Table of Contents
1.Safety Guidelines
2.Specifications
3.Use
4.Parts
Page
2
5
6
6
7
7
7
8
OWNER’S AND
OPERATOR’S
MANUAL
5.Equipment
5-1.Eco Welding
5-2.Remote Control(Option)
5-3.Monitor Lamp
5-4.Frequency Change
5-5.Earth Leakage Relay
5-6.Single Phase Breaker for
the receptacle circuit only
5-7.The Slow-Down Feature
5-8.Voltage Adjusting Dial
6.Initialization and Pre-check
6-1.Checking Engine Oil
6-2.Checking Coolant/Water
6-3.Checking Fuel
10
11
SOUND PROOF DIESEL ENGINE
GENERATOR/WELDER
13
13
14
14
14
15
16
DGW400DM-380A
Vertical, Water-Cooled
4-Cycle Diesel Engine
6-4.Checking Fuel, Engine Oil
and water Leakage
6-5.Checking Battery
7.Operation
7-1.Starting
7-2.Stopping
8.Welding Operation
8-1.Selection-Welding Cable
8-2.Polarity
17
17
19
19
20
21
21
21
21
22
23
24
24
25
26
8-3.Connection-Welding Cable
8-4.Duty Cycle
8-5.Welding
9.Generator Operation
9-1.Output Range
9-2.Output Limitation
9-3.Operation
10.Simultaneous Use of Welding and
Generating
28
28
33
33
35
36
11.Checking and Maintenance
12.Long-term Storage
13.Troubleshooting
14.Engine Wiring Diagram
15.Generator Wiring Diagram
CAUTION: Do not operate the Generator/Welder, or any other appliance, before you
have read and understood the instructions for use.
Shindaiwa Corporation
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1. Safety Guidelines
Danger : Suffocation from exhaust fume
z
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 : Electric Shock
z
Do not touch the output terminals during operation.
z
z
z
Do not insert metal objects (such as pin or wire) into plug-in receptacles.
Do not touch wiring or electric parts inside the equipment during operation.
Before connecting or disconnecting a load cable from output terminals, always
turn the circuit breaker to OFF position.
z
z
Before connecting or disconnecting a welding cable from output terminals, stop
the engine, and remove the engine key.
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.
Danger : Burns
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid sustaining burns from hot vapor.
z
Danger : Injuries
Close all doors and place locks during operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
z
Caution : Suffocation from exhaust fume
Do not point the exhaust fume toward pedestrians or building.
z
Caution : Suffocation from welding fume
z
Be sure to wear a fume proof mask in operation, because welding fume
contains poisonous gas and dust. Pay attention to the airflow direction and
sufficient ventilation also in order to prevent from inhaling the fume.
Caution : Injuries to eyes and skin
z
Be sure to wear spark protection glass(es), long-sleeve shirts, gloves, etc. in
order to protect eyes and skin from harmful spark in welding.
z
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 : Electric shock
Do not flush water onto the equipment nor operate it in the rain.
z
Caution : Explosion
z
Do not use the equipment or charge the battery, in the case the battery fluid
level is lower than the LOWER level.
z
Battery may emit some combustible gas, so keep it away from fire and sparks.
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Caution : Fire
z
The equipment uses Diesel Oil as a fuel. When refueling, always stop the
engine and keep away from fire. Moreover, always wait until the engine cools
down before refueling.
z
z
z
z
Always wipe any drip of Diesel fuel or lubrication oil. Do not use this equipment
when a leak is found. Repair the equipment before use.
Temperature around muffler and exhaust can get extremely high. Keep any
inflammable items (such as fuel, gas, paint, etc.) away from the equipment.
Keep any inflammable items and easily burning items away from the place in
welding, because welding splashes spatters.
Always operate this equipment on flat surface and, at least 1 meter away from
any objects (wall, box, etc.).
z
z
Do not connect AC output to any indoor wiring.
Always wait until the equipment cools down, before placing any covering
materials for storage.
Caution : Burns
z
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
When checking engine oil or changing oil, always stop the engine, and wait until
the engine cools down. If you open either the oil gauge or the oil plug during
operation, hot oil may cause some injury.
z
z
Be sure to wear leather gloves, apron, shoe covers, eye protection glass(es)
(mask), safety shoes, safety cap, and long sleeve shirts, because welding
splashes spatters.
