Shindaiwa DGK150D/EPA3 User manual

SERVICE MANUAL
/EPA3
File№ DGO-292_DGK150D/EPA3

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.
This service manual is edited for authorized person to perform repair, maintenance, and
trouble-shooting to Shindaiwa Diesel Engine Generator, Model DGK 50D/EPA3.
It is inevitably necessary to maintain and adjust Shindaiwa products periodically in order to
use fully and safely for long time. Therefore, understand this service manual fully enough
before use and proper maintenance.
The information contained in this service manual describes equipment available at the time
of publication. While every attempt has been made to give you the very latest information
about your product, there may be some differences between your 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 equipment previously
manufactured.
For servicing the engine, refer to the Workshop Manual provided by the engine
manufacturer described below.
The ISUZU engine “6HK ” is electronically controlled. Read and familiarize the instruction
manual and service manual for the engine before servicing.
MANUFACTURER MODEL
ISUZU 6HK1

Table of Contents
1. Attention Statements ··············································································· 1
2. General Safety Instructions ···································································· 2
3. Specifications ····························································································· 4
4. General ········································································································ 5
4. Appearance ················································································5
4.2 Dimension ··················································································5
5. General Parts Description ······························································ 7
5. Equipment ··················································································7
5.2 Main Parts and Feature ·································································· 0
5.3 Main Component ·········································································· 0
5.4 Component Layout ········································································ 5
5.5 Drain Plug and External Fuel ports ···················································22
6. Ser vice Data ······························································································· 24
6. Service Data ···············································································24
6.2 Generator ···················································································25
7. rouble Shooting procedure ···································································· 29
7. Engine and generator ··································································29
7.2 AVR Test Procedure ······································································3
7.3 Checking Output voltage 480/277V ···················································34
7.4 Checking Output voltage 240/ 39V ···················································35
7.5 Checking Output voltage 240/ 20V ···················································36
7.6 Testing Main Circuit Breaker ···························································37
7.7 Checking Generator or Winding ·······················································38
7.8 Checking the Exciter Stator ····························································39
7.9 Checking the Adjusting Voltage Regulator ··········································40
7. 0 Checking the Voltmeter ································································4
7. Checking the Voltmeter Selector Dial ···············································42
7. 2 Checking the Current Transformer ··················································43
7. 3 Checking the Ammeter ·································································44
7. 4 Resetting the Thermal Relay ·························································45
7. 5 Testing the Thermal Relay ·························································46
7. 6 Testing Voltage Selector Switch ·····················································47
7. 7 Abnormal Frequency or Voltage Drop ···············································48
7. 8 Engine Won’t Start ······································································50
7. 9 Engine Stops Suddenly ································································52
7.20 Monitor Lamp Blinking ·································································53
8. Maintenance ··················································································· 56
8. Layout of the Unit ·········································································57
8.2 Oil change ··················································································58
8.3 Oil Filter Replacement ···································································59
8.4 Cleaning/Replacing the Air Filter Element ········································60
8.5 Replacing Electric Fuel Pump Filter ··················································6
8.6 Draining Water from the Internal Fuel Tank ·········································6
8.7 Replacing LLC Antifreeze ·······························································62
8.8 Cleaning/Replacing the Fuel Filter ····················································63
8.9 Fuel system Air Bleeding ································································65

9. ightening orque ······················································································ 66
9. Specific Tightening Torque ······························································66
9.2 General Tightening Torque ······························································67
10. Wiring Diagram ············································································· 68

1
1. Attention Statements
・Technicians only who own enough knowledge and experience should work for
maintenance and operational check after maintenance.
・Before maintenance, always read this service manual as well as owner’s manual and
familiarize contents thoroughly before starting the service and maintenance of the
equipment for understanding of the equipment, safety instructions and cautions.
・ Throughout this manual are special attention statements.
A statement preceded by the triangular attention symbol and the word “WARNING”
contains information that should be acted upon to prevent serious bodily injury.
A statement preceded by the triangular attention symbol 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 you 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 any other indoor, the equipment for
ventilation must be used to prevent serious
accident caused by suffocation.
NEVER direct the exhaust fume to
houses nearby while considering the wind
flow direction.
Exhaust gas contains many harmful
elements that would cause affect to human.
Be free from suffocation when the
equipment is used in poorly 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 bodily injury by entangled
accident under moving component.
Electric shock/Injuries/Burns
Never inspect equipment during
use .
Never serve and inspect when equipment is
being operated.
It may cause electric shock, injuries or
burns.
WARNING-Use good judgment
① NEVER run the engine when
transporting the equipment.
② ALWAYS stop the equipment
immediately if it suddenly begins to
violate or abnormal noise. Inspect for
broken, missing or improperly installed
parts.
③ ALWAYS keep the equipment as clean
as practical. Keep it free of loose
vegetation, mud, etc.
DO NOT makes unauthorized
modifications or alterations to this equipment
of any of its components. YAMABIKO must
authorize alterations and modifications in
writing. Unauthorized modifications or
alterations may alter the equipment
operation and could jeopardize personal
safety during operation.
WARNING

