Shindaiwa DGK150D User manual

OWNER’S AND OPERATOR’S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
DGK150D/EPA3
X750-02553 0
X750801-560 0
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.

Introduction
Thank you for purchasing this Shindaiwa soundproof diesel engine generator.
Thismanualhas beencreatedto ensuresafeusageof thisgenerator. Besure toreadthis
manualbeforeoperation. Improperoperation/handlingof thisgeneratorwillresultin anaccident
or malfunction.
Handling/Operationof thisgenerator canonlybeperformedbypersonswhounderstand the
contentsof thismanualandcanhandle/operatethegeneratorinasafemanner. Personswho
suffer from an illness, are taking medicine or not feeling way such that safe operation would be
negativelyaffectedmustnotoperate thisgenerator.
Workperformed using this generator and handling/operation of thisgeneratormust bein
accordance with corresponding laws and regulations based on such laws. Consultwiththe
authorizeddistributor where this generator was purchased if you have any inquiriesregarding the
corresponding laws.
Always be sure to include this manual when loaning outthis generator and instruct operating
personnelto readthis manualbeforeoperation.
Store this manual in a specified location where it will be secure and availablefor consulting at any
time. Order another copyfrom theauthorizeddistributorwhere this generatorwaspurchased if
this manual becomesdusty,grimy ortorn.
Consult withtheauthorizeddistributor wherethis generator was purchased if you haveany
inquiries regarding any points relatedtothisgenerator andmanual.
Wheninquiring aboutthisgenerator, besureto provide themodel name and serialnumber.
If disposing of thisgenerator, do so in amanner that is in compliance with laws related to
industrial waste. Contact the authorized distributor where the generatorwaspurchasedif you
haveanyinquiriesregarding proper disposal.
Cautionnotice ranksinthismanualareclassified as follows.
WARNING : Indicates a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided,
canresult inminorormoderateinjury andpropertydamage.
< NOTE > : Othertypes of cautions and indications.
Notethat CAUTION items can also lead to major accidents under somecircumstances if
notcorrectly followed.
All caution notices are important. Besuretofollowallof them.

1
Table of Contents
1. Safety Instructions ..........................................................................2
2. Specifications...................................................................................5
2-1. Specifications............................................................................5
2-2. Ambient Conditions...................................................................6
3. Applications..................................................................................... 6
4. Part Names.......................................................................................6
4-1. External View/Part Names ........................................................6
4-2. Operation Panel Part Names ....................................................8
4-3. Main Terminal Board .................................................................9
4-4. Receptacle Panel......................................................................9
5. Equipment...................................................................................... 10
5-1. Warning Indicators ..................................................................10
5-2. Meters and Gauges.................................................................13
5-3. Voltage Selector Switch........................................................... 19
5-4. Fuel Piping Switch (3Way Fuel Valve).....................................20
6. Transporting/Installing.................................................................. 21
6-1. Transport Procedures.............................................................. 21
6-2. Installation Procedures............................................................ 22
7. Load Connections ......................................................................... 23
7-1. Load Cable Selection.............................................................. 23
7-2. Connecting Load Cables.........................................................24
8. Pre-Operation Inspection.............................................................. 26
8-1. Checking Engine Oil................................................................ 26
8-2. Checking Coolant....................................................................27
8-3. Checking the Fan Belt............................................................. 28
8-4. Checking the Fuel ................................................................... 29
8-5. Checking for Fuel, Oil and Coolant Leaks...............................30
8-6. Checking the Battery...............................................................30
9. Operating Procedures................................................................... 32
9-1. Initial Startup/Pre-Check.......................................................... 32
9-2. Voltage Switching Function .....................................................34
9-3. Procedures during Operation .................................................. 35
9-4. Stopping Operation ................................................................. 35
9-5. Protective Functions................................................................36
9-6. Connecting with External Fuel Tank........................................37
10. Inspection/Maintenance................................................................ 38
11. Long-Term Storage........................................................................ 48
12. Troubleshooting............................................................................. 49
13.Generator Circuit Diagram............................................................ 52
14. Engine Electrical Circuit Diagram................................................ 53

