Shindaiwa DG1000MI Owner's And Operator's Manual
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Shindaiwa DG1000MI Owner's And Operator's Manual

Vertical, water-cooled 4-cycle diesel engine
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'
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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.
DG1000MI/ANZ
X753-005 27 2
X753800-000 2

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Summary of Contents for Shindaiwa DG1000MI

  • 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. DG1000MI/ANZ X753-005 27 2 X753800-000 2...
  • 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 Safety Instructions ................2 2. Specifications ................... 5 2-1. Specifications ................5 2-2. Ambient Conditions ..............6 Applications ..................6 Part Names ..................6 4-1. External View/Part Names ............6 4-2. Operation Panel Part Names ............ 8 4-3.

  • Page 5: Safety Instructions

    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 remove the engine key.
  • Page 6 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.
  • Page 7 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.

  • Page 8: Specifications

    2. Specifications 2-1. Specifications Model Unit DG1000MI/ANZ Rotating Filed, Brushless 3-Phase Generating Type Synchronous Alternator Rated Output Rated Voltage Rated Current Rated Frequency Winding 3-phase, 4-wire Power factor Insulation class Excitation Self-Excitation(Brushless) No. of poles Types Vertical Water-cooled 4-cycle Diesel Engine...

  • Page 9: 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 degree Celsius ■ Relative humidity: 80% or less ■...
  • Page 10 Oil Filler Cap Tie-Down Engine Check Door Coolant Sub-Tank Alternator Check Door Terminal Cover Fuel Inlet Fuel Tank Terminal Cover Battery Oil Level Indicator Oil Drain Plug Alternator Check Door Engine Check Door Air Cleaner Fuel Filter Radiator Tie-Down Battery Oil Filter Water Separator Fuel Drain plug...

  • Page 11: Operation Panel Part Names

    4-2. Operation Panel Part Names ① ⑩ Circuit Breaker Hour Meter ② ⑪ Earth Leakage Relay Water Temperature Gauge ③ ⑫ Voltmeter Fuel Gauge ④ ⑬ Ammeter Preheat Lamp ⑤ ⑭ Frequency Meter Starter Switch ⑥ ⑮ Panel Light & Pilot Lamp Throttle Lever ⑦...

  • Page 12: Equipment

    Equipment 5-1. Warning Indicators WARNING : INJURY Close all doors and place locks during operation, to avoid injuries by unintentionally contact with moving parts such as the cooling fan and fan belt. Before performing any equipment check or maintenance, stop the engine, and remove the engine key.
  • Page 13 (1) WATER TEMP (Coolant Temperature) Warning Indicator (High Water Temp.) CAUTION: BURNS 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.

  • Page 14: Meters And Gauges

    5-2. Meters and Gauges Engine Meters and Gauges (1) Hour Meter Displays the operating time. Use this to schedule periodic inspection. Be careful as the hour meter operates when the starter switch is at RUN regardless of whether the engine is running or stopped.
  • Page 15 Generator Meters and Gauges (1) Voltmeter Voltmeter displays the output voltage (Phase to Phase) from the generator. Please check and confirm it showing 415V at 50Hz during operation. (2) Ammeter Ammeter displays the output current (Phase) from the generator. (3) Frequency Meter Frequency Meter will display the frequency of the generator.
  • Page 16 Switches (1) Starter Switch ① Stop STOP PREHEAT When the switch is set to this position, all power will be off. The switch must be set to this START position to remove the key. ② Run The switch must be set to this position during operation. <...
  • Page 17 (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;...
  • Page 18 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.

  • Page 19: Fuel Piping Switch (3Way Fuel Valve)

    5-3. 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. three-way fuel valve fuel will be supplied from the external tank.

  • Page 20: Transporting/Installing

    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 persons 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.

  • Page 21: 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 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...

  • Page 22: Load Connections

    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.

