Shindaiwa DG25MK Owner's And Operator's Manual
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Shindaiwa DG25MK Owner's And Operator's Manual

Shindaiwa DG25MK Owner's And Operator's 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-400
X750-026 52 1
X750801-610 1

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Summary of Contents for Shindaiwa DG25MK

  • 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-400 X750-026 52 1 X750801-610 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 Safety Instructions ................2 2. Specifications ................... 5 2-1. Specifications ................5 Applications ..................6 Part Names ..................6 4-1. External View/Part Names ............6 4-2. Operation Panel Part Names ............ 8 Equipment ..................9 5-1. Warning Indicators ..............9 5-2.

  • Page 5: Safety Instructions

    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 Before connecting or disconnecting the load cables to/from the output terminal, always turn the output circuit breakers to the OFF position, stop the engine, and remove the engine key.
  • Page 6 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.
  • Page 7 CAUTION : PROPERTY DAMAGE 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.

  • Page 8: Specifications

    2. Specifications 2-1. Specifications Model Unit DG25MK-400 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 9: Applications

    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 degree Celsius ■ Relative humidity: 80% or less ■...
  • Page 10 Radiator Plate Radiator * Shown with side-plate removed. Fuel Filter Oil Filler Air Cleaner Coolant Sub-Tank Alternator Check Door Engine Check Door Oil Level Indicator Battery Oil Filter Water Separator 3way Fuel Valve External Tank Fuel Inlet External Tank Fuel Return Fuel Drain Plug Oil Drain Plug Coolant Drain Plug...

  • Page 11: Operation Panel Part Names

    4-2. Operation Panel Part Names Circuit Breaker Pilot Lamp ① ⑪ Voltmeter Starter Switch ② ⑫ Ammeter Voltage Regulator ③ ⑬ Frequency Meter Throttle Switch ④ ⑭ Water Temperature Gauge 400/440V Output Lamp ⑤ ⑮ Fuel Gauge Frequency Selector Switch (inside) ⑥...

  • Page 12: Equipment

    Equipment 5-1. Warning Indicators 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.

  • Page 13: Meters And Gauges

    (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 gushing out. If the engine oil pressure drops below 0.49 x 100 kPa during operation, the OIL PRESS and ENGINE warning indicators light up, and the engine automatically stops.
  • Page 14 (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 75 to 90 ° C. < Note> If the temperature exceeds normal value, disconnect the load, idle the engine at 1000min , and wait until the reading falls to the normal temperature range.
  • Page 15 Refer to the circuit drawing below if using the Aux Lamp Terminal for a lamp or similar device with a different setting. < Note > Connect a lamp that is DC12V/2A/24W or less to the Aux Lamp Terminal. Pre-caution lamp flushing may take time, as thermal relay detects overload by bimetallic strip systems.
  • Page 16 Voltage Regulator and Throttle Lever (1) Voltage Regulator The dial adjusts generator output voltage. By turning the dial clockwise, an operator can increases the voltage. By turning the dial counter-clockwise, an operator can decrease the voltage. (2) Throttle Switch The switch is to change engine speed (revolution). Turn the switch to [IDLING] when engine start, warm-up or cool-down, and turn to [RUN] when using the equipment at the rated speed.

  • Page 17: Fuel Piping Switch (3Way Fuel Valve)

    (2) Thermal Relay (Over Load Pre-caution Lamp) If changing the frequency or voltage, change the Thermal Relay (Over Load Pre-Caution) Thermal Relay (Over Load Pre-caution Lamp) adjustment dial according to the following table. FREQUENCY 50Hz 60Hz Output Volt 380V 400V 415V 380V 440V 480V Adjustment Dial Value 5-3.

  • Page 18: Transporting/Installing

    Transporting/Installing 6-1. Transport Procedures WARNING : INJURY Do not lift up the unit using tie down. Use of such could result in the generator falling. No persons should be under a lifted generator. CAUTION : INJURY Always be sure to use lifting hooks when lifting up the generator, and raise it slowly at a completely vertical angle.

  • Page 19: Load Connections

    If installing this generator, set up barriers or fencing completely around the boundary line of the construction area and take measures to prevent persons not involved in the construction from entering the area. Always set the generator on a hard, flat and leveled surface that serves as the foundation.

  • Page 20: Connecting Load Cables

    7-2. Connecting Load Cables WARNING : ELECTRIC SHOCK Before connecting or disconnecting the load cables to/from the output terminal, always turn the output circuit breakers to the OFF position, stop the engine, and remove the engine key. The person performing the maintenance should always keep the key. Close the output terminal cover before operating.

  • Page 21: Earth Leakage Relay And Grounding

    For 1-phase load: Terminal voltage is 400/440 V [200/220 V] (50/60Hz). * The values in brackets are for when set to 200/220V. Load Load 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 22: Pre-Operation Inspection

    Before operating the generator, check always if the device can work. ● Actuation test of the Earth Leakage Relay and Breaker Ensure that the breaker and the switches of Circuit Breaker loads are positioned to OFF. Ensure that the circuit breaker positioned to OFF.