2
1. Safety Instructions
WARNING : SUFFOCATION FROM EXHAUST FUME
Do notoperatethegeneratorinpoorlyventilatedareassuchas indoorsortunnels,astheexhaust
gasof the enginecontainssubstancesthat areharmfultohumanhealth.
Do not directexhaustfumesat pedestrians orbuildings.
WARNING : ELECTRIC SHOCK
Before connecting or disconnecting the loadcables to/from theoutput terminal, always turn the
outputcircuitbreakerstothe OFF position, stoptheengine,andremovetheenginekey.
Closethe outputterminalcover beforeoperating.
Do not insert a pin, wireor other metalobject intothe electrical outlet.
Do nottouchthe generatorif theAlternatoror casingbecomeswetduring operation.
Do nottouch outputterminalsor internal electricpartswhilethegenerator isoperating.
If even one of all is unconnected by mistake or accident, it will be muchmore dangerousfor
humanbodythan the NO-RELAY case, because leaking current inevitablygoesthroughthe
body.
Eventhoughalltheearthterminalsof theloadshave beengrounded totheearth,thebonnet
groundingterminal shouldbe groundedtotheearth.
There is always adanger of being electrocuted by short-circuit. Besuretotest generator’s
insulationresistance periodically.
Grounding should bemade after the engine is stopped.
WARNING : INJURY
Closeall doors andlockthemduringoperation.
Closeall doors and place locks during operating thisequipment,to avoid injuriesby
unintentionally touching cooling fanandfan belt.
Before performing anyequipment check or maintenance, stop the engine, andremove the
enginekey.Apersonperforming themaintenanceshouldalwayskeep thekey.
Always be sure to use lifting hooks when lifting up the generator. The other thing could result in
the generator falling.
Thislifting hookis designedtoliftonlythe generator.Do not liftanyadditionaladdedweight such
as fueltanks and/or trailers withthis lifting hook.
No persons shouldbeunder a lifted generator.
Before turningthecircuitbreakertoON position, ensurethat the breaker ortheswitchof loads
arepositionedto OFF.
Operate the circuitbreaker, well-communicating withthe electrician by the load side.

3
CAUTION : EYE/SKIN INJURY
Wear rubbergloves and other protective wear to protecteyes, skin and clothing from the battery
fluid which containsdilutedsulfuricacid. If the batteryfluidcontactseyes or skin, washout
immediately witha sufficient amountof cleanwater. Besuretoreceive medicaltreatment,
especiallyif thefluidcontactstheeyes.
CAUTION : EXPLOSION
Never use or recharge thebattery if the fluid level is belowthe minimum level.
Do not createsparks or bring flamenearthe battery as it generates flammable gas.
CAUTION : FIRE
Do not bring flammable items (suchasfuel,gas and paint) or items that are highlycombustible
nearthegeneratoras themuffler, exhaustgasand otherparts become extremelyhot.
Keepthisgenerator3ft.(1m) or morefrom walls or other hindrances, and on a level surface.
Do not connect thegeneratoroutputto indoorwiring.
Thisgenerator usesdiesel fuel. Alwaysbesureto stoptheengineandnotbring flamesclose
when inspecting fuelor refueling. Waituntiltheengine hascooledbeforeperforming such
procedures.
Do not use this equipment when leak is found, and repair the leaking location before operating.
Always be sure to wipe up any spilled fuelor oil.
Allowthe generator to coolbefore covering withthe protective cover.
Neverallowflameto comeclosetothegenerator.
Always keep environmental contaminants such as dust and moisture from building up on the
terminal block andgenerator control box or arcing from the terminals to the generator control box
or terminalblock mountingscrewsmayresult.
CAUTION : BURNS
Do nottouchthe engineandsurroundingcomponentsimmediatelyafter stoppingthe equipment,
whiletemperature canreach extremelyhigh.
Do not openthe radiator cap immediately after stopping the engine, to avoid sustaining burns
from hot vapor.
Hotsteam gushes out from the coolant sub-tank if the generator overheats. Donottouchthe
coolant sub-tank.
Always be sure to stopthe engine and allowthe engine tocool when performing inspection or
maintenance of engineoil. Opening the oil level indicator or oil filler cap during operation will result
in hot oilcause personalinjury.
CAUTION : INJURY
Always be sure to use lifting hooks whenmoving thegenerator, and lift it slowlyata completely
verticalangle.
Personnel performing lifting workmust wear protective gear suchas helmets, safety shoes and
gloves.
Remove thewoodties if using anchorsto secure thegenerator.
Position thegenerator on alevel stable surface so that it cannot slideor move in any manner.

