Shindaiwa DGK180FP User manual

OWNER’S AND OPERATOR’S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
DGK180FP
X753-008 22 1
X753801-390 1
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.
California Proposition 65
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
Always start and operate the engine in a well ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not run the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING
Cancer and reproductive Harm-
www.P65Warnings.ca.gov
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and
other chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm. WASH HANDS AFTER HANDLING.

Introduction
Thank you for purchasing this Shindaiwa soundproof diesel engine generator.
This manual has been created to ensure safe usage of this generator. Be sure to read this
manual before operation. Improper operation/handling of this generator will result in an
accident or malfunction.
Handling/Operation of this generator can only be performed by persons who understand the
contents of this manual and can handle/operate the generator in a safe manner. Persons
who suffer from an illness, are taking medicine or not feeling well such that safe operation
would be negatively affected must not operate this generator.
Work performed using this generator and handling/operation of this generator must be in
accordance with corresponding laws and regulations based on such laws. Consult with the
authorized distributor where this generator was purchased if you have any inquiries
regarding the corresponding laws.
Always be sure to include this manual when loaning out this generator and instruct operating
personnel to read this manual before operation.
Store this manual in a specified location where it will be secure and available for consulting
at any time. Order another copy from the authorized distributor where this generator was
purchased if this manual becomes dusty, grimy or torn.
Consult with the authorized distributor where this generator was purchased if you have any
inquiries regarding any points related to this generator and manual.
When inquiring about this generator, be sure to provide the model name and serial number.
If disposing of this generator, do so in a manner that is in compliance with laws related to
industrial waste. Contact the authorized distributor where the generator was purchased if
you have any inquiries regarding proper disposal.
■Caution notice ranks in this manual are classified as follows.
Note that CAUTION items can also lead to major accidents under some circumstances
if not correctly followed.
All caution notices are important. Be sure to follow all of them.
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 result in minor or moderate injury and property damage.
< Note > : Other types of cautions and indications.

1
Table of Contents
1. Safety Instructions ······························································2
2. Specifications ·····································································6
2-1. Specifications··································································6
2-2. Ambient Conditions ··························································7
3. Applications········································································7
4. Part Names ·········································································7
4-1. External View/Part Names ·················································7
4-2. Operation Panel Configuration ········································· 11
4-3. Output Terminal ·····························································12
4-4. Receptacle Panel···························································12
5. Equipment ········································································ 13
5-1. Operation Display ··························································13
5-2. Three-phase and Single-phase simultaneous Output ············20
5-3. Available Output Monitor ·················································20
5-4. Spill Containment···························································21
5-5. Warning Indicators ························································· 22
5-6. SCR (Selective Catalytic Reduction) System and Indicators ···24
5-7. Meters(Gauges) and Switches··········································29
5-8. Fuel Piping Switch (3Way Fuel Valve) ································31
5-9. Load Bank Control Switch ··············································· 31
6. Transport/Installation························································· 32
6-1. Transport Procedures ·····················································32
6-2. Installation Procedures ···················································32
7. Load Connections ····························································· 33
7-1. Load Cable Selection ·····················································33
7-2. Connecting Load Cables ·················································35
8. Pre-Operation Inspection ··················································· 39
8-1. Checking Engine Oil·······················································39
8-2. Checking Coolant ··························································40
8-3. Checking the Fan Belt ····················································41
8-4. Checking the Fuel·························································· 42
8-5. Checking the DEF (Diesel Exhaust Fluid) ···························42
8-6. Checking the Spill Containment ········································ 43
8-7. Checking for Fuel, Oil and Coolant Leak····························· 43
8-8. Checking the Battery ······················································ 43
9. Operating Procedures························································ 45
9-1. Starting/Stopping Operation ·············································45
9-2. 208/240/480V Switching Selection ····································55
9-3. Procedures during Operation ···········································56
9-4. Protective Functions·······················································57
9-5. Connecting with External Fuel Tank···································58
10. Inspection/Maintenance···················································· 59
11. Long-Term Storage ·························································· 72
12. Troubleshooting ······························································ 73
13. Generator Circuit Diagram ················································ 76
14. Engine Electrical Circuit Diagram ······································ 77

