
serious injury.
ALWAYS operate the equipment in the
ventilated area.
When the equipment is used in a tunnel, hall
or an other indoor, the equipment for
ventilation must be used to prevent serious
accident caused b suffocation.
NEVER direct the exhaust fume to
houses nearb while considering the wind
flow direction.
Exhaust gas contains man harmful
elements that would cause affect to human.
Be free from suffocation when the
equipment is used in poorl ventilated area
such as inside of the building.
Entangled Injuries under
By Moving Componen t
NEVER reach and touch the moving
component during operation!
ALWAYS stop the engine during inspection
to prevent serious bodil injur b entangled
accident under moving component.
Electric shock/Injuries/Burns
Never inspect equipment during
use .
Never serve and inspect when equipment is
being operated.
It ma cause electric shock, injuries or
burns.
WARNING-Use good judgment
① NEVER run the engine when
transporting the equipment.
② ALWAYS stop the equipment
immediatel if it suddenl begins to
violate or abnormal noise. Inspect for
broken, missing or improperl installed
parts.
③ ALWAYS keep the equipment as clean
as practical. Keep it free of loose
vegetation, mud, etc.
DO NOT make unauthorized
modifications or alterations to this equipment
of an of its components. YAMABIKO must
authorize alterations and modifications in
writing. Unauthorized modifications or
alterations ma alter the equipment
operation and could jeopardize personal
safet during operation.
WARNING

3
Work Safely
Generators and welders operate at ver high
speeds and can do serious damage or
injur if the are misused or abused. Never
allow a person without training or instruction
to operate and serve this equipment!
Attention to CAUTION LABEL！
Caution labels are placed on this equipment
and it would request special attention for
operation. Make sure to locate the labels
and understand the content of the caution.
・Check the caution labels is legible. Alwa s
keep the labels clean or replace them when
worn or damaged
・Clean the labels b cloth, water or
detergent and never use organic solvent or
gasoline which ma cause label peel off due
to adhesive solvent.
・Make sure to replace the labels when
damaged and illegible.
Before replacing the label(s), make sure to
place the new label(s) in the same position.
STOP the equipment immediately when
abnormal circumstances are noticed!
STSTOP the equipment immediatel whenever
abnormal circumstances are noticed such
as unusual noise, smell, vibration and etc.
It ma lead serious accident or fatal damage
of the equipment or properties.
Inflammables！
Keep the equipment far awa from fire such
as cigarettes when refueling fuel, oil or
batter fluid.
NEVER operate or service the equipment
nearb fire as the equipment ma catch
fire.
No Modification！
NEVER modif the equipment without
manufacturer’s advanced approval. .
It ma lead serious safet issue and damage
the equipment.
Inspect the equipment before engine
start for operation and periodical inspection
without fail！
Make sure to serve initial check before start
engine and periodical inspection for safet
and longer life of the equipment.
CAUTION

3. Specifications
Model Unit DGK11F
Alternator
Generator Type - Revolving Field Brushless
Armature Connection - ZigZag-W
Rated Frequency Hz 0
Rated Output(Prime) kVA 11
kW 11
Standby Output kVA 12
kW 12
Rated Voltage V 240/120
Rated Current A 45.8
Phase Single phase
Power Factor - 1.0
Insulation class - F
Excitation - Self Excitation (brushless)
No. of Poles - 4
Engine
Type - Vertical Water-Cooled 4-Cycle Diesel
Model(Manufacturer) - Kubota D1503
No. of Cylinders
(bore × stroke) (in./mm) 3 (3.27×3.64/83×92.4)
Continuous Rated
Output hp 19.5
Rated Speed rpm 1800
Displacement
c
u.in.
/liters
91.5
/1.499
Combustion System - Indirect Injection
Cooling Method - Radiator
Lubricating Method - Forced Lubrication
Starting Method - Electric
Fuel - No.2-D,S15 EPA regulation
Lubricating Oil - CD class or higher
Fuel Tank Capacity
gal.
/liters
16
/ 2
Lubricant Volume
gal.
/liters
1.9
/7.3 (including filter
0.1
/0.3)
Cooling Water Volume
gal.
/liters
2.3
/8.8 (including sub-tank
0.
3
/1.1)
Starting Motor Capacity
V-kW 12-1.4
Charging Alternator
Capacity V-A 12-30
Battery Capacity V-Ah 12-55
Unit
Length
i
n.
/mm
55
/1390
Width
in.
/mm
28
/704
Height
in.
/mm
40
/1012
Dry Weight
lbs.
/kg
1246
/5 5
Net Weight
lbs.
/kg
1411
/ 40
**Specifications subject to change without notice.
4

5
4. General
4.1 Appearance
4.2 Dimension
Unit in the drawings below is shows b mm.

