Shindaiwa DG1000MIM User manual

OWNER’S AND OPERATOR’S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
DG1000MIM/ANZ
X753-009 30 0
X753800-330 0
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.

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.
 Handling/Operation of this generator can only be performed by persons who understand the
contents of this manual and can handle/operate the generator in a safe manner. Persons who
suffer from an illness, are taking medicine or not feeling way such that safe operation would be
negatively affected must not operate this generator.
 Work performed using this generator and handling/operation of this generator must be in
accordance with corresponding laws and regulations based on such laws. Consult with the
authorized distributor where this generator was purchased if you have any inquiries regarding
the corresponding laws.
 Always be sure to include this manual when loaning out this generator and instruct operating
personnel to read this manual before operation.
 Store this manual in a specified location where it will be secure and available for consulting at
any time. Order another copy from the authorized distributor where this generator was
purchased if this manual becomes dusty, grimy or torn.
 Consult with the authorized distributor where this generator was purchased if you have any
inquiries regarding any points related to this generator and manual.
When inquiring about this generator, be sure to provide the model name and serial number.
 If disposing of this generator, do so in a manner that is in compliance with laws related to
industrial waste. Contact the authorized distributor where the generator was purchased if you
have any inquiries regarding proper disposal.
 Caution notice ranks in this manual are classified as follows.
WARNING : Indicates a potentially hazardous situation which, if not
avoided, can result in death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided,
can result in minor or moderate injury and property damage.
< NOTE > : Other types of cautions and indications.
 Note that CAUTION items can also lead to major accidents under some circumstances if
not correctly followed.
All caution notices are important. Be sure to follow all of them.

1
Table of Contents
1. Safety Instructions .......................................................................... 2
2. Specifications ................................................................................... 5
2-1. Specifications ............................................................................ 5
2-2. Ambient Conditions ................................................................... 6
3. Applications ..................................................................................... 6
4. Part Names ....................................................................................... 6
4-1. External View/Part Names ........................................................ 6
4-2. Operation Panel Part Names .................................................... 8
4-3. Main Terminal Board ................................................................. 8
5. Equipment ........................................................................................ 9
5-1. Controller ................................................................................... 9
5-2. Switches .................................................................................. 11
5-3. Voltage Regulator and Throttle Lever ...................................... 13
5-4. Fuel Piping Switch (3Way Fuel Valve) ..................................... 14
6. Transporting/Installing .................................................................. 15
6-1. Transport Procedures .............................................................. 15
6-2. Installation Procedures ............................................................ 16
7. Load Connections ......................................................................... 17
7-1. Load Cable Selection .............................................................. 17
7-2. Connecting Load Cables ......................................................... 18
7-3. Earth Leakage Relay and Grounding ....................................... 19
8. Pre-Operation Inspection .............................................................. 22
8-1. Checking Engine Oil ................................................................ 22
8-2. Checking Coolant .................................................................... 23
8-3. Checking the Fan Belt ............................................................. 25
8-4. Checking the Fuel ................................................................... 26
8-5. Checking for Fuel, Oil and Coolant Leaks ............................... 27
8-6. Checking the Battery ............................................................... 27
9. Operating Procedures ................................................................... 29
9-1. Initial Startup/Pre-Check .......................................................... 29
9-2. Procedures during Operation .................................................. 31
9-3. Stopping Operation ................................................................. 32
9-4. Protective Functions ................................................................ 33
9-5. Connecting with External Fuel Tank ........................................ 34
10. Inspection/Maintenance ................................................................ 35
11. Long-Term Storage ........................................................................ 43
12. Troubleshooting ............................................................................. 44
13. Generator Circuit Diagram ............................................................ 48
14. Engine Electrical Circuit Diagram ................................................ 49

2
1. 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 turn the Power Switch
to the OFF position.
 Close the output terminal cover before operating.
 Do not insert a pin, wire or other metal object into the electrical outlet.
 Do not touch the generator if the Alternator or casing becomes wet during operation.
 Do not touch output terminals or internal electric parts while the generator is operating.
 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
bonnet 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.
 Grounding should be made after the engine is stopped.
 Whenever the Earth leakage breaker is activated, you should always repair the leaking
place first of all.
WARNING : INJURY
 Close all doors and lock them during operation.
 Close all doors and place locks during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
 Before performing any equipment check or maintenance, stop the engine, and turn the
Power Switch to the OFF position.
 Use the lifting hook to lift the machines, and do not lift up the unit using tie-downs. Use of
such could result in the generator falling.
 Do not lift any additional weight such as fuel tanks or trailers.
 No persons should be under a lifted generator.
 Before turning the circuit breaker to ON position, ensure that the breaker or the switch of
loads are positioned to OFF.
Operate the circuit breaker, well-communicating with the electrician by the load side.