  • Page 23: Checking Engine Oil

    8-1. Checking Engine Oil To check the engine oil, keep the equipment in leveled position, remove the oil level indicator and wipe so that no oil remains, and then re-insert the dipstick fully. Prior to starting the engine, make sure to fill the engine oil through the oil filler until it reaches the MAX line.
  • Page 24 Check that the subtank coolant level is in between FULL and LOW. If the subtank coolant is lower than the LOW level, add coolant to the subtank and radiator. (1) Filling the Sub-Tank Sub-tank Remove the sub-tank cap. FULL Fill the sub-tank with coolant until it reaches the FULL line.

  • Page 25: Checking The Fan Belt

    8-3. Checking the Fan Belt (1) Fan Belt Tension Press your finger against the middle of the fan belt. (approx. 98N) If the slack is 7 to 9 mm, the tension is normal. (2) Fan Belt Condition Check the fan belt for damage and replace if any damage Slack or other fault is found.

  • Page 26: Checking The Battery

    Open the check door and check for fuel, oil and coolant leakage from fuel piping connections and similar locations. 8-6. 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 27 WARNING : INJURY Always be sure to check that the breaker 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 before operating the breaker.

  • Page 28: Procedures During Operation

    < Note > Change the Frequency Selector Switch if the frequency in the area where using this generator changes. (Refer to "5-2.Meters,Throttle Lever,(3)Freqency Slector Switch") Adjust the voltage regulator dial to the specified voltage. 50Hz Operation 400V [200V] 60Hz Operation 440V [220V] * The values in brackets are for when set to 200/220V.

  • Page 29: Protective Functions

    Turn the switches and breakers on the load side to OFF. Turn the breaker on the operation panel to OFF. Turn the Throttle switch to IDLING. The engine cools down for approximately 3 minutes. Turn the starter switch to STOP. 9-4.

  • Page 30: Connecting With External Fuel Tank

    9-5. Connecting with External Fuel Tank CAUTION : FIRE Always make sure that the engine is stopped 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 31: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/INJURY Do not touch internal electric parts while the generator is operating. Do not open the check door during operation. Be careful of pinching or catching of moving parts such as the cooling fan and fan belt. Always be sure to stop the engine and remove the engine key when performing inspection or maintenance.
  • Page 32 Every Every Every Every Every Every Every Description Daily 1,000 1,500 100 hrs 200 hrs 400 hrs 500 hrs 800 hrs Each parts  (Clean/Tightening) Engine oil  (Check/Add)  Engine oil time  (Replace) 50 hrs  time Oil filter (Replace) ...
  • Page 33 (1) Engine Oil Replacement First Time 50 hours Thereafter Every 200 hours Remove the oil filler cap. Oil Filler After removing the oil drain plug and packing (a rubber seal is attached), drain the engine oil. Oil Level After the oil has been drained, reinsert the oil Indicator drain plug with new packing(a rubber seal is attached).
  • Page 34 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. < Note > Always be sure to turn the cleaner cap in the direction indicated by the arrow. Replace the elements earlier if using in an excessively Air Filter Elements dusty location.
  • Page 35 (5) Fuel Filter Cleaning/Replacement Cleaning Every 200 hours Replace Every 400 hours Close the fuel valve. Fuel Valve Open Turn the retainer ring to the left and remove the cup and Close Retainer element. Ring Remove any water or foreign material from the cup and clean the element using compressed air.(Or replace the Open element.)
  • Page 36 Fill the radiator with coolant until it reaches the Sub tank filler neck. Re-attach and tighten the radiator cap. FULL Attach the radiator plate. < Note > Refer to section “8-2. Checking Coolant” for coolant information. Replace the packing of the coolant drain plug with new Coolant Drain packing each time the coolant is changed.

  • Page 37: Long-Term Storage

    Accumulation of carbon (soot, unburned fuel) in the exhaust pipe line and muffler could cause only a system derates or an engine fault occurs. To destroy the soot and unburned fuel, run the unit at rated power for some period of time until the exhaust gas become mostly colorless every 200 hours operation time.

  • Page 38: Troubleshooting

    (2) Double-Stacking 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. Set in a location with a flat hard floor capable of withstanding the double-stacking weight.
  • Page 39 Problem Suspected cause Action Starter motor 1. Battery output is weak 1. Check / battery liquid/ or does not drive Charge or speed is 2. Battery is deteriorated 2. Change battery low. 3. Battery terminal is OFF or loose 3. Fix / Tighten terminal 4.
  • Page 40 Overheated 1. Engine thermostat is defective 1. Ask our distributor to repair 2. Water temp sensor is defective 2. Ask our distributor to repair 3. Water temp meter is defective 3. Ask our distributor to repair 4. Fan belt tension is weak 4.

  • Page 41: Generator Circuit Diagram

    13. Generator Circuit Diagram (1) 400/440V...
  • Page 42 (2) 200/220V...

  • Page 43: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 44 ©2015...

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