2
WARNING : EXHAUST GAS POISONING
Do not operate the generator in poorly ventilated areas such as indoors or tunnels, as the
exhaust gas of the engine contains substances that are harmful to human health.
Do not direct exhaust fumes at bystanders or buildings.
WARNING : ELECTRIC SHOCK
Do not operate the equipment with any doors or covers open.
Always turn all breakers OFF, then press power switch to turn off the main power and stop
the engine before connecting / disconnecting the load cable to the output terminal or
receptacle.
The bus could be energized or hot at all times due to paralleling operation.
Please make sure the bus is not energized and all power switches are in the OFF position
prior to any service work to the output terminals.
Do not change operation selector switch while the generator is running.
Close the output terminal cover before operating.
Do not insert a pin, wire or other metal object into the electrical outlet.
Do not touch the generator if the generator or casing or your body becomes wet during
operation.
Do not touch internal electric parts while the generator is operating.
Always press power switch to turn off the main power and stop the engine, then close and
lock OPERATION PANEL DOOR before checking or maintaining the engine or any
equipment.
WARNING : INJURY
Close all doors and lock them during operation.
Do not open the check door when the power switch is turned and the main power is on. It
will cause injury by rotating parts such as cooling fans and fan belt.
Always press power switch to turn off the main power and stop the engine, then close and lock
OPERATION PANEL DOOR before checking or maintaining the engine or any equipment.
Always be sure to use Lifting Hook when lifting up the generator. Using other parts when
lifting up the generator could cause the result of falling.
Do not attempt to lift the equipment with any additional weight such as optional fuel tanks
or trailers.
No persons should ever be under a lifted generator.
Always be sure to check that the breakers on load side and switches for any equipment
using the generator are at OFF before turning the breaker to ON. Also be sure to advise
personnel on the load side that power will be turned on or off before operating the breaker.
Do not modify the equipment and do not operate with parts removed.
CAUTION : EYE/SKIN INJURY
Wear rubber gloves and other protective wear to protect eyes, skin and clothing from the
battery fluid which contains diluted sulfuric acid. If the battery fluid contacts eyes or skin,
wash out immediately with a sufficient amount of clean water. Be sure to receive medical
treatment, especially if the fluid contacts the eyes.
1. Safety Instructions

3
CAUTION : EXPLOSION
Never use or recharge the battery if the fluid level is below the minimum level.
Do not create sparks or bring flame near the battery as it generates flammable gas.
CAUTION : FIRE
Do not carry flammable items (such as fuel, gas and paint) or items that are highly
combustible near the generator as the muffler, exhaust gas and other parts become
extremely hot.
Position this generator 3 ft. (1 m) or more from walls or other hindrances, and on a level
surface.
Do not connect the generator output to indoor wiring.
This generator uses diesel fuel. Always be sure to stop the engine and not bring flames
close when inspecting fuel or refueling. Wait until the engine has cooled before performing
such procedures.
If fuel spills, always be sure to wipe and drain off spilled fuel.
Do not operate the equipment with liquid accumulated in the spill containment.
If fuel or oil is leaking, repair the leaking location before operating.
Always be sure to wipe up any spilled fuel or oil.
Allow the generator to cool before covering with the protective cover.
Never allow flame to come close to the generator.
Always make sure that the engine is stopped when working on piping.
After working on the piping, check that there is no fuel leakage.
Absolutely never inspect or perform maintenance to the equipment near fire or other open
flame.
Do not put anything other than DEF (gasoline, diesel fuel, etc.) in the DEF tank. Also, do
not put DEF diluted with water or other liquids.
CAUTION : ELECTRIC SHOCK
Do not sprinkle water on equipment or used where exposed to rain.
CAUTION : BURNS
Do not touch the engine and surrounding components immediately after stopping the
engine as they are still extremely hot.
Do not open the radiator cap immediately after stopping the engine. Doing so will result in
hot steam gushing out.
Hot steam gushes out from the coolant sub-tank if the generator overheats. Do not touch
the coolant sub-tank.
Always be sure to stop the engine and allow the engine to cool when performing
inspection or maintenance of engine oil. Opening the oil level gauge or oil filler cap during
operation will result in hot oil gushing out.
While the engine is running, the SCR system is purging, and immediately after operating,
the SCR system and exhaust piping is extremely hot. Be careful not to inadvertently touch
them.
Do not touch the SCR system and surrounding components immediately after stopping the
engine as they are still extremely hot.