Caution : Injuries
z
z
z
When lifting the equipment, always use a lift hook. Do not lift a handle, for it
may cause equipment to drop due to handle breaking off.
Always place the equipment on a flat and stable surface, to keep the
equipment from sliding. Be sure to lock the wheels for the wheeled models.
When starting the engine, turn off the connected equipment and set the circuit
breaker to OFF position.
z
z
z
Do not move the equipment during operation.
When performing equipment check and maintenance, always stop the engine.
Do not operate the equipment, if the equipment is being modified or if the parts
are removed.
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„ Location of Warning labels
When the warning labels become unreadable or damaged, place new labels on
the appropriate locations, as specified in the following figure.
When ordering the label, use the following part numbers.
① Suffocation from exhaust fume (No. 19402-00194)
② Suffocation from welding fume (No. 19402-00195)
③ Electric shock (No. 19402-00192)
④ Electric shock (No. 19402-00193)
⑤ Injuries (No. 19402-00199)
⑥ Burns (No. 19402-00201)
⑦ Burns (No. 19402-00200)
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2. Specifications
Model
DGW400DM
Rotating Field
370 / 390
Generating Method
Rated Current (A)
Rated Voltage (V)
Duty Cycle (%)
Rated Speed (min-1 )
No Load Voltage (A)
34.8 / 35.6
60
3000 / 3600
MAX 85
Single
Current Adj. Range (A)
90 – 380 / 110 - 400
Welding Rod (Ф)
2.6 - 8.0
Dual
Eco
Current Adj. Range (A)
50 – 190 / 55 - 210
Welding Rod (Ф)
2.0 - 4.0
40 - 240
2.0 - 5.0
Current Adj. Range (A)
Welding Rod (Ф)
Rated Frequency (Hz)
Rated Speed (min-1 )
50 / 60
3000 / 3600
Phase
1-Phase
1.0
3-Phase
380-415
Rated Voltage (V)
380-415
220-240
3
Power Factor
0.8
15
Rated Output (kVA)
12
Rating
Continuous
Kubota D1005
Model
Type
Vertical, Water-Cooled 4-Cycle Diesel Engine
1.001
Displacement (L)
Rated Output (kW/min-1)
Fuel
16.5 / 3000 or 19.1 / 3600
ASTM No.2 Diesel Fuel or Equivalent
Lubricant Oil
API Class CC or Higher
5.1 (Effective 1.4)
Lubrication Oil Volume (L)
Cooling Water Volume (L)
4.3 (Sub Tank Capacity 0.6 L included)
Starting Method
Starter Motor
Battery
55B24L
37
Fuel Tank Capacity (L)
Length (mm)
1519
700
Width
Height (mm)
Dry Weight (kg)
(mm)
760
469
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3. Usage
z
z
z
Arc Welding
Electric Tools and Home Appliances
Power Source for lights
Caution : Damage to the equipment or other properties
z
z
The equipment is designed for the above purposes only. Do not use it for the other
purpose. When it will be used for the equipment with the microcomputers control or
for the ultra-precision devices, the load may be malfunctioned.
Whenever connecting to use medical equipment or appliances, be sure to consult
with the medical equipment company, doctor or hospital personnel.
4. Parts
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5. Equipment
5-1 Eco Welding
The equipment is incorporated in Eco welding features that are aimed at performing
the lower noise, the lower fuel consumption and the lower gas emission than
conventional models.
When you turn the selector switch to Eco, you will be able to weld with Max.
5.0mmφwelding rod at the slow down speed.
<Caution>
z When welding is performed, do not turn the output selector switch, which causes
the burnout of the switch.
z Eco is designed for welding only. The 3-phase circuit breaker trips and
simultaneously the outputs of welding and generating would fall down and you will
not do anything when Eco is used for AC power supply.
5-2 Remote Control (Option)
Using the remote control box, the remote control to adjust the welding current
makes it possible.
Remote Control Box Connection
Remove “Eco” plate. (M4 Screw 2 pieces)
Insert the plug of the extension cable reel
into A side or B side receptacle
Insert the plug of the remote control box
into the receptacle of the extension cable
reel.
<Caution>
z Never connect the plug of the remote control box to the receptacle of the
extension cable reel when the reel is connected to 1-P receptacle.
z Never connect the other loads additionally than the remote control box.
z In the case the extension cable reel is installing the breaker, use the equipment to
have turned the breaker ON.
