SERVICE MANUAL

DGM60MK/LU

WARNING

Read this manual and familiarize yourself with its contents.

This equipment is designed for power source for electric tools, home appliances and lights.

Do not operate or serve this equipment unless you clearly understand this manual.

This generator is for 60Hz ONLY.

Specifications subject to change without notice.

File № DG0-132_DGM60MK/LU

This service manual is edited for authorized person to perform repair, maintenance, and trouble-shooting to shindaiwa Diesel Engine Generator

Welder, Model Designation DGM60MK/LU.

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 equipments 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 equipments previously manufactured.

For service of the engine, refer to Workshop (Service) Manual provided by the engine manufacturer described below.

MANUFACTURER

Kubota

MODEL

V3800DI-TI

WORKSHOP MANUAL

Table of Contents

1. Attention Statements

····························································································

1

2. General Safety Instructions

···············································································

2

3. Specifications

···········································································································

4

4. General

························································································································

5

4-1 Appearance ····································································································· 5

4-2 Dimension ······································································································· 6

5. General Par ts Description ········································································· 7

5-1 Equipment ······································································································· 7

5-2 Main Parts and Feature ···················································································· 9

6. Control Par ts Description

···················································································

17

6-1 Function of Control Panel ················································································· 17

6-2 Protective Device ····························································································· 17

7. Main Circuit

··············································································································· 17

7-1 Generator Circuit ····························································································· 17

8. Engine Control Circuit

················································································ 18

8-1 Auto Pre-heating System ·················································································· 18

8-2 Control Power ·································································································· 18

8-3 Starting ············································································································ 18

8-2 Stopping ·········································································································· 18

8-5 Protecting ········································································································ 18

9. Excitation System ························································································ 19

9-1 Generating······································································································· 19

10. AVR

················································································································ 19

10-1 Adjustment ····································································································· 20

11. Generator ····································································································· 21

11-1 Exploded Diagram ·························································································· 21

11-2 Technical Specification ··················································································· 22

11-3 Generator······································································································· 23

11-4 Insulated Resistance ······················································································ 23

11-5 Bearing ·········································································································· 23

11-6 Characteristic ································································································· 24

12. Coolant

········································································································· 25

12-1 Antifreeze ······································································································ 25

12-2 Maintenance ·································································································· 25

13. Troubleshooting

························································································· 26

13-1 Generator ······································································································ 26

13-2 Engine ··········································································································· 27

14. Wiring Diagram ··························································································· 28

14-1 Main Circuit ··································································································· 28

14-2 Control Circuit ································································································ 29

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.

WARNING

A statement preceded by the triangular attention symbol and the word “WARNING”

CAUTION

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.

1

2. General Safety Instructions

ELECTRIC SHOCK

NEVER touch the output terminals

during operation

WARNING

Entangled Injuries under

By Moving Componen

t

NEVER touch the output terminal during

operation even though the breaker on the load is being set at “OFF” position.

NEVER reach and touch the moving

component during operation!

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.

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

.

Fumes from engine exhaust cause serious injury.

ALWAYS operate the equipment in the

Never serve and inspect when equipment is

being operated.

It may cause electric shock, injuries or burns.

ventilated area.

When the equipment is used in a tunnel, hall or any other indoor, the equipment for

WARNING-Use good judgment

①

NEVER run the engine when ventilation must be used to prevent serious accident caused by suffocation. transporting the equipment.

②

ALWAYS stop the equipment

immediately if it suddenly begins to

NEVER direct the exhaust fume to

violate or abnormal noise. Inspect for houses nearby while considering the wind broken, missing or improperly installed flow direction. parts.

Exhaust gas contains many harmful

③

ALWAYS keep the equipment as clean

elements that would cause affect to human. as practical. Keep it free of loose

Be free from suffocation when the vegetation, mud, etc.

equipment is used in poorly ventilated area

DO NOT make unauthorized

such as inside of the building. 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.

2

CAUTION

Work Safely

STOP the equipment immediately when

Generators and welders operate at very high

abnormal circumstances are noticed!

if they are misused or abused. Never allow a

person without training or instruction to operate and serve this equipment!

abnormal circumstances are noticed such as unusual noise, smell, vibration and etc.

It may lead serious accident or fatal damage

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. of the equipment or properties.

Inflammables

！

Keep the equipment far away from fire such as cigarettes when refueling fuel, oil or battery fluid.