4
CAUTION : INJURY
Always be sure to use Lifting Hook when lifting up the generator, and slowly lift it straight
up.
Personnel performing lifting work must wear protective gear such as helmets, safety shoes
and gloves.
Position the generator on a level stable surface so that it cannot slide or move in any
manner.
Check that the surrounding area is safe, before set to auto mode.
Be sure to communicate mutually before attempting to set "AUTO MODE" by multiple
operators to avoid mechanical trouble and incidents.
Before starting operation, always be sure to turn off all switches of equipment using the
generator and all breakers to OFF.
Do not move the generator during operation.
Do not operate the generator if it has been modified or any parts have been removed.
Securely fix the equipment with rope or similar item to avoid any unexpected move when
transporting by truck or other vehicle.
CAUTION : PROPERTY DAMAGE
Do not use the equipment for any improper applications. Improper usage can result in an
accident or malfunction.
If using this generator for medical equipment, check before use with the medical
equipment manufacturer, doctor, hospital or similar entity.
Check that the generator output setting, output terminal connection and load power source
are consistent.
Cable burnout can occur due to generated heat if the load current exceeds the allowable
current of the cable.
The voltage drop between cables is large if the cable is excessively long or thin, resulting
in decreased input voltage to equipment using the generator, thereby causing decreased
performance, faulty operation and malfunction.

5
■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
Caution: Do not change voltage
Part no. :X505-004620
②
Warning caution
Part no. :X505-010910
③
Caution: Auto start
Part no. :X564-000550
④
Warning: Proposition 65 Gen
Part no. :X505-010400
⑤
EPA emission complied notice
Part no. :X505-008400
⑥
Warning: Fire
Part no. :X505-007650
⑦
Notice: Capacity of the external
tank
Part no. :M709-000140
⑧
Terminal cover instructions
Part no. :M704-002250
⑨
Continuous output
Part no. :M705-001500
⑩
Warning: Electric shock
Part no. :X564-000400
⑪
DEF / AdBlue Complied notice
Part no. :M708-000070
⑫
Warning: Injury
Part no. :X505-007550
⑬
Caution: GM SPEC LLC
Part no. :X505-007840
⑭
Warning: Proposition 65 Battery
Part no. :X505-010410
⑮
Warning: Injury
Part no. :X564-000530
⑯
Warning: Electric shock
Part no. :X564-000560
⑰
Warning: Electric shock
Part no. :X505-009300
Ⓡ

