Shindaiwa DG100MI Owner's And Operator's Manual
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Shindaiwa DG100MI Owner's And Operator's Manual

Diesel engine generator
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'
OWNER
S AND OPERATOR
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.
'
S MANUAL
DG100MI-200/TWN
X753-007 04 0
X753801-090 0

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Summary of Contents for Shindaiwa DG100MI

  • 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. DG100MI-200/TWN X753-007 04 0 X753801-090 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 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 ...
  • 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.

  • Page 8: Specifications

    2. Specifications 2-1. Specifications Model Unit DG100MI-200 Rotating Filed, Brushless 3-Phase Generating Type Synchronous Alternator Rated Frequency Rated Output Rated Voltage 200 [400] *1 220 [440] *1 Rated Current 231 [115] *1 262 [131] *1 Winding 3-phase, 4-wire Power factor...

  • 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: 85% or less ■...
  • Page 10 Coolant Sub-Tank Oil Filler Air Cleaner Alternator Check Door Radiator Engine Check Door Battery Oil Level Indicator Oil Drain Plug Oil Drain Faucet (Inside) Water Separator 3way Fuel Valve Oil Filter Fuel Filter Alternator Check Door Engine Check Door Battery External Fuel Ports Coolant Drain Hose Fuel Drain Valve (Inside)

  • Page 11: Operation Panel Part Names

    4-2. Operation Panel Part Names ① ⑪ Circuit Breaker Over Load Pre-caution Lamp 3-Phase ② ⑫ Voltmeter Preheat Lamp ③ ⑬ Ammeter Voltage Regulator ④ ⑭ Frequency Meter Ammeter Selector Switch ⑤ ⑮ Water Temperature Gauge Starter Switch ⑥ ⑯ Fuel Gauge Throttle Lever ⑦...

  • Page 12: Output Panel Part Names

    4-3. Output Panel Part Names 3-Phase Output Terminal “R” ① ⑥ Circuit Breaker 1-Phase 3-Phase Output Terminal “S” ② ⑦ 1-Phase Output Terminal 3-Phase Output Terminal “T” ③ ⑧ 1-Phase Receptacle 3-Phase Output Terminal “O” ④ ⑨ Bonnet Grounding Terminal ⑤...

  • Page 13: 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 14: Meters And Gauges

    (2) OIL PRESS (engine oil pressure) Warning Indicator (Low Oil Press.) 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.
  • Page 15 (3) 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. Generator Meters and Gauges (1) Voltmeter The voltmeter displays the 3-phase output voltage (voltage between R-T) from the generator.
  • Page 16 Refer to the circuit drawing below if using the Aux Lamp Terminal for a lamp or similar device with a different setting. < Note >  Connect a lamp that is DC24V/2A/48W or less to the Aux Lamp Terminal.  lamp flashes when more than 80% of the rated output lasts for 20 The pre-caution seconds.
  • Page 17 (3) Earth Leakage Relay 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). < Note >  Do not use this relay as the ON/OFF switch to the load. Voltage Regulator and Throttle Lever (1) Voltage Regulator The dial adjusts generator output voltage.

  • Page 18: Fuel Piping Switch (3Way Fuel Valve)

    5-3. Fuel Piping Switch (3Way Fuel Valve) CAUTION : FIRE  Always make sure that the engine is stopped 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. Change the 3way fuel valve to switch to supply fuel from the external tank.

  • Page 19: Installation Procedures

    (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.

  • Page 20: 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 21: Connecting Load Cables

    Length 50 m 75 m 100 m or less Current 100A 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.
  • Page 22  For 1-phase load  Terminal voltage is 115/127 V [230/254 V] (50/60Hz). * The values in brackets are for when set to 400/440V. Load Load Load TOTAL 64/80kVA（64/80kW）  For 1-phase load  Terminal voltage is 200/220 V [400/440 V] (50/60Hz). * The values in brackets are for when set to 400/440V.
  • Page 23 (2) 1-Phase Output Terminals and Receptacle  For 1-phase load  The terminal Voltage: 100V/110V at 50Hz/60Hz only. In the case of no use of 3-Phase output power, refer to the Following drawing and chart CON1 CON2 U1-U0 W1-W0 Sub Total Total Voltage 100V/110V only Unit...

  • 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: Pre-Operation Inspection

    Ensure that the breakers and the switches of 3-Phase Circuit Breaker loads are positioned to OFF. Ensure that the 3-Phase circuit breaker and the 1-Phase circuit breaker are positioned to OFF. (Refer to "4-2.Operation Panel") Following the procedure in 9-1, Initial Startup / Pre-Check,start an engine.

  • Page 26: Checking Engine Oil

    8-1. Checking Engine Oil To check the engine oil, keep the equipment in leveled position, remove the oil level indicator 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 27 Check that the subtank coolant level is in between FULL and LOW. If the subtank coolant is lower than the LOW level, add coolant to the subtank and radiator. (1) Filling the Sub-Tank Sub-tank Remove the sub-tank cap. FULL Fill the sub-tank with coolant until it reaches the FULL line.

