Shindaiwa DG1000MIM Owner's And Operator's Manual
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Shindaiwa DG1000MIM Owner's And Operator's Manual

Shindaiwa DG1000MIM Owner's And Operator's Manual

Vertical, water-cooled 4-cycle diesel engine
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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.
DG1000MIM/ANZ
X753-009 30 0
X753800-330 0

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Summary of Contents for Shindaiwa DG1000MIM

  • 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. DG1000MIM/ANZ X753-009 30 0 X753800-330 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 DG1000MIM/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 Circuit Breaker ② Earth Leakage Relay ③ Controller ④ Voltage Regulator ⑤ Power Switch / Air Bleeding ⑥ Battery Isolator ⑦ Emergency Stop Button ⑧ Frequency Adjusting Screw ⑨ Throttle Lever 4-3. Main Terminal Board Main Terminals Plexiglass Cover...

  • Page 12: Equipment

    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 13 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. UP button ⑦...

  • Page 14: Switches

    5-2. Switches (1) 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 15 (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 16: Voltage Regulator And Throttle Lever

    5-3. 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...

  • Page 17: Fuel Piping Switch (3Way Fuel Valve)

    5-4. 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 18: 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 ...

  • Page 19: 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 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

    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.  Close the output terminal cover before operating. ...

  • Page 22: 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 23 (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.
  • Page 24 (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 25: Pre-Operation Inspection

    Pre-Operation Inspection WARNING : ELECTRIC SHOCK/INJURY  Before performing any equipment check or maintenance, stop the engine, and turn the Power Switch to the OFF position.  Close all doors and place locks during operating this equipment, to avoid injuries by unintentionally touching cooling fan and fan belt. CAUTION : BURNS ...

  • Page 26: 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 27 (2) Filling the Radiator Remove the radiator plate. RADIATOR CAP Remove the 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 28: 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 29: Checking The Fuel

    8-4. Checking the Fuel CAUTION : FIRE  This generator uses diesel fuel. Always be sure to stop the engine and turn the Power Switch to the OFF position. Wait until the engine has cooled before performing inspection or periodical maintenance. ...

  • Page 30: 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 31  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 32: 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. ...
  • Page 33 Circuit Breaker Voltage Regulator Battery Isolator Fixing Screw Nut Frequency Adjusting Screw Throttle Lever INCREASE DECREASE RUN POSITION START POSITION FREQUENCY ADJUST THROTTLE Power Switch Throttle Lever < NOTE >  If you need to restart, wait at least 30 seconds before the retry. Let engine idles for approximately 5 minutes.

  • Page 34: 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 35: Stopping Operation

    9-3. Stopping Operation CAUTION : BURNS  Do not touch the engine and surrounding components immediately after stopping the equipment, while temperature can reach extremely high. Turn the switches and breakers on the load side to OFF. Turn the circuit breaker on the operation panel to OFF. Turn the Throttle Lever to <START POSITION>.

  • Page 36: 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 turn the Power Switch to the OFF position. CAUTION : BURNS ...

  • Page 37: 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 38: Inspection/Maintenance

    10. Inspection/Maintenance WARNING : ELECTRIC SHOCK/INJURY  Before performing any equipment check or maintenance, stop the engine, and turn the Power Switch to the OFF position.  Do not touch the generator if the Alternator or casing becomes wet during operation.
  • Page 39  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 40 (1) Engine Oil Replacement First Time 50 hours Thereafter Every 250 hours Remove the oil filler cap. OIL FILLER 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 41 < NOTE >  Request the authorized distributor where the generator was purchased to perform this procedure if you do not have a filter wrench.  Oil filter : ISUZU Part No. 8983758600 (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 42 (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 > DRAIN PLUG ...
  • Page 43 (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 44 < 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. ...
  • Page 45 (10) Changing Coolant / Water Replace Every 0.5 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 46: 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 the OFF position. CAUTION : FIRE  Always be sure to wipe up any spilled fuel or oil. ...

  • Page 47: 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. ...
  • Page 48 Problem Suspected cause Action Starter motor Battery Isolator is OFF Turn Battery Isolator to does not drive Battery output is weak or speed is Check/ battery liquid/ or low. Battery is deteriorated Charge Battery terminal is OFF or loose Change battery Battery terminal is corroded Fix/Tighten terminal Power Switch or relay is defective...
  • Page 49 Overheated Engine thermostat is defective Ask our distributor to Water temp sensor is defective repair Controller is defective Ask our distributor to Fan belt tension is weak repair Coolant is insufficient Ask our distributor to Radiator core is clogged repair Check/Adjust fan belt Check/Supply coolant Clean radiator core...
  • Page 50 The voltage drops 1. AVR is defective Ask our distributor to drastically when 2. Unbalanced loads sharing to each repair connecting to load terminal Balance the loads sharing 3. Loads total exceeds the rated current to each terminal 4. Frequency Adjusting Screw is set wrong Decrease the loads to meet the rated output...

  • Page 51: Generator Circuit Diagram

    13. Generator Circuit Diagram...

  • Page 52: Engine Electrical Circuit Diagram

    14. Engine Electrical Circuit Diagram...
  • Page 56 ©2023...

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