3
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.
CAUTION : EXPLOSION
 Never use or recharge the battery if the fluid level is below the minimum level.
 Do not create sparks or bring flame near the battery as it generates flammable gas.
CAUTION : FIRE
 Do not bring flammable items (such as fuel, gas and paint) or items that are highly
combustible near the generator as the muffler, exhaust gas and other parts become
extremely hot.
 Keep this generator 1m or more from walls or other hindrances, and on a level surface.
 Do not connect the generator output to indoor wiring.
 This generator uses diesel fuel. Always be sure to stop the engine and not bring flames
close when inspecting fuel or refueling. Wait until the engine has cooled before performing
such procedures.
 Do not use this equipment when leak is found, and repair the leaking location before
operating.
 Always be sure to wipe up any spilled fuel or oil.
 Allow the generator to cool before covering with the protective cover.
 Never allow flame to come close to the generator.
CAUTION : BURNS
 Do not touch the engine and surrounding components immediately after stopping the
equipment, while temperature can reach extremely high.
 Do not open the radiator cap immediately after stopping the engine, to avoid sustaining
burns from hot vapor.
 Hot steam gushes out from the coolant sub-tank if the generator overheats. Do not touch
the coolant sub-tank.
 Always be sure to stop the engine and allow the engine to cool when performing inspection
or maintenance of engine oil. Opening the oil level indicator or oil filler cap during operation
will result in hot oil cause personal injury.
CAUTION : INJURY
 Always be sure to use lifting hooks when moving the generator, and lift it slowly at a
completely vertical angle.
 Personnel performing lifting work must wear protective gear such as helmets, safety shoes
and gloves.
 Remove the wood ties if using anchors to secure the generator.
 Position the generator on a level stable surface so that it cannot slide or move in any
manner.
 Before starting operation, always be sure to turn off all switches of equipment using the
generator and all breakers to OFF.
 Do not move the generator during operation.
 Do not operate the generator if it has been modified or any parts have been removed.

4
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.
 The voltage drop between cables is large if the cable is excessively long or thin, resulting in
decreased input voltage to equipment using the generator, thereby causing decreased
performance, faulty operation and malfunction.
 Warning/Caution Label Locations
If warning or caution labels become damaged and difficult to read, replace with new
labels in the indicated locations. Order labels using part number indicated in the
parenthesis.

Injury (Part no. : X505-004630)

Caution: gm spec LLC (Part no. : X505-004650)

Danger caution (Part no. : X505-004660)

Danger: Electric Shock (Part no. : X505-004640)

5
2. Specifications
2-1. Specifications
Model Unit DG1000MIM/ANZ
Alternator
Generating Type - Rotating Filed, Brushless 3-Phase
Synchronous Alternator
Rated Output kVA 80
kW 64
Rated Voltage V 415
Rated Current A 111
Rated Frequency Hz 50
Winding - 3-phase, 4-wire
Power factor % 80
Insulation class - H
Excitation - Self-Excitation(Brushless)
No. of poles - 4
Engine
Types - Vertical Water-cooled 4-cycle Diesel Engine
Model (Manufacturer) - DD-6BG1T(ISUZU)
No. of Cylinders (bore x stroke) mm 6 (105 x 125)
Continuous rated output kW 73.1
PS 99.4
Rated speed min-1 1500
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 24 - 4.5
Charging dynamo capacity V-A 24 - 30
Battery - 95D31R x 2
Unit
Length
mm
2750
Width
mm
1000
Height
mm
1400
Dry Weight
kg
1800
Installed Weight
kg
2041

6
Lifting Hook
Tie-Down
Operation Panel Door
Emergency Stop Button
Radiator Plate
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
■ Elevation: 300 m or less
3. Applications
 Power source for submerged pumps and similar civil engineering equipment
 Power source for lighting and similar equipment
 Power source for electrical tools and household appliances
4. Part Names
4-1. External View/Part Names
CAUTION : PROPERTY/SECONDARY DAMAGE
 Do not use for any application other than those listed above.
 If using this generator for medical equipment, check before use with the
medical equipment manufacturer, doctor, hospital or similar entity.

