Shindaiwa DG1000MI User Manual

OWNER’S AND

OPERATOR’S MANUAL

Sound Proof Diesel Engine Generator

DG1000MI

CAUTION : Do not operate the Generator, or any other appliance,

before you have read and understood the instructions for use.

1 Safety Guidelines 2 Specifications

2.1 Specification Matrix

2.2 Ambient Condition

3 Use 4Parts

4.1 External View

4.2 Control Panel

5 Equipment

5.1 Monitor Display

5.2 Gauges

5.3 Fuel Line Changeover Valve

6 Transportation and installation

6.1 Transportation

6.2 Installation

7 Connection

7.1 Selecting Cable

7.2 Connecting Cable

7.3 Earth Leakage Relay and Grounding

8 Initialization and Pre-check

8.1 Checking Engine Oil

8.2 Checking Coolant/Water

8.3 Checking Fan Belt

8.4 Checking Fuel

8.5 Checking Fuel, Engine oil, and water leakage

8.6 Checking Battery

9 Operation

9.1 Initializing / Preparation

9.2 200/400 Voltage Changeover

9.3 During Operation

9.4 Stopping Generator

9.5 Protection Features

9.6 Connecting to External Fuel Tank

10 Maintenance 11 Long-term Storage 12 Troubleshooting 13 Generator Wiring Diagram 14 Engine Wiring Diagram

Page Table of Contents

2 6 6 7 7 7 7 8 9

9 11 15 17 17 18 18 18 20 22 24 25 26 27 28 29

29 31 31 33 34 35 35 36 37 45 47 50 51

- 1 -

Shindaiwa Corporation

71021-94310

Introduction

Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator.

z This user’s manual was created to ensure the safe operation of this equipment. Therefore, the

manufacturer of this equipment strongly recommends that the user follow the instructions herein,

to avoid unnecessary accidents and repairs.

z Please operate this equipment after thoroughly reviewing and understanding the contents of this

manual.

z Please attach this manual, if the equipment will be sub-leased.

z Please store this manual near the equipment for easy reference.

Following convention will be used throughout the manual to indicate the degree of cautions.

Danger

Caution

Can cause severe injuries or death.

Can cause minor injuries or damage to the equipment or other properties

<Caution> Other types of caution

z Even some of the items noted in may lead to severe injuries.

Caution

Please read all items and follow all the safety guidelines.

- 1 -

1 Safety Guidelines

Danger

:Suffocation from exhaust fume



Exhaust fume from the engine contains many elements harmful to human. Do not operate

this equipment in poorly ventilated area, such as inside a room or in a tunnel

Danger



Do not touch the output terminals during operation.



Be sure to place covers over the output terminals and fasten with fasteners.



Do not insert metal objects (such as pin or wire) into plug-in receptacles.



Do not touch wiring or any electronic parts inside equipment during operation.



Ground the every earth grounding terminal to the earth as set out in the manual.



If even one of all is unconnected by mistake or accident, it will be much more dangerous for

:Electrical Shock

human body than the NO RELAY case, because leaking current inevitably goes through the

body.



Even though all the earth terminals of the loads have been grounded to the earth, the earth

grounding terminal and the outer bonnet (canopy) grounding terminal should be grounded

to the earth.



There is always a danger of being electrocuted by short-circuit. Be sure to test generator’s

insulation resistance periodically.



Before connecting or disconnecting a load cable to/from output terminals, always turn a

circuit breaker to OFF position, stop the engine, and remove the engine key. A person

performing the maintenance should always keep the key.



Before performing any equipment check or maintenance, stop the engine, and remove the

engine key. A person performing the maintenance should always keep the key.

Danger

:Injuries



Close all doors and place locks during operating this equipment, to avoid injuries by

unintentionally touching cooling fan and fan belt.

Caution

:Suffocation from exhaust fume



Do not point the exhaust fume toward pedestrians or building.

- 3 -

Caution

:Injuries to eyes and skin



Battery fluid contains diluted sulfuric acid. Avoid contact with eyes, skin or on clothing. If

the acid comes in contact, especially with eyes, flush with a lot of water, and contact your

physician immediately.

Caution

: Explosion



Do not use the equipment or charge the battery, in the case the battery fluid level is lower

than the LOWER level.



Battery may emit some combustible gas, so keep it away from fire and sparks.

Caution

:Fire



This equipment uses Diesel Oil as a fuel. When refueling, always stop the engine, and keep

away from fire. Moreover, always wait until the engine cools down before refueling.



Always wipe any drip of Diesel fuel or Lubrication oil. Do not use this equipment when a

leak is found. Repair the equipment before use.



Temperature around muffler and exhaust can get extremely high. Keep any inflammable

items (such as fuel, gas, paint, etc.) away from the equipment.



Battery may emit some combustible gas, so keep it away from fire and sparks.



