Shindaiwa DG1000MI manual

1 Safety Guidelines 2 Specifications 2.1 S pecification Matrix 2.2 Ambient Condition 3 Use 4P a r t s 4.1 External View 4.2 Control Panel 5 Equipment 5.1 Monitor Display 5.2 Gauges 5.3 Fuel Line Changeover V alve 6 T ransport ation and installation 6.1 T ransport ation 6.2 Installat ion 7 Connection 7.1 Selecting Cable 7.2 Connecting Cable 7.3 Eart[...]

- 1 - Introduction Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator . z This user ’ s manual was created to ensure the safe operatio n of this equipment. Therefore, the manufacturer of this equipment strongly recommends that the user follow the instructions herein, to avoid unnecessary accidents and rep airs. z Please operat[...]

- 3 - 1 Safety Guidelines :Suffocation from ex h aust fume  Exhaust fume from the engine conta i n s m any el e ments harmful to human. Do not operate this equipment in poor ly ventilated area, such as inside a room or in a tunn e l :Electrical Shock  Do not touch the output terminals during oper ation.  Be sure to place covers over the ou[...]

- 4 - :Injuries to ey es a nd skin  Battery fluid cont ains d i luted su lfuric acid. Avoid cont act with eyes, skin or on clothing . If the acid comes in contac t, especially w ith eyes, flush with a lot o f water , a nd contact y our physician immediately . : Explosion  Do not use the equip m e nt or charge the batte ry , in the case the ba[...]

- 5 - :Injuries  W h en lift i ng the equipment, alway s use a lift hook.  Do not use Side rope-throu gh, for it may cause equipment to drop .  Always pl a ce the equipment on a fl a t and stable surface , to keep the e qu ipment from sliding.  W h en star ting the e ng i n e, turn off the connected equipment and set the cir c uit break[...]

- 6 - Location of W arning labels When the warning labels become unreadable or damag e d, place new labels on the appropriate location, as spec i fied in the following figure. W hen orde r ing the label, use follow ing part nu m bers. 1 Operational Instruction Part Number 19401 - 00 361 2 Safety Instruction Part Number 19402 - 00 188 3 Suffocation [...]

- 7 - 2 Spec i fica tions 2.1 S pecification Matrix Name of Gen erat o r DG1000MI-400 T ype Unit Blushless, Rotating Field, 3-Phase, 4-Po le, Synchronous AC Generator kV A 80 100 Rated O u tput kW 64 8 0 Rated V oltage (or the below ) V 200 220 Rated Curr ent (or the below) A 231 262 Rated V oltage V 400 440 Rated Curr en t A 1 15 131 Frequency Hz [...]

- 8 - 2.2 A mbient Condition Use the equipmen t under the following a mbient condition. The other condition may cause trouble, insuffic ient output powe r or deterioration of durabi lity . Ambient T empera ture : -15ºC 40ºC Humidity : less than 80% Altitude : less than 300m 3 Use  Power source for cons truction –use equipment, su ch as subme[...]

- 9 - 4.2 Control p anel No. Name No. Name 1 3-phase circuit breake r 1 1 Wat er T emperature Gau ge 2 1-phase circuit breake r 12 Oil Pressure Gauge 3 V oltage Mete r 13 Fuel Gauge 4 Amp Meter 14 Hour Meter 5 Frequency Meter 15 Emergency S top Button 6 Earth Leakage Relay 16 Preheat Lamp 7 Panel Light & Generat ing Lamp 17 S tarter Sw itch 8 V[...]

- 10 - WA TER TE MP 5 Equipment 5.1 Monitor Display This generator is equ i pp ed with m on i tori n g functi on fo r water /coolant temperature, oil pressure, battery charge, air filter flow , batte ry fluid level, and fuel level. When the e q uip ment is s tarted u nder normal condition, Oil Pr es sure and Battery Charge l a mps will flash whe n [...]

- 11 - If the water leve l is n ormal, check for loose f an b elt o r poss ible w ater lea k in the c o o ling system, afte r the engine is coo led down. <Caution>  I f the w ater l ev el is too low , the sensor cannot detect the w ater temperature. Be sure to chec k the wat e r l eve l in the radiator and the Coolant r eserv o ir tank pri[...]

- 12 - 0 0 0 0 0 HOUR METER 5.1.3 Battery C ha rge Monitoring Lamp (c harge lamp) W h en the battery is not ab le to be charged d ur ing operat ion, t he battery charge-monitoring lamp will flash. In the event this occurs, sto p the engine consult with the authorized distr ibutor or our engineering section . <Caution>  Battery Charge Monit[...]

- 13 - 5.2.4 Fuel Ga u ge It shows the volume in the fuel tan k . W hen filled up , it show s F . W h en the hand is approach ing to E , the volume is coming to e mpty . Replenish fuel enough pr om p tly . 5.2.5 Generato r Ga uges 5.2.5.1 V oltage Meter V oltage M e ter display s the output vo ltage (Phase t o Phase ) from the generator . Please ch[...]

