Shindaiwa DG150MI, DG250MI User Manual

before you have read and understood the instructio

ns for use.

OWNER’S AND

OPERATOR’S MANUAL

Sound Proof Diesel Engine Generator

DG150MI DG250MI

1 Safety Guidelines 2 Specifications

2.1 Specification Matrix

2.2 Ambient Condition

3 Use 4 Parts

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,

8.6 Checking Battery

9 Operation

9.1 Initializing / Preparation

9.2 During Operation

9.3 Stopping Generator

9.4 Protection Features

9.5 Connecting to External Fuel Tank

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

Table of Contents

and water leakage

Page

2 5 5 6 6 6 6 7 8

8 11 14 15 15 16 17 17 18 21 23 23 24 26 27 28

28 29 29 30 31 31 32 33 38 39 41 45

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

- 1 -

71000-94011

Introduction

Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator.

 This user 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.

 Please operate this equipment after thoroughly reviewing and understanding the contents of this manual.

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

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

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

Can cause severe injuries or death.

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

Other types of caution

Danger

Caution

 Even some of the items noted in

follow all the safety guidelines.

Caution

may lead to severe injuries. Please read all items and

- 2 -

1 Safety Guidelines

Danger

 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 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

:Suffocation from exhaust fume

:Electrical Shock

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

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

touching cooling fan and fan belt.

Caution

 Do not point the exhaust fume toward pedestrians or building.

:Injuries

:Suffocation from exhaust fume

- 3 -

Caution

 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

 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.

:Injuries to eyes and skin

:Fire

Caution

 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.

Caution

 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.

:Burns

:Injuries

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

- 4 -

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 Safety guidelines Part Number 19402-00188

2 Suffocation from exhaust fume Part Number 19402-00161

3 Electrical Shock Part Number 19402-00163

4 Injuries Part Number 19402-00167

5 Injuries Part Number 19402-00162

6 Burns Part Number 19402-00165

7 Burns Part Number 19402-00164

8 Fire Part Number 19402-00166

9 Lift points Part Number 19401-00153

10 Tie (Sleeper) Marker Part Number 19401-00207

11 Bonnet Grounding Terminal Part Number 19401-00206

- 5 -

2 Specifications

2.1

Specification Matrix

Name of Generator DG150MI DG250MI

Alternator

Engine

Operation Device

Protection Device

Control Panel

Unit

Type Unit

Rated Output

Rated Voltage (or the below) V 200 220 200 220 Rated Current (or the below) A 36.1 39.4 57.7 65.6 Rated Voltage V 400 440 400 440 Rated Current A 18 19.7 28.8 32.8 Frequency Hz 50 60 50 60 Rated speed min Winding - 3-phase, 4-wire, Star with neutral Power factor % 80 Insulation class - F Excitation - Self-excitation with AVR No. of poles - 4 Types - Vertical Water-cooled 4-cycle Diesel Engine Model (Manufacturer) - 3LD1(ISUZU) AA-4LE1(ISUZU) No. of Cylinders (bore x stroke) mm 3 (83.1 x 92) 4 (85 x 96)

Continuous rated output

Rated speed min Displacement L 1.496 2.179 Combustion system - Swirl Chambered Cooling method - Radiator Lubricating method - Forced lubrication Starting method - Electric start Fuel Lubricant oil - CD class Fuel tank capacity L 65 Lubricant volume (Full) L 7.4 8.5 Cooling water volume L 5.8 8.6 Starting motor capacity Charging dynamo capacity V-A 12-20 Battery - 80D26R x 1 75D31R x 1 Volt/Freq/Amp meter - O O Voltage regulator - O O Oil pressure, Water temp. - Lamp indication (Engine stops) Battery charge - Lamp indication Hour meter - O O

Dimensions (L x W x H) mm 1390 x 650 x 890 1550x 650 x 890 Dry weight kg 493 566

kVA

kW 10 12 16 20

kW 12.6 14.9 19.1 23.5

PS 17.1 20.3 26 32

V- kW

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

Synchronous AC Generator

12.5 15 20 25

-1

1500 1800 1500 1800

-1

Diesel Fuel （ASTM No. 2-D） or Equivalent

12 - 1.2 12 - 1.8

1500/1800

- 6 -

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

- 7 -

4.2 Control panel

[DG150MI] [DG250MI]

No.

Name No.

Name

1 3-Phase Circuit Breaker 11 Monitor Indication Lamp

2 Pilot Lamp 12 Water Temperature Gauge

3 Single-Phase Circuit Breaker 13

Tachometer (Hour Meter incorporated)

4 Earth Leakage Relay 14 Oil Pressure Gauge 5 Voltage Meter 15 Preheat Lamp 6 Amp. Meter 16 Emergency Stop Button 7 Frequency Meter 17 Throttle Handle 8 Panel Light 18 Starter Switch 9 Panel Light Switch 19 Hour meter

10 Voltage Regulator

- 8 -

5 Equipment

5.1 Monitor Display

[DG250MI] [DG150MI]

++++ ----

WATER TEMP OIL PRESS CHARGE AIR FILTER

++++ ----

BATTERY LOW LEVEL

FUEL LEVEL

DG250MI is equipped with monitoring function for water/coolant temperature, oil pressure, battery charge, air

filter flow, battery fluid level, and fuel level. DG150MI is equipped with monitoring function for water/coolant

temperature, oil pressure and battery charge.