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5-3 Monitor Lamp
The equipment is incorporated in monitoring function of WATER TEMP, BATTERY
CHARGING, OIL PRESSURE, Hz/OVERHEAT.
Under normal condition, when the starter switch changes from STOP to RUN, all the
lamps of BATTERY CHARGING, OIL PRESSURE and Hz/OVERHEAT turn ON.
When the engine starts, all the lamps turn OFF. When abnormality is detected on
other than Hz/OVERHEAT, the corresponding monitor lamp will flash, and the engine
automatically shutoff.
When the automatic shutoff is engaged, turn the starter switch to STOP position
once, and then restart the engine. In the event the automatic shutoff is engaged next
time, check which lamp turns ON or OFF and point out where is the abnormality.
(1) Coolant/Water Temperature Monitor Lamp
Danger: Injuries
z Close all doors and place during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
Danger: Burns
z Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid sustaining burns from hot vapor.
Caution: Burns
z
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
When the water temperature rises abnormally, the coolant/water temperature
monitor lamp will flash, and the automatic shutoff will be engaged.
When this occurs, check the coolant/water reservoir tank, and replenish if needed.
(Refer to No. 6-2 Checking coolant/water temperature.)
If the water level is normal, there may be a possibility of overloading. Always use the
equipment within the rated duty cycle and output power.
(2) Battery Charge Monitor Lamp
When the battery turns unable to be charged during operation, the battery
charge monitor lamp will flash and the automatic shutoff will be engaged.
In the event this occurs, consult with the authorized distributor or our ngineering
section.
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<Caution>
z The battery charge monitor cannot detect the degradation of the battery nor the
battery fluid level. Check the battery fluid level periodically. (Refer to No. 6-5
Checking Battery)
(3) Oil Pressure Monitor Lamp
Danger : Injuries
z Close all doors and place locks during operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Caution : Burns
z Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
z When checking engine oil, always stop the engine, and wait until the engine
cools down. If you open either the oil gauge or the oil filter cap during operation,
hot oil may cause some injury.
When the engine oil pressure drops during operation, the oil pressure monitor lamp will
flash, and the automatic shutoff will be engaged.
When this occurs, check the engine oil level, and replenish to the maximum level if
needed.
<Caution>
z The engine oil pressure monitor cannot detect the degradation of engine
oil itself. Please check the engine oil periodically, and change if needed.
(Refer to No. 11. Maintenance.)
z Check the fuse next, when the abnormality, other than WATER TEMP,
BATTERY CHARGED OR OIL PRESSURE is detected. If the fuse is burned
out, consult with our authorized distributor or our engineering section, because
there may be an abnormality of electric/electronic parts or wiring and repairing
may be required.
(4) Hz/Overheat Monitor Lamp
z Unless the frequency selector lever position
and the bus bars in the equipment are
correspondent to each other, Hz/OVERHEAT
FLASH
monitor lamp will turn ON.
OVERHEAT
z Hz/OVERHEAT monitor lamp may flash
in the case the machine is used excessively
over the duty cycle.
<Caution>
z When Hz/OVERHEAT monitor turns ON, as the output power reduces
remarkably, the AC output power can hardly be used.
z There may be a case that the lamp will not flash, depending on the welding
type or the weather condition.
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5-4 Frequency Change
Danger : Injuries
z Frequency change should be done, after stopping the engine. Moreover, close
doors and place locks during operating this equipment, to avoid injuries by
unintentionally touching cooling fan and fan belt.
Danger: Electric Shock
z Never touch the frequency change bus bar during operation.
Caution: Burns
z Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
The equipment can be used to 50Hz and 60Hz. Select the frequency according to the
load.
Stop the engine.
Open the side door.
Turn the selector switch and the metal bus bars to the other frequency as per the
drawing.
Start the engine. (Refer to 7-1. Starting)
Turn the slow-down switch to OFF. (Refer to 5-7. Slow-Down)
Check the frequency in the frequency meter in the control panel.
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5-5 Earth Leakage Relay
Danger : Electric Shock
z Ground every 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 NO RELAY case, because leaking current
inevitably goes through the body.
z Even though all the terminals of the loads have been grounded to the earth, the
earth grounding terminal and the bonnet (canopy) grounding terminal should be
grounded to the earth.
z Grounding should be made after the engine is stopped.
z
Whenever the earth leakage relay has activated, you should always repair the
leaking place first of all.
