Shindaiwa DG60MI Owner's And Operator's Manual
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Shindaiwa DG60MI Owner's And Operator's Manual

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'
'
OWNER
S AND OPERATOR
S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
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.
DG60MI-400M/R
X753-007 96 0
X753801-360 0

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Summary of Contents for Shindaiwa DG60MI

  • Page 1 S AND OPERATOR S MANUAL Vertical, Water-Cooled 4-Cycle Diesel Engine 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. DG60MI-400M/R X753-007 96 0 X753801-360 0...
  • Page 3 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.

  • Page 4: Table Of Contents

    Table of Contents 1. Safety Instructions ................2 2. Specifications ..................6 2-1. Specifications ................6 2-2. Ambient Conditions ..............7 3. Applications ..................7 4. Part Names ..................7 4-1. External View/Part Names ............7 4-2. Operation Panel Part Names ............ 9 4-3.

  • Page 5: Safety Instructions

    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 ...
  • Page 6 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 carry 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.
  • Page 7 CAUTION : PROPERTY DAMAGE  Do not use the equipment for any improper applications. Improper usage can result in an accident or malfunction.  If using this generator for medical equipment, check before use with the medical equipment manufacturer, doctor, hospital or similar entity. ...
  • Page 8  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. : X505-007550)  Electric shock (Part no.

  • Page 9: Specifications

    2. Specifications 2-1. Specifications Model Unit DG60MI-400M Rotating Filed, Brushless 3-Phase Generating Type Synchronous Alternator Rated Frequency Rated Output Rated Voltage 400 [200] *1 440 [220] *1 Rated Current 72 [144] *1 78.5 [157] *1 3-Phase Receptacle Output 22.2/23.0 1-Phase Receptacle Output 3.5x2/3.6x2...

  • Page 10: Ambient Conditions

    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 °C ■ Relative humidity: 85% or less ■...
  • Page 11 Coolant Sub-Tank Oil Filler Air Cleaner Alternator Check Door Radiator (Inside) Engine Check Door Oil Level Gauge Battery Fuel Drain Plug Oil Drain Plug Coolant Drain Hose Alternator Check Door Oil Filter Fuel Filter Engine Check Door Water Separator External Tank Fuel Return 3way Fuel Valve External Tank Fuel Inlet Accessories...

  • Page 12: Operation Panel Part Names

    4-2. Operation Panel Part Names ① Circuit Breaker ② Controller ③ Power Switch ④ Hour Meter ⑤ Voltage Regulator ⑥ Earth Leakage Relay...

  • Page 13: Output Panel Part Names

    4-3. Output Panel Part Names 3-Phase Output Terminal “R” ① ⑥ 3-Phase Breaker (32A) 3-Phase Output Terminal “S” ② ⑦ 1-Phase Breaker (15A) 3-Phase Output Terminal “T” ③ ⑧ 3-Phase Receptacle 3-Phase Output Terminal “O” ④ ⑨ 1-Phase Receptacle ⑤ ⑩...

  • Page 14: Equipment

    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.(Refer to section "5-1. Controller (2)Operation Display".) (1) Button Lamp Test / Auto Mode Button...
  • Page 15 (2) Operation Display Button Button Button Operation Display Button Button Contents Button, Button Switches the main screen displayed on the Operation Display. Button, Button Displays the detailed status of the main screen. < Note>  If an error occurs during operation, the Operation Display automatically switches to the Alarm screen.
  • Page 16 ○ Generator Status Screen Contents Phase-Neutral voltage meter. Generator Voltage (ph-N) Phase-Phase voltage meter. Generator Voltage (ph-ph) Generator Frequency Frequency meter. Generator Current (A) Current meter. Generator Earth Current (A) No use. Generator Load Ph-N Real power and load factor. (kW)(%) Generator Total Load Total of real power and load factor.

  • Page 17: Warning Indicators

    (3) Editor This generator has with the Controller Editor function, which allows you to change frequency, date and contrast of the controller. Press the Stop Mode Button. Press the Stop Mode Button and " " button together to enter the editor display.
  • Page 18 (1) Low Oil Pressure CAUTION: BURNS  Always be sure to stop the engine and allow the engine to cool when performing inspection or maintenance of engine oil. Opening the oil gauge or oil filler cap during operation will result in hot oil gushing out. If the engine oil pressure drops below 0.98 x 100 kPa during operation, the Low Oil Pressure indicator illuminates on the controller, and "Oil Pressure Low Switch"...

