Shindaiwa DG150MI manual

- 1 - 1 Safety Guidelines 2 Specificati ons 2.1 S pecification Matrix 2.2 Ambient Condition 3 Use 4 Parts 4.1 External V ie w 4.2 Control Panel 5 Equipment 5.1 Monitor Disp lay 5.2 Gauges 5.3 Fuel Line Changeover V a lve 6 T ransport a tion and inst allation 6.1 T ransporta tion 6.2 Insta llation 7 Connection 7.1 Selecting Cable 7.2 Connecting Cab [...]

- 2 - Introduction Thank you f or purc hasing Shindaiwa Sound Proof Diesel Engine G enerator .  This us er manual was created to ensure t he s afe o peration of this equipment. T herefore, the manuf acturer of this equipment strongly recommends that the user follow the instructions herein, to avoid unn ecess ary accidents and repairs.  Please[...]

- 3 - 1 Safety Guidelines ! Danger :Suffocation f rom exhaus t fume  Exhaust fume from the e ngine contains many eleme nts h armful to human. Do not operate this equipment in poorly ventilated are a, such as inside a room or in a tunnel ! Danger :Electri cal Shock  Do not t ouch the output t erminals during o peration.  Be sure t o place c[...]

- 4 - ! Caution :Injuries t o eyes and skin  Battery fluid co ntains diluted sulfuric ac id. Avoid contact with ey es, skin or on clot hing. I f t he acid comes in contact, es pecially with eyes, flush wit h a lot of wat er , and contact your physician imme diately . ! Caution :Fire  This equipment uses Diesel Oil as a fuel. W hen refueling, [...]

- 5 - Location of W arning l abels W hen the warning labels b ecome unr eadable or damaged, place new lab els o n t he a ppropriate location, as specified in the following figure. W hen ordering t he label, use following part numbers . 1 Safet y g uideli nes Part N umber 19402-0 0188 2 Suffocati on from exha ust fume Par t Number 19402-00161 3 Elec[...]

- 6 - 2 S pecifications 2.1 Spec ification Matrix Name of Generator DG150MI DG250MI T ype Unit Blushless, Ro tating F ield, 3-Phase, 4-Pole, Synchronous AC Generato r kV A 12.5 15 20 25 Rated O utput kW 10 12 16 20 Rated V oltage (or the below) V 200 220 200 220 Rated Curr ent (or the below) A 36.1 39.4 57.7 65.6 Rated V oltage V 400 440 400 440 Ra[...]

- 7 - 2.2 Ambient Condition Use the equipment under t he following ambi ent c ondition. The other condition ma y cause trouble, insufficient output power or deterioration of durabilit y . Ambient T emperature: -15ºC 40ºC Humidity : less than 80% Altitude : less than 300m 3 Use  Power s ource f or construction –use equipment , such as submers[...]

- 8 - 4.2 Control p anel [DG150MI] [DG250MI] No. Name No. Name 1 3-Phase Circuit Brea ker 1 1 Monitor Ind ication Lamp 2 Pilot Lamp 12 Wa ter T emperature Ga uge 3 Single-Phase Circuit Breaker 13 T acho meter (Hour Meter incorpora ted) 4 Earth Leakage Re lay 14 Oil Pressure Gauge 5 V oltage Meter 15 Preheat Lamp 6 Amp. Meter 16 Emergency S t op But[...]

- 9 - 5 Equipment 5.1 Monitor Display [DG250MI] [DG150MI] WATER TEMP OIL PRESS CHARGE AIR FILTER FUEL LEVEL BATTERY LOW LEVEL DG250MI is equipped with mon itoring function for water/coolant temperatur e, oil press ure, battery charge, air filter f low , battery fluid level, and fuel level. DG150MI is equipped with monitoring fu nction f or water/co[...]

- 10 - W hen the water temperat ure reache s 1 10 degrees Cels ius during operation, the water te mperature-monit oring lamp will flash, an d the automatic shutoff will be engaged. W hen this occurs, chec k the Coolant reservoir tank, and replen ish if needed (refer to 8- 2 Checking coolant / w ater level ). If the wat er level is normal, check for[...]