- 14 - 5.2.6.2 Panel Li ght / Pilot Lamp Pilot Lamp indicates w hether or not generator is g enerating electric ity , when the engine is driv ing. 5.2.7 S w i tch 5.2.7.1 St arter Switch STOP W h en the switch is set to this position, all powe r will be of f. The switch must be se t to this position to remove the key . RUN The switch must be se t t[...]

- 15 - Thermal Relay 5.2.7.4 Thermal Relay This relay se nds the s i g n a l to the 3-Phase c ircuit brea k er a n d the 1-Phase breaker to trip-o ff when over-current flows in the c ircuits. W h en the breaker trips-off, it is set at the m id dle o f ON and O FF . In the case, please recover the brea k er , according to the following procedure; S [...]

- 16 - FIXING SC REW N UT FREQUEN CY ADJUSTING SCR E W THROTTLE LEVER 5.2.8.2 Throttle Lever Throttle Lever The lever is to ad just the engine speed. Set it to IDLING when the engine sta rts and warms-up or cools dow n. W h en the rated pow er is used, set it to RUN (50 or 60Hz). Frequency Adju sting Screw Set the th rottle lever to RUN and loosen [...]

- 17 - <Caution>  Always set the lever for 3-way valve b ac k to A position and cover t he external fue l inta ke and return port with the supplied plugs, a fter the hoses a r e re m oved. 5.3.2 Using fuel from external fuel ta n k Connect hoses fro m the external fuel t a n k to the external fue l in take a n d the external fuel return po[...]

- 18 - 6 T ransport and Inst allation 6.1 T ransportation :Injuries  W h en lift i ng the equipment, alway s use a lift hook.  Do not use Side rope-throu gh to attach y our l ift h ook, f o r i t may cause equip ment to drop. 6.1.1 Lif ting Equipment Alway s use a Lift H oo k, when lifting the equipme nt f or transporta t ion . 6.1.2 T ranspo[...]

- 19 - 6.2 Inst allation :Suffocation from ex haust fume  Exhaust fume from the engine conta i n s m any el e ments harmful to human. Do not operate this equipment in poor ly ventilated area, such as inside a room or in a tunn e l :Suffocation fr om exhaust fume  Do not point the exhaust fume toward pedestr ians or building. :Fire  Always [...]

- 20 - :Electrical da mages  If the load exceed s the allowa ble amperage, the overheat ing may da m age the cable.  If the cable i s either t o o l o n g or too small a gauge, there will be greater vo l t age dro p to loads, which m a y result in reduced performance in t he c o nnect e d loads , m a lfunction, or damages. <Caution> [...]

- 21 - 7.2 Connecting Cable :Electrical Shoc k  Before connecting o r disconnecting a loa d cable from ou tput t er m in als, a lways tu rn a circuit breaker to OFF po sition, s top the eng ine, a nd remove t h e engine key . A person p erformi ng the maintenance shou ld always keep the key . : Fire  Do not connect AC output to any indoor w i[...]

- 22 - 7.2.1.3 For 1-Phase Load(2) T erminal V o ltage: 200V/220 V (or 400V/440V) at 5 0Hz/60Hz 7.2.2 1-Phase O utput T erminals & Recept acles The ter minal V oltage : 1 00V/1 10V at 50Hz/60Hz only In the case of no use o f 3-Phase output pow e r , refer to the Following dra wing and chart. V oltag e (100V/1 10V) only (Unit: kV A) U1-U0 W 1- W[...]

- 23 - 7.3 Earth Leakage Relay and Grounding : Electrical Sh ock  Ground the every earth grounding terminal to the earth as set o ut i n the m a nual. If e ven one of all is unconnected by m is take or acciden t, it will b e m u ch mo re dangerous for human body than the –relay case , because leaking current inev itably goes thro ugh the body [...]

- 24 - GROUNDING ROD EAR TH GROUNDIN G TERMINA L BONN ET GROUNDI NG TERMINA L INDI CA TING LAMP EAR TH LEAKAGE RELA Y TEST BUTTON RESET BUTTON <Caution>  In the even t y ou cannot ground the generator to the earth, co nsult w ith the authorized distributor o r our engineering section 7.3.2 Operat ion Check :Electrical Shock  Before turn[...]

- 25 - 7.3.3 The earth leakage breaker relay has activa ted In the even t the earth leakage breaker relay ha s activated, t h e earth leakage indicating l a mp T urns ON and the 3-Phase ea rth lea kage breaker ( le ve r) trips of f to b e positioned in the middle between ON and OFF positions. In the a b ove cond i t ion, even t h ough y ou stop the[...]