Always operate this equipment on flat surface and, at least 1 meter away from any objects

(wall, box, etc.).



Do not connect AC output to any indoor wiring.



Always wait until the equipment cools down, before placing any covering materials for

storage.

Caution

:Burns



Do not open the radiator cap while operating this equipment or immediately after stopping

the equipment, to avoid sustaining burns from hot vapor.



Do not touch the engine and muffler during operation and immediately after stopping the

equipment, for the temperature can reach extremely high.



When checking engine oil or changing oil, always stop the engine, and wait until the engine

cools down. If you open either the oil gauge or the oil filler cap during operation, hot oil may

cause some injury.

- 4 -

Caution

:Injuries



When lifting the equipment, always use a lift hook.



Do not use Side rope-through, for it may cause equipment to drop.



Always place the equipment on a flat and stable surface, to keep the equipment from

sliding.



When starting the engine, turn off the connected equipment and set the circuit breaker to

OFF position.



Do not move the equipment during operation.



When performing equipment check and maintenance, always stop the engine.



Do not operate the equipment, if the equipment is being modified or if the parts are

removed.

- 5 -

■

Location of Warning labels

When the warning labels become unreadable or damaged, place new labels on the appropriate location, as specified in the following figure. When ordering the label, use following part numbers.

1 Operational Instruction Part Number 19401-00361 2 Safety Instruction Part Number 19402-00188 3 Suffocation from exhaust fume Part Number 19402-00161 4 Electrical Shock Part Number 19402-00163 5 Injuries Part Number 19402-00167 6 Injuries Part Number 19402-00162 7 Burns Part Number 19402-00165 8 Burns Part Number 19402-00164

9 Fire Part Number 19402-00166 10 Lift points Part Number 19401-00153 11 Tie (Sleeper) Marker Part Number 19401-00207 12 Bonnet Grounding Terminal Part Number 19401-00206

- 6 -

2 Specifications

2.1 Specification Matrix

Name of Generator DG1000MI-400

Type Unit

Rated Voltage (or the below) V 200 220 Rated Current (or the below) A 231 262 Rated Voltage V 400 440

Alternator

Engine

Device

Panel

Rated Current A 115 131 Frequency Hz 50 60 Rated speed min Winding - 3-phase, 4-wire, Star with neutral Power factor % 80 Insulation class - H Excitation - Self-excitation with AVR No. of poles - 4 Types - Vertical Water-cooled 4-cycle Diesel Engine Model (Manufacturer) - DD-6BG1T(ISUZU) No. of Cylinders (bore x stroke) mm 6 (105 x 125)

Rated speed min Displacement L 6.494 Combustion system - Direct Fuel Injection with Turbo Charger Cooling method - Radiator Lubricating method - Forced lubrication Starting method - Electric start Fuel - Diesel Fuel （ASTM No. 2-D） Lubricant oil - CD class Fuel tank capacity L 219 Lubricant volume (Full) L 22 Cooling water volume L 22.8 Starting motor capacity V-kW Charging dynamo capacity V-A 24 - 30 Battery - 95D31R x 2 Volt/Freq/Amp meter - O Operation Voltage regulator - O Oil pressure, Water temp. - Lamp indication (Engine stops) Protection Battery charge - Lamp indication Hour meter - O Control

- Dimensions (L x W x H) mm 2750 x 1000 x 1400 Unit Dry weight kg 1800

Blushless, Rotating Field, 3-Phase, 4-Pole,

Synchronous AC Generator

kVA

-1

kW 73.1 91.2 Continuous rated output

PS 99.4 124

-1

80 100 Rated Output

64 80

1500 1800

24 - 4.5

- 7 -

EXTERNAL

FUEL INTAKE

EXTERNAL

WATER

SEPARATOR

FUEL DRAIN PLUG

COOLANT

INSPECTION

3-PHASE

EARTH

OUT TERMINAL

INSPECTION

1-PHASE

NNET

2.2 Ambient Condition

Use the equipment under the following ambient condition. The other condition may cause

trouble, insufficient output power or deterioration of durability.

■ Ambient Temperature : -15ºC ～ 40ºC

■ Humidity : less than 80%

■ Altitude : less than 300m

3 Use



Power source for construction –use equipment, such as submersible pump



Power source for lighting



Power source for electric tools and home appliances

4 Parts

4.1 External view

LIFTING LUG

DOOR FOR GENERATOR

ROPING LUG

FUEL FILTER

RADIATOR

DOOR FOR ENGINE

PANEL DOOR

OIL FILLER CAP

FUEL INTAKE

FUEL TANK

RESERVOIR TANK

DOOR FOR ENGINE

BATTERY

ROPING LUG

OIL GAUGE

OIL DRAIN PLUG

BATTERY

ROPING LUG

OUTPUT TERMINAL

OIL FILTER

AIR CLEANER

GROUNDING TERMINAL

FUEL RETURN

COVER

DOOR FOR GENERATOR

OUTPUT TERMINAL

OUTPUT RECEPTACLES

GROUNDING TERMINAL

DRAIN PLUG

- 8 -

4.2 Control panel

No.