6
EXHAUST GAS OUTLET
WATER OUTLET

7
. General Parts Description
5.1 Equipment

8

9

10
5.2 Main Parts and Feature
(1) Unit Serial Number
(2) Engine Serial Number
5.3 Main Component
Provide both serial number of unit and engine to your
local service shop for update parts and warranty
information.
Circuit Breaker
Feature: Protect electrical
circuit from damage by
overload or short circuit.
M
onitor Lamp
Feature: Light a monitor
lamp when equipment is
malfunctioned.
Volt Meter Selector Dial
Feature: Dial to change
voltage.
Idle Control Switch
Feature: Switch to set the engine speed
idle when electric supply is not performed
to reduce noise and fuel consumption. Set
the switch to DL NG at starting and
change it to RUN during operation.
Fuel Meter
Feature: Display volume of
the fuel left in the fuel tank.
Ampere Meter Selector
Switch
Feature: Select the output
current.
Frequency Meter
Feature: Display frequency
of the generator.
Ampere Meter Selector Dial
Feature: Dial to select the
output current.

11
Right Side Door
Fuel
Inlet
Feature: nlet to the inject fuel.
Fuel
Drain Plug
Feature: Drain the old fuel from the
fuel tank.
Cooling ater
Drain Plug
Feature: Drain cooling water
(coolant) from the top cover.
Fuel Return
Feature: Outlet to return fuel from
the external tank.
Spill Containment Drain
Plug
Feature: Drain a liquid from the spill
containment. Refer to page 36 in the
operator’s manual.
Oil Drain Plug
Feature: Drain the old oil from the oil
tank.
Spill Containment Drain Plug
Feature: Drain a liquid from the spill
containment. Refer to page 34 - 35 in
the operator’s manual.

12
3
-
Way Valve
Feature: Valve to change fuel supply from a
built
-
in or external tank.
3
-
Way Valve
Position A (to se a b ilt-in f el tank)
Position the 3-way valve lever to LEFT to se
f el from the external f el tank.
Position B (to se an external f el tank)
Position the 3-way valve lever to RIGHT to
se f el from a b ilt-in f el tank.
Note: The 3-way valve lever is set at position A at
delivery from a factory.
Position A Position B
3-Way Valve
Lever

13
Left Side Door
Standa d Accesso y
① Owners Manual 1 copy
② Engine Warranty Manual 1 copy
③ Starter Key 1 set (2 pcs)

14
6. Service Data
ELECTRIC SHOCK
WA NING
Never touch the output terminal during operation to avoid electric
shock. Always stop the engine and remove the starter key during a
service maintenance.
Stop the engine before you will start any maintenance!
6-1 Technical Specification
Items Reference Val e Note
Ins lation
Armat re
winding 3MΩ or more DC500V
Megger Tester
Exciter field
Preheat time
Approx. 1 sec. with coolant temperat re
30℃(86 °F) and a pprox. 10 sec. with
coolant temperat re -15℃(5 °F)
A tomatic
preheating system
Min. rpm at no load 1200min
-1
Max. rpm at no load 60Hz: 1800min
-1
L bricant oil press re 0.24~0.44MPa{2.5~4.5kgf/cm²}
Coolant temperat re 70~95℃ (158~203
°F)
Frame temperat re limit within 80℃ (176
°F)
Sealed bearing temperat re limit within 80℃ (176
°F)
Speed reg lation Momentary within 10%
Steady-state
deviation within 5%
Voltage reg lation
Momentary within 20%
Steady-state
deviation within 1.0%
Freq ency Idle: 40 Hz, Rated: 60 Hz
Variable voltage (60Hz) 197~255V 60±0.1Hz
Protective device
1
Low oil pressure Working Press re 0.0481MPa{0.5kgf/cm²} Engine Stop
2
High water temp. Working Temperat re 115℃ (239
°F) Engine Stop
3
Diagnosis
Engine Malf nction - -
4
nsufficient Battery
Charge
- Battery voltage: below 8V -
5
Over Speed
- above 2070 min
-1
Engine Stop
6
Boost
Intake Temperat re 85℃ (185 °F) -

15
6-2 Generator
Stator
Rotor
Rotor
Exciter field
Main bearing
Exciter armature
Main stator
Fan cover
Armature
T
hermo label
R
ear bracket
Bolt
Exciter stator
T
hermo label

16
(1) Exciting Amperage
Amperage fluctuates based upon the winding temperature. Following is for reference only.
Frequency/Rated Output Load Exciting Amperage (Measured)
3-Phase 60Hz: 11kVA No load 0.38A
Full load( power factor=1.0) 0.63A
(2) Resistance Value
Nominal resistance of the winding is tolerated within ± 10% at 32 °F( 220℃) of the ambient
temperature.The resistance must be measured by low resistance tester. It can not be measured
by multi-purpose tester cause of index error.
Main Stator Exciter Stator Rotor
1 2 3 4 5
Armature
Exciter Winding J－K Exciter Field Armature
U-W
A – B
B – C
C – A
- -
0.25 Ω 0.97 Ω 23.2 Ω 11.0 Ω 2.7 Ω
[Color Code]
(B) (W) (R) (G) (Y) (Br) (L) (Or) (Gr)
(Vi)
Black
White
Red Green
Yellow
Brown
Blue
Orange
Gray
Vioret
(3) Armature (Main Stator)
Low resistance tester
Measu e the esistance among the U~W by the low ohm teste . Each shall be 0.25Ω.
U W

17
(4) Excitation Winding (Main Stator)
Remove the wire harness from the AVR and measure;
the esistance among A~B, B~C and C~A by the low ohm teste . Each shall be 0.97Ω.
C (Or) B (Y) A (Br)
AVR