6
2-1. Specifications
Model
Unit
DGK180FP
Alternator
Generator Type
-
Revolving Field Brushless
Rated Frequency
Hz
60
Rated Output(Prime)
Three phase
kVA
180
kW
144
Single phase
kVA
108 [54] *1
kW
108 [54] *1
Standby Output
Three phase
kVA
198
kW
158
Single phase
kVA
118.8 [59.4] *1
kW
118.8 [59.4] *1
Rated Voltage
Three phase
V
208/240/ [480] *1
Single phase
V
120/139/240/[277] *1
Rated Current
Three phase-
208V
A
500
240V
A
433
480V
A
216
Single phase-
120V
A
（U-N/W-N)
450 × 2 [225 x 2]*1
240V
A
（U-W)
450 [225]*1
Single phase-
120V
A
（L1-N/L3-N)
400 × 2
139V
A
（L1-N/L3-N)
345 × 2
277V
A
（L1-N/L3-N)
173 × 2
Power Factor
-
Three phase 0.8, Single phase 1.0
Insulation class
-
F
Excitation
-
Self Excitation (brushless)
No. of Poles
-
4
Engine
Type
-
Vertical Water-Cooled 4-Cycle Diesel
Model(Manufacturer)
-
6HK1X(ISUZU)
No. of Cylinders
(bore × stroke)
(in./mm)
6(4.53x4.92/115x125)
Continuous Rated Output
hp
227.3
Rated Speed
rpm
1,800
Displacement
cu.in./liters
475/7.790
Combustion System
-
Direct injection (Turbo-charged)
Cooling Method
-
Water cooled
Starting Method
-
Electric
Fuel
-
No.2-D,S15 EPA regulation
Diesel Exhaust Fluid
ISO 22241 or API standard
Lubricating Oil
-
API service-type CJ-4 class
Fuel Tank Capacity
gal./liters
275.3/1042
DEF Tank Capacity
gal./liters
7.4 x 2/28 x 2
Lubricant Volume
gal./liters
10.5/40
Cooling Water Volume
gal./liters
8.7/33
Starting Motor Capacity
V-kW
24-5
Charging Alternator
Capacity
V-A
24-50
Battery Capacity
V-Ah
12-100
Unit
Length
in./mm
143.7/3,650
Width
in./mm
52.8/1,340
Height
in./mm
87.8/2,230
Dry Weight
lbs./kg
9,392/4,260
Net Weight
lbs./kg
11,751/5,330
*1:Output in the brackets shows when the selector switch is set at 480V.
2. Specifications

7
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
■Altitude: 984 ft. (300 m) or less
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
4-1. 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.
3. Applications
4. Part Names
Terminal Cover
Operation Panel Door
Lifting Hook
Radiator Plate
Tie hole
DEF Inlet Cover
Spill Containment
Drain Plug
Inspection/Cleaning
Panel
Receptacle Cover
Fuel Drain Plug
Tie Hole

8
SCR Check Panel
Inspection / Cleaning Panel
Tie hole
Fuel Inlet Cover
DEF Tank
Check Panel
Tie Hole
Output Terminal
Terminal Cover
Receptacle Cover
Paralleling
Communication Connector
Remote Start
Terminal
Receptacle Panel

9
Engine
Check Door
Intercooler Drain Plug
Alternator
Check Door
Radiator
Intercooler
Fan Guard
Air Cleaner
Oil Level Gauge
Oil Filler
Oil Filter
Coolant Sub-Tank
Fan Guard
Alternator
Check Door
Fuel Filter
(Pre)
Coolant Drain Plug
Fuel Filter
(Main)
Electromagnetic
Fuel Pump
Oil Drain Plug
Fuel Tank
(Inside)
3way Fuel Valve
External Fuel Inlet
External Fuel Return
Battery
Engine
Check Door

10
Supply Module / Filter
DEF Tank
Muffler
(SCR)
Dosing Module
SCR Check Panel
DEF Check Panel
Accessories
Owner’s
and
Operator’s
Manual
Engine
Warranty
Manual
Option
Paralleling Communication
Cable (Parts No. 579000)
Product
Warranty
Manual