  • Page 23: Connecting Load Cables

    7-2. Connecting Load Cables 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 remove the engine key. The person performing the maintenance should always keep the key. Close the output terminal cover before operating.

  • Page 24: Earth Leakage Relay And Grounding

    7-3. Earth Leakage Relay and Grounding WARNING : ELECTRIC SHOCK Ground the every grounding terminal to the earth as set in the manual. If even one of all is unconnected by mistake or accident, it will be much more dangerous for human than the NO-RELAY case, because leaking current inevitably goes through the body.
  • Page 25 (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 26 (3) The earth leakage breaker relay has activated In the event the earth leakage breaker relay has activated, the earth leakage indicating lamp Turns ON and the Circuit breaker (lever) trips off to be positioned in the middle between ON and OFF positions. In the above condition, even though you stop the engine once and start it again, the Circuit breaker (lever) does not restore to ON or OFF, and the reset button does not function, because the device keeps detecting current leakage.

  • Page 27: Pre-Operation Inspection

    Pre-Operation Inspection WARNING : ELECTRIC SHOCK/ / / / INJURY 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. Close all doors and place locks during operating this equipment, to avoid injuries by unintentionally touching cooling fan and fan belt.

  • Page 28: Checking Coolant

    (1) Types of Engine Oil Use the API class CD grade or higher. (2) Engine Oil Viscosity Use a diesel engine oil with an appropriate viscosity corresponding to the ambient temperature (refer to the table).  Relation of Viscosity/Temperature SAE40 SAE20/20W SAE10W SAE30...
  • Page 29 (2) Filling the Radiator Remove the radiator plate. Remove the radiator cap. RADIATOR CAP WATER INTAKE Fill with coolant through the filler neck until the radiator is full. RADIATOR PLATE Re-attach and tighten the radiator cap. Attach the radiator plate. <...

  • Page 30: Checking The Fan Belt

    8-3. Checking the Fan Belt (1) Fan Belt Tension Tension should be optimum when the fan belt has 10 to 15mm slacks, when applying finger pressure (about 98N{approximately 10kgf}) at midpoint between fan pulley and alternator pulley. (2) Fan Belt Condition Check the fan belt for damage and replace if any damage or other fault is found.

  • Page 31: Checking The Fuel

    8-4. Checking the Fuel CAUTION : FIRE This generator uses diesel fuel. Always be sure to stop the engine and remove engine key. Wait until the engine has cooled before performing inspection or periodical maintenance. Always wipe any drip of Diesel fuel or oil. Do not use this equipment when leak is found.

  • Page 32: Checking For Fuel, Oil And Coolant Leaks

    8-5. Checking for Fuel, Oil and Coolant Leaks CAUTION : FIRE Do not use this equipment when leak is found, and repair the leaking location before operating. Open the check door and check for fuel, oil and coolant leakage from fuel piping connections and similar locations.
  • Page 33 Replacing the Battery Two batteries are connected in series order. Whenever you replace battery or disconnect cables, always proceed with the following steps, otherwise battery may short-circuit. (1) Replacing the battery installed on the left side toward the control panel: Remove the clamp and cable from negative (-) post from the battery on the right side (always remove negative side first)

  • Page 34: Operating Procedures

    Operating Procedures 9-1. Initial Startup/Pre-Check WARNING : SUFFOCATION FROM EXHAUST FUME 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. Do not direct exhaust fumes at pedestrians or buildings.
  • Page 35 Circuit Breaker Preheat Lamp Voltage Regulator Fixing Screw Nut Frequency Adjusting Screw Throttle Lever INCREASE DECREASE START POSITION FREQUENCY ADJUST THROTTLE Throttle Lever Battery Isolator Starter Switch < NOTE > Do not continuously operate the starter motor for 10 sec. or more. If repeating starter switch operation, wait 30 sec.

  • Page 36: Procedures During Operation

    9-2. Procedures during Operation (1) Checks after Startup Make sure that all meters and indicators 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 37: Protective Functions

    9-4. Protective Functions WARNING : INJURY 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 remove the engine key. A person performing the maintenance should always keep the key.

