Shindaiwa DGA50CM Owner's And Operator's Manual
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Shindaiwa DGA50CM Owner's And Operator's Manual

Shindaiwa DGA50CM 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.
DGA50CM
X750-031 07 0
X750802-140 1

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  • 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. DGA50CM X750-031 07 0 X750802-140 1...
  • Page 3 Introduction Thank you for purchasing this IPSGenSet 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 Guidelines ························································································· 1 2. Specifications ······························································································ 5 2-1. Data ······································································································ 5 2-2. Ambient Condition ····················································································· 6 3. Use ············································································································· 6 4. Parts ··········································································································· 6 4-1. Outer and Main Components ······································································· 6 4-2. Operation Panel ······················································································· 7 4-3.

  • Page 5: Safety Guidelines

    1 Safety Guidelines WARNING : EXHAUST GAS POISONING  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 bystanders or buildings. WARNING : ELECTRIC SHOCK ...
  • Page 6 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.  Position this generator 3 ft. (1 m) or more from walls or other hindrances, and on a level surface.
  • Page 7 CAUTION : INJURY  Always be sure to use Lifting Hook when lifting up the generator, and slowly lift it straight up.  Personnel performing lifting work must wear protective gear such as helmets, safety shoes and gloves.  Position the generator on a level stable surface so that it cannot slide or move in any manner.
  • Page 8  Warning / Caution Label Locations When warning / caution labels become unreadable or damaged, place new labels at the appropriate locations as specified in the following figure. When ordering the labels, use the following part numbers. 1. Injuries ····································· (Part no.: X505-004630) 2.

  • Page 9: Specifications

    2 Specifications 2-1. Data Unit DGA50CM Generating Method Rotating Filed, Brushless 3-Phase Synchronous Generator Rated Output Rated Voltage Rated Current 69.6 Rated Frequency Rated Speed 1500 Phase & Wiring 3-Phase 3-Wire Power Factor Insulation Class Alternator: F Exciter: B Exciting Method...

  • Page 10: Ambient Condition

    2-2. Ambient Condition Be sure to use the equipment under the following ambient condition range. Otherwise the condition may cause damage, insufficient output or durability shortage to the equipment. ■ Ambient: Temperature: from -15 to 40 degree Celsius ■ Relative: Humidity: less than 80% ■...

  • Page 11: Operation Panel

    Accessories Operator’s Fuse (3A) Manual Fuse (10A) Nipple (2 pieces) 4-2. Operation Panel 3-Phase Breaker(50A) 3-Phase Breaker(32A) Main Circuit Breaker Controller 3-Phase Breaker(20A) 1-Phase Breaker(15A) Emergency Stop Button Voltage Regulator Power Switch / Air Bleeding Battery Isolator...

  • Page 12: Output Panel

    4-3. Output Panel 3-Phase RCCB 1-Phase RCCB 1-Phase Receptacle (15A) Bonnet Grounding 3-Phase Receptacle (20A) Terminal 3-Phase Receptacle 3-Phase Receptacle (50A) (32A)

  • Page 13: 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. (1) Front panel elements STOP button ①...
  • Page 14 HORN RESET button ⑤ Use this button deactivate the horn output without acknowledging the alarms. FAULT RESET button ⑥ 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.

  • Page 15: Switches

    5-2. Switches 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.

  • Page 16: Voltage Regulator

    (5) 3-Phase Residual Current Circuit Breaker (3P RCCB) 1-Phase Residual Current Circuit Breaker (1P RCCB) Each receptacle, 3-Phase and 1-Phase is incorporated with RCCB respectively. When current leak occurs, it trips to stop power transmission to load. 1P RCCB 3P RCCB <...

  • Page 17: Fuel Line Changeover Valve (3-Way Valve)

    5-4. Fuel Line Changeover Valve (3-way valve) CAUTION : Fire  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 a leak is found. Repair the equipment before use. Be sure to confirm that there is no leakage in the piping.

  • Page 18: Transportation & Installation

    6 Transportation and installation 6-1. How to transport WARNING : Injuries  When lifting the equipment, always use a lift hook.  Never use roping lug for lifting the unit, for it may cause equipment to drop. (1) Lifting the equipment Always use a Lift lug, when lifting the equipment for transportation.

  • Page 19: Installation

    6-2. Installation WARNING : Suffocation from exhaust gas  Exhaust fumes from the engine contains many elements harmful to humans. Do not operate this equipment in poorly ventilated area, such as inside a room or in a tunnel CAUTION : Suffocation from exhaust gas ...