7
Fuel Inlet
Fuel Tank
Coolant Sub-Tank Engine Check Door
Battery
Alternator Check Door
Oil Level Indicator
Tie-Down Oil Filler Cap
Oil Drain Plug
External Tank Fuel Inlet
External Tank Fuel Return
Fuel Drain plug
Coolant Drain plug
Water Separator
Battery
Alternator Check Door Engine Check Door
Fuel Filter
Oil Filter
Radiator
Air Cleaner
Tie-Down
Terminal Cover
Terminal Cover
Accessories
Owner’s
Manual
Nipple (2 pieces) Fuse (10A)
Fuse (3A)

8
4-2. Operation Panel Part Names
①
Circuit Breaker
②
Earth Leakage Relay
③
Controller
④
Voltage Regulator
⑤
Power Switch / Air Bleeding
⑥
Battery Isolator
⑦
Emergency Stop Button
⑧
Frequency Adjusting Screw
⑨
Throttle Lever
4-3. Main Terminal Board
Main Terminals
Plexiglass Cover

9
5. Equipment
5-1. Controller
This generator has a Controller which is used for starting or stopping the power
generator or the engine, for monitoring. If you turn the Power Switch to ON
position, the status Screen appears.
(1) Front panel elements
① STOP button
Press this button to initiate the stop sequence of the gen-set.
② START button
Press this button to initiate the start sequence of the engine.
③ LEFT button
Use this button to move left or to change the mode. The button can change the
mode only if the main screen with the indicator of currently selected mode is
displayed.
④ RIGHT button
Use this button to move right or to change the mode. The button can change the
mode only if the main screen with the indicator of currently selected mode is
displayed.
⑤ HORN RESET button
Use this button deactivate the horn output without acknowledging the alarms.
15
1
2
3
4
5 6
7
8
9 10
11
12
13 14

10
⑥ FAULT RESET button
Use this button to acknowledge alarms and deactivate the horn output. Inactive
alarm will disappear immediately and status of active alarms will be changed to
“confirmed” so they will disappear as soon as their reasons dismiss.
⑦ UP button
Use this button to move up or increase value.
⑧ PAGE button
Use this button to switch over display pages.
⑨ DOWN button
Use this button to move down or decrease value.
⑩ ENTER button
Use this button to finish editing a setpoint or moving right in the history page.
⑪ GCB button
No use.
⑫ GENERATOR status indicator
There are two states – Gen-set OK (indicator is green) and Gen-set failure (indicator
is red). Green LED is on if the generator voltage is present and within limits. Red
LED starts flashing when gen-set failure occurs. After FAULT RESET button is
pressed, goes to steady light (if an alarm is still active) or is off (if no alarm is active).
⑬ GCB on
No use.
⑭ Load
No use.
⑮ Operation Display
< Note>
 The displayed information is structured into “pages” and “screens”. USE PAGE button
to switch over the pages.

11
5-2. Switches
(1) Power Switch / Air Bleeding
This is the main Power Switch of the generator.
When the Power Switch turned to OFF position, the Controller is OFF.
When the Power Switch turned to AIR BLEEDING position,
automatically starts air-bleeding device.
(2) Emergency Stop Button
This button is used to stop the engine in emergency.
By inserting the button, the engine stops.
Be sure to restore the Power Switch to OFF and re-set the button,
turning clockwise after using the emergency stop button.
(3) Circuit Breaker
By turning this circuit breaker on the control panel to ON,
Power will be transferred to the output receptacles and to the
load side.
The breaker trips to OFF, either overload or short-circuit.

12
(4) Thermal Relay
This relay sends the signal to the circuit 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.
< NOTE >
Do not change the preset value of the thermal relay.
(5) Battery Isolator
When turning the switch to OFF, the engine
electric circuit does not activate due to no
battery power.
(6) Earth Leakage Relay Unit
Sensing the earth leakage current, the unit (relay) send a signal to
the 3-phase breaker to trip-off in order to shut-off the circuit to the
terminals (loads).
(Refer to section “7-3. Earth Leakage Relay and Grounding”.)
Thermal Relay
OFF position ON position
Reset Button

