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

Sound proof diesel engine generator
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OWNER'S AND
OPERATOR'S MANUAL
Sound Proof
DG1000MI
CAUTION : Do not operate the Generator, or any other appliance,
before you have read and understood the instructions for use.
Shindaiwa Corporation

Table of Contents

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Transportation and installation
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Summary of Contents for Shindaiwa DG1000MI

  • Page 1: Table Of Contents

    4.2 Control Panel Equipment 5.1 Monitor Display 5.2 Gauges 5.3 Fuel Line Changeover Valve Transportation and installation 6.1 Transportation DG1000MI 6.2 Installation Connection 7.1 Selecting Cable 7.2 Connecting Cable 7.3 Earth Leakage Relay and Grounding Initialization and Pre-check 8.1 Checking Engine Oil 8.2 Checking Coolant/Water...

  • Page 2: Diesel Engine Generator

    Introduction Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator. This user’s manual was created to ensure the safe operation of this equipment. Therefore, the manufacturer of this equipment strongly recommends that the user follow the instructions herein, to avoid unnecessary accidents and repairs.

  • Page 3: Safety Guidelines

    1 Safety Guidelines Danger :Suffocation from exhaust fume Exhaust fume from the engine contains many elements harmful to human. Do not operate this equipment in poorly ventilated area, such as inside a room or in a tunnel Danger :Electrical Shock Do not touch the output terminals during operation.
  • Page 4 Caution :Injuries to eyes and skin Battery fluid contains diluted sulfuric acid. Avoid contact with eyes, skin or on clothing. If the acid comes in contact, especially with eyes, flush with a lot of water, and contact your physician immediately. Caution : Explosion Do not use the equipment or charge the battery, in the case the battery fluid level is lower...
  • Page 5 Caution :Injuries When lifting the equipment, always use a lift hook. Do not use Side rope-through, for it may cause equipment to drop. Always place the equipment on a flat and stable surface, to keep the equipment from sliding. When starting the engine, turn off the connected equipment and set the circuit breaker to OFF position.
  • Page 6 Location of Warning labels ■ When the warning labels become unreadable or damaged, place new labels on the appropriate location, as specified in the following figure. When ordering the label, use following part numbers. Operational Instruction Part Number 19401-00361 Safety Instruction Part Number 19402-00188 Suffocation from exhaust fume Part Number 19402-00161...

  • Page 7: Specifications

    2 Specifications 2.1 Specification Matrix Name of Generator DG1000MI-400 Blushless, Rotating Field, 3-Phase, 4-Pole, Type Unit Synchronous AC Generator Rated Output Rated Voltage (or the below) Rated Current (or the below) Rated Voltage Alternator Rated Current Frequency Rated speed 1500...

  • Page 8: Ambient Condition

    Ambient Condition Use the equipment under the following ambient condition. The other condition may cause trouble, insufficient output power or deterioration of durability. ■ Ambient Temperature : -15ºC ～ 40ºC ■ Humidity : less than 80% ■ Altitude : less than 300m 3 Use Power source for construction –use equipment, such as submersible pump Power source for lighting...

  • Page 9: Control Panel

    4.2 Control panel Name Name 3-phase circuit breaker Water Temperature Gauge 1-phase circuit breaker Oil Pressure Gauge Voltage Meter Fuel Gauge Amp Meter Hour Meter Frequency Meter Emergency Stop Button Earth Leakage Relay Preheat Lamp Panel Light & Generating Lamp Starter Switch Voltage Regulator Throttle Lever...
  • Page 10 5 Equipment 5.1 Monitor Display This generator is equipped with monitoring function for water/coolant temperature, oil pressure, battery charge, air filter flow, battery fluid level, and fuel level. When the equipment is started under normal condition, Oil Pressure and Battery Charge lamps will flash when the Starter Switch is turned from STOP to OPERATING, and all lamps will go off, immediately after the engine is started.
  • Page 11 If the water level is normal, check for loose fan belt or possible water leak in the cooling system, after the engine is cooled down. <Caution> If the water level is too low, the sensor cannot detect the water temperature. Be sure to check the water level in the radiator and the Coolant reservoir tank prior to operating the equipment.