・

Check the caution labels is legible. Always keep the labels clean or replace them when

NEVER operate or service the equipment

worn or damaged

・

Clean the labels by cloth, water or nearby fire as the equipment may catch fire.

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.

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.

3

3. Specifications

Note: This generator is for 60Hz ONLY.

4

4.

General

4.1

Appearance

5

4.2

Dimension

Unit in the drawing below is shown by mm.

6

5.

General Parts Description

5.1

Equipment

7

8

5.2

Main Parts and Feature

(1) Serial Number

Serial Number Location (Upper Right in the Control Panel)

(2)

Main Components

9

(3)

Control Panel - Inside

Engine Control Unit (ECU)

Feature: Controls engine.

Automatic Voltage Regulator (AVR)

Feature: Electrical regulator designed to automatically maintain a constant voltage

Fuse

Feature: A device to protect from excessive current

Circuit Breaker

Feature: Automatically operated electrical switch to protect an electrical circuit from damage by overload or short circuit.

10

(4)

Control Panel - Outside

Printed Circuit Board

Feature: Display monitor.

11

No.

1

Nomenclature

Circuit Breaker (3-phase)

2 Circuit Breaker (1-Phase)

3

4

Voltage Meter

Ampere Meter (AC)

7

8

9

5

6

Frequency Meter

Panel Light

Voltage Adjusting Dial

AM Meter Selector Switch

Breaker Trip Selector Switch

10

11

Warning Lamp

Engine Monitor

12

13

14

15

16

17

Oil Pressure/Water

Temperature/Speed Selector

Switch

Display Selector Switch

Output Monitor

Fuel Gauge

Hour Meter

Pre-Heating Lamp

18

19

Starter Switch

Throttle Switch

Feature

Automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow.

Automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow.

An instrument used for measuring and display voltage.

A measuring instrument used to measure the electric current in a circuit. Electric currents are measured in amperes.

An instrument used for measuring and display frequency.

Illuminate the control panel to indicate that power is generated.

A dial to adjust a voltage.

A switch to select the output current.

A switch to select the tripping order due to short-circuit or overload.

Light a monitor lamp when equipment is malfunctioned.

Monitor engine and light a monitor lamp when detecting an unusual situation.

A switch to select a monitor field for the oil pressure, water temperature and engine speed.

A switch to select display .

Display an output.

Display the amount of fuel left in the fuel tank.

Display the operating “accumulated” hours.

Pre-Heating Lamp is ON when a starter switch is turned to

“PREHEAT” position.

Engine is stopped at OFF position and it starts at ON position.

Switch to change the engine speed. Turn the switch to “IDLE” for starting, warm-up and cool down the engine and turn the switch to “RUN” for operation.

Switch to change the voltage. 20 Voltage Selector Switch

12

Important: Warning Lamp in the front panel displays important caution as described below.

①

BATTERY: when a battery charge is insufficient.

②

OIL PRESSURE: when oil pressure is dropped below 7 psi.

③

WATER TEMPERATURE: when a coolant temperature rises higher than 230

° in

Fahrenheit.

④

OVER SPEED: when the engine speed exceeds more than 2,070 rpm.

⑤

AIR FILTER: when an air filter is plugged.

⑥

SPILL CONTAINMENT: when a liquid spills more than approx. 10 gallons out of the container

⑦

ENGINE: when unusual situation is detected in the engine.

① ② ③ ④ ⑤ ⑥ ⑦

(5)

Main Pats and Feature

(5) Main parts and Feature

Alternator

Function: Charge a battery and caution lamp.

Starter Assy

Function: Start engine.

13

14

Air Filter Sensor

Function: Caution signal when filter is plugged.

Air Filter Assy

Function: Remove solid particulates such as dust from the air.

Oil Separating Filter

Function: Separate oil in the blowby gas.

Return Hose

Function: Return the oil to the oil pan.

Coolant Water Temp. Sensor

Function: Measure a coolant temperature.

Air Temp. Sensor

Function: Increase an air temperature.

Electromagnetic Pump

Function: Transmit fuel.

15

EGR Valve

Function: Recirculate a portion of an engine’s exhaust gas back to the combustion.

Rail Pressure Sensor

Function: Sensor pressure in a common rail system.

Common Rail System

Function: A high-pressure pump stores a reservoir of fuel at high pressure.

