Shindaiwa DGA50CM, Owner'S And Operator'S Manual

Page 1: ...L Vertical Water Cooled 4 Cycle Diesel Engine DGA50CM X750 031 07 0 X750802 140 1 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 ...

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Page 3: ...eration Store this manual in a specified location where it will be secure and available for consulting at any time Order another copy from the authorized distributor where this generator was purchased if this manual becomes dusty grimy or torn Consult with the authorized distributor where this generator was purchased if you have any inquiries regarding any points related to this generator and manu...

Page 4: ...llation 15 7 Connecting load 16 7 1 Select Load Cable 16 7 2 Connecting Load Cable 17 7 3 RCCB and Grounding 18 8 Initialization and Pre check 21 8 1 Engine Oil 21 8 2 Coolant Water 22 8 3 Fan Belt 24 8 4 Fuel 24 8 5 Fuel Oil and Coolant Leakage 25 8 6 Battery 25 9 Operation 27 9 1 Initialization and Preparation 27 9 2 Procedures during Operation 29 9 3 Stopping 30 9 4 Protection Functions 31 9 5 ...

Page 5: ...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 Always be sure to use Lifting Hook when lifting up the generator Using other parts when lifting up the generator could cause the result of falling Do not attempt to lift the equipment with any additional weight su...

Page 6: ...ow the generator to cool before covering with the protective cover Never allow flame to come close to the generator Always make sure that the engine is stopped when working on piping After working on the piping check that there is no fuel leakage Absolutely never inspect or perform maintenance to the equipment near fire or other open flame CAUTION ELECTRIC SHOCK Do not sprinkle water on equipment ...

Page 7: ...or similar item to avoid any unexpected move when transporting by truck or other vehicle CAUTION PROPERTY DAMAGE Do not use the equipment for any improper applications Improper usage can result in an accident or malfunction 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...

Page 8: ...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 Caution coolant Part no X505 004650 3 Caution Electric Shock Part no X505 004640 4 Safety Precaution Part no X505 004660 ...

Page 9: ...BB 4BG1T Cylinder bore x stroke mm 4 105 x 125 Continuous Rated Output kW PS 48 5 66 0 Speed min 1 1500 Displacement L 4 329 Combustion Method Direct Injection Turbo charged Cooling Method Water cooling radiator Lubricating Trochoid pump force feed lubrication Starting Starter Motor Fuel Diesel Oil SAE Class CD or higher Fuel Tank Capacity L 160 Lubricant Volume L 13 2 including filter 1 1 L Coola...

Page 10: ... Altitude Less than 300m Power Supply for submersible Pump etc Power Supply for lightings etc Power Supply for electric tools home appliances 4 1 Outer and Main Components 3 Use 4 Parts Components Roping Lug Lifting Lug Operation Panel Door Emergency Stop Button Coolant Drain Roping Lug Oil Drain Plug Engine Check Door Fuel Inlet Air Cleaner Check Door Sub Tank Output Terminal Cover Fuel Tank Fuel...

Page 11: ...r 32A 3 Main Circuit Breaker 4 Controller 5 3 Phase Breaker 20A 6 1 Phase Breaker 15A 7 Emergency Stop Button 8 Voltage Regulator 9 Power Switch Air Bleeding 10 Battery Isolator 3 4 1 5 6 7 8 2 9 10 Nipple 2 pieces Fuse 10A Operator s Manual Accessories Fuse 3A ...

Page 12: ...8 4 3 Output Panel 3 Phase RCCB 1 Phase RCCB 1 Phase Receptacle 15A 3 Phase Receptacle 50A 3 Phase Receptacle 20A 3 Phase Receptacle 32A Bonnet Grounding Terminal ...

Page 13: ...f the gen set START button Press this button to initiate the start sequence of the engine LEFT button Use this button to move left or to change the mode The button can change the mode only if the main screen with the indicator of currently selected mode is displayed RIGHT button Use this button to move right or to change the mode The button can change the mode only if the main screen with the indi...