- 26 - OIL FILLER OIL GAUGE OK NOT ENOU GH TOO MUCH LOWER LIMIT UPPER LIMI T OIL GAUGE 8.1 Checking Engine Oil Please refer to the us e r’s manual for Eng i ne sep arately W h en checking f or eng ine oil, be sure to k eep the equipment leveled, and insert the oil gauge all the w ay . Prior to s t a r ting the equip ment, m a ke sure to fill the [...]

- 27 - FULL LOW 8.2 Checking Coolant/water Also refer to the User’s Manual for Engine :Injuries  B e f o re pe rf o rmi ng any equipment check or maintenance, stop th e engine , and re move the engine key . A person performing the maintenance should alway s k eep th e key . :Burns  D o not ope n t he radiator cap while operating this equipm[...]

- 28 -  Replace LLC every 2 y e a rs or 1000 hours Mixture ratio (for reference only) : Ambienr temperature (Celsius) -15 -20 -30 Mixture ratio 30% 35% 45% 8.2.3 Coola nt Capac ity ( Unit: L) T ota l Coolant V olume ( including reservoir ta nk) 22.8 (1.5) T h e value of ( ) shows the reservoir ta nk`s volume. 8.3 Checking Fan Belt Also refer to [...]

- 29 - 8.3.2 Conditio n Check for any da mage on the fan belt. Replace if necessa ry . <Caution>  Refer to the User’s manual for Engine for adjusting and replacing o f the fan belt. 8.4 Checking Fuel :Fire  Alway s w ipe any drip of Diesel fuel or o i l. Do not use this e quipment when a leak is found. Repair the equ i pment be fore u[...]

- 30 - Notice: Do no t use home hea t ing oil o r gasoline in y our diesel eng ine; either ma y cause engine damage. 8.5 Checking Fuel, Engine Oil, and W ater le akage :Fire  Do not use this equipment w hen a leak is found. Repair the eq uipment before use. Be sure to check for a ny fuel leak at the hose connection, and oil and coolant leak by o[...]

- 31 -  Replaci ng the battery T wo batteries are connected in series order . Whenever you replace battery or dis connect cables, alway s p roceed with the following steps, otherwise battery ma y short-circuit. 8.6.1 Replacing the battery inst alled o n the lef t s id e toward the control p anel: Remove the clamp a n d cable from negative (-) po[...]

- 32 - FIXING SCREW FREQUENCY AD JUST IN G S CR EW THROTTLE LEVE R 9 Ope r ati on 9.1 Initializing / prepa ration :Suffocation from ex haust fume  Exhaust fume from the en g ine co n t ains many elements ha rmf u l to human. Do not ope rate th is equip ment i n poorly ventilated a rea , such a s i ns ide a roo m or in a tunne l :Suffocation fr o[...]

- 33 - <Caution>  Do not drive the sta rt e r motor for more than 10 seconds successively  If you need to resta rt, wait at least 30 se conds before the retry . Release the sta rt e r sw it c h, as soon as the engine is started Keep the engine idle f or a t least 5 minutes Set the throttle lever t o R UN. Ensure that the frequ ency mete[...]

- 34 - 9.2 200/400 V oltage Changeover - Dual V oltage System The generator is incorporated w it h dua l vol tage s ystem. So, you can easily change 400/440V to 200 /220V or adverse ly . Y o u can get 200V or 400 V by changing the combin ation of output ter minals with bus plates :Electrical Shock  Be sure to set the circu it breaker OFF and sto[...]

- 35 - 3-PHASE 400/440 V The 3-phase volt a g e is energized to the 3 -phase output termina ls. Refer to 7-2. Connec t ing cable S tarting t he engine and turning the 3-phase breaker to ON, the 3-phase current is sent to the 3-phase output ter minals. 9.3 During Operation 9.3.1 P ost startu p c heck  Make sure that a ll meters (gauges) a nd disp[...]

- 36 - :Fire  Always w ipe a ny dri p o f ga soline or oil. Add fuel to the fue l tank T urn the s tarter switch to <RUN> position. It will take app roximately 30 seconds to vacuum the air ou t. <Caution>  Ensure that all the air is completely e xtracted from fuel line, by setti n g the throttle lever to IDLING and sta rt the engi[...]

- 37 - EXTER NAL FUEL INT AKE (PLUG : PT -1/2) EXTE RNAL FUEL RETURN (PLUG : PT -1/2) 3 - Way va l ves A posi tion 3-Way valves 9.6 Connecting to External Fuel T a nk :Fire  Alway s stop the engine , w hen w orking on the fuel line.  Alway s w ipe any drip of Diesel fuel or o i l. Do not use this equ ipm e nt when a leak is found. Repair the [...]