Oil/Water Separator

Function: Separate water from the engine oil.

Terminal Panel

Oil Drain

3-Phase

Terminal

Terminal Panel Wiring – Inside

Standard Accessory

Cooling

Water

Drain

16

Single Phase

Terminal

Terminal

Starter Key- 2 sets

Engine Manual by

Engine Manufacturer

Operator’s Manual

6. Control Parts Description

ELECTRIC SHOCK

Never touch the output terminals during operation.

Never touch the output terminal during operation even though the breaker on the load being set at

OFF.

Be sure to check and confirm the engine stop whenever touching terminals to connect loads.

Function

Starting and Stopping

Feature

Control fuel flow. Electronic Governor.

When engine run, the stop solenoid pulls rack and supply fuel to the injection pump.(RUN-ON solenoid)

Voltage Control (AVR)

Adjust voltage by setting the dial for the loads.

Variable voltage

60Hz

：

228

～

252V

CAUTION: This generator is for 60Hz only.

6-1 Function of Control Panel

Function of the control panel is to control the engine rotation and display status of the generator unit.

6-2 Protection Device

Protection device is to confirm function of a breaker, engine stop and warning display to protect the unit by a short circuit of protecting device.

7. Main Circuit

(3 Phase 4 Wire)

7-1 Generator Circuit

・

Armature winding

： parallel and series double star connection. Variable.

・ Supplementary power (240/480V) ： 2 circuit type, phase U and phase W.

17

8. Engine Control Circuit

8-1 Auto Pre-heating System

When a starter switch is set to “ON” position, electricity is transmitted to the glow plug and display pre-heating time. The time fluctuates by coolant temperature managed by the coolant temperature sensor.

8-2 Control Power

When a starter switch is set to “ON” position, electricity for control power is supplied from the battery.

The stop solenoid is turned on electricity and starts fuel supply to the injection pump.

8-3 Starting

When a starter switch is set to “START” position, engine starts operation. The starter key returns to

“ON” position automatically.

8-4 Stopping

After a starter switch is set to “STOP” position, fuel supply is cut by ECU to stop the engine run.

8-5 Protecting

(1)

Over current

When output amperage exceeds the standard, the circuit breaker trips and its knob positions between “ON” and “OFF”.

Set the knob to “OFF” position first and, then, set the knob to “ON” position to reset the circuit

breaker.

(2)

Low oil pressure

When lubricating oil pressure becomes lower than the standard, the oil pressure sensor stops the engine.

(3)

High coolant temperature

When coolant becomes higher than the standard, the coolant temperature sensor stops the engine.

(4)

Battery Charge Fault

When it fails to charge a battery, a warning lamp turns to ON. Then, engine will finally stop.

18

9. Excitation System

9-1 Generating

When a starter switch is set to “RUN” position, an initial excitation current flows through 84X relay to the excitor stator (exciter field winding). AC voltage is generated in the exciter rotor (exciter armature winding).

The exciter rotor output is transmitted to the exciter rotor winding (Main rotor) through 2 phases full wave bridge rectifier.

The rectifier is protected by a surge suppressor against surges that is produced by a short-circuit, for instance.

In the self-excitation system, the main stator provides power through AVR to the exciter stator.

10. AVR

CAUTION

Do not adjust while operating the generator! It is caused to damage the AVR or the load.

When a megger testing of the generator is conducted, always remove the connectors from the AVR.

19

10-1 Adjustment

(1) Adjustment a. Voltage adjustment

Turn the VRE clockwise to increase voltage. b. Adjustment of frequency to voltage characteristic

Turn the VRF clockwise to increase a slope of the curve.

(2) When AVR is replaced, confirm below.

(a) Variable voltage: Connect a voltage regulator and set the maximum voltage, 60Hz, 255

±

2V.

(b) Confirm that voltage does not drop when a fluorescent light is connected to the generator and the light should not flicker.

VRF VRE

No VRF adjustment is required as it is preset at factory.

20

11. Generator

11-1 Exploded Diagram

The main component to consist the generator is rigid casting that is excellent in quality and durability.

Thus, this generator features a powerful damper winding to minimize wave distortion.

