Shindaiwa DG25MK Assembly And Instruction Manual
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Shindaiwa DG25MK Assembly And Instruction Manual

Diesel engine generator
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OWNER
S AND OPERATOR
S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
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.
DG25MK-400M/R
X753-007 95 1
X753801-350 1

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  • Page 1 S AND OPERATOR S MANUAL Vertical, Water-Cooled 4-Cycle Diesel Engine 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. DG25MK-400M/R X753-007 95 1 X753801-350 1...
  • Page 3 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.

  • Page 4: Table Of Contents

    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 Part Names ............ 9 5.

  • Page 5: Safety Instructions

    1. Safety Instructions WARNING : SUFFOCATION FROM EXHAUST FUME  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 pedestrians or buildings. WARNING : ELECTRIC SHOCK ...
  • Page 6 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.
  • Page 7 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. ...
  • Page 8  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.  Injury (Part no. : X505-007550)  Electric shock (Part no.

  • Page 9: Specifications

    2. Specifications 2-1. Specifications Model Unit DG25MK-400M Rotating Filed, Brushless 3-Phase Generating Type Synchronous Alternator Rated Frequency Rated Output Rated Voltage 400 [200] *1 440 [220] *1 Rated Current 28.9 [57.7] *1 32.8 [65.6] *1 Winding 3-phase, 4-wire Power factor...

  • Page 10: Ambient Conditions

    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: -15 to 40 °C ■ Relative humidity: 85% or less ■...
  • Page 11 Radiator * Shown with side-plate removed. Fuel Filter Water Separator Oil Filler Coolant Sub-Tank Air Cleaner Engine Check Door Alternator Check Door Oil Level Gauge Battery Oil Filter External Tank Fuel Return 3way Fuel Valve External Tank Fuel Inlet Coolant Drain Plug Oil Drain Plug Fuel Drain Plug Accessories...

  • Page 12: Operation Panel Part Names

    4-2. Operation Panel Part Names (Inside) ① Circuit Breaker ② Controller ③ Power Switch ④ Hour Meter ⑤ Voltage Regulator ⑥ Earth Leakage Relay ⑦ Frequency Selector Switch (inside)

  • Page 13: Equipment

    5. Equipment 5-1. Controller This generator has a Controller which is used for starting or stopping the power generator or the engine, for monitoring. If you turn the Power Switch to ON position, the status Screen appears.(Refer to section "5-1. Controller (2)Operation Display".) (1) Button Lamp Test / Auto Mode Button...
  • Page 14 (2) Operation Display Button Button Button Operation Display Button Button Contents Button, Button Switches the main screen displayed on the Operation Display. Button, Button Displays the detailed status of the main screen. < Note>  If an error occurs during operation, the Operation Display automatically switches to the Alarm screen.
  • Page 15 ○ Generator Status Screen Contents Phase-Neutral voltage meter. Generator Voltage (ph-N) Phase-Phase voltage meter. Generator Voltage (ph-ph) Generator Frequency Frequency meter. Generator Current (A) Current meter. Generator Earth Current (A) No use. Generator Load Ph-N Real power and load factor. (kW)(%) Generator Total Load Total of real power and load factor.

  • Page 16: Warning Indicators

    (3) Editor This generator has with the Controller Editor function, which allows you to change frequency, date and contrast of the controller. Press the Stop Mode Button. Press the Stop Mode Button and " " button together to enter the editor display.
  • Page 17 (1) Low Oil Pressure 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 gushing out. If the engine oil pressure drops below 0.49 x 100 kPa during operation, the Low Oil Pressure indicator illuminates on the controller, and "Oil Pressure Low Switch"...

  • Page 18: Meters And Switches

    (6) Water in Fuel If the liquid stored in the water separator exceeds approximately 110 ml during operation, "Water in Fuel" appear on the Operation Display. If it illuminates, immediately stop the engine and drain the liquid stored in the water separator. (Refer to section “10. Inspection/Maintenance (4) Draining Liquid in Water Separator”.) (7) Charge Alt Failure "Charge Alt Failure"...