  • Page 20: Connecting Load

    7 Connecting Load 7-1. Select Load Cable Select the cable with proper gauge, based on its allowable amperage and the distance between the generator and the machinery to be connected. CAUTION : Damage to properties  If the load exceeds the allowable amperage, the damage to the cable may be damaged in overheating.

  • Page 21: Connecting Load Cable

    7-2. Connecting Load Cable WARNING : Electric Shock  Before connecting or disconnecting a load cable from output receptacles, always turn a circuit breaker to OFF position, stop the engine, and turn the Power Switch to the OFF position. CAUTION : Fire ...

  • Page 22: Rccb And Grounding

    7-3. Residual Current Circuit Breaker (RCCB) 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 23 (2) Operation Check WARNING : Electric Shock / Injuries  Before turning RCCB to ON position, ensure that the breakers or the switches of loads are positioned to OFF. You should communicate well with the electrician by the load side when operating RCCB.
  • Page 24 (3) RCCB has activated. When the RCCB has activated, repair the leakage point and restore it by the following procedure. (Overload happens when the breaker activates but the Residual Current Circuit Breaker does not activate.) Turn the 3-Phase RCCB to ON to restore. Turn the 1-Phase RCCB to RESET to restore.

  • Page 25: Initialization And Pre-Check

    8 Initialization and Pre-check WARNING : Electric Shock / Injuries  Before performing any equipment check or maintenance, stop the engine, and turn the Power Switch to the OFF position. CAUTION : Fire / Burns  When checking engine, always stop the engine, and keep away from fire. Wait until the engine cools down, before performing any checks.

  • Page 26: Coolant / Water

     Viscosity and temperature (3) Replacing Engine Oil Volume (Unit: Liter) Lubrication Oil (including the oil in filter) 13.2 (1.1) Value in ( ) shows the oil in filter 8-2. Checking Coolant / Water WARNING : Injuries  Before performing any equipment check or maintenance, stop the engine, and turn the Power Switch to the OFF position.
  • Page 27 (2) Checking coolant in Sub Tank / Adding coolant Check to see if the water/coolant level is between FULL and LOW line in the Sub Tank. Fill up to the FULL line, if the water/coolant level is low. < Note > ...

  • Page 28: Fan Belt

    8-3. Checking Fan Belt WARNING : Injuries  Before performing any equipment check or maintenance, stop the engine, and turn the Power Switch to the OFF position.  Close and lock all doors during operating this equipment, to avoid injuries by unintentionally touching cooling fan and fan belt.

  • Page 29: Fuel, Oil And Coolant Leakage

    This blended fuel is usually called also No.2-D. It can be used in colder temperature than N0.2-D fuel, which has not been winterized. Check with service station operator to be sure you can get the proper blend fuel.  Fuel requirements: NOTICE: The fuel injection pump, injector or other parts of the fuel system and engine can be damaged if you use any fuel or fuel additive other than those specifically recommended by Isuzu.
  • Page 30 ■Replacing the Battery +Post -Post +Post -Post < Note > ●Dual batteries has been connected in a series. Always follow the below instruction when replacing the Battery or Remove the Battery cables to avoid Battery short circuit. (1) Replacing the Right ( R ) side Battery Disconnect the negative (-) terminal from Fixing Clamp the Right Battery always.

  • Page 31: Operation

    9 Operation 9-1. Initialization and Preparation WARNING : Suffocation from exhaust gas  Exhaust fumes from the engine contains many elements harmful To humans. Do not operate this equipment in poorly ventilated area, such as inside a room or in a tunnel CAUTION : Suffocation from exhaust gas ...
  • Page 32 Let engine idles for approximately 5 minutes. Ensure that the tachometer shows the following frequency at no load. No Load Frequency (Revolving Speed) 50Hz RUN 52.5Hz (about) (1575min < Note >  By setting frequency to the above frequency under no load, 50Hz(almost) will be obtained at the rated output load.

  • Page 33: Procedures During Operation

    9-2. Procedures during Operation (1) Checks after Startup  Make sure that the controller is in normal status.  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 34: Stopping

    9-3. Stopping Turn the switch on the equipment and the circuit breaker on the load to OFF. Turn every circuit breaker to OFF position. Let engine idles for approximately 3 minutes. (for cool down) Press the Stop button to shut off the engine. Turn the Power Switch to OFF position.

  • Page 35: Protection Functions

    9-4. Protection Functions WARNING : INJURY  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.  Always turn the Power Switch to the OFF position and stop the engine, then close and lock OPERATION PANEL DOOR before checking or maintaining the engine or any equipment.