Name No.

Name 1 3-phase circuit breaker 11 Water Temperature Gauge 2 1-phase circuit breaker 12 Oil Pressure Gauge 3 Voltage Meter 13 Fuel Gauge 4 Amp Meter 14 Hour Meter 5 Frequency Meter 15 Emergency Stop Button 6 Earth Leakage Relay 16 Preheat Lamp 7 Panel Light & Generating Lamp 17 Starter Switch 8 Voltage Regulator 18 Throttle Lever 9 Ammeter Change-Over Switch 19 Frequency Adjusting Screw

10 Monitor Display

- 9 -

5 Equipment

5.1 Monitor Display

This generator is equipped with monitoring function for water/coolant temperature, oil pressure, battery charge, air filter flow, battery fluid level, and fuel level.

When the equipment is started under normal condition, Oil Pressure and Battery Charge lamps will flash when the Starter Switch is turned from STOP to OPERATING, and all lamps will go off, immediately after the engine is started.

When the abnormality is detected either in water temperature or in oil pressure, the corresponding monitor lamp will flash, and the automatic shutoff shall be engaged.

When the automatic shutoff is engaged, turn the starter switch to STOP position, then restart the engine. When the automatic shutoff is engaged next time, check all parts of the corresponding alarm.

5.1.1 Water Temperature Monitoring Lamp (for temperature High)

Danger

: Injuries



Close all doors and place locks during operating this equipment, to avoid injuries by

unintentionally touching cooling fan and fan belt.

Caution



Do not open the radiator cap while operating this equipment or immediately after stopping

: Burns

the equipment, to avoid sustaining burns from hot vapor.



Do not touch the engine and muffler during operation and immediately after stopping the

equipment, for the temperature can reach extremely high.

When the water temperature reaches 105 degrees Celsius during operation, the water temperature-monitoring lamp will flash, and the automatic shutoff will be engaged.

When this occurs, check the Coolant reservoir tank, and replenish if needed

WATER TEMP

(refer to 8-2 Checking coolant / water level).

- 10 -

If the water level is normal, check for loose fan belt or possible water leak in the cooling system, after the engine is cooled down.



If the water level is too low, the sensor cannot detect the water temperature.

Be sure to check the water level in the radiator and the Coolant reservoir tank prior to operating the equipment.

5.1.2 Engine Oil Monitoring Lamp (for oil pressure low)

OIL PRESS

Danger

: Injuries



Close all doors and place locks during operating this equipment, to avoid injuries by

unintentionally touching cooling fan and fan belt.

Caution

: Burns



Do not touch the engine and muffler during operation and immediately after stopping the

equipment, for the temperature can reach extremely high.



When checking engine oil or changing oil, always stop the engine, and wait until the

engine cools down. If you open either the oil gauge or the oil filler cap during operation, hot oil may cause some injury.

When the engine oil pressure drops below 0.98 x 100kPa (1kgf/cm2) during operation, the oil pressure monitoring lamp will flash, and the automatic shutoff will be engaged.

When this occurs, check the engine oil level, and replenish to the maximum level if needed



The engine oil pressure monitor cannot detect the degradation of engine oil itself.

Please check the engine oil periodically, and change if needed (refer to 8-1 Checking Engine Oil).

- 11 -

5.1.3 Battery Charge Monitoring Lamp (charge lamp)

When the battery is not able to be charged during operation, the battery charge-monitoring lamp will flash.

In the event this occurs, stop the engine consult with the authorized distributor or

CHARGE

our engineering section.



Battery Charge Monitor cannot detect the degradation of battery life nor the battery

fluid level (refer to 8-6 Checking Battery)

5.2 Gauges

5.2.1 Hour Meter (built into the Tachometer)

Hour Meter keeps track of utilization time. Use this meter to schedule your

HOUR METER

0 0 0 0 0

Preventative Maintenance. Note that the Hour Meter will operate, as long as

the start switch is in RUN position, regardless of whether the engine is operating

or stopped.

5.2.2 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 degree Celsius.



If the temperature exceeds normal value, disconnect the load, idle the

engine at 1000min-1, and wait until the reading falls to the normal temperature range.

5.2.3 Oil Pressure Gauge

Oil Pressure Gauge displays the pressure of engine oil. Normal pressure may

vary depending on the environment, but it should display 0.98 – 4.9 x 100kPa

(1-5kgf/cm2). However, under cold weather, the pressure gauge may displays

higher reading. Continue idling until the pressure falls to normal range.