4
Before starting operation, always be sureto turnoff allswitches of equipment using the
generatorand all breakerstoOFF.
Do not move the generator during operation.
Do not operatethe generatorif it has beenmodified oranypartshavebeenremoved.
CAUTION : PROPERTY DAMAGE
If using this generator for medical equipment,check before use withthemedicalequipment
manufacturer,doctor, hospitalorsimilar entity.
Check that the generator output setting, output terminal connection and load powersource
areconsistent.
Cable burnout can occur due to generated heat if the loadcurrent exceeds the allowable
current of the cable.
Thevoltage drop between cables is large if thecable is excessivelylong or thin, resulting in
decreased input voltage to equipment using the generator,thereby causing decreased
performance, faultyoperationandmalfunction.
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
Warning：Injury
（Part no.：X505-007550）
②
Warning：Electric Shock
（Part no.：X505-007560）
③
Caution：GM Spec LLC
（Part no.：X505-004650）
④
Warning／Caution
（Part no.：X505-007571）
⑤
Warning：Keep Terminal
（Part no.：X505-007580）
⑥
Caution：Neutral bonded to frame
（Part no.：X505-004750）
⑦
Caution：Do not change
（Part no.：X505-004620）

5
2. Specifications
2-1. Specifications
Model
Unit
DGK150D/EPA3
Alternator
Generating Type
-
Rotating Filed, Brushless 3-Phase
Synchronous Alternator
Rated Output
kVA
150
kW
120
Voltage –Three phase
V
208 / 480
Voltage –Single phase
V
120 / 240 / 277
Amps
Three phase –480V
A
180
Three phase –208V
A
416
Single phase –240V
A
361 (zigzag)
Single phase –120V
A
361 x 2 (zigzag)
Rated Frequency
Hz
60
Winding
-
3-phase, 4-wire
Star with neutral / Zig-zag
Power factor
%
80
Insulation class
-
F
Excitation
-
Self-Excitation(Brushless)
No. of poles
-
4
Engine
Types
-
Vertical Water-cooled 4-cycle Diesel Engine
Model (Manufacturer)
-
6HK1 (ISUZU)
No. of Cylinders (bore x stroke)
(in. / mm)
6 ( 4.53x4.92 / 115x125 )
Continuous rated output
kW
142
HP
190
Rated speed
rpm
1800
Displacement
cu.in. / liters
475.4 / 7.790
Combustion system
-
Direct Fuel Injection with Turbo Charger
Cooling method
-
Radiator
Lubricating method
-
Forced lubrication
Starting method
-
Electric start
Fuel
-
Diesel
Lubricant oil
-
CD class
Fuel tank capacity
gal. / liters
74 / 280
Lubricant volume (Full)
gal. / liters
10 / 38
Cooling water volume
gal. / liters
6.3 / 23.8
Starting motor capacity
V-kW
24 –5.0
Charging dynamo capacity
V-A
24 - 50
Battery
-
105E41R x 2
Battery capacity
V-AH
12(V) –100AH
Unit
Length
in. / mm
135.8 / 3450
Width
in. / mm
48.8 / 1240
Height
in. / mm
72.8 / 1850
Dry Weight
lbs. / kg
6504 / 2950
Installed Weight
lbs. / kg
7187 / 3260