- 11 - 5.1.3 Battery Charge Monitoring Lamp (cha rge lamp) W hen the battery is una ble to be c harged during opera tion, t he battery charge-mo nitoring lam p will flash. Check the belt for damages or c ut, and replace if needed. <Caution>  For changing the belt, refer to t he User Manual f or Engine.  B attery Charg e Monitor cannot d[...]

- 12 - When t he battery fluid level is low , Bat tery Fluid Monit oring Lamp will f lash. If the lamp is flashing, quickl y add some distilled water . (refer t o 8.6 Checking Bat tery ) 5.1.6 Fluid Level M onitoring Lamp [DG250 MI only ] ! Caution : Fire  This equi pment uses Diesel fuel as a fuel. W hen r efueling, alw ays stop t he engine, an[...]

- 13 - 5.2.3 W ater T emperature Gauge [DG250MI only] Water T emperature Gauge displays the te mperature o f engine coolant. Normal t emperature may vary depending on the environment , but it should be between 75 to 90 degree Celsius. <Caution> If t he temperature e xceeds normal v alue, disconnect the load, idle t he engine at 1000min -1 , a[...]

- 14 - 2.2. 6.2 Pilot Lamp [D G250MI only] Pilot Lamp indicates whether or not the generat or is generating elec tricity , when t he engine is driving. 5.2.7 Switch 5.2. 7.1 St arter Swit ch ST OP W hen the switch is set to this position, all power will be off. The switch must be set t o this position to remove the key . RUN / PREH EA T The switch [...]

- 15 - 5.2.8 V olt age Regulator and Th rottle Handle 5.2.8.1 V oltage Regulato r The dial ad justs outpu t voltage. By t urning th e dial clockwise, an operator can increase voltage. By turning th e dial c ounter-clock wise, an operator can decrease v oltage. 5.2. 8.2 Throttle Handle This han dle c ontrols the engine r evolution. B y turning the t[...]

- 16 - 5.3.1 Using fuel from built-in fuel t ank The lever for 3-way v alve is set to A when t he equipment is shipped. I n addit ion, both the ex ternal fuel intake and the external f uel r eturn ar e safeguarded with PT -3/8 plugs. Do not remove the plugs, when using the bu ilt- in fuel tank. <Caution> Always set the lever f or 3-way valve [...]

- 17 - 6.1.2 T ran sport ation W hen transporting t his equipment, make su re that the equipment is secured pr operly with ropes tied to t he Side Rope Through. <Caution> Always use ext reme care when loading, unloading, and trans porting t he equipment. Failure t o do so m ay result in damages and malfunct ion of the equipment. 6.2 Inst alla[...]

- 18 -  Do not block t he airf low from radiat or v ent or muffler ex haust. It may res ult in reduced en gine performance, overheat ing, or damage t o the elect rical parts.  O perating in dusty area or salt y air (by t he ocean), or any other particulate environm ent may result in clogged r adiator , which may c ause ov erheating, other mal[...]

- 19 - Select ion of cab le ( Example) 220V and V oltage Drop 1 1 V 3- Phase 3-Wire Cap T ire Cable, Single Core (Unit: mm 2 ) Length Current 50m or below 75m 1 00m 125m 150m 200m 20A 3.5 5.5 8 8 14 14 40A 8 14 14 14 22 22 60A 14 14 22 22 30 38 80A 14 22 22 30 38 50 (Example) 100V an d V oltage D rop 5V 1-Phase 2-Wire Cap T ire Cable, Single Core ([...]

- 20 - 7.2.1 Load Connect ion T erminal Plate (3-Pha se / 1-phase) For 3-Phase Load T erminal V oltage 200V / 220 V (or 400V / 440V) at 50Hz / 60Hz Load For 1-Phase Load (1) T erminal V oltage 1 15V / 127V (or 230V / 254 V) at 50Hz / 60Hz Load Load Load For 1 -Phase Load (2) T erminal V o ltage: 200V/220 V (or 400V/440V) at 50Hz/60Hz Load Load Load[...]