  • Page 36: Connecing With External Fuel Tank

    9-5. Connecting to External Fuel Tank CAUTION Always stop the engine, when working on the fuel line.   Always wipe any drip of Diesel fuel or oil. Do not use this equipment when a leak is found. Repair the equipment before use. ...

  • Page 37: Check And Maintenance

     Just after having connected to External Fuel Tank, there may be a case that engine speed is unstable and engine stops due to insufficient air extraction. Therefore, be sure to confirm that the air is extracted completely and the engine speeds keeps stable before leaving the equipment under people-less operation.
  • Page 38 Startup Every Every Every Every Description 1000hrs check 200hrs 400hrs 500hrs Engine Side Clean each parts / tightening ◯ Engine oil checks / add oil ◯ Engine oil change (1 time at 50 hr mark) ◯ Oil Filter change (1 time at 50 hr mark) ◯...
  • Page 39 (1) Change engine oil Initial 50 hours and after Every 200 hours Remove the Oil Filler Cap. Oil Gauge Oil Filler Remove the Oil Drain Plug and then turn The Oil Drain Lever to OPEN and drain engine oil. Turn the Oil Drain Lever to CLOSE and tighten the Oil Drain Plug.
  • Page 40 < Note >  If an oil filter wrench is not at hand, contact our authorized distributor or our engineering section to replace.  Oil Filter Part No. Isuzu Part No. 8943212190 (3) Cleaning / Changing Air Filter Element Air Cleaner Clean Every 200 hours Change...
  • Page 41 (4) Drain water in the Water Sedimentor Check Startup Clean Every 200 hours When a float (red) in the cup is floating at drain level, drain water. Float Loosen the Cock. After draining finishes, tighten the Cock Water Drain Level Cock.
  • Page 42 (7) Clean Gauze Filter in Water Separator Clean Every 500 hours Air Extraction Plug Ring Nut Loosen the Cock and then loosen the air extraction plug. Gauze Filter Float Turn the ring nut counter-clockwise Cock to remove the cup and the Gauze Filter Water Drain Level after the fuel inside does not come out from the lever.
  • Page 43  Change both Gauze Filter and eyebolt GAUZE FILTER when Gauze Filter is damaged.  Extract the air in fuel line after Gauze Filter washing finishes. (Refer to 『9-2. Procedures during Operation』.) EYEBOLTS  Ensure that there is no fuel leakage after reinstallation.
  • Page 44 (11) Change Coolant Change 2 years or 1000 hours Radiator Plate Remove the Radiator Plate. Water Inlet Remove the Radiator Cap. Radiator Cap Loosen the Radiator Drain Cock and the Drain Plug on the engine side. After draining finishes, tighten the Radiator Drain Cock and the Drain Plug on the engine side.

  • Page 45: Long Term Storage

    11 Long-term storage WARNING : Electric Shock/Injuries Before performing any equipment check or maintenance, stop the  engine, and turn the Power Switch to the OFF position. CAUTION : Fire/Injuries  Temperature around muffler and exhaust can get extremely high levels. Keep any inflammable items (such as fuel, gas, paint, etc.) away from the equipment.

  • Page 46: Troubleshooting

    (2) Stacking WARNING : Injuries If you have to stack two generators at warehouse, always proceed with the following steps. Ensure that there is no dent on bonnet, loose bolt or no bolt in the equipment.   Always place the equipment horizontal on a flat and stable surface to be endurable for the total weight, and to keep the equipment from sliding.
  • Page 47 Symptom Presumable Cause Action Starter motor does not Battery Isolator is OFF Turn Battery Isolator to ON drive or speed is low. Battery output is weak Check / battery liquid/ or Battery is deteriorated Charge Battery terminal is OFF or loose Change battery Battery terminal is corroded Fix / Tighten terminal...
  • Page 48 Overheated Engine thermostat is Ask our distributor to repair defective Ask our distributor to repair Water temp sensor is Ask our distributor to repair defective Check / Adjust fan belt Controller is defective Check / Supply coolant Fan belt tension is weak Clean radiator core Coolant is insufficient Radiator core is clogged...
  • Page 49 The voltage drops drastically 1. AVR is defective 1. Ask our distributor to repair when connecting to load 2. Unbalanced loads sharing to 2. Balance the loads sharing to each terminal each terminal 3. Wrong frequency is used 3. Set the switch to the load frequency 4.

  • Page 50: Generator Circuit Diagram

    13 Generator Circuit Diagram...

  • Page 51: Engine Circuit Diagram

    14 Engine Circuit Diagram...
  • Page 52 ©2021...

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