6
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 )
■Relative humidity: 85% or less
■Elevation: 3280 ft ( 1000 m ) or less
3. Applications
Power source for submerged pumps and similar civil engineering equipment.
Power source for lighting and similar equipment.
Power source for electrical tools and household appliances.
4. Part Names
4-1. External View/Part Names
CAUTION : PROPERTY/SECONDARY DAMAGE
Do not use for any application other than those listed above.
If using this generator for medical equipment, check before use with the
medical equipment manufacturer, doctor, hospital or similar entity.
Lifting Hook
Operation Panel Door

7
Coolant Drain
Battery
Alternator Check Door
Engine Check Door
Radiator
3Way Fuel Valve
EGR Cooler
Terminal block
External Tank Fuel Inlet
External Tank Fuel Return
LEFT SIDE
RIGHT SIDE
Fuel Inlet
Fuel Tank
Coolant Sub-Tank
Engine Check Door
Alternator Check Door
Oil Filler Cap & Oil Level Indicator
Oil Drain
Fuel Drain
Water Sedimenter
Fuel Filter
Oil Filter
Air Cleaner
Receptacle Panel Cover
Terminal Cover
Electromagnetic Pump
PCV Filter
Receptacle Panel
Voltage Selector Switch
Accessories
Owners
Manual
Engine Key (2 pieces)
Engine
Warranty

8
4-2. Operation Panel Part Names
1
Circuit Breaker
12
Voltage Adjust Regulator
2
Pilot Lamp
13
Monitor Lights
3
Panel Light
14
Hour Meter
4
Voltmeter
15
Water Temperature Gauge
5
Ammeter
16
Oil Pressure Gauge
6
Frequency Meter
17
Fuel Gauge
7
Auto start Panel (Optional)
18
Glow Lamp
8
Auto start Switch (Optional)
19
Emergency Stop Button
9
Panel Light Switch
20
Starter Switch
10
Voltmeter Selector Switch
21
Throttle Switch
11
Ammeter Selector Switch

9
4-3. Main Terminal Board
4-4. Receptacle Panel
< NOTE >
All duplexreceptacles are GFCI protectedandarerated at 20 amps.
All twist loc receptacles are rated at 50 amps.
Plexiglass Cover
Main Terminals

10
5. Equipment
5-1. Warning Indicators
This generator is equipped with the following warning indicators "DIAG" (diagnostic),
"BOOST" (boost temperature),"CHARGE" (battery charging), "OIL PRESS" (oil
pressure), "OVER HEAT" (water temperature), and "OVER SPEED" (engine
overspeed).
Warning indicators light up if some fault occurs during operation and the engine might
be automatically stopped depending on the type of fault.
Under normal operating conditions these monitoring lamps will come on momentarily
when the engine is first started but will go off very shortly thereafter.
WARNING : INJURY
Close all doors and place locks during operation, to avoid injuries by
unintentionally contact with moving parts such as the cooling fan and fan belt.
Before performing any equipment check or maintenance, stop the engine, and
remove the engine key. A person performing the maintenance should always
keep the key.
CAUTION : BURNS
Do not touch the engine and surrounding components immediately after
stopping the equipment, while temperature can reach extremely high.

11
(1)WATER TEMP (Coolant Temperature) Warning Indicator (High Water
Temp)
CAUTION: BURNS
Do not open the radiator cap immediately after stopping the engine, to avoid
sustaining burns from hot vapor.
Hot steam gushes out from the coolant sub-tank if the generator overheats.
Do not touch the coolant sub-tank.
When the water temperature reaches 221 ° F (105 ° C), the coolant/water temperature
monitor lamp will flash, and the automatic shutoff will be engaged.
When this occurs, check the coolant/water reservoir tank, and replenish if needed.
(Refer to “8-2. Checking Coolant”)
If the water level is normal, there may be a possibility of loose fan belt or water leakage
in coolant lines. Check it after the engine cools down.
< NOTE >
Thecoolant temperature cannot bedetected if thecoolant level isexcessivelylow. Always
be sure tocheckthecoolantlevel intheradiator coolantsub-tankbeforestartingwork.
(2) OIL PRESS (engine oil pressure) Warning Indicator (Low Oil Press)
CAUTION: BURNS
Always be sure to stop the engine and allow the engine to cool when
performing inspection or maintenance of engine oil. Opening the oil gauge or
oil filler cap during operation will result in hot oil cause personal injury.
When the engine oil pressure drops below 14.5 psi (100 kPa) during operation, the oil
pressure monitor lamp will flash, and the automatic shutdown will be engaged.
When this occurs, check the engine oil level, and replenish to the maximum level if
needed.
< NOTE >
This oil pressure warning indicator cannot detect oildeterioration. Change the engineoil
periodically. (Refer to section “8-1. Checking Engine Oil”)
(3) BATTERY (Battery Charge) Warning Indicator (Low Battery Voltage)
The BATTERY warning indicator lights up when charging is not possible during
operation.
If this occurs, contact the authorized distributor where the generator was purchased.
< NOTE >
This battery charging warning indicator cannot detect battery deterioration or insufficient
battery fluid. (Refer to section “8-6. Checking the Battery”)