Exploded Diagram

Thermo label

Screw

Screw

End cover

Bracket

Main stator

Serial number

Screw

Exciter stator

Screw

Thermo label

Bearing

Exciter rotor

Main rotor assy

Fan Cover

21

11-2 Technical Specification

Insulation

Items

Armature winding

Exciter field

Pre-heating time

Low idling speed

High idling speed

Lubricant oil pressure

Coolant temperature

Temperature of generator frame

Temperature of sealed bearing

Voltage regulation

Transient

Deviation

Steady-state deviation

60Hz Variable Voltage

Protective device

Low oil pressure

Working pressure

High water temperature

Working temperature

If coolant temperature reads -15

℃

, pre-heating time becomes 5 seconds.

If coolant temperature reads 20

℃

, pre-heating time becomes 2 seconds.

1000±25 min-1

60Hz:up to 1800 min-1

0.1

～

0.49MPa{1

～

5kgf/cm²}

70

～

100

℃

Within 80

℃

Within 80

℃

110±2

℃

Reference value

1M Ω or more

Within 20%

Within ±1.0%

228

～

255V

0.098MPa{1.0±0.2kg/cm²}

22

Note

DC500V

Megger Tester

Automatic pre-heating system

Electronic

Governor

Full to No load

Set to 60±0.1Hz

[Close] when activated

Thermister

Temp. Sensor

11-3 Generator

(1) Exciting Amperage

Amperage fluctuates based upon the winding temperature. Following is for reference only.

Frequency/Rated Output Load Exciting Amperage

(Measured)

60Hz/25kVA

No load

Full load( power factor=1.0)

0.49A

0.68A

(2) Resistance Value

Nominal resistance of the winding is tolerated within ± 10% at 20

℃

of the ambient temperature.

The resistance must be measured by low resistance tester. It can not be measured by multi-purpose tester cause of index error.

Generator

Measurement value ( Ω）

Exciter

(Measured)

Armature

Stator

Exciter armature

Rotor

Exciter

Field

Stator

J(gray)

－

K(purple)

Rotor

Armature

Between

1-10,11-O (U)

2-20,21-O (V)

3-30,31-O (W)

Between

A (brown) - B (yellow)

B (yellow) - C(orange)

C (orange) - A (brown)

0.048

11-4 Insulated Resistance

1.06

-

6.14

-

26.9

-

0.66

Follow the procedure below to check a main circuit.

(1) Inspect insulated resistance at every 50 hours of operation.

(2) Use a 500V megger tester to measure the insulated resistance.

(3) It should be 1.0M

Ω or higher.

11-5 Bearing

Sealed type of the bearing is used and it must be replaced when engine is overhauled or at every

10,000 hours of operation.

When engine will make a noise during operation, replace the bearing(s).

23

11-6 Characteristic

(1) Capacity of Battery

Capacity of the battery refers to a quantity of electricity and multiply the discharge amperage by the time that achieves the voltage of 7.2 gives the capacity.

Capacity (Ah) = Discharge amperage (A) X Time that achieves the voltage of 10.5 at 5 hour rate

(hour).

Relation of temperature to capacity

(2) Relation of Temperature to Capacity

A battery provides a stable source of electricity by chemical reaction. It becomes more active by

Capacity

increasing in electrolyte temperature and it becomes inactive by decrease of electrolyte temperature.Capacity of the battery fluctuates by electrolyte temperature . Rated capacity of the battery is specified under 25

℃

.

(3) Relation of discharging capacity to the specific gravity of the electrolyte. Discharge electricity of a battery, specific gravity of the

Specific gravity of

Electrolyte

Electrolyte temperature

Relation of Discharging capacity to

Specific gravity of Electrolyte

electrolyte becomes lower according to the capacity. The specific gravity drops lower to

1.08. Therefore, the discharging capacity

(Reserve capacity) is measured by the

Discharge

Capacity

specific gravity of electrolyte.

(4) Standard Battery

Type 5 hour rate (Ah)

CCA (A)

NOTE 1

RC (min)

NOTE 2

Outside Dimension (mm)

Total

Height

Height Wide Length

233 213 176 410 130E4R 92 638 228

NOTE 1:Cold Cranking Amperage (CCA) refers to high-rate discharge current that achieves 7.2 volts after 30 seconds of discharging at -18

℃

. This value shows the low temperature engine cranking performance of a battery.

NOTE 2: Reserve Capacity (RC) refers to the time that achieves 10.5 volts under discharging

25 amperes

24

12. Coolant

12-1 Antifreeze

Use an antifreeze type coolant for long life. The coolant has advantages not only antifreeze but anti-rusting in the cooling system.