  • Page 38: Connecting With External Fuel Tank

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

  • Page 39: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/ / / / INJURY 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. Do not touch the generator if the Alternator or casing becomes wet during operation.
  • Page 40 When check doors are open during maintenance, take measures so that unrelated personnel cannot accidentally come close to the generator. Close all doors and covers if you are going to be away from this generator. In the event you are using Fuel Oil (A) as a fuel, the interval of replacing engine oil, oil filter and fuel filters and the inspection of fuel injection nozzle will be more frequently at every half the hours shown in the matrix.
  • Page 41 (1) Engine Oil Replacement First Time 50 hours Thereafter Every 200 hours OIL FILLER OIL FILLER CAP Remove the oil filler cap. Remove the oil drain plug and drain the engine oil. OIL DRAIN PLUG Reinstall the drain plug. Add oil through the oil filler until it is at the maximum level while checking the fuel level using the oil level indicator.
  • Page 42 < NOTE > Request the authorized distributor where the generator was purchased to perform this procedure if you do not have a filter wrench. Oil filter part no ISUZU Part No. 1132402321 (3) Air Filter Element Cleaning/Replacement Clean Every 200 hours Replace Every 500 hours Loosen the bolt that is holding the air cleaner and remove the cleaner cap...
  • Page 43 (4) Draining Water from the Water Separator Drain water when the float (red) inside the cup floats to the water draining position. Loosen the drain plug and drain water. Screw the drain plug, when finishing drain. < NOTE > After draining finishes, extract the air in fuel line. (Refer to “9-2.
  • Page 44 (6) Clean gauze filter in water separator Clean Every 500 hours Loosen the lever and then loosen the air RING NUT EXTRACTION extraction plug. PLUG Turn the ring nut counter-clockwise to GAUZE FILTER remove the cup and the gauze filter after the fuel inside does not come out from the lever.
  • Page 45 < NOTE > Put a tray under the lever in order to catch spilled fuel when loosing GAUZE FILTER the lever. Gaskets are attached to both ends of joint pipe. Be careful not to lose and install them in the unit without fail. Change both gauze filter and eyebolt when gauze filter is damaged.
  • Page 46 (10) Changing Coolant / Water Replace Every 2 years or 1000 hours RADIATOR Remove the radiator cap cover. DRAIN PLUG Remove the radiator cap. Loosen the draining plug on both the engine and radiator. After draining all the water, tighten the draining plug on both the engine and radiator.

  • Page 47: Long-Term Storage

    11. Long-Term Storage WARNING : INJURY 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. CAUTION : FIRE Always be sure to wipe up any spilled fuel or oil. Allow the generator to cool before covering with the protective cover.

  • Page 48: Troubleshooting

    (2) Double-Stacking Procedures WARNING : INJURY Always be sure to observe the following items when double stacking this generator in a warehouse or similar location. Check that the Top cover of this generator is not dented, and that bolts are not loosen or missing. Set in a location with a flat hard floor capable of withstanding the double-stacking weight.
  • Page 49 Problem Suspected cause Action Starter motor Battery Isolator is OFF Turn Battery Isolator to ON does not drive Battery output is weak Check/ battery liquid/ or or speed is Charge low. Battery is deteriorated Change battery Battery terminal is OFF or loose Fix/Tighten terminal Battery terminal is corroded Clean terminal...
  • Page 50 Overheated Engine thermostat is defective Ask our distributor to repair Water temp sensor is defective Ask our distributor to repair Water temp meter is defective Ask our distributor to repair Fan belt tension is weak Check/Adjust fan belt Coolant is insufficient Check/Supply coolant Radiator core is clogged Clean radiator core...

  • Page 51: Generator Circuit Diagram

    13. Generator Circuit Diagram...

  • Page 52: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 56 ©2015...

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