Shindaiwa DG1000MI User manual

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
OWNER’S AND
OPERATOR’S MANUAL
Sound Proof
Diesel Engine Generator
DG1000MI
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PageTable of Contents
CAUTION : Do not operate the Generator, or any other appliance,
before
y
ou have read and understood the instructions for use.
- 1 -
Shindaiwa Corporation
71021-94310

- 1 -
Introduction
Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator.
zThis 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.
zPlease operate this equipment after thoroughly reviewing and understanding the contents of this
manual.
zPlease attach this manual, if the equipment will be sub-leased.
zPlease store this manual near the equipment for easy reference.
Following convention will be used throughout the manual to indicate the degree
of cautions.
Danger Can cause severe injuries or death.
Caution Can cause minor injuries or damage to the equipment or other
properties
<Caution> Other types of caution
zEven some of the items noted in may lead to severe injuries.
Please read all items and follow all the safety guidelines.
Caution

- 3 -
1 Safety Guidelines
: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
:Electrical Shock
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 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.
:Injuries
Close all doors and place locks during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
:Suffocation from exhaust fume
Do not point the exhaust fume toward pedestrians or building.
Caution
Danger
Danger
Danger

- 4 -
: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.
: 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.
: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.
: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.
Caution
Caution
Caution
Caution

- 5 -
: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.
Caution

- 6 -
■ 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

- 7 -
2 Specifications
2.1 Specification Matrix
Name of Generator DG1000MI-400
Type Unit Blushless, Rotating Field, 3-Phase, 4-Pole,
Synchronous AC Generator
kVA
80 100Rated Output
kW 64 80
Rated Voltage (or the below) V 200 220
Rated Current (or the below) A 231 262
Rated Voltage V 400 440
Rated Current A 115 131
Frequency Hz 50 60
Rated speed min
-1
1500 1800
Winding - 3-phase, 4-wire, Star with neutral
Power factor % 80
Insulation class - H
Excitation - Self-excitation with AVR
Alternator
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)
kW 73.1 91.2Continuous rated output
PS 99.4 124
Rated speed min
-1
1500 1800
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
Engine
Battery - 95D31R x 2
Volt/Freq/Amp meter - OOperation
Device Voltage regulator - O
Oil pressure, Water temp. - Lamp indication (Engine stops)Protection
Device Battery charge - Lamp indication
Hour meter - OControl
Panel -
Dimensions (L x W x H) mm 2750 x 1000 x 1400Unit
Dry weight kg 1800

- 8 -
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
PANEL DOOR
ROPING LUG
BATTERY
OIL FILTER
EXTERNAL
FUEL INTAKE
EXTERNAL
FUEL RETURN
WATER
SEPARATOR
FUEL DRAIN PLUG
COOLANT
DRAIN PLUG
INSPECTION
DOOR FOR
GENERATOR
ROPING LUG
FUEL FILTER
RADIATOR
INSPECTION
DOOR FOR
ENGINE
OIL FILLER CAP
RESERVOIR TANK
OIL GAUGE
ROPING LUG
AIR CLEANER
INSPECTION
DOOR FOR
ENGINE
FUEL INTAKE
FUEL TANK
BATTERY
OIL DRAIN PLUG
3
-
PHASE
OUTPUT
TERMINAL
EARTH
GROUNDING
TERMINAL
OUT TERMINAL
COVER
INSPECTION
DOOR FOR
GENERATOR
1
-
PHASE
OUTPUT
TERMINAL
1
-
PHASE
OUTPUT
RECEPTACLES
BO
NNET
GROUNDING
TERMINAL

- 9 -
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

- 10 -
WATER TEMP
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)
: Injuries
Close all doors and place locks during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
: 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 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
(refer to 8-2 Checking coolant / water level).
Danger
Caution

- 11 -
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.
<Caution>
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)
: Injuries
Close all doors and place locks during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
: 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/cm
2
) 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
<Caution>
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).
Danger
OIL PRESS
Caution

- 12 -
0 0 0 0 0 H
HOUR METER
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
our engineering section.
<Caution>
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
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.
<Caution>
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/cm
2
). However, under cold weather, the pressure gauge may displays
higher reading. Continue idling until the pressure falls to normal range.
CHARGE

- 13 -
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.