Page 14: ...Use this button to move down or decrease value ENTER button Use this button to finish editing a setpoint or moving right in the history page GCB button No use GENERATOR status indicator There are two states Gen set OK indicator is green and Gen set failure indicator is red Green LED is on if the generator voltage is present and within limits Red LED starts flashing when gen set failure occurs Afte...

Page 15: ... OFF and re set the button turning clockwise after using the emergency stop button 3 Main Circuit Breaker By turning this circuit breaker on the control panel to ON Power will be transferred to the output receptacles and to the load side The breaker trips to OFF either overload or short circuit Note Do not use RCCB as the ON OFF switch to the load 4 3 Phase Circuit Breaker 1 Phase Circuit Breaker ...

Page 16: ...mission to load Note Do not use this breaker as the ON OFF switch to the load 6 Battery Isolator When turning the switch to OFF the engine electric circuit does not activate due to no battery power 5 3 Voltage Regulator 1 Voltage Regulator The dial adjusts generator output voltage By turning the dial clockwise you can increase the voltage By turning the dial counter clockwise you can decrease the ...

Page 17: ...nnect hoses from the external fuel tank to the external fuel intake and the external fuel return ports and set the lever for 3 way valve to B position You can now supply the fuel from the external gas tank For detailed instructions refer to 9 5 Connecting to External Fuel Tank CAUTION Fire Always stop the engine when performing any work on the fuel line Always wipe any drip of Diesel fuel or engin...

Page 18: ...e a Lift lug when lifting the equipment for transportation 2 Transporting the equipment When transporting the equipment make sure that the equipment is secured properly with ropes tied to the roping lugs through Note Always use extreme care when loading unloading and transporting the equipment otherwise damages and malfunction of the equipment may bring 6 Transportation and installation Lif ting L...

Page 19: ...paint etc away from the equipment Always set the equipment on hard flat surface Keep the equipment at least 1m from a wall or any obstacles to allow workable space to access the control panel and opening of the panel door Note This equipment must be operated on hard and flat surface Operating under any other conditions may result in malfunctions Do not block the airflow from radiator vent or muffl...

Page 20: ... be greater voltage drop between cables which brings voltage drop to loads It may result in reduced performance in the connected loads malfunction or damages Note It is recommended to select the proper gauge and length of cable in consideration of the maximum 5 marginal drop only for the rated voltage between the terminals of loads and generator via the cables Expedient Formula the voltage drop of...

Page 21: ...put to any indoor wiring Note Divide loads into 3 circuits proportionally as possible when using the maximum output power especially and connect them to each phase R S T respectively Be careful to limit the current under the rated current per the phase Note that the 1 phase output power decreases when 3 phase output power is used simultaneously Be careful to limit the total current under the rated...

Page 22: ...uld always repair the leaking place first of all The generator is provided with the Residual Current Circuit Breaker RCCB to detect any Leakage produced due to such the trouble as insulation failure of the load while the generator is running and to cut off the circuit for protection against any accident such as electrical shock resulting from the trouble The specification of RCCB Rated Sensitive C...

Page 23: ...splay Push the TEST button Yellow on 3 Phase RCCB Indicator changes to Green from RED and RCCB trips to OFF Which shows NORMAL Push the TEST button Blue on 1 Phase RCCB Red lamp turns to OFF and RCCB trips to OFF Which shows NORMAL In the event you cannot complete every step of the above procedure to the end the device is out of order Consult with our authorized distributor or our engineering sect...

Page 24: ...estore 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 By the above procedure you can reset the RCCB to ON positions 1 ...

Page 25: ...o keep the equipment leveled and insert not screw in forcibly the oil gauge all the way in Prior to starting the equipment make sure to fill the engine oil to the UPPER LIMIT line through the oil filler Note Check engine oil volume IN 10 20 MINUTES LATER always after stopping engine or replenishing fuel If the equipment is not leveled you cannot obtain accurate oil level Do not overfill the engine...

Page 26: ...adiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor or water Do not touch the engine and muffler during operation and immediately after stopping the equipment for the temperature can reach extremely high levels Check the radiator and coolant reservoir tank for water and add water in case of shortage 1 Checking Radiator Add...

