Shindaiwa DGK150DU User manual

OWNER’S AND OPERATOR’S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
DGK150DU/01
X750-022 32 5
X750801-400 5
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 forpurchasing thisShindaiwa soundproof diesel engine generator.
This manual has been created to ensure safe usage ofthis generator.Be sure to read this
manual before operation.Improperoperation/handlingof thisgeneratorwillresultinanaccident
or malfunction.
Handling/Operation of this generatorcanonlybe performed bypersonswho understandthe
contents ofthismanual and canhandle/operate thegeneratorin a safemanner.Persons who
sufferfrom an illness, are taking medicine or not feeling waysuchthat safe operation would be
negativelyaffectedmustnotoperate this generator.
Workperformedusingthisgeneratorandhandling/operationofthisgeneratormustbe in
accordance with corresponding laws and regulationsbased on such laws.Consult with the
authorized distributor where this generatorwas purchased if you have any inquiriesregarding the
correspondinglaws.
Always be sure to include this manual when loaning out this generator and instruct operating
personnel to read thismanualbeforeoperation.
Store this manual in a specified location where itwill be secure andavailablefor consulting at any
time.Order anothercopyfromtheauthorizeddistributorwhere thisgeneratorwaspurchasedif
thismanualbecomes dusty, grimyor torn.
Consult with the authorized distributor where this generator was purchased if you have any
inquiries regarding any points relatedtothis generator and manual.
When inquiringaboutthis generator,besure to providethemodel nameandserial number.
If disposing of this generator, do so in a manner that is in compliance with laws related to
industrialwaste. Contactthe authorized distributor where the generator was purchased if you
have any inquiries regardingproperdisposal.
Caution notice ranks in this manual are classified 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,
can resultinminor or moderate injuryandpropertydamage.
< NOTE > : Other types ofcautions and indications.
Note that CAUTION itemscanalsoleadtomajoraccidents undersomecircumstancesif
notcorrectlyfollowed.
All cautionnotices areimportant.Besuretofollow all ofthem.

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 notoperate the generator in poorly ventilated areas such as indoors or tunnels,asthe exhaust
gas ofthe engine contains substances that are harmful to humanhealth.
Do notdirect exhaust fumes at pedestrians or buildings.
WARNING : ELECTRIC SHOCK
Beforeconnectingordisconnecting theloadcables to/fromtheoutputterminal,always turnthe
output circuitbreakers to the OFF position,stop the engine, and remove the engine key.
Closetheoutputterminalcoverbefore operating.
Do notinsert a pin,wire or other metal object into the electrical outlet.
Do nottouch thegeneratoriftheAlternator or casing becomes wet during operation.
Do nottouch output terminalsor internal electric parts whilethe generator is operating.
Ifeven one of all is unconnected by mistake or accident, it will be muchmore dangerous for
human body than the NO-RELAY case, because leaking current inevitably goes through the
body.
Even though all theearth terminals of the loads have been grounded to the earth, thebonnet
grounding terminal should be grounded tothe earth.
Thereis always a danger of being electrocuted by short-circuit. Be sure totest generator’s
insulationresistanceperiodically.
Groundingshould be madeaftertheengine is stopped.
WARNING : INJURY
Closeall doors and lock them during operation.
Closealldoorsand placelocksduringoperating thisequipment,toavoidinjuriesby
unintentionally touchingcooling fan and fanbelt.
Before performinganyequipmentcheckormaintenance,stopthe engine, andremove the
engine key.Aperson performingthe maintenanceshould always keep the key.
Always be sure to use lifting hooks when lifting up the generator. The other thing could result in
the generator falling.
This lifting hook is designed to lift only the generator. Do notlift any additional added weightsuch
as fuel tanks and/or trailers with this lifting hook.
No persons should be under a lifted generator.
Before turning the circuit breakertoON position, ensure that the breaker or theswitch of loads
are positioned to OFF.
Operatethecircuit breaker,well-communicatingwiththeelectricianbytheloadside.