The equipment is provided with the earth leakage relay in the 3-Phase Circuit Breaker
to detect any leakage arisen due to the troubles as insulation failure of the load while
the generator is running. And cutting off the circuit for protection against any accident
such as electrical shock resulting from the trouble.
<Caution>
z The earth leakage relays (3-Phase 380V and 1-Phase 220V) activate the AC
to the terminals but not to receptacles.
z The 3-phase circuit breaker trips to protect the loads, whenever AC power is
used where the selector switch is in the Eco position.
The specifications of the earth leakage relay:
z Rated Sensitive Current: 30mA (or below)
(Grounding resistance: 500Ω or below)
z Sensitive time: Within 0.1 second
(1) Grounding Work
The qualified electrician should perform the grounding work of the following 3 points
(500Ω or below).
z The earth grounding terminal in the output terminals
z The Outer Bonnet of the equipment (bonnet grounding terminal)
z The Outer Bonnet of the load
<Caution>
z In the event you cannot ground the generator to the earth, consult with the
authorized distributor or our engineering section.
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(2) Operation Check
Before operating the equipment, check always if the device can work duly as
shown in the following procedure.
① Turn the starter switch from STOP to RUN.
② Turn (Push-up) the 3-P circuit breaker (lever) to ON position.
③ Push the test button. The device is found to be normal as the earth leakage
indication lamp turns ON and the 3-P circuit breaker positions in the middle of
ON and OFF.
④ Push the reset button. (The earth leakage indication lamp turns OFF.)
⑤ Turn (Push-down) the 3-P circuit breaker (lever) to OFF position.
⑥ Restore the switch to STOP once, when starting the engine.
z In the event you cannot complete all steps in the above procedure to the end,
the device is out of order. Consult with our authorized distributor or our
engineering section to repair.
(3) The Earth Leakage Relay has activated
Caution : Electric Shock / Injuries
Be sure to disconnect all the loads to the equipment when turning the breakers ON
again, after the earth leakage relay has activated.
When the earth leakage relay has activated, the earth leakage indication lamp
turns ON and also the 3-P circuit breaker (lever) trips to the middle of ON and OFF.
In the case, stop the engine promptly and find the leakage point to repair.
After repairing leakage point(s), proceed with the following restoration steps.
① Push the reset button or stop the engine.
② Restore (push-down) the 3-P circuit breaker (lever) to OFF position.
By the above procedures, you can reset the breaker to ON position.
<Caution>
When the breaker has tripped to the middle but the lamp does not turn ON
simultaneously, the cause to have tripped is OVER-LOAD or the output selector
switch is positioned to ECO. Restore as per the procedures No. 9-3 Operation.
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5-6 Single Phase Breaker for the receptacle circuit only
Caution : Electric Shock・Injuries
z Be sure to disconnect all the loads to the generator when turning the breakers
ON again, after the 1-Phase Breaker has activated.
① Disconnect all the loads.
② Turn the breaker to ON.
<Caution>
z Do not exceed the maximum output. Refer to 9-2 Output Limitation.
z The 1-P breaker protects the receptacle circuit only.
5-7 The Slow-Down Feature
The slow-down feature is to set the engine speed low automatically (in about 8
seconds) for the purpose of reducing noise and fuel consumption, whenever no
welding operation or electric supply is performed.
In the case of using the SLOW-DOWN feature, turn the slow-down switch to ON. By
the condition, the engine automatically moves to high speed, whenever welding
operation or electric supply starts.
Caution : Damage to the equipment or other properties
z Turn always the slow-down switch to OFF, when the load is incorporated with
any magnet switch.
<Caution>
z When the load of less than 0.5A is connected to use, the Slow-Down feature
does not function sometimes. Therefore, turn the switch to OFF.
z When welding operation or electric supply performs alternately or intermittently,
turn the switch to OFF.
z When the output selector switch is positioned to Eco, the engine does not turn
to high speed.
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5-8 Voltage Adjusting Dial
Adjust the dial whenever the AC Output adjustment is necessary. Set the dial in the
center usually.
<Caution>
z
When raising the voltage, the current is decreasing. (Use the output within the
output capacity.)
z
In you raise the voltage exceeding the allowable voltage range, which causes
the damage to the loads. (Especially using the output terminals connected to
the 1-P loads.