Page 27: ...ame type of coolant with identical mixture ratio for the Sub Tank Mixture ratio of the coolant should be between 30 to 50 depending on the ambient temperature When replenishing LLC be sure to use the same brand as the LLC left in the Radiator and Sub Tank Never use the mixed LLC by different brands or specifications Replace LLC every 2 years or 1000 hours Mixture ratio for reference only Ambient t...

Page 28: ...ernator Pulley 2 Condition Check for any damage on the Fan Belt Replace if necessary 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 Check for the fuel level in the tank Add if necessary Note Use Diesel fuel ASTM D975 No 2 D in the event ambient temperature reaches down to 5 Always use the Dies...

Page 29: ... printed no other fuel additive was recommended See your authorized dealer to find out if this has changed 8 5 Checking Fuel Engine Oil and Coolant Leakage CAUTION Fire Never use this equipment when a leak is found Repair the equipment first of all Be sure to check for any fuel leak at the fuel hose connections and oil and coolant leak by opening Side Doors 8 6 Checking Battery CAUTION Injuries to...

Page 30: ...e R Battery Reinstall a new Battery in the reverse order always install the cable to the positive post of the new Battery first 2 Replacing the Left L Battery Disconnect the positive terminal from the L Battery Disassemble the fixing clamp of the L Battery Remove the L Battery Reinstall a new Battery in the reverse order always install the cable to the positive post of the new Battery first Note M...

Page 31: ...e items such as fuel gas paint etc away from the equipment Always operate this equipment on flat surface and at least 1 meter away from any objects wall box etc CAUTION Injuries 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 Turn every circuit breakers t...

Page 32: ...Adjusting the Voltage Regulate Dial set it to the required voltage 50Hz RUN 415V Turn the circuit breakers to ON to send power to the load side WARNING Electric Shock Injuries Before turning RCCB to ON to send power to the load side always ensure that any circuit breaker and switch of loads are positioned to OFF In the case the generator and the load are away from each other proceed with the above...

Page 33: ...operation check the voltage on the Operation Display and finely adjust voltage using the voltage regulator dial Extracting the air out of the fuelling system for engine stop due to no fuel This generator is equipped with automatic extracting feature Thus if the engine stops due to running out of fuel follow the next steps to extract the air out Add fuel to the fuel tank Turn the Power Switch to AI...

Page 34: ... 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 Turn the Battery Isolator to OFF position 4 5 1 2 3 6 ...

Page 35: ...lly stop operation when there is a fault malfunction during operation and this is to warn the operator of the fault location by use of the Operation Display Check the fault location when the engine is automatically stopped or appear warning on the Operation Display Protection Feature List No Action Abnormality RCCB Trip Breaker Trip Engine Automatic Shutdown Controller display Cause 1 Low Oil Pres...

Page 36: ...meter as connecting hose The fuel level in the external fuel tank should be 0 to 3m higher than the bottom of the equipment Otherwise it may cause engine malfunction or stoppage To avoid any leak from the external fuel intake and return ports always turn the lever for 3 way Valve to A position whenever piping work is performed Use extreme caution when connecting the hoses If the lever position is ...

Page 37: ... and keep away from fire Wait until the engine cools down before performing any checks CAUTION Fire Always wipe any drip of fuel or oil Do not use this equipment when a Leak is found Repair the equipment before use To optimize the use of this generator we recommend the periodical equipment checks and maintenance based on following maintenance matrix Note The authorized technicians only should perf...

Page 38: ... Drain water from Fuel Tank Clean water separator and clean Gauze Filter in Engine Feed Pump Clean Change filter in the Magnet Pump for air extraction in fuel line Replace Clean inside Fuel Tank Leak check fuel oil and coolant Replacing fuel hose or 1 yr Clean or replace Air Cleaner Element Clean Replace Battery fluid level check Battery hydrometer check Fan Belt check Radiator Flush Cleaning Chec...

Page 39: ...king Engine Oil 2 Oil Filter Change Drain the engine oil fully as described in 1 CHANGE ENGINE OIL Loosen and remove the oil filter using an oil filter wrench Smear a little engine oil on the rubber gasket of the new oil filter Screw a new filter into place and tighten it by hand until the gasket contacts the seat Then give it additional 2 3 turns using an oil filter wrench after the gasket touch ...