12
(4) Diagnosis Indicator
CAUTION: BURNS
Always be sure to stop the engine and allow the engine to cool when
performing inspection or maintenance of engine oil. Opening the oil gauge or
oil filler cap during operation will result in hot oil cause personal injury.
If the electronic control module detects a fault that could affect engine operation it will
flash the diagnosis lamp to indicate that further diagnosis as to the source of fault is
necessary.
This will not shut the engine down.
If this occurs, contact the authorized distributor where the generator was purchased.
< NOTE >
This battery charging warning indicator cannot detect battery deterioration or insufficient
batteryfluid. (Refer to section “8-6. Checking the Battery”)
(5) Boost Indicator
CAUTION: BURNS
Always be sure to stop the engine and allow the engine to cool when
performing inspection or maintenance of engine oil. Opening the oil gauge or
oil filler cap during operation will result in hot oil cause personal injury.
If the intake temperature to the intake manifold exceeds 185 ° F (85 ° C) the boost
temperature lamp will flash but will not shut the engine down.
If this occurs, contact the authorized distributor where the generator was purchased.
(6) Over Speed Indicator
CAUTION: BURNS
Always be sure to stop the engine and allow the engine to cool when
performing inspection or maintenance of engine oil. Opening the oil gauge or
oil filler cap during operation will result in hot oil cause personal injury.
This generator is equipped with this function that automatically stops the engine if some
fault occurs in the engine causing the engine speed to increase a considerable amount.
If the engine speed increases to 2,070 rpm / 60Hz or more during operation, the
overspeed and engine malfunction indicators light up, and the engine is automatically
stopped.
When this occurs, it is probable that there is some internal malfunction of the engine.
If this occurs, contact the authorized distributor where the generator was purchased.

13
5-2. Meters and Gauges
Engine Meters and Gauges
(1) Hour Meter
Displays the operating time. Use this to schedule periodic
inspection. Be careful as the hour meter operates when the
starter switch is at RUN regardless of whether the engine is
running or stopped.
(2) Water Temperature Gauge
Water Temperature Gauge displays the temperature of engine
coolant. Normal temperature may vary depending on the
environment, but it should be between 167 to 194 ° F ( 75 to 90 ° C ).
< NOTE >
If the needleof the watertemperaturemeter exceedsthestandard value, immediately stop
the equipment being used, allowthe generator to coolby idling theengine, and wait until the
watertemperature decreases.
(3) Oil Pressure Gauge
Oil Pressure Gauge displays the pressure of engine oil. Normal
pressure may vary depending on the environment, but it should
display 43.5 - 87.0 psi (3.0 - 6.0 x 100kPa).
However, under cold weather, the pressure gauge may display
higher reading. Continue idling until the pressure falls to normal
range.
(4) Fuel Gauge
It shows the volume in the fuel tank.
When filled up, it shows 『F』.
When the indicator is approaching to 『E』, the amount of fuel is
close to empty.
Replenish fuel enough promptly.