- 21 - 7.2.2 1-Phase Outp ut T ermi nals & Recept acles 7.2.2.1 200 / 220V The te rminal V oltage: 100V /1 10V at 50Hz/60Hz on ly In the cas e of no use of 3-Phase output power , refer to the f ollowing drawings and ch arts. [DG150MI] (Max 3kV A) [DG250MI] (Max 6kV A) less than less than less t han less th an less t han less than 1.5kV A 1.5kV [...]

- 22 - 7.3 Earth Leakage Rela y and Grounding ! Danger :Electri cal Shock  G round the every earth gr ounding terminal to t he earth as set out in the manual. If ev en one no of all is unconnect ed by mistake or accident, it will be muc h more dangero us for human b ody than t he –relay case, because leaking c urrent inevitably goes through th[...]

- 23 - 7.3.2 Operation Check ! Danger : Electrical Shock Before t urning the 3-Phase circuit br eaker t o ON Posit ion, ens ure that t he breaker or the s witch of loads are positioned t o OFF . Operate t he 3-Phase c ircuit breaker , well-communicatin g with The elect rician by t he load side. Before oper ating the generator , c heck always if t h[...]

- 24 - Push the re set button or stop the engine. Restore (Push-down) the 3-Phase ci rcuit breaker (lever) and t he 1-Phase c ircuit b reaker (le ver) to OFF position. By the above procedure, you can reset the breakers to ON pos itions. 8 Initializatio n and pre-c heck ! Danger :Electri cal Shock I njuries Before performing any equipment check or m[...]

- 25 - V a lue in ( ) s hows the o il in filter 8.1.3 Engine Oil Capa city 8.2 Checking Coolant / W at er Also re fer to t he User ’s Manual for Engine ! Danger :Injuries Before perform ing any equipment check or maintenance, stop the engine, and remove the engine key . A person performing t he maintenanc e should alwa ys keep t he key . Lubricat[...]

- 26 - ! Caution :Burns  D o not open the radiator cap while operat ing this equipment or immediatel y after stopping the equipment, to avoid sustaining burns fr om hot v apor .  D o not t ouch the engine an d muffler during operation a nd immediatel y after stopping the equipment, for t he temperature c an reach extr emely high. Check t he r[...]

- 27 - 8.2.3 Coolant Cap acity (Unit : L) T otal Coolant V olume (including reservoir tank) DG150MI 7.4 (0.4) DG250MI 8.5 (0.4) V alue in ( ) shows the reservoir tank’s volume 8.3 Checking Fan Belt Also re fer to t he user ’s manual for Engine separately ! Danger :Injuries  Befor e perf orming any equipment check or maintenanc e, stop t he e[...]

- 28 - 8.4 Checking Fuel ! Caution :Fire Always wipe an y drip of Diesel f uel or oil. Do n ot use this equipme nt when a l eak is f ound. Repair the equipment before use. Check f or the fuel lev el in the tank. Ad d if necessar y . <Caution>  Use Diesel fuel, ASTM D 975 No.2-D in the event ambie nt temperatu re reaches down to -5 .  Al[...]

- 29 - 8.5 Checking Fuel, Engine Oil, and W ater 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 t he hose connect ion, and oil and coolant leak by openi ng side doors. 8.6 Checking Battery ! Caution :Injuries to eyes and ski n Battery fluid con tains dil[...]

- 30 - 9 Operati on 9.1 Initializing / prepara t ion ! Danger :Suffocatio n from exhau st fume Exhaust f ume from t he engine contains many ele ments harmful to human. Do not operate this equipm ent in poorly ventilated area , such a s inside a room o r in a tunnel . ! Caution :Suffocation f rom exhaus t fume Do not point the exh aust fume toward p[...]