  • Page 12: Gauges

    5.1.3 Battery Charge Monitoring Lamp (charge lamp) When the battery is not able to be charged during operation, the battery charge-monitoring lamp will flash. In the event this occurs, stop the engine consult with the authorized distributor or CHARGE our engineering section. <Caution>...

  • Page 13: Voltage Meter

    5.2.4 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. 5.2.5 Generator Gauges 5.2.5.1 Voltage Meter...
  • Page 14 5.2.6.2 Panel Light / Pilot Lamp Pilot Lamp indicates whether or not generator is generating electricity, when the engine is driving. 5.2.7 Switch 5.2.7.1 Starter Switch S TOP ① When the switch is set to this position, all power will be off. The switch must be set to this position to remove the key.
  • Page 15 5.2.7.4 Thermal Relay This relay sends the signal to the 3-Phase circuit breaker and the 1-Phase 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: Fuel Line Changeover Valve

    5.2.8.2 Throttle Lever T hrottle Lever ① The lever is to adjust the engine speed. Set it to ＜ I DLING ＞ w hen the engine starts and FIXING SCREW NUT warms-up or cools down. When the rated power is used, set it to ＜ R UN ＞ (50 or 60Hz).
  • Page 17 外 部 燃 料 供 給 口 外 部 燃 料 戻 り 口 （ プ ラ グ P T １ / ２ ） EXTERNAL FUEL INTAKE EXTERNAL 3-Way valves (PLUG : PT-1/2) 3-Way valves FUEL RETURN （ ＜ A ＞ p osition ）...

  • Page 18: Transportation

    6 Transport and Installation 6.1 Transportation Danger :Injuries When lifting the equipment, always use a lift hook. Do not use Side rope-through to attach your lift hook, for it may cause equipment to drop. 6.1.1 Lifting Equipment Always use a Lift Hook, when lifting the equipment for transportation. LIFTING LUG 6.1.2 Transportation When transporting this equipment, make sure that the equipment is secured properly with...

  • Page 19: Installation

    6.2 Installation Danger :Suffocation from exhaust fume Exhaust fume from the engine contains many elements harmful to human. Do not operate this equipment in poorly ventilated area, such as inside a room or in a tunnel Caution :Suffocation from exhaust fume Do not point the exhaust fume toward pedestrians or building.
  • Page 20 Caution :Electrical damages If the load exceeds the allowable amperage, the overheating may damage the cable. If the cable is either too long or too small a gauge, there will be greater voltage drop to loads, which may result in reduced performance in the connected loads, malfunction, or damages. <Caution>...

  • Page 21: Connecting Cable

    7.2 Connecting Cable Danger :Electrical Shoc Before connecting or disconnecting a load cable from output terminals, always turn a circuit breaker to OFF position, stop the engine, and remove the engine key. A person performing the maintenance should always keep the key. Caution Fire Do not connect AC output to any indoor wiring.
  • Page 22 7.2.1.3 For 1-Phase Load(2) Terminal Voltage: 200V/220V (or 400V/440V) at 50Hz/60Hz Load Load Load 7.2.2 1-Phase Output Terminals & Receptacles 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 CON3 CON2...

  • Page 23: Earth Leakage Relay And Grounding

    7.3 Earth Leakage Relay and Grounding Danger Electrical Shock Ground the every earth grounding terminal to the earth as set out in the manual. If even one of all is unconnected by mistake or accident, it will be much more dangerous for human body than the –relay case, because leaking current inevitably goes through the body.