14
Generator Meters and Gauges
(1) Voltmeter
The volt meter displays the voltage output from the generator.
The voltage will be displayed depend on the position of the voltage
selector switch.
Only L1 or L3 voltage will be displayed for single-phase operation.
(2) Ammeter
The amp meter displays the electrical current output from the
generator.
The amperage will be displayed depend on the Amp meter selector
switch position.
Only L1 or L3 phase amperage will be displayed for single-phase
operation.
(3) Frequency Meter
Frequency meter will display the frequency of the generator.
Please check it showing 60Hz during operation.
Lamps
(1) Glow Lamp
When the start switch is turned to the Run/Preheat position, the Glow
Lamp will light to indicate that the glow plugs are energized and
preheating the engine cylinders.
When the preheating is completed, the lamp will go off, indicating that
the engine is ready to be started.
Preheating time may vary from 1 to 15 seconds, depending on the
coolant temperature.

15
(2) Pilot Lamp
The pilot lamp is located on the generator control panel and indicates
whether or not the engine is running.
When the lamp is lit the engine is running.
When the lamp is not lit the engine is not running.
(3) Panel Light
The panel light is located on the generator control panel and is used to
illuminate the generator and engine control panels.
This light is turned on and off with the panel light toggle switch which is
also located on the generator control panel next to the panel light.
This light can only be energized when the engine is running.
Switches
(1) Starter Switch
①Stop
When the switch is set to this position, all power will be off.
The switch must be set to this position to remove the key.
②Run / Preheat
The switch must be in this position during operation.
This position also is used to begin the engine preheat
cycle and to remove air from the fuel system.
< NOTE >
Do not leave the switch to this position, while the engine is
stopped. Otherwise the battery is discharged.
③Start
This position will allow user to start the engine. When the
key is released,the setting will automatically return to
<RUN> position.
STOP
RUN
PREHEAT
START

16
(2) Emergency Stop Button
This button is used to stop the engine in emergency.
Keep pressing the button until the engine comes to complete
stop.
< NOTE >
Keep pressing the button until the engine stops in several
seconds.
After the engine stops, be sure to return the starter switch
to the ＜STOP＞position.
(3) Circuit Breaker
By turning this circuit breaker on the control panel to ON,
Power will be transferred to the output receptacles and to the
load side.
The breaker trips to OFF, when overload or short-circuit
occur.
(4) Thermal Relay
This relay sends the signal to the circuit breaker to trip-off
when over-current flows in the circuits.
When the breaker trips-off, it is set at the middle in between
ON and OFF position.
Reset the breaker, to the ON position according to the
following procedure;
①Stop the engine.
②Open the control panel and push the reset button of the
thermal relay.
< NOTE >
Do not changethe preset value of the thermalrelay.
Reset Button

17
(5) Voltmeter Selector Switch
The voltmeter selector switch is a 5 position switch located on the
control panelto the leftof thevoltmeter.
The voltmeter selector switch selects which phase voltage is displayed
on the voltmeter.
Positions:
Off:
Thereare twooff positionsonthevoltmeter selector switch.One atthefullclockwise
positionandoneat thefullcounter-clockwisepositionof the switch.
Ineither offpositionthe voltmeter willnot displayanyvoltage.
L1-L2:
In the L1-L2positionthe voltmeter will display the phase voltagebetween L1 and L2.
L2-L3:
In the L2-L3positionthe voltmeter will display the phase voltagebetweenL2 and L3.
L3-L1:
In the L3-L1positionthe voltmeter will display the phase voltagebetween L3 and L1.
(6) Ammeter Selector Switch
The ammeter selector switch is a 5 position switch located on the
control panelto the leftof theammeter.
The ammeter selector switch selects which phase current is displayed
on the ammeter.
Positions:
Off:
Thereare twooff positionsontheammeter selectorswitch. Oneat the full clockwise
positionandoneat thefullcounter-clockwiseposition of theswitch. Ineitheroff position
the ammeter will not display any amps.
Thisswitchmust bein the L1or L3positiontoread singlephasecurrent.
L1:
IntheL1 positiontheammeterindicatesthe3-Phase ampsfor L1 andsingle-Phaseamps
for L1.
L2:
IntheL2 position the ammeter indicatedthe3-Phaseamps forL2.
L3:
IntheL3 positiontheammeterindicatesthe3-Phase ampsfor L3 andsingle-Phaseamps
for L3.