- 31 - And t hen adjust t he speed by speed control knob and adjust to the No-loa d revolut ion. No-load revolut ion 50 Hz Operation 1575 min -1 (52.5 Hz) 60 Hz Operation 1890 min -1 (63.0 H z) <Caution> By adjusting t he speed to the above rev olutions, the freque ncy will be 50Hz or 60Hz. Lock the S peed Cont rol handle with locknut <Cau[...]

- 32 - 9.2.2 Adjustmen t During operation  Make minor adjus tment to v oltage and speed using t he S peed Cont rol Knob and V ol tage Regulator , by monitoring T achometer , frequency meter , and voltage meter ■ V acu uming the ai r out of t he fuelling s y stem in event of no fuel Refer to the <User ’s manual for Engine> separately . [...]

- 33 - Protection Feature List Action No. Symptoms Circuit Breaker OFF Automatic Engine Shutoff Alarm Lamp Flash Cause 1 High Coolant temperat ure -- Engine coolant temperature is too high (default at 1 10 degrees Celsius ) 2 Oil pressure drop -- Engine oil pressure dropped (default at 0.98x100kPa) (1.0kgf/c m 2 ) 3 Insufficient batt ery charge -- [...]

- 34 - T urn the lever for 3-way valve to B position. V acuum out the air from c onnected hoses. This will allow t he us e of t he fu el from an external fuel tank <Caution>  T o vacuum out the air from the f uel line, refer t o <9.2 During Oper ation> sect ion.  Use always oil -proof hos e in 8-10mm inner diamet er as c onnecting[...]

- 35 - <Caution>  The aut horized tec hnicians should per form all mainten ance work, except f or the pre-st artup checks.  Request for the maintenan ce ite ms with ● mark t o the authorized dealer or our engineering se ction.  This chart only covers the s imple checks and maintenance for the engine. For more detailed gui de, pleas[...]

- 36 - 10.1 Oil Change First t ime 50 hour mark From second time Every 200 hours Remove Oil F iller cap Loosen t he eng ine oil drain plug and allo w the oil to drain fully Reinstall the drain plug Add oil f rom oil filler and fi ll up to t he MAX level. Y o u s hould check t he oil level on t he dipstick Reinstall the f iller cap hand-t ight <C[...]

- 37 - 10.3 Cleaning / Changing A ir Filter Elem ent Clean Every 200 hours Replace Every 500 hours Unscr ew the wingnut a nd remove t he filter element Clean or rep lace t he f ilter element, and reinstall it in reverse order W ith respect to DG150MI, unfasten clip in cleaner c ap and remove before unsc rewing the wingn ut. <Caution>  C le[...]

- 38 - Reassemb le it back The fu el strainer in D G150MI has the water separating f eatur e as well. W hen the float (red) in the st rainer comes up by 20mm f rom the bottom, drain the water <Caution>  B e sure t o c heck for any contaminants on t he O-r ing, whenever reinstalling the cup  O pen the f uel line valve t o OPE N after ass[...]

- 39 - Install the r eservoir tank back, an d fill the coolant/ water to t he MAX level. Fill the rad iator with coolant/water t o the top Reinstall the radiator cap <Caution> For th e types of engine oil to use, refer to <8-2 Checkin g Coolant /Wat er > 1 1 Long -term Storage ! Danger :Electri cal Shock ● Injuries  Before performi[...]

- 40 - 1 1.2 St acking ! Danger : Injuries If you have t o stack two generators in warehouse, alwa ys proceed with the following steps.  Ensure t hat th ere is no dent on bonnet, loosing bolt or no bolt in the generator s.  Always place the gene rat ors on a flat and stab le surface, to keep t he equi pment from sliding, And to be endurable f[...]

- 41 - ! Caution :Injuries  W hen performing equipme nt check and maintenance, always stop the engine. ! Caution :Fire ● B urns  Battery ma y emit s ome combustible gas , so keep it away from f ire and sparks.  T emperat ure around muffler and ex haust can get ext remely high. Keep any inflamm able items (such as fuel, gas, pain t, etc.)[...]

- 42 - 13 Generator W iring Diagram[...]

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- 46 - 14 Engine Wiri ng Diagram[...]

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