12-2 Maintenance

(1) Long Life Coolant

Use a coolant that has advantage by 5

℃

from the expected lowest temperature in your area. Also, use the coolant that is durable in the temperature that meets between 30% and 60% of the year in your area.

A coolant less than 30% concentration does not provide sufficient corrosion protection. A coolant with more than 60% concentration can adversely affect antifreeze protection characteristic and cause for overheat of the engine.

Ambient Temperature (lowest)

Concentration Ratio

~ -15

℃

30%

~ -25

℃

40%

~ -35

℃

50%

~ -45

℃

60%

25

13. Troubleshooting

13-1 Generator

Problem Possible Cause

No output voltage. 1. Faulty volt meter.

2. Faulty generator.

Inspection Remedy

1. Check the volt meter voltage. 1. Replace the volt meter.

2. Verify the exciting amperage and resistance value.

2. Replace the generator.

No voltage increase 1. Faulty volt meter.

2. Faulty generator.

3. Faulty AVR or voltage adjuster.

4. Slow rotation.

5. Faulty initial excitation.

High output voltage. 1. Faulty volt meter.

1. Check the volt meter voltage.

2. Verify the exciting amperage and the value of resistance.

3. Broken wires, loose or disconnected 3. Repair or replace the parts. cable.

4. Check the rotation speed of the engine.

5. Broken or loose the wire.

1. Check the voltage of the volt meter

1. Replace the volt meter.

2. Replace the generator.

4. Adjust the rotation speed of the engine properly.

5. Repair.

1. Replace the volt meter.

2. Faulty adjusting AVR.

3. Broken wire, loose or disconnected cable of the voltage adjuster circuit.

2. Check the dial gauge [VR1] on the

AVR.

2. Adjust the voltage properly.

3. Check wiring of voltage adjuster.

Single wire disconnected: 240 to 280V.

3. Inspect and repair the cable.

Double wire disconnected: 260 to 300V.

Abnormal frequency or voltage drop

1. Unbalanced load.

2. Low rotation speed. when load is increased. 3. Over load.

Can't be turned on the circuit breaker.

1. The handle of the breaker is positioned between [ON] and

[OFF] position.

2. Over load.

1. Check the amperage of each phase.

2. Check the rotation speed.

3. Check the amperage of each phase.

1. Check the position of the handle.

2. Check the load.

1. Balance the current.

2.

Adjust appropriate speed.

3. Decrease the load.

1. Press the handle to the

[OFF] position first, then set the handle to the [ON] position to reset.

2. Decrease the load.

26

13-2 Engine

Problem

Engine does not start.

Engine stopped suddenly.

Possible Cause

1. Starter does not turn.

Inspection

1-1. Check voltage, electrolyte level, specific gravity of the battery.

1-2. Check the starter relay.

Confirm that the starter relay turns on electricity when the starter switch is set to [ON] position.

1-3. Check the starter.

Confirm that the starter turns on electricity when the stator switch is set to [ON] position.

Remedy

1. Recharge and supply refined water.

2. Replace the starter relay.

3. Repair the starter in reference to the workshop of the engine.

2. Starter rotates abnormally.

2-1. Check the stop solenoid.

Confirm that the stop solenoid turns on electricity while the starter switch is set to [ON] position.

2-2. Check pre-heating.

Confirm that it turns on

2-1. Replace the stop solenoid or the fuse for solenoid.

2-2. Repair wiring, replace the glow timer. electricity to glow plug and glow indicator when the starter switch is set to [ON] position.

2-3. Check fuel system. 2-3. Refer to the engine manual

1. Activation of protective Check oil level. devices.

Low oil pressure.

High water temperature.

Check overload, ventilation, coolant level. and the product manual.

Add oil as needed.

Decrease load, improve ventilation, adds coolant.

2. Air or water entering fuel system, clogged fuel filter.

2. Check fuel system.

Refer to the engine manual.

2. Repair the system.

File № DGM60MK/LU

27

14. Wiring Diagram

14-1 Main Circuit

28

14-2 Control Circuit

29

YAMABIKO CORPORATION

35 SHIN-UJIGAMI, KITA-HIROSHIMA-CHO

YAMAGATA-GUN, HIROSHIMA 731-1597 JAPAN

Telephone: (81)826-72-5140

Fax: (81) 826-72-7004 www.yamabiko-corp.co.jp