Shindaiwa DGK25F User manual

File №DGO-391_DGK25F
SERVICE MANUAL
DGK25F

WARNING
This equipment is designed and built with safety in mind. However, your overall safety can be
increased by your full understand followed by the content in this manual.
Read this manual and familiarize yourself with its contents for your safety.
This equipment should only be operated and maintained by trained and qualified personnel.
This equipment is designed for generating power source of electric tools, home appliances and lights.
Do not install, operate or service this equipment without reading this manual and unless you clearly
understand this manual.
This service manual is edited for authorized person to perform repair,
maintenance, and trouble-shooting to Shindaiwa diesel engine generators,
designated as DGK25F
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 equipment
available at the time of publication. hile 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. e 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 orkshop (Service) Manual provided by
the engine manufacturer described below.
MANUFACTURER
MODEL
REMARKS
ISUZU
4LE2TA Tier 4

File №DGO-391_DGK25F
Table of Contents
1. Attention Statements ················································································ 1
2. General Safety Instructions ·····································································
3. Specifications ······························································································ 4
4. General ········································································································· 5
4-1 Dimension ·························································································· 5
5. General Parts Description ································································ 7
5-1 Main Parts and Feature ········································································· 7
5- Main Components ················································································ 8
6. Ser vice Data ······························································································· 1
6-1 Technical Specification ········································································ 1
6- Generator ························································································· 13
(1) Exciting Amperage ········································································· 14
( ) Resistance Value ··········································································· 14
7. ightening orque ······················································································ 17
7-1 Specific Tightening Torque ·············································································· 17
7- General Tightening Torque ·············································································· 18
8. Periodical Check for Engine ···································································· 19
9. rouble Shooting ························································································ 0
9-1 Engine ····························································································· 0
9- Generator ························································································· 0
10. Engine Error Code ···················································································
10-1 Engine Code (Digital Display) ······························································
10- Error Code (Flash Pattern) ··································································
10-3 After Repair ····················································································· 4
10-4 Elimination of “Repair” Malfunction························································ 4
11. Wiring Diagram ············································································· 6

1
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.
A statement preceded by the triangular attention symbol and the word “ ARNING”
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.
WARNING
CAU ION

2
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
stopped before you will connect the loads to
the output terminals.
Suffocation by exhaust gas
NEVER run the engine indoors! Make
sure there is a ways good venti ation.
Fumes from engine exhaust cause
serious injury.
ALWAYS operate the equipment in the
ventilated area.
hen the equipment is used in a tunnel, hall
or any other indoor, the equipment for
ventilation must be used to prevent serious
accident caused by suffocation.
NEVER direct the exhaust fume to
houses nearby while considering the wind
flow direction.
Exhaust gas contains many harmful
elements that would cause affect to human.
Be free from 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 and touch the moving
component 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 serve and inspect when equipment 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 violate or abnormal
noise. 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
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.
WARNING

3
Work Safe y
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 and serve this equipment!
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.
・Check the caution labels is 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 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.
STOP the equipment immediately when
abnormal circumstances are noticed!
STSTOP the equipment immediately whenever
abnormal circumstances are noticed such
as unusual noise, smell, vibration and etc.
It may lead serious accident or fatal damage
of the equipment or properties.
Inflammables！
Keep the equipment far away from fire such
as cigarettes when refueling 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 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.
CAU ION

4
3. Specifications
Model Unit DGK 5F
Alternator
Generator Type - Revolving Field Brushless
Rated Frequency Hz 60
Rated Output(Prime)
Three phase kVA
5
kW
0
Single phase kVA
15 [7.5] *1
kW
15 [7.5] *1
Standby Output
Three phase kVA
7.5
kW
Single phase kVA
16.5 [8.3] *1
kW
16.5 [8.3] *1
Rated Voltage Three phase V 08/ 40/ [480] *1
Single phase V 1 0/139/ 40/[ 77] *1
Rated Current
Three phase- 08V
A 60
Three phase- 40V
A 60
Three phase-480V
A 30
Single phase-1 0V
A 6 .5× [31.3 x ]*1
Single phase- 40V
A 6 .5 [31.3]*1
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) - 4LE T(ISUZU)
No. of Cylinders
(bore × stroke) (in./mm) 4(3.35x3.78/85x96)
Continuous Rated
Output hp
33.5
Rated Speed rpm 1,800
Displacement
cu.in.
/liters
133
/ .179
Combustion System - Direct injection
(T rbo-charged)
Cooling Method - Water cooled
Starting Method - Electric
Fuel - No. -D,S15 EPA regulation
Lubricating Oil - API service-type CJ-4 class
Fuel Tank Capacity
gal.
/liters
51.5
/195
Lubricant Volume
gal.
/liters
2.7
/10.4(including filter
0.1
/0.4)
Cooling Water Volume
gal.
/liters
2.6
/10(including sub-tank
0.3
/1.0)
Starting Motor Capacity
V-kW 1 - .0
Charging Alternator Capacity
V-A 1 -50
Battery Capacity V-Ah 1 -7
Unit
Length
in.
/mm
63
/1,603
Width
in.
/mm
33
/850
Height
in.
/mm
55
/1,400
Dry Weight
lbs.
/kg
1,929
/875
Net Weight
lbs.
/kg
2,359
/1,070
*Specifications subject to change without notice.
**Generating application is 60Hz ONLY.