  • Page 28: Checking The Fan Belt

    8-3. Checking the Fan Belt (1) Fan Belt Tension Press your finger against the middle of the fan belt. (approx. 98N) If the slack is 10-15mm, the tension is normal. (2) Fan Belt Condition Check the fan belt for damage and replace if any damage or other fault is found.

  • Page 29: Checking The Battery

    Open the check door and check for fuel, oil and coolant leakage from fuel piping connections and similar locations. 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.

  • Page 30: Operating Procedures

    Remove the clamp and cable from positive (+) post from the battery on the left side. Remove the left side battery from the seat. ※Reinstall the new battery in the reverse order (always install the cable to the positive (+) post of the new battery first). 8.6.2 Replacing the battery installed on the right side toward the operation panel: Remove the clamp and cable from negative (-) post...
  • Page 31 < Note >  Check that the surrounding area is safe before starting the engine.  When there are multiple workers who are working together, they must mutually signal each other before starting the engine.  Do not use in an area with high temperature or humidity, or an area with a large amount of dust. ...

  • Page 32: 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 33: Protective Functions

    9-4. Protective Functions WARNING : INJURY  Do not open the check door during operation. Be careful of pinching or catching of moving parts such as the cooling fan and fan belt.  Always be sure to stop the engine and remove the engine key when performing inspection or maintenance.

  • Page 34: 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 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 35: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/INJURY  Do not touch receptacles or internal electric parts while the generator is operating.  Do not open the check door during operation. Be careful of pinching or catching of moving parts such as the cooling fan and fan belt. ...
  • Page 36 Every Every Every Every Description Daily 200 hrs 400 hrs 500 hrs 1,000 hrs Each parts  (Clean/Tightening) Engine oil  (Check/Add)   time at Engine oil (Replace) 50 hrs   time at Oil filter (Replace) 50 hrs Coolant ...
  • Page 37 (1) Engine Oil Replacement First Time 50 hours Thereafter Every 200 hours Set a container to catch spilled engine oil. Oil Filler Remove the oil filler cap. Oil Level After removing the oil drain plug and packing, Indicator Oil Drain open the oil drain faucet and drain the engine Faucet oil.
  • Page 38 (3) Air Filter Element Cleaning/Replacement Cleaner Cap Clean 200 hours Replace Every 500 hours Fixing Bolt Loosen the bolt that is holding the air cleaner and remove the cleaner cap. Air Cleaner Unscrew the wing nut and remove the filter element.
  • Page 39 (5)Fuel Filter Replacement (Water Separator) Replace Every 500 hours Fuel Filter element Set a container to catch spilled fuel. Air Bleeder Plug Loosen the air bleeder plug of the fuel filter sufficiently. Loosen the faucet on the bottom to drain the fuel. Remove the outer case of the filter using the specified filter wrench.
  • Page 40 < Note >  When attaching the cup, check that there is no foreign material adhering to the O-ring.  Be sure to wipe away any fuel that has spilled out of the piping when removing the filter.  Fuel filter element part no.:8980366540 (ISUZU part no.) (7) Clean gauze filter in engine feed pump Every 500 hours Clean...
  • Page 41 (9) Draining Water from the Fuel Tank Drain Water Every 200 hours Fuel Drain Faucet Set a container to catch spilled water. Open the fuel drain faucet. Close the drain faucet, after draining water fully (10) Coolant Replacement Replace Every 2 year or Every 1000 hours Radiator Cap Set a container to catch spilled coolant.

  • Page 42: Long-Term Storage

    (11) Elimination of carbon in the exhaust pipe line and muffler 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 43 CAUTION : FIRE  Always be sure to wipe up any spilled fuel or oil.  Allow the generator to cool before covering with the protective cover. CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the equipment, while temperature can reach extremely high.

  • Page 44: Troubleshooting

    12. Troubleshooting WARNING : ELECTRIC SHOCK/INJURY  Do not touch output terminals or internal electric parts while the generator is operating.  Close all doors and place locks during operating this equipment, to avoid injuries by unintentionally touching cooling fan and fan belt. ...
  • Page 45 Problem Suspected cause Action Starter motor 7. Fuel cut solenoid (motor) does not work 7-1. Check/Change fuse drives but 7-2. Check/Change fuel cut engine does Solenoid not start 8. Fuel pump defective 8-1. Check/Change fuse 8-2. Check/Change fuel pump <Ambient 1.
  • Page 46 Problem Suspected cause Action Pointer (hand) does 1. Voltage meter is defective 1. Ask our distributor to repair not move in voltage 2. AVR is defective 2. Ask our distributor to repair meter 3. Disconnected circuit, loose terminal or 3. Ask our distributor to repair departed 4.

  • Page 47: Generator Circuit Diagram

    13. Generator Circuit Diagram (1) 200/220V...
  • Page 48 (2) 400/440V...

  • Page 49: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 52 ©2018...

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