6. Initialization and Pre-check
Caution : Fire・Burns・Injuries
z When checking engine, always stop the engine, and keep away from fire. Wait
until the engine cools down, before performing any checks.
6-1 Checking Engine Oil
When checking for engine oil, be sure to keep the equipment leveled, and insert
the oil gauge all the way in.
Prior to starting the equipment, make sure to fill the engine oil to the UPPER line
through the oil inlet.
<Caution>
z If the equipment is not leveled, you cannot obtain accurate oil level.
Do not overfill (over UPPER line) the engine oil. The excessive amount of
engine oil may damage the engine (inside the cylinders)
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„ Selecting proper engine oil
<Caution>
Use the API class CC or higher.
Viscosity and Temperature
Temperature
Viscosity
Over +20℃
SAE30
+10～+20℃
-10～+40℃
SAE20
SAE10W/30
6-2 Checking Coolant / Water
Danger : Injuries
z Close all doors and place locks during operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Danger : Burns
z Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid sustaining burns from hot vapor.
Caution : Burns
z Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
Check to see if the coolant/water level is between FULL and LOW levels in the sub
tank. If the coolant/water is below the LOW level, fill the tank and the radiator
accordingly.
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(1) Filling to the Reservoir Tank
① Remove the sub tank cap.
② Fill up the sub tank to the FULL level.
③ Install the cap back.
(2) Filling to the Radiator
① Remove the top plate.
② Remove the radiator cap.
③ Fill the radiator up to the top.
④ Install the cap back and tighten.
⑤ Reinstall the top plate.
<Caution>
z Use soft water, such as tap water.
z If the ambient temperature is near freezing, use Long Life Coolant (LLC) (30%
mixture LLC is filled when shipped from factory)
z Mixture ratio of the coolant should be 30%-45%, depending on the ambient
temperature.
z Replace LLC at every year or 2000 hours.
Mixture Ratio (for reference only)
Lowest Ambient
-15℃
-20℃
-30℃
Temperature
Mixture Ratio
30%
35%
45%
6-3 Checking Fuel
Caution : Fire
z Always wipe any drip of fuel. Do not use this equipment when any leak is found.
Repair the equipment before use.
Check for the fuel level in the tank. Add if necessary.
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<Caution>
z Use Diesel fuel, ASTM D975 No.2-D in the event ambient temperature reaches
down to -5℃.
z The engine is designed to use either No.1-D or No.2-D Diesel fuel. However,
for better economy, use No. 2-D Diesel Fuel whenever possible. At
temperatures less than -7 (20℉), No.2-D fuel may pose operating problems
(see “Cold Weather Operation which follows). At colder temperatures, use
No.1-D fuel (if available) or use a “winterized” No.2-D (a blend of No.1-D and
No.2-D). This blended fuel is usually called No.2-D also, but can be used in
colder temperatures than No.2-D fuel which has not been “winterized”. Check
with the services stations operator to be sure you can get the properly blended
fuel. Note that Diesel fuel may foam during a fill-up. This can cause the
automatic pump nozzle to shut off even though your tank is not full.
z Always use the fuel strainer.
z Fill the fuel tank slightly less than the FULL tank.
6-4 Checking Fuel, Engine Oil and Water Leakage
Caution : Fire
z Do not use this equipment when a leak is found. Repair the equipment before
use.
Be sure to check any leakage for fuel, oil and coolant/water at the hose
connections by opening side doors. Whenever checking any fuel leakage, turn
the fuel lever OPEN and be sure to close the fuel lever after checking.
6-5 Checking Battery
Caution : Injuries to eyes and skin
z Battery fluid contains diluted sulfuric acid. Avoid contact with eyes, skin or
clothing.
z If the acid comes to contact, especially with eyes, flush with a lot of water, and
contact your physician immediately.
Caution : Explosion
z Do not use the equipment or charge the battery, in the case the battery fluid
level is lower than the LOWER level.
z Battery may emit some combustible gas, so keep it away from fire and sparks.
Caution : Fire
z Battery may emit some combustible gas, so keep it away from fire and sparks.
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① Check the fluid level. If the level is near or lower than LOWER level, add
distilled water until the fluid level reaches UPPER level.
② Make sure that the battery cables are firmly secured to the posts. Tighten the
clamps if necessary.
<Caution>
z Check the hydrometer of the battery fluid. If it falls below 1.23, the battery
requires recharging. Please consult with our authorized distributor or our
engineering section.