5
4. General
4-1 Dimension
Unit in the drawings below is shown by mm.

6

5. General Parts Description
5-1 Main Parts and Feature
(1) Serial Number
Unit Serial Number
Engine Serial Number

8
5-2 Main Component
⑳
Voltage Selector Switch
Feature: Switch to change the voltage.
Caution
This switch shoul never be change while the generator is running or serious
amage may occur.

9
Panel Inside
Engine Operation Switch Table
Nomenclature
Function
Remarks
ISOCHLONOUS Maintain rate spee (1800 rpm)
automatically at any loa factor.
SPEED INC. Increase rpm. per 10 sec/Hz. Increase up to 110% of rate rpm.
Spee Manual switch ON.
SPEED DEC. Decrease rpm. per 10 sec/Hz. Decrease own to 1000rpm.
Spee Manual switch ON.
MEMORY CLEAR Clear recor of the engine fault.
1. Starter Switch ON.
2. Push Memory Clear switch for 3 sec.
3. Memory Clear switch ON.
4. Turn Starter Switch “STOP” an ,
after10 sec., turn the switch
“RUN”.
Refer to “How to clear Trouble Code” in
“Engine Troubleshooting Manual”
prepared by Isuzu for details.
AVR
Engine
O
peration
S
witch
ECM
(Engine Control Mo ule)
Feature: Control engine in
accor ance to emission
stan ar .

10
Output Terminal Cover Inside
Engine
Terminal Rest
Feature: Relay terminal
block of the power output
from the alternator.
Circuit Breaker (
-
Phase)
Feature: Protect electrical circuit
from amage cause by
overloa or short-circuit.
Circuit Breaker (
-
Phase
240/ 20
)
Feature: Protect electrical circuit
from amage cause by
overloa or short-circuit.
-
Phase Receptacle (20A)
Feature: Supply AC output.
-
Phase Receptacle C (30A)
( 20/240V)
Feature: Supply AC output.

11
Accessory
Sta
ndard Accessory
① Owners Manual
② Starter Key – 2 sets
③ Warranty Statement
④ Instruction Manual of
the engine
Air Cleaner
Feature: Clean intake
air.
Pre Fuel Filter
Feature: Filter water
or ust in the fuel.
Main Fuel Filter
Feature: Filter water
or ust in the fuel.

12
. Service Data
ELECTRIC SHOCK
WARNING
Never touc t e 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.
6-1 Tec nical Specification
Items Reference Val e Note
Ins lation
Armat re
winding 3MΩ or more DC500V
Megger Tester
Exciter field
Preheat time
Preheat time wo ld be approx. 5 sec.
when coolant temp. read -15℃ and
it wo ld be 2 sec. when coolant temp.
read 20℃. Glow lamp ON for 10 sec.
A tomatic
Preheat System
Min. rpm at no load 1000±50 min
-1
Max. rpm at no load 1930 min
-1
L bricant oil press re 0.1~0.49MPa{1~5kgf/cm²}
Coolant temperat re 70~100℃
Frame temperat re limit within 80℃
Sealed bearing temperat re limit within 80℃
Speed reg lation Momentary within 10%
Steady-state
deviation within 5%
Voltage reg lation
Momentary within 20%
Steady-state
deviation within 1.0%
Freq ency Idle: 33.3 Hz
Rated: 60 Hz
Variable voltage 456~504V
Protective device Low oil press re
Working pressure
Low oil
pressure Working press re
0.098MPa{1.019±0.2kgf/cm²} [Close] when
activated
High water
temp.
Working
temperat re 110±2℃