11
4-2. Operation Panel Configuration
①
Three-Phase & Single-Phase
Main Circuit Breaker (MCB)
⑧
Speed Monitor (Engine Tachometer)
⑨
Available Output Monitor
②
Operation Display
⑩
Fuel Leak Detected Lamp
③
Power Switch
⑪
DEF Level
④
Operation Selector Switch
⑫
Glow Lamp
⑤
Breaker Trip Selector Switch
⑬
Voltage Selector Switch
⑥
Warning Indicators
⑭
Load Bank Control Switch
⑦
SCR Indicators
⑮
Generator Circuit Breaker (GCB)
(Inside)

12
4-3. Output Terminal
4-4. Receptacle Panel
< NOTE >
All duplex receptacles are GFCI protected and are rated at 20 amps. All twist lock
receptacles are rated at 50 amps.
①
Single-Phase Circuit Breaker (50A)
②
Single-Phase Circuit Breaker (20A)
③
Single-Phase Twist Lock 240/120V Receptacle (50A)
④
Single-Phase GFCI 120V Receptacle (20A)
⑤
Paralleling Communication Connector
⑥
Remote Start Terminal
Three-Phase
Output Terminals
Single-Phase
Output Terminals

13
5-1. Operation Display
This generator has an Operation Display which is used for starting or stopping the power
generator or the engine, for monitoring and for maintenance. If you twist the power switch, the
Status Lamp on the Operation Display illuminates, and the Main Screen appears. Press the
"↑" button or the "↓" button to select between screens shown on the display. There are 7
different screens that appear on the display: "Parallel (Main) " (1st screen), "Single " (2nd
screen), "Engine Info. " (3rd screen), "Tank Indicator " (4th screen) , "Synchro " (5th screen),
"Service Timer " (6th screen), and "Voltage Adjust " (7th screen).
(1) Parallel (Main) (1st screen)
Screen Objects
Parallel / Single
Operation
Monitor
: "Parallel Operation" or "Single Operation" will be displayed
based on selector position.
("Single operation" will be displayed when the engine is
stopped.)
Gen V Ph-N[V]
: Phase(L1/L2/L3) - Neutral voltage meter
Current[A]
: Phase(L1/L2/L3) Current meter
Gen V Ph-Ph[V]
: Phase-Phase voltage meter
Gen freq[Hz]
: Frequency meter
5. Equipment
Power Switch
Status Lamp
↑ Button
↓ Button
Gen V Ph (L1/L2/L3)-N
(L1/L2/L3) Current
Mode Button
History Button
Fault Reset Button
AlarmList Button
Parallel / Single
Operation
Monitor
Mode Monitor
Synchro Button
Open/Close GCB Button
INTERNAL
TANK
Fuel Meter
INTERNAL
TANK
DEF Meter

14
RPM[RPM]
: Engine speed
3P Output[kW]
: Three-Phase Power output meter
Batt Volt[V]
: Battery voltage meter
Coolant Temp[°F]
: Coolant temperature meter
Displays the temperature of the engine coolant. Normal
temperature displayed during operation should generally
between 167°F (75℃) and 194°F (90℃) depending on
usage.
If the coolant temperature rises above 212 °F(100℃),
immediately stop all connected equipment to the generator,
and keep the engine running with No-load while cooling down
the coolant temperature.
EngOilPress[psi]
: Engine Oil pressure meter
Normal pressure displayed during operation should generally
between 42 and 71 psi (2.90 – 4.90 x 100 kPa) depending on
usage. However, the pressure may rise above this range just
after starting a cold engine. Keep the engine running with No-
load the engine until it reaches the normal pressure.
Run Hours[h]
: Hour meter
INTERNAL TANK
Fuel Meter[gal]
: The capacity of the fuel tank on this generator appears here.
INTERNAL TANK
DEF Meter[%]
: The capacity of the DEF tank on this generator appears here.
Mode Monitor
: The currently selected control mode appears here.
Buttons
History Button
: Press this button to display the controller history.
Open/Close
GCB Button
: Press this button when "Close GCB" is displayed to send
electrical voltage to the output terminal. Press this button
when "Open GCB" is displayed to stop the output.
AlarmList Button
: Press this button to display the controller active alarms. If
you keep the "Fault Reset" button pressed, the error
messages disappear.
Synchro Button
: Press this button to access the Synchro Screen.
Mode Button
: Selects the different control modes. Available selections are
Manual(MAN), Auto(AUT), and Off(OFF) Modes. If you
select "OFF," the "Start" button is disabled and the engine
cannot be started. The Test mode is not available.