„ Replacing battery
① Remove the clamp and cable from negative (-) post in the battery.
(Remove always negative side first)
② Remove the hold-down clamp from the battery.
③ Remove the clamp and cable from positive (+) post in the battery.
④ Remove the battery from the seat.
※ Reinstall a new battery in the reverse order.
(Install always the cable to the positive (+) post in the new battery first.)
<Caution>
z Use the following battery.
55B24L
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7. Operation
Danger : Suffocation from exhaust fume
z 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
z Do not point the exhaust fume toward pedestrians or building.
Caution : Fire
z Temperature around muffler and exhaust can get extremely high.
Keep any inflammable items (such as fuel, gas, paint, etc.) away from the
equipment.
z Always operate this equipment on flat surface and, at least 1 meter away from
any objects (wall, box, etc.)
Caution : Injuries
z
Always place the equipment on a flat and stable surface, to keep the
equipment from sliding. Be sure to lock the wheels for the wheeled models.
z Before starting the engine, be sure to disconnect the loads and set the
breakers (1-P and 3-P) to OFF position.
7-1 Starting
① Turn the breakers (1-P and 3-P) to OFF position.
② Turn the fuel lever to OPEN.
③ Turn the Slow-Down switch to ON.
④ When the temperature is below -5℃,turn and keep the starter switch to
PREHEAT until the preheat lamp turns OFF (about 5 seconds).
⑤ Turn the starter switch to START and then the engine starts by the starter
motor.
<Caution>
z Do not drive the starter motor for more than 15 seconds successively.
z If you need to restart, wait for 30 seconds or more before retry.
⑥ Release the switch, as soon as the engine has started.
<Caution>
z Once the engine has started, never turn the starter switch to START.
⑦ Keep the engine idle for about 5 minutes.
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„ Restart after stopping due to fuel shortage
This equipment is incorporated in automatic vacuuming air feature. Therefore,
even though the engine stops due to running out of fuel, you can restart the
engine easily by the following steps.
① Turn the starter switch to STOP.
② Fill the fuel.
③ Turn the Slow-Down switch to ON.
④ Turn the starter switch to START and dive the starter motor for about 10
seconds.
⑤ Release the starter switch, as promptly as the engine started.
⑥ Wait for about 1 minute to vacuum the air out. The engine speed becomes
stable when the air is extracted.
<Caution>
z
Never turn the engine NORMAL speed or connect the loads until the air is
extracted completely (the engine speed becomes stable)
7-2 Stopping
① Turn (Push-down) the breakers (1-P and 3-P) to OFF.
② Turn the Slow-Down switch to ON.
③ Keep the engine idle (cooling down) for about 5 minutes.
④ Turn the starter switch to STOP.
⑤ After the engine has stopped, turn the fuel lever to CLOSE.
<Caution>
z When the engine does not stop in spite of turning the starter switch to STOP,
turn the fuel lever to CLOSE, then the engine will stop in a few minutes.
In this case, be sure to consult with our authorized distributor or our
engineering section and ask to repair.
- 20 -
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8. Welding Operation
8-1 Selection – Welding Cable
Select the cable with proper gauge, based on the allowable amperage and the
length, per the table shown below.
The welding capacity is to reduce if the small gauge cable is used.
<Caution>
z Welding cables should be used unstrained. When the welding cables are used
in swirl, the welding capacity is to reduce.
Size of Cable (Unit: mm2)
Return Length
20m
30m 40m
60m
80m
100m
Welding Current
400A
350A
300A
250A
200A
150A
38
30
30
22
22
22
50
50
38
30
30
22
60
60
50
38
30
22
100
80
80
60
50
38
125
125
100
80
200
150
125
100
80
60
50
60
100A
22
22
22
30
30
38
8-2 Polarity
There are two welding output terminals, 『+』and 『-』.
Select the polarity according to the operation, referring to the table below.
<Caution>
z Follow the instruction of the welding rods, the polarity of which is specified.
Application
Connection
Generals Welding, such
as construction
Plus to the Earth (Material)
Minus to holder (Rod)
Normal Polarity
Reverse Polarity
Thin Plate, Build-Up
Plus to holder (Rod)
Welding, Stainless Steel
Minus to the Earth (Material)
8-3 Connection – Welding Cable
Danger : Electric Shock
z Before connecting or disconnecting a welding cable from welding output
terminals, stop the engine, and remove the engine key. A person performing
should always keep the key.