  • Page 19: Meters And Switches

    (6) Water in Fuel If the liquid stored in the water separator exceeds approximately 100 ml during operation, "Water in Fuel" appear on the Operation Display. If it illuminates, immediately stop the engine and drain the liquid stored in the water separator. (Refer to section “10. Inspection/Maintenance (4) Draining Liquid in Water Separator”.) (7) Charge Alt Failure "Charge Alt Failure"...

  • Page 20: Frequency Change

    (2) Circuit Breaker This switch is for transmitting electrical power to the load side. Turn to ON position to output voltage to the output terminals. Output to the load side is cut off when there is a short circuit or overload on the load side. (3) 3-Phase Earth Leakage Relay When current leak occurs, it trips to stop power transmission to load.

  • Page 21: Transporting/Installing

    < Note >  When disconnecting piping from the external tank, turn the lever to the “A” side, and attach the connecting hose to the external tank fuel inlet/return. (2) If using an external fuel tank Connect hoses from the external fuel tank to the external fuel inlet and the external fuel return.

  • Page 22: Installation Procedures

    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 ...

  • Page 23: Connecting Load Cables

     Load Cable Selection Tables (Ex.) If used voltage is 440V and voltage drops by 22 V. 3-phase: Cabtyre cables (Unit: AWG) Length 30 m 61 m 91 m 122 m 152 m 183 m or less Current 20 A 40 A 60 A 70 A...
  • Page 24 (1) 3-Phase Output Terminal and Receptacle  For 3-phase load  Terminal voltage is 400/440 V [200/220 V] (50/60Hz). * The values in brackets are for when set to 200/220V. CON1 Load Load TOTAL 50/60kVA (40/48kw) 3-phase total output capacity 3-phase load Receptacle load Unit...

  • Page 25: Earth Leakage Relay And Grounding

     For 1-phase load  Terminal voltage is 400/440 V [200/220 V] (50/60Hz). * The values in brackets are for when set to 200/220V. Load Load Load TOTAL 40/48kVA (40/48kW) 1-phase total output capacity 1-phase load Receptacle load Unit Total R-O,S-O,T-O R-S,S-T,T-R CON2...

  • Page 26: Pre-Operation Inspection

    (2) Operation Check WARNING : ELECTRIC SHOCK  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. Before operating the generator, check always if the device can work.

  • Page 27: Checking Engine Oil

    8-1. Checking Engine Oil To check the engine oil, keep the equipment in leveled position, remove the oil level gauge and wipe so that no oil remains, and then re-insert the dipstick fully. Prior to starting the engine, make sure to fill the engine oil through the oil filler until it reaches the MAX line.

  • Page 28: Checking The Fan Belt

    (2) Filling the Radiator Radiator Plate Remove the radiator plate. Remove the radiator cap. Filler Neck Fill with coolant through the filler neck until the 給水口 radiator is full. Re-attach and tighten the radiator cap. Attach the radiator plate. Radiator Cap <...

  • Page 29: Checking The Fuel

    (4) Replacing the Fan Belt Request the authorized distributor where the generator was purchased to replace the fan belt. < Note >  Use of a loose or damaged fan belt could result in overheating or insufficient charging.  Do not operate the generator if fan guard has been removed. 8-4.

  • Page 30: Checking The Battery

    8-6. Checking the Battery 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 large amount of water.

  • Page 31: Operating Procedures

    9. Operating Procedures 9-1. Initial Startup/Pre-Check WARNING : EXHAUST GAS POISONING  Do not operate the generator in poorly ventilated areas such as an indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health. ...
  • Page 32 Controller Circuit Breaker Manual Mode Button Start Button Frequency Voltage Adjust Screw Regulator Power Switch Auto Mode Button Stop Mode Button (1) Manual Start Set frequency of the controller. (Refer to section"5-4. Frequency change" ) Turn the Circuit Breaker to OFF position. Turn the Power Switch to ON position.
  • Page 33 (2) Auto Start This generator has an Auto Start function that automatically start the engine by closing the RS1/RS2 terminals. The engine stops automatically when the RS1/RS2 terminals open. Before operating Auto Start, connect the RS1/RS2 terminals to the equipment. RS1 terminal RS2 terminal <...