- 12 -

5.2.4 Fuel Gauge

It shows the volume in the fuel tank. When filled up, it shows 『F』. When the hand is approaching to『E』, the volume is coming to empty. Replenish fuel enough promptly.

5.2.5 Generator Gauges

5.2.5.1

Voltage Meter

Voltage Meter displays the output voltage (Phase to Phase) from the generator. Please check and confirm it showing 200V (400V) at 50Hz and 220V (440V) at 60Hz during operation.

5.2.5.2 Amp Meter

Amp Meter displays the electrical (Phase) current output from the generator.

5.2.5.3 Frequency Meter

Frequency meter will display the frequency of the generator. Please check it showing 50Hz or 60Hz during operation.

5.2.6 Lamp

5.2.6.1 Preheat Lamp

When the start switch is turned to <Pre-heating> position, the Preheat (Status) Lamp will be turned on in 25 seconds, indicating that the preheating is completed.

- 13 -

5.2.6.2 Panel Light / Pilot Lamp

Pilot Lamp indicates whether or not generator is generating electricity,

when the engine is driving.

5.2.7 Switch

5.2.7.1 Starter Switch

①

STOP

When the switch is set to this position, all power will be off.

The switch must be set to this position to remove the key.

②

RUN The switch must be set to this position during operation.

③

START This position will allow user to start the engine. When a user release the key, the setting will automatically return to <RUN> position.

④

PREHEAT This position will allow generator to preheat the glow plug during startup in cold environment



Do not leave the switch to this position, while the engine is

stopped.A battery discharges.

5.2.7.2 Emergency Stop button

This button is used to stop the engine in emergency. Keep pressing the button until the engine comes to complete halt.



Keep pressing the button until the engine stops in several seconds.

After the engine stops, be sure to return the starter switch to the

＜

STOP＞Position.

5.2.7.3 Circuit Breaker

By turning this circuit breaker switch to ON position, power will be transferred to the output terminal and to the load side. By turning to OFF position, it will shut down all power to the load side, preventing overload and short-circuit, and also breaking the earth leakage.



Do not use this breaker as the ON/OFF switch to the load.

- 14 -

5.2.7.4 Thermal Relay

Thermal Relay

This relay sends the signal to the 3-Phase circuit breaker and the 1-Phase breaker to trip-off when over-current flows in the circuits. When the breaker trips-off, it is set at the middle of ON and OFF. In the case, please recover the breaker, according to the following procedure;

①

Stop the engine.

② Open the control panel and push the reset button of the

thermal relay.

You can recover the breaker to the ON position.



Do not change the preset value of the thermal relay.

5.2.7.5 Earth Leakage Relay Unit

Sensing the earth leakage current, the unit (relay) send a signal To the

3-phase and the 1-phase breaker to trip-off in order to shut-off The circuit

to the terminals (loads).

(refer to.7-3 Earth Leakage Relay Unit and Grounding)

5.2.7.6 Amp Meter Changeover Switch

Using this switch, the current between the phases (R.S.T) will be

displayed on the Amp meter.

5.2.8 Voltage Regulator and Throttle Lever

5.2.8.1 Voltage Regulator

The dial adjusts output voltage.

By turning the dial clockwise, an operator can increase the voltage.

By turning the dial counter-clockwise, an operator can decrease the

voltage.

- 15 -

5.2.8.2 Throttle Lever

FIXING SCREW NUT

FREQUENCY ADJUSTING SCREW

①

Throttle Lever The lever is to adjust the engine speed. Set it to ＜IDLING＞when the engine starts and

warms-up or cools down. When the rated power is used, set it to ＜RUN＞

THROTTLE LEVER

(50 or 60Hz).

②

Frequency Adjusting Screw

Set the throttle lever to ＜RUN＞and loosen the fixing Screw nut. Turn the screw to＜HIGH＞to get high frequency and to＜LOW＞to low frequency.



The equipment is set it at 50Hz and delivered.

Re-set it to 60Hz according to the above procedure



You can get the frequency of 50Hz or 60Hz under the rated output load in case

adjusting it as per the following frequency under no load.

No-load frequency(Revolution)

50Hz Operation 52.5Hz（1575min

60Hz Operation 63.0Hz（1890min

5.3 Fuel Line Changeover Valve (3-way valve)

Caution



Always stop the engine when performing any work on the fuel line.



Always wipe any drip of Diesel fuel or engine oil. Do not use this equipment, when leak is

found. Repair the equipment before use.

By switching the 3-way valve, you can use fuel from external fuel tank. In this case, the Diesel fuel in the built-in tank will not be used.

:Burns

-1

）

-1

）

5.3.1 Using fuel from built-in fuel tank

The lever for 3-way valve is set to A when the equipment is shipped. In addition, both the external fuel intake and the external fuel return are safeguarded with PT-1/2 plugs. Do not remove the plugs, when using the built-in fuel tank.

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