13
6-2 Generator
Stator
Rotor
Rotor
Exciter field
Main bearing
Exciter armature
Main stator
Fan cover
Armature
T
hermo label
R
ear bracket
Bolt
Exciter stator
T
hermo label

14
(1) Exciting Amperage
Amperage fluctuates based upon the winding temperature. Following is for reference only.
Freq ency/Rated O tp t Load Exciting Amperage (Measured)
3-Phase 60Hz: 20 kW No load 0.34A
F ll load( power factor=1.0) 0.60A
( ) Resistance Value
Nominal resistance of the winding is tolerated within ± 10% at 0℃ of the ambient temperature.
The resistance must be measured by low resistance tester. It can not be measured by
multi-purpose tester due to index error.
Measurement value (Ω）
Main Stator Exciter Stator Rotor
1 2 3 4 5
Armature Exciter Win ing
J－K Exciter Fiel Armature
Between
1-2 (L1)
2-3 (L2)
3-1 (L3)
A – B
B – C
C – A
- - -
#1
0.65 Ω 1.35
Ω 23.2 Ω 13.4 Ω 2.7 Ω
#2
0.16Ω
1. Arma ure (Main S a or ) #
Measure he resis ance among he U-W by he low ohm es er. Each shall be 0.16 x 4=0.65Ω.
(B) (W) (R) (G) (Y) (Br) (L) (Or) (Gr)
(Vi)
Black
White
Red Green
Yellow
Brown
Blue
Orange
Gray
Violet
1-2 (L1)
2-3 (L2)
3-1 (L3)
when the voltage selector switch is
set at 480V：

15
2. Arma ure (Main S a or ) #2
Measure he resis ance among he U-W by he low ohm es er. Each shall be 0.16Ω.
3. Exci a ion Winding (Main S a or)
Remove the wire harness from the AVR and measure;
The resis ance among A~B, B~C and C~A by he low ohm es er. Each shall be 1.34Ω.
C B A
AVR
when the voltage selector switch is
set at 40V：

16
4. S a or J (Gray)－ K(Viole )
5. Ro or
There are two windings in the rotor and measure the resistance between #1~#4 and # ~#3.
Rotor
Measure resistance among the J~K by the low ohm tester. It shall be 23.2Ω.
K (Vi) J (Gr)
Remove the varnish by a sand paper and measure;
Exciter Field : he resis ance among he wo poin s as shown in he pho o above by
he low ohm es er. I shall be 13.4Ω.
Armature : he resis ance among he wo poin s as shown in he pho o above by he
low ohm es er. I shall be 2.7Ω.
#1
#4 #3
#
Rectifier

1
7. Tightening Torque
7-1 Specific Tig tening Torque
No Nomenclat re
Part to
be
tighten
Size Qty
Torq e
Allowance
Nm(kgf/cm)
Reference
1 Exciter Stator Bolt M5x45 4 3.0-4.9
(30-50)
2 Rear Bracket
(Main Stator) Bolt M12x160 4 29.5-32.3 (300-330)
3 Generator Stator Bolt,
Shim M10x30 8 19.7-24.5 (200-250)
4 Rotor Bolt M10x1.25x30
4 40.7-49.5
(415-505) 7T
5 Fan Bolt,
Shim M8x25 6 9.9-14.7 (100-150)
6
Front Bracket
(Alternator Assy
to install)
Bolt M10x1.25x25
8 40.7-49.5
(415-505) 7T
7 Engine Stay Bolt M10x1.25x25
8 28.5-34.3
(290-350)
Small Head
(Opposite
Side
Distance
14)
8 Socket Drain
Pl g M12x1.25x13
3 39.3-49
(400-500)
9 Flexible T be Flange
N t M8 6 17.7-21.5 (180-220)
10 Terminal Rest
(Welding Terminal)
N t M10 4 17.7-21.5
(180-220) Brass
11
Battery
(Terminal
Attachment)
N t M8 2 5.0-6.0
(50-62)
Battery
Accessory
12 Battery
(Wiring) N t M8 2 6.9-8.8 (70-90)
Battery
Accessory
13 Glow Pl g
(Terminal) N t M4 1 1.0-1.7 (10-18)
Engine
Accessory
14 Oil Press re
Switch
Bolt,
Shim M4x8 1 1.4-1.9 (14-20)
Engine
Accessory
15 F el Strainer Bolt M8x65 1 17.7-21.5
(180-220)
Opposite
Side
Distance
12