15
(2) Single(2nd screen)
Screen Objects
Gen V Ph-N[V]
: Three-Phase(L1/L2/L3) - Neutral voltage meter
Current[A]
: Three-Phase(L1/L2/L3) Current meter
Current[A]
: Single-Phase(U/W) Current meter
Button
Main Button
: Press this button to access the Main Screen (1st screen).
(3) Engine Info.(3rd screen)
Screen Objects
Coolant Temp[°F]
: Coolant temperature meter
EngOilPress[psi]
: Engine Oil pressure meter
Ubat[V]
: Battery voltage meter
Fuel Temp[°F]
: Engine fuel temperature meter
Intake Temp[°F]
: Intake air temperature meter
Fuel Rate[L/H]
: Amount of fuel consumed by engine per unit of time
Fuel Inject[mm3]
: Fuel injection meter
Pwr factor[PF]
: Generator power factor meter
(U/W)Current
Gen V Ph (L1/L2/L3)-N
(L1/L2/L3) Current
Main Button

16
(4) Tank Indicator(4th screen)
Screen Objects
INTERNAL
TANK
Fuel Meter[gal]
: The capacity of the fuel tank on this generator appears here.
INTERNAL
TANK
DEF Meter[%]
: The capacity of the DEF tank on this generator appears
here.
EXTERNAL
TANK
Fuel Meter[%]
: The capacity of the external fuel tank is displayed here in %
(percent). If you wish to use an external fuel tank, contact
the distributor. When the product is shipped, "####" is
displayed here.
(5) Synchro(5th screen)
Screen Objects
Communication
: This indicates the number of generators that have the
Paralleling Communication Cable connected. The items
displayed on the screen differ depending on the address
assigned to each generator. If there are any connected
generators with "1" and "3" assigned as "Contr.address,"
"1010...0" is displayed.
INTERNAL
FUEL
TANK
EXTERNAL
FUEL
TANK
INTERNAL
DEF
TANK

17
Brk. Clsd
: This value indicates the number of the generator connected
to the load. The items displayed on the screen differ
depending on the address assigned to each generator. If the
GCB closes, the displayed value is "1".
Slip freq[Hz]
: This indicates the delta between the generator frequency
and the BUS frequency.
Angle [° ]
: This indicates the difference in phase angle between the
BUS and generator.
Gen Volts[V]
: This indicates the Phase to Neutral Generator voltage.
Bus Volts[V]
: This indicates the Phase to Neutral Bus voltage.
3P Output[kW]
: This indicates actual (Three-Phase Output) generator
kilowatts used.
Speed Bias
: This meter indicates the amount of speed bias being used to
control engine speed. 50% equals no bias. The higher the
bias % the more KW or more speed the control wants the
engine to take.
Voltage Bias
: This meter indicates the amount of DC voltage bias being
driven to the Automatic Voltage Regulator.
208V(39.5%),240V(50%),408V(50%) equals no bias. The
higher the bias % the move kvar or more volts the control
wants the generator to take.
(6) Service Timer(6th screen)
Provides set the maintenance interval timers, these timers count down from a value and
alarm when they reached to zero. If you wish to remove the alarm message, set the timer
give value again. (Refer to section "(8)Setpoint".)
< NOTE >
If you see an alarm message for "WrnServiceT1+2" or "WrnService T3+4", these messages
indicate that one of these counters reached to zero and require periodical maintenance.
ECU ON Button
ECU OFF Button
ESCAPE ON Button