Shindaiwa DGK70F User manual

File № DGO-530_DGK70F
SERVICE MANUAL
Disassembly & Assembly
DGK70F

File № DGO-530_DGK70F
Table of Contents
Attention Statement ········································································ 1
General Safety Instructions ····························································· 2
Disassembly & Assembly ································································· 4
Disassembly ···················································································· 4
1. Remove the battery ········································································ 4
2. Remove the bonnet ········································································ 5
3. Remove the door ··········································································· 8
4. Remove the side door ····································································· 9
5. Remove the front cover ·····································································12
6. Remove the flexible tube ····································································18
. Remove the alternator ····································································19
8. Remove the rotor ···········································································21
Assembly ························································································25
1. Mount the stator and rotor ·······························································25
2. Mount the flexible tube ·······································································31
3. Reinstall the cover and rewire ··························································32
4. Rewire the side door ·········································································3
5. Reinstall the bonnet ·······································································39
6. Mount the door ·············································································42
. Mount the battery ··········································································43
Tightening Torque ···········································································44
1. Specific Tightening ·········································································44
2. General Tightening ·········································································4

1
Attention Statement
・Only technicians with enough knowledge and experience should perform maintenance
and operational checks after maintenance.
・Before maintenance, always read this service manual as well as the owner’s manual and
be familiar with the contents thoroughly before starting the service and maintenance of
the equipment. Completely understand the equipment, safety and caution notifications.
・ hroughout 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 “CAU ION” contains
information that should be acted upon to prevent mechanical damage.
WARNING!
CAUTION!

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 has
fully stopped before you 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 a well
ventilated area.
When the equipment is used in a tunnel, hall
or any other indoor area, ventilation
equipment must be used to prevent serious
injury caused by suffocation.
NEVER direct the exhaust fumes to
houses nearby. Consider the wind flow
direction.
Exhaust gas contains many harmful
elements that can cause effects to humans.
Prevent 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 or touch moving
components 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 service or inspect equipment while it
is being operated.
It may cause electric shock, injuries or burns.
WARNING-Use good judgment
NEVER run the engine when transporting
the equipment.
ALWAYS stop the equipment immediately if
it suddenly begins to vibrate or an abnormal
noise is heard. Inspect for broken, missing or
improperly installed parts.
ALWAYS keep the equipment as clean as
practical. Keep it free of loose vegetation,
mud, etc.
DO NOT make unauthorized
modifications or alterations to this equipment
or 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 or service this equipment!
Attention to CAU ION LABEL！
Caution labels are placed on this equipment
and require special attention for operation.
Make sure to locate the labels and
understand the content of the caution.
・Check that caution labels are 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 to peel off.
・Make sure to replace the labels when
damaged or illegible.
Before replacing the label(s), make sure to
place the new label(s) in the same position.
STOP the equipment immediately when
abnormal circumstances are noticed!
S STOP the equipment immediately whenever
abnormal circumstances are noticed such
as unusual noise, smell vibration and etc.
It may lead to a serious accident or fatal
damage of the equipment or properties.
Inflammables！
Keep the equipment far away from fire such
as cigarettes when filling 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 to serious safety issues and
damage the equipment.
Inspect the equipment before engine
start for operation and periodical inspection
without fail！
Make sure to inspect before starting engine
and periodically inspect for safety and longer
life of the equipment.
CAUTION!

4
DGK70F
Disassembly & Assembly
Disassembly
1. Remove the battery.
1. Disconnect the clamp and terminal from negative (-) post from the battery first.
2. Disconnect the clamp and terminal from positive (+) post from the battery.
3. Remove the wing nut counter-clockwise.
4. Remove the holder and battery.
WARNING!
Before start servicing, prepare;
1. top engine and make sure it stopped.
2. Allow the engine and other moving component to cool before servicing.
3. Work on a flat open area. Do not serve the equipment on the tilted ground.
4. Wear a safety glove and/or eye protection such as goggles.
5. Always wear a safety shoes.
IMPORTANT!
Always disconnect the negative (-) terminal first. It might be short-circuited when a metal
tool will contact to the bonnet as the negative (-) terminal is grounded with the bonnet.
There might be a risk of scalds when it is disconnected from the positive (+) terminal.
Wing Nut
2
1
3
WARNING!
Wear safety goggles and gloves to protect your eyes and hands.