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

 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 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.

- 9 -

: Injuries

: Burns

When the water temperature reaches 110 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

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

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)

Danger

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

unintentionally touching cooling fan and fan belt.

Caution

 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

: Injuries

: Burns

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).

- 10 -

5.1.3 Battery Charge Monitoring Lamp (charge lamp)

When the battery is unable to be charged during operation, the battery charge-monitoring lamp

will flash.

Check the belt for damages or cut, and replace if needed.

 For changing the belt, refer to the User Manual for Engine.

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

level (refer to 8-6 Checking Battery)

5.1.4 Air Filter Monitoring Lamp (clogged filter element) [DG250MI only]

Danger

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

unintentionally touching cooling fan and fan belt.

Caution

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

the equipment, for the temperature can reach extremely high.

When the air filter element becomes dirty or clogged, the air filter monitoring lamp will flash.

Turn off the engine and clean the filter element or replace if needed.

(refer to 10. Maintenance)

: Injuries

: Burns

5.1.5 Battery Fluid Monitoring Lamp (insufficient battery fluid) [DG250MI only]

Caution

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

: Injuries to eyes and skin

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

your physician immediately.

Caution

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

- 11 -

: Fire

When the battery fluid level is low, Battery Fluid Monitoring Lamp will flash.

If the lamp is flashing, quickly add some distilled water. (refer to 8.6 Checking Battery)

5.1.6 Fluid Level Monitoring Lamp [DG250MI only]

Caution

 This equipment uses Diesel fuel 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 oil. Do not use this equipment when a leak is

found. Repair the equipment before use.

When the fuel level reaches less than 1/4 tank, Fluid Level Monitoring Lamp will flash.

If the lamp is flashing, add fuel.

: Fire

Just after the engine started, lamp will not flash promptly even in the event of

1/4 tank level fuel, which is not malfanction.

5.2 Gauges

5.2.1 Tachometer [DG250MI only]

Tachometer displays the revolution of engine and the generator.

The frequency of the generator is 50Hz at 1500min-1 and 60Hz at 1800min-1.

5.2.2 Hour Meter

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

Maintenance. Note that the Hour Meter will operate, as long as the start switch is in ON

position, regardless of whether the engine is perating or stopped.

DG250MI incorporates Hour Meter in Tachometer.

- 12 -

5.2.3 Water Temperature Gauge [DG250MI only]

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.

5.2.4 Oil Pressure Gauge [DG250MI only]

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

depending on the environment, but it should display 2.9 – 4.9 x 100kPa (3-4kgf/cm2).

However, under cold weather, the pressure gauge may display higher reading. Continue

idling until the pressure falls to normal range.

5.2.5 Generator Gauges

5.2.5.1 Voltage Meter

5.2.5.2 Amp Meter

5.2.5.3 Frequency Meter

5.2.6 Lamp

5.2.6.1 Preheat Lamp

Voltage Meter displays the voltage output (Phase to Phase) from the generator.

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

Frequency meter will display the frequency of the power source

When the start switch is turned to <Operation or Pre-heating> position, the Preheat Lamp will

be turned. When preheating is completed, preheat lamp turns off and operation can start.

Pre-heating may vary depending on the environment, but it should finishes

in about 1-5 seconds.

- 13 -

2.2.6.2 Pilot Lamp [DG250MI only]

5.2.7 Switch

Pilot Lamp indicates whether or not the generator is generating electricity,

when the engine is driving.

5.2.7.1 Starter Switch

①①①①

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.

②②②②

RUN / PREHEAT

The switch must be set to this position during operation. This position is also

used during cold season, to preheat Glow Plug.

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

A battery discharges.

③③③③

START

This position will allow user to start the engine. When a user release the key,

the setting will automatically return to <Operating / Preheating> position.

5.2.7.2 Panel Light Switch

This switch turns Panel Light to ON and OFF. The switch can only be used when the

Start switch is in OPERATING position.

5.2.7.3 Emergency Stop button [DG250MI only]

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.

5.2.7.4 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.

The earth leakage breaking function is for 3-Phase circuit only, not 1-Phase Circuit.

- 14 -

5.2.8 Voltage Regulator and Throttle Handle

5.2.8.1 Voltage Regulator

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

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

5.2.8.2 Throttle Handle

This handle controls the engine revolution. By turning the throttle clockwise,

engine speed slows down; turning the handle counter-clockwise increases the

speed. The lock of the handle at the required position (speed) can be done by

turning the Locknut clockwise. Always lock the handle while the generator is

operating. The engine speed can also be changed to high or low by pulling the

handle all the way out or pushing all the way in, while the release button on the

knob pressed.

Always lock the handle while the generator is operating. Failure to do so may result in fluctuation

in frequency (engine speed).

5.2.8.3 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).

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

:Burns

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.

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