  • Page 34: Procedures During Operation

    9-2. Procedures during Operation (1) Checks after Startup  Make sure that the controller and hour meter are in normal status. (Refer to section “5. Equipment”.)  Check that there is no abnormal vibration or noise.  Check that the exhaust gas color is normal. When operation is normal, the exhaust gas should be colorless or slightly bluish.

  • Page 35: Protective Functions

    < Note >  Set the Power Switch to OFF position if the generator will not be used for a prolonged period. If you leave the Power Switch in the OFF position, the standby current may drain the battery. 9-4. Protective Functions WARNING : INJURY ...

  • Page 36: Connecting With External Fuel Tank

    9-5. Connecting with External Fuel Tank CAUTION : FIRE  Always make sure that the Power Switch is OFF position when working on piping.  Always be sure to wipe up any spilled fuel.  After working on the piping, check that there is no fuel leakage. Turn the 3way fuel valve lever to the “A”...

  • Page 37: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/INJURY  Do not touch output terminals or internal electric parts while the generator is operating.  Do not open the check door when the Power Switch is in the ON position. It will cause injury by rotating parts such as cooling fans and fan belt. ...
  • Page 38 Every Every Every Every Every Every Every Description Daily 1,000 1,200 1,500 Remarks 200 hrs 400 hrs 500 hrs 600 hrs Each parts  (Clean/Tightening) Engine oil  (Check/Add)  Engine oil time (Replace) 50hrs  time Oil filter (Replace) 50hrs Coolant ...
  • Page 39 (1) Engine Oil Replacement Oil Filler First Time 50 hours Oil Level Thereafter Every 200 hours Indicator Set a container to catch spilled engine oil. Oil Drain Valve Remove the oil filler cap. After removing the oil drain plug and packing, Oil Drain Plug open the oil drain valve and drain the engine Packing...
  • Page 40 (3) Air Filter Element Cleaning/Replacement Clean Every 200 hours Air Cleaner Clip Replace Every 500 hours Remove the air cleaner clips and cleaner cap. Remove the element. Clean or replace the element. Replace by performing the above procedures in reverse order.
  • Page 41 (5)Fuel Filter Replacement (Water Separator) Replace Every 500 hours Fuel Filter element Set a container to catch spilled fuel. Loosen the air bleeder plug of the fuel filter sufficiently. Bleeder Plug Loosen the valve on the bottom to drain the fuel. Remove the outer case of the filter using the specified filter wrench.
  • Page 42 (7) Draining Water from the Fuel Tank Drain Water Every 200 hours Fuel Drain Plug With Rubber Seal Set a container to catch spilled water. Remove the fuel drain plug and packing (with rubber seal). After the water has been drained, reinsert the fuel drain plug with new packing (with rubber seal).
  • Page 43 (9) Elimination of excessive carbon in the exhaust system by extensive light load WARNING : EXHAUST GAS POISONING  Do not operate the generator in poorly ventilated areas such as an indoors or tunnels, as the exhaust gas of the engine contains substances that are harmful to human health.

  • Page 44: Long-Term Storage

    11. Long-Term Storage WARNING : INJURY  Before performing any equipment check or maintenance, stop the engine, and turn the Power Switch to OFF position. CAUTION : FIRE  Always be sure to wipe up any spilled fuel or oil. ...

  • Page 45: Troubleshooting

    12. Troubleshooting WARNING : ELECTRIC SHOCK/INJURY  Do not touch output terminals or internal electric parts while the generator is operating.  Do not open the check door when the Power Switch is in the ON position. It will cause injury by rotating parts such as cooling fans and fan belt. ...
  • Page 46 Problem Suspected cause Action Engine starts but 1. Fuel filter is clogged. 1. Clean/Change fuel filter. stalls immediately 2. Water is interfused in fuel line. 2. Drain water in water separator, fuel filter or fuel tank. 3. Air is interfused in fuel line. 3.
  • Page 47 Problem Suspected cause Action Cannot turn the 1. The breaker positions at between ON and 1. Once turning the lever to breaker to ON OFF. OFF, turn it to ON. 2. Short circuit on the load. 2. Check the load circuit. 3.

  • Page 48: Generator Circuit Diagram

    13. Generator Circuit Diagram (1) 400/440V...
  • Page 49 (2) 200/220V...

  • Page 50: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 52 ©2019...

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