3
Work Safely
Generators and welders operate at very high
speeds and can do serious damage or
injury if they 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. Always
keep the labels clean or replace them when
worn or damaged
・Clean the labels by cloth, water or
detergent and never use organic solvent or
gasoline which may 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 immediate y when
abnorma circumstances are noticed!
STSTOP the equipment immediately whenever
abnormal circumstances are noticed such
as unusual noise, smell vibration and etc.
It may lead serious accident or fatal damage
of the equipment or properties.
Inflammables！
Keep the equipment far away from fire such
as cigarettes when refueling fuel, oil or
battery fluid.
NEVER operate or service the equipment
nearby fire as the equipment may catch
fire.
No Modification！
NEVER modify the equipment without
manufacturer’s advanced approval. .
It may lead serious safety 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 safety
and longer life of the equipment.
CAUTION

4
3. Specifications
Model Unit DGK150D/EPA3
Alternator
Generating Type - otating Filed, Brushless 3-Phase
Synchronous Alternator
ated 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)
ated 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 Pole - 4
Engine
Type - Vertical Water-Cooled 4-cycle Diesel Engine
Model (Manufacturer) - 6HK1 (ISUZU)
No. of Cylinder (Bore x Stroke) (in. /mm) 6 (4.53x4.92/115x125)
ated Output (Continuous) kW 142
HP 190
ated Speed rpm 1800
Displacement cu.in. /liter 475.4/7.790
Combustion System - Direct Fuel Injection with Turbo Charger
Cooling - adiator
Lubricating - Forced Lubrication
Starting - Electric Start
Fuel - Diesel
Lubricant Oil - CD Class
Fuel Tank Capacity gal. /liter 74/280
Lubricant Capacity gal. /liter
10/38
Cooling Water Capacity gal. /liter
6.3/23.8
Starting Motor Capacity V-kW 24-5.0
Charging Dynamo Capacity V-A 24-50
Battery - 105E41 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 l s. /kg 6504/2950
Installed Weight l s. /kg 7187/3260
*Specifications subject to change without notice.

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

6

7
5. General Parts Description
5.1 Equipment

8

9

10
5.2 Main Parts and Feature
(1) Unit Serial Number
(2) Engine Serial Number
5. 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.
Water Temp. Meter
Feature: Display water
temp. in the radiator.
Fuel Meter
Feature: Display volume of
the fuel left in the fuel tank.
Oil Pressure Meter
Feature: Display oil pressure.
Emergency Stop Button
Feature: ngine stops when emergency by
pressing it. Turn it to clockwise to release
the button.
mpere Meter Selector Dial
Feature: Dial to select the
output current.
Voltage djusting Dial
Feature: A dial to adjust a
voltage.

11
Control Panel (Internal View)

12
Engine Operation Switch Tab e (refer to No. 3 on page 11)
Nomenclature
Function
Remarks
LOAD ADVANC This function is not available in this
equipment.
R GULATION
MOD
Decrease rpm in accordance with
the load to be put when the
switch turns to ON.
THROTTL Change idle mode. Start: low idle mode
Run: high idle mode
SP D Change engine rpm. to 1500 or
1800 min
-1
.
SP D INC. Increase rpm. per 10 sec/Hz. Increase up to 110% of rated rpm.
Speed Manual switch ON.
SP D D C. Decrease rpm. per 10 sec/Hz. Decrease down to 1000rpm.
Speed Manual switch ON.
SP D MANUAL A switch for Speed Inc. and
Speed Dec.
Always Speed Manual switch ON to
operate Speed Increase/decrease
switch.
M MORY CL AR Clear record of the engine fault.
1. Starter Switch ON.
2. Push Memory Clear switch for
3 sec.
3. Memory Clear switch ON.
4. Turn Starter Switch “STOP” and,
after10 sec., turn the switch
“RUN”.
Refer to “How to clear Trouble Code” in
“Engine Troubleshooting Manual”
prepared by Isuzu for details.

13
Right Side Door
Left Side Door
Terminal Rest
Feature: Relay terminal block of
the power output from the
alternator.
External Fuel Inlet
Feature: Inlet to refuel from the
external tank.
External Fuel Return
Feature: Outlet to return fuel
from external tank.
Fuel Drain Plug
Feature: Drain the old fuel from the
fuel tank.
Oil Drain Plug
Feature: Drain the old oil from the oil
tank.

14
3
-
Way Valve
Position A (to use a built-in fuel tank)
Position the 3-way valve lever to UPWARD to use
fuel from the external fuel tank.
Position B (to use an external fuel tank)
Position the 3-way valve lever to DOWNWARD to
use fuel from a built-in fuel tank.
Note: The 3-way valve lever is set at position A at
delivery from a factory.
Note:
Do not remove the plugs when
fuel is supplied from a built-in tank.
(when the 3-way valve positions at
position A.)
3
-
Way Valve
Feature: Valve to change fuel supply
from a built-in or external tank.
Position A
Position B
3-Way Valve
Lever

15
5.4 Co ponent Layout

16