Page 40: ...requently if the equipment used in dusty environment Element Part No Isuzu Part No 9142151351 Clean Air Filter Element Dried contaminants adhered Blast the compressed air to Element from inside Carbon and oil adhered Change to a new Filter Clog Indicator The clog indicator to display clog in the Air Filter Element is incorporated to air filter unit Whenever RED SIGNAL appears in the indicator wind...

Page 41: ... the Filter Apply little amount of the diesel fuel onto new Fuel Filter Gasket Tighten the Fuel Filter using finger until the filter gently seated to the bracket Then tighten the Filter 2 3 rotation using fuel filter wrench Reassemble the Fan Guard to the original position with fixing screw Note Do not operate the generator without reassembling the Fan Guard to avoid injury After draining finishes...

Page 42: ...e lever in order to catch spilled fuel when loosing the lever Extract the air in fuel line after Gauze Filter washing finishes Refer to 9 2 Procedures during Operation Ensure that there is no fuel leakage after reinstallation 8 Clean Gauze Filter in Engine Feed Pump Clean Every 500 hours Remove Eyebolts Remove Gauze Filter in Eyebolts Wash Gauze Filters in Diesel fuel and Reinstall in the reverse ...

Page 43: ...Filter Reinstall a replacing Filter in the reverse order Note Put a tray under the lever in order to catch spilled fuel when changing Filter Extract the air in fuel line after filter changing finishes Refer to 9 2 Procedures during Operation Ensure that there is no fuel leakage after reinstallation Filter Part No 10 Drain water in fuel tank Turn the Fuel Drain Lever to OPEN After draining water tu...

Page 44: ...e the Sub Tank Stay and drain coolant in the Sub Tank Reinstall the Sub Tank and fill coolant up to FULL level Fill coolant into Radiator up as far as the water inlet level Tighten the Radiator Cap Reinstall the Radiator Plate Note Refer Coolant to 8 2 Checking Coolant Water 2 3 4 5 6 7 9 1 Change 2 years or 1000 hours 8 Radiator Cap Radiator Plate Water Inlet Radiator Drain Cock Drain Plug Coolan...

Page 45: ...ait until the engine cools down before performing any checks 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 1 Storage Procedures If the generator will not be used for more than two months perform the following maintenance and storage procedures Remove Battery Change engine oil Drain fuel in the Fuel Tank and Fu...

Page 46: ... lower equipment firstly and then stack the upper equipment on it All the ties should be the same size dimension and longer than the width of the lower generator Do not stack more than 2 units The lower generator should be bigger than the upper generator in size and weight Do not operate the stacking stacked equipment WARNING Electric Shock Do not operate the equipment if the equipment or you are ...

Page 47: ...er in water separator fuel filter or fuel tank 5 Extract the air 6 Check piping connection 7 check lever 3 way valve 8 1 Check Change fuse 8 2 Check Change fuel cut solenoid Ambient temperature falls down below zero 1 Fuel is frozen 2 Water in fuel line is frozen 3 Pre heater is defective 1 Use winterized fuel 2 Drain water in fuel line 3 Ask our distributor to repair Engine starts but stalls imme...

Page 48: ...el tank 3 Ask our distributor to repair 4 Warm up driving is needed 5 Ask our distributor to repair Voltage value does not change 1 Controller is defective 2 AVR is defective 3 Disconnected circuit loose terminal or departed 4 Initial exciter is defective 5 Alternator is defective 6 AVR protective device has activated 1 Ask our distributor to repair 2 Ask our distributor to repair 3 Ask our distri...

Page 49: ...the protective device Cannot turn the breaker to ON 1 The Main breaker positions at between ON and OFF 2 Short circuit on the load 1 Once turning the lever to OFF turn it to ON 2 Check the load circuit Controller does not turn on 1 Battery output is weak 2 Battery is deteriorated 3 Battery terminal is OFF or loose 4 Battery terminal is corroded 5 Fuse is blown 6 Disconnected circuit loose terminal...

Page 50: ...46 13 Generator Circuit Diagram ...

Page 51: ...47 14 Engine Circuit Diagram ...

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