- 14 -
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.
<Caution>
Do not leave the switch to this position, while the engine is
stopped.A battery discharges.
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
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.
<Caution>
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.
<Caution>
Do not use this breaker as the ON/OFF switch to the load.

- 15 -
Thermal Relay
5.2.7.4 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.
<Caution>
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.

- 16 -
FIXING SCREW NUT
FREQUENCY ADJUSTING SCREW
THROTTLE LEVER
5.2.8.2 Throttle Lever
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 ＞
(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.
<Caution>
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.
5.3 Fuel Line Changeover Valve (3-way valve)
:Burns
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.
5.3.1 Using fuel from built-in fuel tank
The lever for 3-way valve is set to Awhen 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.
No-load frequency(Revolution)
50Hz Operation 52.5Hz （ 1575min
-1
）
60Hz Operation 63.0Hz （ 1890min
-1
）
Caution

- 17 -
<Caution>
Always set the lever for 3-way valve back to Aposition and cover the external fuel
intake and return port with the supplied plugs, after the hoses are removed.
5.3.2 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 Bposition. You can now supply the fuel
from the external fuel tank. For detail instruction, refer to 9-6 Connecting to the external
Fuel tank
外部燃料供給口 外部燃料戻り口（プラグ PT１/２）
EXTERNAL
FUEL INTAKE
(PLUG : PT-1/2)
EXTERNAL
FUEL RETURN
(PLUG : PT-1/2)
3-Way valves
（＜ A ＞ position ）
3-Way valves
T
o EXTERNAL FUEL TANK
3-Way valves
( ＜ B ＞ position)

- 18 -
6 Transport and Installation
6.1 Transportation
:Injuries
When lifting the equipment, always use a lift hook.
Do not use Side rope-through to attach your lift hook, for it may cause equipment to drop.
6.1.1 Lifting Equipment
Always use a Lift Hook, when lifting the equipment for transportation.
6.1.2 Transportation
When transporting this equipment, make sure that the equipment is secured properly with
ropes tied to the Side Rope Through.
<Caution>
Always use extreme care when
loading, unloading, and transporting
the equipment.
Failure to do so may result in damages and malfunction of the equipment.
Danger
LIFTING LUG
ROPING LUG

- 19 -
6.2 Installation
: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
:Suffocation from exhaust fume
 Do not point the exhaust fume toward pedestrians or building.
:Fire
Always operate this equipment on flat surface and, at least 1 meter away from any objects
(wall, box, etc.).
Temperature around muffler and exhaust can get extremely high. Keep any inflammable
items (such as fuel, gas, paint, etc.) away from the equipment.
Always set the equipment on hard, flat surface.
Keep the equipment at least 1m from a wall or any obstacles, to allow workable space to
access the control panel and opening of the panel door.
<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.
7 Connection
7.1 Selecting Cable
Select the cable with proper gauge, based on its allowable amperage and the distance
between the generator and the machinery to be connected.
Danger
Caution
Caution

- 20 -
:Electrical damages
If the load exceeds the allowable amperage, the overheating may damage the cable.
If the cable is either too long or too small a gauge, there will be greater voltage drop to loads,
which may result in reduced performance in the connected loads, malfunction, or damages.
<Caution>
It is recommended to select the proper gauge and length of cable, with consideration of
the maximum 5% marginal drop only for the rated voltage, between the terminals of
loads and generator via the cables.
■ Expedient Expression : the voltage drop of cables
3-Phase 3-Wire
1 Length(m)
Voltage Drop (V) = ----- x ----------------- x Current (A) x √3
58 Gauge(mm
2
)
1-Phase 2-Wire
1 Length(m)
Voltage Drop (V) = ------ x ------------------ x Current (A) x 2
58 Gauge(mm
2
)
■ Selection of cable
(Example) 220V and Voltage Drop 11V
3-Phase 3-Wire Cap Tire Cable, Single Core (Unit: mm
2
)
Length
Current
50m
or below 75m 100m 125m 150m 200m
50A 8 14 14 22 30 30
100A 14 22 30 38 50 60
200A 38 50 60 80 100 125
300A 50 60 100 100 125 150
(Example) 100V and Voltage Drop 5V
1-Phase 2-Wire Cap Tire Cable, Single Core
(Unit: mm
2
)
Length
Current
50m
or below 75m 100m
10A 5.5 5.5 8
20A 8 14 22
30A 14 22 22
50A 22 30 30
100A 30 50 60
Caution