3
CAUTION : EYE/SKIN INJURY
Wear rubber gloves andother protective wear to protecteyes, skin and clothing from thebattery
fluidwhich containsdiluted sulfuricacid. If the battery fluidcontacts eyes or skin, wash out
immediatelywith asufficient amountofclean water. Besure to receive medicaltreatment,
especially if the fluid contacts the eyes.
CAUTION : EXPLOSION
Neveruse or recharge thebattery if the fluid level is below the minimumlevel.
Donotcreatesparksorbringflamenear thebattery asitgenerates flammablegas.
CAUTION : FIRE
Do notbring flammable items (such as fuel,gas and paint)oritems that are highly combustible
near the generator as the muffler, exhaust gas and other parts become extremely hot.
Keep this generator 3ft.(1m) or more from walls or other hindrances,and on a level surface.
Donotconnectthegeneratoroutput toindoor wiring.
This generatoruses dieselfuel.Always be sure to stop the engine and not bring flames close
when inspecting fuel orrefueling. Wait until the enginehas cooled before performing such
procedures.
Do notuse this equipment when leak is found, and repair the leaking location before operating.
Alwaysbe suretowipe up anyspilled fuelor oil.
Allow the generator to cool before covering with theprotective cover.
Neverallow flame to come close to the generator.
Alwayskeepenvironmentalcontaminantssuchasdustandmoisture frombuildinguponthe
terminal block and generatorcontrol box or arcing from the terminals to the generator control box
or terminal block mounting screws may result.
CAUTION : BURNS
Do nottouch theengine andsurrounding components immediately after stopping the equipment,
whiletemperaturecanreach extremely high.
Do notopen the radiator capimmediately after stopping theengine, to avoid sustaining burns
fromhotvapor.
Hot steam gushes outfrom thecoolant sub-tank if thegeneratoroverheats.Do not touch the
coolantsub-tank.
Alwaysbe sure to stop the engine andallow the engine to cool when performing inspection or
maintenance of engine oil. Opening the oil level indicator or oil fillercap during operation will result
inhotoilcausepersonalinjury.
CAUTION : INJURY
Alwaysbe sure to use lifting hooks when moving the generator, and lift it slowly at a completely
verticalangle.
Personnel performing liftingwork mustwear protective gear such as helmets, safety shoes and
gloves.
Remove the wood ties ifusing anchors to secure the generator.
Position thegenerator on a level stable surface so that it cannotslide or movein any manner.

4
Before starting operation,always be sure to turn off all switches of equipment using the
generatorandall breakerstoOFF.
Do notmove the generator during operation.
Donotoperate thegeneratorifithasbeenmodifiedoranyparts have beenremoved.
CAUTION : PROPERTY DAMAGE
If using this generator for medical equipment, check before use with the medical equipment
manufacturer, doctor, hospitalor similar entity.
Check that thegeneratoroutput setting, outputterminal connection and load power source
are consistent.
Cable burnout canoccur due to generated heat if the load current exceeds the allowable
currentofthecable.
Thevoltage dropbetween cables islargeifthe cableisexcessivelylongor thin, resultingin
decreased inputvoltage to equipment using thegenerator, therebycausing decreased
performance, faulty operation and malfunction.
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 DGK150DU/01
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
External Tank Fuel Inlet
External Tank Fuel Return
Accessories
Owners
Manual
Engine Key (2 pieces)
Coolant Drain
Battery
Alternator Check Door Engine Check Door
Radiator
3Way Fuel Valve
EGR Cooler
Terminal block
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
A
View
“A”

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 GFCIprotectedandare rated at 20amps.
All twist loc receptacles are rated at 30 amps.
Main Terminals
Plexiglass Cover

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 >
Thecoolanttemperaturecannotbedetectedifthecoolantlevelis excessivelylow.Always
be sure to check thecoolant level in the radiator coolant sub-tank before starting work.
(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 warningindicatorcannotdetect oildeterioration.Changetheengineoil
periodically.(Refertosection“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 batterychargingwarningindicatorcannot detectbatterydeteriorationorinsufficient
batteryfluid. (Refertosection“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 batterychargingwarningindicatorcannot detectbatterydeteriorationorinsufficient
batteryfluid. (Refertosection“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 inlet temperature to the inlet 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 needleofthe watertemperature meterexceeds the standard value, immediately stop
the equipment being used,allow the generator tocool by idling the engine, and wait until the
water temperature 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
①
①①
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.
②
②②
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.
③
③③
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 >
Donotchange thepresetvalueofthe thermal relay.
Reset Button

17
(5) Voltmeter Selector Switch
The voltmeter selector switch is a 5 position switch located on the
controlpanel to theleft of thevoltmeter.
The voltmeter selector switch selects which phase voltage is displayed
on thevoltmeter.
Positions:
Off:
Thereare two off positions on the voltmeter selector switch. One at the full clockwise
positionand oneatthefullcounter-clockwiseposition of theswitch.
In either off position the voltmeter will notdisplay any voltage.
L1-L2:
In the L1-L2 positionthe voltmeter will displaythe phasevoltage between L1 and L2.
L2-L3:
In the L2-L3 positionthe voltmeter will displaythe phasevoltage between L2 and L3.
L3-L1:
In the L3-L1 positionthe voltmeter will displaythe phasevoltage between L3 and L1.
(6) Ammeter Selector Switch
The ammeter selector switch is a 5 position switch located on the
controlpanel to theleft of theammeter.
The ammeter selector switch selects which phase current is displayed
on theammeter.
Positions:
Off:
Thereare two offpositions on the ammeter selector switch. One at the full clockwise
positionand oneatthefullcounter-clockwiseposition oftheswitch. In either offposition
the ammeterwill notdisplayanyamps.
This switch must be in the L1 or L3 position toread single phase current.
L1:
In theL1position the ammeter indicatesthe 3-Phase amps for L1 andsingle-Phase amps
for L1.
L2:
In the L2 position the ammeter indicated the3-Phase amps forL2.
L3:
In theL3position the ammeter indicatesthe 3-Phase amps for L3 andsingle-Phase amps
for L3.