  • Page 24: Earth Leakage Relay

    <Caution> In the event you cannot ground the generator to EARTH BONNET GROUNDING the earth, consult with the authorized distributor or GROUNDING TERMINAL TERMINAL our engineering section 7.3.2 Operation Check GROUNDING ROD Danger :Electrical Shock Before turning the 3-Phase circuit breaker to ON position, ensure that the breaker or the Switch of loads are positioned to OFF.

  • Page 25: Initialization And Pre-Check

    7.3.3 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 3-Phase earth leakage breaker (lever) trips off to be positioned in the middle between ON and OFF positions.

  • Page 26: Checking Engine Oil

    8.1 Checking Engine Oil Please refer to the user’s manual for Engine separately When checking for engine oil, be sure to keep the equipment leveled, and insert the oil gauge all the way. Prior to starting the equipment, make sure to fill the engine oil to the MAX line through the oil filler.

  • Page 27: Checking Coolant/Water

    8.2 Checking Coolant/water ※ ※ ※ ※ Also refer to the User’s Manual for Engine Danger :Injuries 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 :Burns Do not open the radiator cap while operating this equipment or immediately after stopping...

  • Page 28: Checking Fan Belt

    Replace LLC every 2 years or 1000 hours Mixture ratio (for reference only) : Ambienr temperature ℃ ℃ ℃ ℃ ℃ ℃ ℃ ℃ ℃ ℃ ℃ ℃ (Celsius) Mixture ratio 8.2.3 Coolant Capacity ( Unit: L) Total Coolant Volume ( including reservoir tank) 22.8 (1.5) The value of ( ) shows the reservoir tank`s volume.

  • Page 29: Checking Fuel

    8.3.2 Condition Check for any damage on the fan belt. Replace if necessary. <Caution> Refer to the User’s manual for Engine for adjusting and replacing of the fan belt. 8.4 Checking Fuel Caution :Fire 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 30: Checking Fuel, Engine Oil, And Water Leakage

    Notice: Do not use home heating oil or gasoline in your diesel engine; either may cause engine damage. 8.5 Checking Fuel, Engine Oil, and Water leakage Caution :Fire Do not use this equipment when a leak is found. Repair the equipment before use. Be sure to check for any fuel leak at the hose connection, and oil and coolant leak by opening side doors.
  • 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. 8.6.1 Replacing the battery installed on the left side toward the control panel: ①...

  • Page 32: Operation

    9 Operation 9.1 Initializing / preparation :Suffocation from exhaust fume Exhaust fume from the engine contains many elements harmful to human. Do not operate this equipment in poorly ventilated area, such as inside a room or in a tunnel Caution :Suffocation from exhaust fume Do not point the exhaust fume toward pedestrians or building.
  • Page 33 <Caution> Do not drive the starter motor for more than 10 seconds successively If you need to restart, wait at least 30 seconds before the retry. ④ ④ ④ ④ Release the starter switch, as soon as the engine is started Keep the engine idle for at least 5 minutes ⑤...

  • Page 34: 200/400 Voltage Changeover

    9.2 200/400 Voltage Changeover - Dual Voltage System The generator is incorporated with dual voltage system. So, you can easily change 400/440V to 200/220V or adversely. You can get 200V or 400V by changing the combination of output terminals with bus plates Danger :Electrical Shock Be sure to set the circuit breaker OFF and stop operation before setting.

  • Page 35: During Operation

    3-PHASE 400/440V TERMINALS BUS PLATES 2 PLATES OVERLAPPED The 3-phase voltage is energized to the 3-phase output terminals. ③ ③ ③ ③ Refer to 7-2. Connecting cable ④ ④ ④ ④ Starting the engine and turning the 3-phase breaker to ON, the 3-phase current is sent to the 3-phase output terminals.

  • Page 36: Stopping Generator

    Caution :Fire Always wipe any drip of gasoline or oil. Add fuel to the fuel tank ① ① ① ① ② ② ② ② Turn the starter switch to <RUN> position. It will take approximately 30 seconds to vacuum the air out. <Caution>...