- 38 - 10 Maintenance :Electrical Shock ● Injuries  B e f o re pe rf o rmi ng any equipment check or maintenance, stop th e engine , and re move the engine key . A person performing the maintenance should alway s k eep th e key . :Fire ● Burns  W he n chec king e ngine, always s top the engine, and keep aw a y from fire. W a it until the [...]

- 39 - Description S tartup check Every 200hrs Every 400hrs Every 500hrs Every 1000hrs Engine Side Clean each part s / tightening Engine oil checks / add oil Engine oil change ( 1 st time at 50 hr mark ) Oil Filter change ( 1 st time at 50 hr mark) Coolant level chec k / add coolant Exhaust color check Coolant change or 2 yr . Drain ex c e ss w ate[...]

- 40 - 10.1 Oil Change Remove Oil Filler cap Loosen the engine o il drain plug and a llow the oil to drain fully Reinstal l the drain plug Add oil from oil filler an d fill up to the MAX level . Y ou should check the oil level on the o i l gauge Reinstal l the filler cap hand-t i ght <Caution>  For the ty pes o f e ng i n e oil to u se a n[...]

- 41 - 10.3 Cleaning / Changing A ir Filter Elem e n t Clean E ve ry 200 hours Replace Every 500 hours Loosen the bo lt that is holding the a ir cleaner and re move the cleaner ca p Unscrew the wing nut and remove the filter element Clean or replace the filter element, and reins tall it in reverse order <Caution>  Always make sure that th [...]

- 42 - 10.4 Draining W ater from W ater Se p arator W h en a float ( red) is at drain level, dra in water . Loosen the drain plug an d drain water . Screw the drain plug , w hen finishing drain. <Caution>  Afte r draining finishes, ex tract the air in fue l lin e . (Refer to 9-3 During operation. ) 10.5 Cleaning / Changing Fuel Filter Loos[...]

- 43 - 10.6 Clean gauze filter in water sep arator Clean Every 500 hours Loosen the lever and the n loosen the air extraction plug. T urn the ring nut counter -clockwise to remove the cup a nd the ga uze filt er after the fuel inside does no t come out from the l ever . Wa sh the gauze filter in Diesel fuel and reinsta ll the unit in the reverse or[...]

- 44 - <Caution>  Put a tray under the l e v er in order to catch spilled fuel wh en loosing the lever .  Gaskets are attached to both end s of joint pipe. Be careful not to lose and install them in the unit without fail.  Change both gauz e filter and eyeb o lt when gauze filter is damaged .  Extract the air in fuel line after ga[...]

- 45 - 10.9 Draining W ater from Fuel T ank Drain wate r Every 200 hours Unscrew the F uel drain plug Reinstall t he drain plug, after draining water fully 10.10 Changing Coolant / W ater Replace Every 2 ye ar s or 1000 h ours Remove the radia tor cap cover Remove the radia tor cap Loosen the draining plug on both the engine and radiator Afte r d r[...]

- 46 - 1 1 long-term S torage : Electrica l Shock ● Injuries  Before performing any e quipment check or ma intenance, stop the engine, and remove the engine key . A person performing the maintenance should alway s keep th e key . :Fire ● Burns  T emperature around mu ffler and exhaust can ge t ex tremely high. Keep any i nflammable items [...]

- 47 - 1 1.2 St acking :Injuries  If y ou have t o st ack two generators in w arehouse, alway s proceed w ith the following step s .  E nsure that there is no d ent on bonnet, loosing b olt or no bolt in the gener a tors.  Al w a y s pla c e the generators on a flat and stable surface, to keep the equip ment from sliding,  A nd to b e e[...]

- 48 - 12 T rouble shooting :Electrical Shock  Do not operate the equ ipment, if the equip m ent or you are wet.  Before performing any eq u i p ment check or maintenance , stop the engine. :Injuries  W h en per forming equipment check a nd maintenance, alw ays stop the engine. :Fire ● Burns  Battery may emit some combustible gas, so [...]

- 49 - Symptom Presumabl e Cause Action S tarter motor does not drive or speed is low . 1. Batter y ou tput is weak 2. Batter y i s d eteriorated 3. Batter y terminal is OFF or loo se 4. Batter y terminal is cor roded 5. S tart er switch or relay is defec tive 6. S t arter motor is defect i ve 1. Check / battery liquid/ or Charge 2. C ha nge ba tt [...]

- 50 - Overheated 1. Engine thermostat is defective 2. Water temp sensor i s defect i ve 3. Water temp meter i s defect i v e 4. Fan b elt tension i s w eak 5. Coolant is insufficient 6. Radiat or core is clogged 1. Ask our distributor t o repa ir 2. Ask our distributor t o repa ir 3. Ask our distributor t o repa ir 4. Chec k/Adjust fan belt 5. Che[...]

- 51 - 13 Generator Wir ing Diagram[...]

- 52 - 14 Engine Wiri ng D i agra m[...]