5
2. Remove the bonnet
(1) Unfasten the 18 bolts (M8 x 20) and 4 bolts (M16 x 30) and remove the bonnet.
Right ide
Left ide
WARNING!
Always wear safety shoes, gloves and eye protection for your safety!
Bonnet：2 bolts (M16×30)
：M8 × 20
：M16 × 30
Bonnet：2 bolts (M16×30)
：M8 × 20
：M16 × 30

6
Bonnet：12 bolts (M8 x 20)

7
(2) Loosen the screw that adjusts the metal band and remove the intake hose.
Left Side
(3) emove the negative pressure sensor and mass air flow sensor that locate in the air
cleaner.
Left Side
(4) Lift and remove the bonnet.
1. Cut the tie band by the nippers.
2. Disconnect the connector.
Screw
Intake Hose
Mass air flow sensor
Negative pressure sensor
Bonnet
1. Loosen the screw in the metal band.
2. emove the intake hose.
WARNING!
Always wear safety shoes, gloves and eye protection for your safety!

8
3. Remove the door
(1) Unlock and open the door.
(2) Lift the door up slightly until the two hinges separate.
Left Side
ight Side
WARNING!
1. Always wear safety shoes, gloves and eye protection for your safety.
2. Hold the upper door to prevent a fall when removed the hinge pin.

9
4. Remove the side door
(1) Remove the 2 bolts (M6 x 16) and open the side door.
Left ide
(2) Remove the 8 bolts (M6 x 16) in order as per the number.
Left ide Cover (back)
WARNING!
Remove the bolts in order as per the numbers that are described in 4-(2) for your
safety. Incorrect removal may cause for a door fall and serious injury.
1. Remove the 8 bolts (M6 x 16) as per the
number below by the wrench.
2. Remove the #8 bolt while holding the
black cover to prevent a door fall.
3. Remove the “back” cover.
Bolt (M6 x 16)
WARNING!
Firmly hold the cover before removing the last
bolt to prevent a door fall.
7
6
5
8
WARNING!
Hold the black cover by hand to prevent a door fall during the bolts are removed.
3
2
4
1
Bolt
Side Door

10
(3) emove the 6 pcs. M12 nuts and 1 pc. of the M8 nut.
(4) Turn the 2 knobs to counter-clockwise and open the operation panel.
Operational Panel
(5) Disconnect the connector in the control box.
Unfasten the nut with the wrench and
remove the terminal.
(M8) 1 location
(M12)
6
locations
Knob
Disconnect the connector.

11
(6) emove the bolt (M8 x 35) that tighten the stopper cable.
Left Side
(7) Slightly lift the side door up until the two hinges separate.
Left Side
Inside view after the panel cover removed.
Stopper Cable
Bolt

12
. Remove the front cover
(1) Disconnect the cable.
Left View
Loosen the bolt (M10 x 25) and
remove the cable.
D sconnect the connector.
D sconnect the connector.
Loosen the nut (M10) and
remove the cable.
Loosen the screw (M5 x 10)
and unfasten the cable.

13
Dynamo
Loosen the bolt (M12 x 25) and
remove the cable.
D sconnect the connector.
uel Pump
D sconnect the connector.
Right ide
Oil ilter
Loosen the nut (M8) and
remove the cable.
D sconnect the connector.

14
(2) emoval of the cables between the alternator and front cover.
1. Unlock and open the front door.
2. Slightly lift the front door until the
two hinges separate.
Front Door
Disconnect the connector.
Unscrew the 3 of M4 x 10 located at
the lower breaker and re ove the
cable.
Breaker
Control Unit
Loosen the 5 bolts at the upper of the breaker
with a hex. wrench and re ove the 2 ea. of the
red cable and 1 pc. of the white cable.

15
Left Side
Loosen the 2 bolts. (M6 x 16)
Switch
C
ase
Loosen the 2 bolts (M6 x
16) while
holding the switch case.
Loosen the 3 bolts. (M6 x 16)
Switch Case

16
Voltage Selector Switch (Top View)
(1) Loosen the 8 bolts. (M6 x 12)
Left View
Right View
U1
11
21
31
W1
10
20
30

17
(3) Unfasten the 4 bolts (M10 x 25) and separate the front cover and base frame.
Left ide Right ide
(4) Hold the front cover with the nylon slings.
(5) lowly lift the front cover up and separate it from the base frame.
NOTE: The below photos show the top cover mounted but the cover should already be
removed per “2. Remove the bonnet” on page 5.
WARNING!
Tightly hold the front cover with the nylon slings before
removing the cover to prevent a front cover fall.
ront Cover
Top Cover
Front Cover (white cover in a photo on the left.)
Base rame
Nylon Slings

18
6. Remove the flexible tube
(1) Remove the 7 nuts (M8) that tighten the flexible tube.
Right ide
lexible Tube
lexible Tube
Gasket
Gasket
Nut
Nut
1. Unfasten the 7 nuts (M8).
2. Remove the flex ble tube and gasket.
NOTE: Carefully remove the flexible
tube to prevent a damage of the gasket.
Gasket may reuse if it was not visuall
damaged.