  • Page 37: Connecting To External Fuel Tank

    9.6 Connecting to External Fuel Tank Caution :Fire 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. Ensure that there is no fuel leakage on the fuel line after the fuel line working finished.

  • Page 38: Maintenance

    10 Maintenance Danger :Electrical Shock ● Injuries 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 ● Burns When checking engine, always stop the engine, and keep away from fire. Wait until the engine cools down, before performing any checks.
  • Page 39 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 time at 50 hr mark) ◯...
  • Page 40 10.1 Oil Change First time 50 hour mark From second time Every 200 hours Remove Oil Filler cap ① ① ① ① OIL FILLER OIL FILLER CAP ② ② ② ② Loosen the engine oil drain plug and allow the oil to drain fully Reinstall the drain plug ③...
  • Page 41 10.3 Cleaning / Changing Air Filter Element Clean Every 200 hours Replace Every 500 hours ① ① ① ① Loosen the bolt that is holding the air cleaner and remove the cleaner cap Unscrew the wing nut and remove the filter element ②...
  • Page 42 10.4 Draining Water from Water Separator When a float (red) is at drain level, drain water. Loosen the drain plug and drain water. ① ① ① ① Screw the drain plug, when finishing drain. ② ② ② ② <Caution> After draining finishes, extract the air in fuel line. (Refer to 9-3 During operation.) 10.5 Cleaning / Changing Fuel Filter Clean...
  • Page 43 10.6 Clean gauze filter in water separator RING NUT EXTRACTION Clean Every 500 hours PLUG GAUZE FILTER Loosen the lever and then loosen the air ① ① ① ① extraction plug. ② ② ② ② Turn the ring nut counter-clockwise to remove the cup and the gauze filter after the fuel inside does not come out from the lever.
  • Page 44 <Caution> GAUZE FILTER Put a tray under the lever in order to catch spilled fuel when loosing the lever. Gaskets are attached to both ends of joint pipe. Be careful not to lose and EYEBOLTS install them in the unit without fail. Change both gauze filter and eyebolt when gauze filter is damaged.
  • Page 45 10.9 Draining Water from Fuel Tank Drain water Every 200 hours ① Unscrew the Fuel drain plug Reinstall the drain plug, after draining water fully ② FUEL DRAIN PLUG 10.10 Changing Coolant / Water RADIATOR CAP Replace Every 2 years or 1000 hours ①...

  • Page 46: Long-Term Storage

    11 long-term Storage Danger Electrical Shock ● Injuries 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 ● Burns Temperature around muffler and exhaust can get extremely high. Keep any inflammable items (such as fuel, gas, paint, etc.) away from the equipment.
  • Page 47 11.2 Stacking Danger :Injuries If you have to stack two generators in warehouse, always proceed with the following steps. Ensure that there is no dent on bonnet, loosing bolt or no bolt in the generators. Always place the generators on a flat and stable surface, to keep the equipment from sliding, And to be endurable for the total weight.

  • Page 48: Troubleshooting

    12 Troubleshooting Danger :Electrical Shock Do not operate the equipment, if the equipment or you are wet. Before performing any equipment check or maintenance, stop the engine. Caution :Injuries When performing equipment check and maintenance, always stop the engine. Caution :Fire ●...
  • Page 49 Symptom Presumable Cause Action Starter motor does not Battery output is weak Check/ battery liquid/ or Charge drive or speed is low. Battery is deteriorated Change battery Battery terminal is OFF or loose Fix/Tighten terminal Battery terminal is corroded Clean terminal Starter switch or relay is defective Ask our distributor to repair Starter motor is defective...
  • 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 Wiring Diagram

    13 Generator Wiring Diagram - 51 -...

  • Page 52: Engine Wiring Diagram

    14 Engine Wiring Diagram - 52 -...

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