13
5-3. 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 Lever
① Throttle Lever
The lever is to adjust the engine speed.
Set it to ＜START POSITION＞when the engine
starts and warms-up or cools down.
When the rated power is used, set it to
＜RUN POSITION＞(50Hz).
② Frequency Adjusting Screw
Set the throttle lever to ＜RUN POSITION＞
and loosen the fixing Screw nut.
Turn the screw to＜INCREASE＞to get high
frequency and to＜DECREASE＞to low
frequency.
< NOTE >
 The equipment is set it at 50Hz and delivered.
 You can get the frequency of 50Hz 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-1）
RUN POSITION START POSITION DECREASE INCREASE
FREQUENCY ADJUST THROTTLE LEVER
Throttle Lever
Frequency Adjusting Screw
Fixing Screw Nut

14
5-4. Fuel Piping Switch (3Way Fuel Valve)
CAUTION:
 Always make sure that the engine is stopped when working on fuel line.
 Always be sure to wipe up any spilled fuel.
 After working on the piping, check that there is no Diesel fuel leakage.
By switching three-way fuel valve fuel will be supplied from the external tank.
In that case, the built-in tank will not be used.
(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.
< NOTE >
 Always set the lever for 3-way valve back to A position and cover the
external fuel intake and return port with the supplied plugs, after the hoses
are removed.
(2) Using fuel from external fuel tank
Connect hoses from the external fuel tank to the external fuel intake and the
external fuel return ports, and set the lever for 3-way valve to B position.
You can now supply the fuel from the external fuel tank.
For detail instruction, refer to “9-5. Connecting with External Fuel Tank”
（＜A＞position
）
3-Way valves
外部燃料供給口 外部燃料戻り口（プラグ PT１/２）
EXTERNAL
FUEL
INTAKE
(PLUG
:
EXTERNAL
FUEL
RETURN
(PLUG
:
3-Way
3-Way valves
(＜B＞position)
To EXTERNAL FUEL TANK

15
6. Transporting/Installing
6-1. Transport Procedures
WARNING : INJURY
 Use the lifting hook to lift the machines, and do not lift up the unit using tie-downs. Use
of such could result in the generator falling.

No per
sons 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.
 Personnel performing lifting work must wear protective gear such as helmets,
safety shoes and gloves.
 Do not move the generator during operation.
(1) Lifting Procedures
Always be sure to use lifting hooks when lifting up the generator, and raise it slowly at a
completely vertical angle.
(2) Transport
When transporting this generator, tie rope to the left and right tie-downs, and securely
fix the generator.
< NOTE >
 Handle this generator with extreme care when raising, lowering and transporting. Rough
handling of this generator may result in damage or malfunction.
Lifting Hook
Tie-Down

16
6-2. Installation Procedures
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.
CAUTION : FIRE
 Do not bring flammable items (such as fuel, gas and paint) or items that are
highly combustible near the generator as the muffler, exhaust gas and other
parts become extremely hot.
 Keep this generator 1m or more from walls or other hindrances, and on a
level surface.
 Remove the wood ties if using anchors to secure the generator
 Do not connect the generator output to indoor wiring.
 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.
 Keep the generator 1 m or more from walls or other hindrances so that the
operation panel door and left/right check doors are accessible for internal
inspection/maintenance.
< Caution >
 This equipment must be operated on hard and flat surface. Operating under any other
conditions may result in malfunctions.
 Do not block the airflow from radiator vent or muffler exhaust. It may result in reduced
engine performance, overheating, or damage to the electrical parts.
 Operating in dusty area or salty air (by the ocean), or any other particulate environment may
result in clogged radiator, which may cause overheating, other malfunctions and insulation
deterioration. Use extreme care, frequent checks and maintenance.

17
7. Load Connections
7-1. Load Cable Selection
CAUTION : PROPERTY DAMAGE
 Cable burnout can occur due to generated heat if the load current exceeds
the allowable current of the cable.
 The voltage drop between cables is large if the cable is excessively long or
thin, resulting in decreased input voltage to equipment using the generator,
thereby causing decreased performance, faulty operation and malfunction.
Select cable for use that has sufficient thickness and an allowable current possible for
use, giving consideration to the distance from the generator to the equipment using the
generator.
< NOTE >
 Select cable with a thickness that ensures that the voltage drop across the cable will be
within 5% of the rated voltage.
 Expedient Formula: the voltage drop of cables
 3-Phase 3-Wire
1 Length (m)
Voltage Drop (V) = × × Current (A) × √3
58 Dia (mm2)
 1-Phase 2-Wire
1 Length (m)
Voltage Drop (V) = × × Current (A) ×2
58 Dia (mm2)