  • Page 19: Frequency Change

    (2) Circuit Breaker This switch is for transmitting electrical power to the load side. Turn to ON position to output voltage to the output terminals. Output to the load side is cut off when there is a short circuit or overload on the load side. (3) 3-Phase Earth Leakage Relay When current leak occurs, it trips to stop power transmission to load.

  • Page 20: Fuel Piping Switch (3Way Fuel Valve)

    5-5. Fuel Piping Switch (3Way Fuel Valve) CAUTION : FIRE  Always make sure that the Power Switch is OFF position when working on piping.  Always be sure to wipe up any spilled fuel.  After working on the piping, check that there is no fuel leakage. Change the 3-way fuel valve to switch to supply fuel from the external tank.

  • Page 21: Installation Procedures

    (2) Transport When transporting this generator, tie rope to the left and right tie downs, and securely fix the generator. Lifting Tie-Down Hook < Note >  Handle this generator with great care when raising, lowering and transporting. Rough handling of generator can result in damage or malfunction.

  • Page 22: Load Connections

    7. Load Connections 7-1. Load Cable Selection CAUTION : PROPERTY DAMAGE  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.
  • Page 23 < Note >  When connecting a load, check that the generator output setting, output terminal connection position, and load power source are all matching.  If using the O terminal, be careful that the currents of each phase are uniform. ...

  • Page 24: Earth Leakage Relay And Grounding

    7-3. Earth Leakage Relay and Grounding WARNING : ELECTRIC SHOCK  Ground the every grounding terminal to the earth as set in the manual.  If even one of all is unconnected by mistake or accident, it will be much more dangerous for human than the NO-RELAY case, because leaking current inevitably goes through the body.

  • Page 25: Pre-Operation Inspection

    Push the reset button. The earth leakage indicator turns OFF subsequently. Turn (Push-down) the circuit breaker (lever) to OFF position. In the event you cannot complete every step of the above procedure to the end,the device is out of order. Consult with our authorized distributor or our engineering section and ask to repair.

  • Page 26: Checking Coolant

    (2) Engine Oil Viscosity Use a diesel engine oil with an appropriate viscosity corresponding to the ambient temperature (refer to the table).  Relation of Viscosity/Temperature SAE30 Temp. (°C) SAE 10W-30 (3) Engine Oil Replacement Amount (Unit: L) Total Lubrication Oil Amount 9.7 (0.3) Value in parenthesis is the filter capacity.

  • Page 27: Checking The Fuel

     When replenishing LLC, be sure to use the same brand as the LLC remaining in the radiator and sub-tank.  Never use an LLC mixture of two different brands.  Be sure to completely change every 2 years or 2,000 hours or less. ...

  • Page 28: Checking The Battery

    8-5. Checking the Battery 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 large amount of water.

  • Page 29: Operating Procedures

    9. Operating Procedures 9-1. Initial Startup/Pre-Check WARNING : EXHAUST GAS POISONING  Do not operate the generator in poorly ventilated areas such as an indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health. ...
  • Page 30 Stop Mode Manual Mode Button Button Circuit Breaker Voltage Regulator Start Button Power Switch Auto Mode Button (1) Manual Start Set frequency. (Refer to section"5-4. Frequency change" ) Turn the Circuit Breaker to OFF position. Turn the Power Switch to ON position. <...

  • Page 31: Procedures During Operation

    Set frequency. (Refer to section"5-4. Frequency change" ) Turn the Circuit Breaker to OFF position. Turn the Power Switch to ON position. < Note >  When turn the Power Switch to the ON position, the “Low Oil Pressure” and “High Coolant Temperature”...

  • Page 32: Stopping Operation

    9-3. Stopping Operation CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the engine as they are still extremely hot. (1) Manual Start Turn the switches and breakers on the load side to OFF position. Turn the breaker on the operation panel to OFF position.
  • Page 33 Protection Feature List Earth Engine Warning Action Leakage Breaker Controller Automatic Indicator Cause Relay Trip display Shutdown Flash Abnormality Active Low Oil Activate due to low oil pressure in the engine      Default : 0.49  100 kPa Pressure High Coolant Activates due to high water temperature in the...

  • Page 34: Connecting With External Fuel Tank

    9-5. Connecting with External Fuel Tank CAUTION : FIRE  Always make sure that the Power Switch is OFF position when working on piping.  Always be sure to wipe up any spilled fuel.  After working on the piping, check that there is no fuel leakage. Turn the 3way fuel valve lever to the “A”...

  • Page 35: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/INJURY  Do not touch output terminals or internal electric parts while the generator is operating.  Do not open the check door when the Power Switch is in the ON position. It will cause injury by rotating parts such as cooling fans and fan belt. ...
  • Page 36 Every Every Every Every Every Every Every Description Daily Remarks 100 hrs 200 hrs 450 hrs 500 hrs 800 hrs 1500 hrs 2000 hrs Each parts  (Clean/Tightening) Engine oil  (Check/Add)  time Engine oil (Replace) at 50hrs  time Oil filter (Replace) at 50hrs...
  • Page 37 (1) Engine Oil Replacement First Time 50 hours Thereafter Every 200 hours Oil Filler Remove the oil filler cap. After removing the oil drain plug and packing Oil Level Gauge (a rubber seal is attached), drain the engine oil. Oil Drain Plug After the oil has been drained, reinsert the oil Packing drain plug with new packing(a rubber seal is...
  • Page 38 (3) Air Filter Element Cleaning/Replacement Clip First Time (clean) 50 hours Air Cleaner Thereafter (clean) 100 hours once in 6 times cleaning or Replace Every 1 year Remove the air cleaner clips and cleaner cap. Remove the element. Clean or replace the element. Replace by performing the above procedures in reverse order.
  • Page 39 (5) Fuel Filter Cleaning/Replacement Replace Every 450 hours Fuel Valve Open Close the fuel valve. Close Turn the retainer ring to the left and remove the cup Retainer Ring and element. Remove any water or foreign material from the cup Open and clean the element using compressed air.(Or replace the element.)
  • Page 40 (8) Coolant Replacement Radiator Plate Replace Every 2 years or Every 2000 hours Filler Neck Remove the radiator plate. Remove the radiator cap. Remove the coolant drain plug and packing. Radiator Cap After the coolant has been drained, reinsert the coolant drain plug with new packing.

  • Page 41: Long-Term Storage

    Clean Every 200 hours Accumulation of carbon (soot, unburned fuel) in the exhaust system could cause engine output loss and/or engine fault. To eliminate soot and unburned fuel, run the unit at more than 70% of the rated output for about half an hour, until the exhaust gas become mostly colorless.

  • Page 42: Troubleshooting

    (2) Double-Stacking Storage Procedures WARNING : INJURY Always be sure to observe the following items when double stacking this generator in a warehouse or similar location.  Check that the Top cover of this generator is not dented, and that bolts are not loosen or missing. ...
  • Page 43 Problem Suspected cause Action Starter motor 1. Battery output is weak. 1. Check / battery liquid/ or does not drive Charge. or speed is low 2. Battery is deteriorated. 2. Change battery. 3. Battery terminal is OFF or loose. 3. Fix / Tighten terminal. 4.
  • Page 44 Problem Suspected cause Action White smoke comes 1. Too much or too little oil to cylinder. 1. Ask our distributor to repair. out from muffler 2. Water is interfused in fuel line. 2. Drain water in water separator, fuel filter or fuel tank.

  • Page 45: Generator Circuit Diagram

    13. Generator Circuit Diagram (1) 400/440V...
  • Page 46 (2) 200/220V...

  • Page 47: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 48 ©2019...

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