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① Stop the engine.
② Connect a welding cable to a crimping terminal, a welding rod holder, and a
material holder.
③ Connect the welding cables to the output terminals per the table below.
Eco (Single)
Single
Dual
Welding Rod
Welding Rod
Welding Rod
φ2.0 – φ4.0
φ2.0 – φ5.0
φ2.6 – φ8.0
Welding Output Terminal A
and
Welding Output Terminal A Welding Output Terminal A
Welding Output Terminal B
④ Close the output terminal cover, after finishing connections, and fix the cover
with bolts.
<Caution>
z Be sure to crimp a crimping terminal to a cable and connect the cable to
welding output terminal. Otherwise, welding output terminals may burn out by
the heat caused by insufficient connections.
z Do not use a cable without a crimping terminal. If you use the cable, the
insulation is peeled off partly, to bind to an output terminal, the output terminal
may burn out by the heat caused by insufficient connections and also a bare
part of the cable may touch the bonnet to short-circuit.
8-4 Duty Cycle
Duty cycle means the weldable time ratio for 10 minutes. This equipment is the
rated duty cycle is 60%, namely, the weldable time is 6 minutes or less. Be sure to
take 4 minutes recess after 6 minutes welding.
<Caution>
z The equipment may be damaged due to overheat, if welding more than 6
minutes successively or short time recess after the welding.
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8-5 Welding
Caution : Suffocation from welding fume
z Be sure to wear a fume proof mask in operation, because welding fume
contains poisonous gas and dust. Pay attention to the airflow direction and
sufficient ventilation also in order to prevent from inhaling the fume.
Caution : Injuries to eyes and skin
z Be sure to wear spark protection glass(es)(Refer to the table below),
long-sleeve shirts, gloves, etc. in order to protect eyes and skin from harmful
spark in welding.
Standard for Spark Protection Glass (Japan Industrial Standard)
No.
7
8
9
10
11
12
13
Welding Current (A)
30-75
76-200
201-400
Caution : Fire
z Keep any inflammable items and easily burning items away from the place in
welding, because welding splashes spatters.
Caution : Burns
z Be sure to wear leather gloves, apron, shoe covers, eye protection
glass(es)(mask), safety shoes, safety cap and long sleeve shirts, because
welding splashes spatters.
<Caution>
z Never turn the output selector switch during welding, because it causes
burnout of the switch.
2 persons can weld simultaneously.
Each person can adjust the welding current individually.
The current adjustable range by the current adjust dial, depends on the position
each of the welding output selector switch.
① Set the selector switch, base on the application to use.
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② Adjust the current amperage by the current adjust dial, per the table below.
Welding Current at the dial position
Position Freq
MIN
1
2
3
4
5
MAX
240
380
400
190
210
Eco
40
60
100 140 180
190 250 320
200 260 320
100 130 160
110 140 170
220
360
380
180
200
1 Person
50Hz 90
120
Single
Use
60Hz 110 140
50Hz 50
60Hz 55
70
70
Dual
Use
2 Persons
The values shown in the table are for reference only. The length and the ambient
temperature affect the value.
When the remote control box is used, the values change to some degree.
9. Generator Operation
9-1 Output Range
(1) 3-Phase 380-415V Output (3-Phase 4-Wire)
Maximum output from the terminals is 15KVA.
(2) 1-Phase 380-415V Output Terminals
1-Phase 380-415V Output is available, using the output terminals. Maximum output
available for the one set of the terminals is 9kVA but the total output for 3 sets is
12KVA, which please note and care. You should use the 3 sets wires evenly as
much as possible.
(3) 1-Phase 220-240V Output Receptacles
1-Phase 220-240V Output is available through 2 receptacle sets.
Maximum output is 3kVA for 2 receptacle sets.
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9-2 Output Limitation
Please refer to the following table, because electric tools and home appliances
cannot be judged only by the rated output or the power consumption due to the
efficiency and character of the components.
Applicable Load (For reference purpose only)
Capacity (kW)
1-Phase
220-240V
Receptacle
total
1-Phase
3-Phase
380-415V
Terminal
380-415V
Loads
Terminal
1 set
Terminal
3 set pairs
use
Electric Bulb, Heater, etc.
3.0
1.5
1.2
9.0
4.5
3.6
12.0
6.0
-
-
-
Electric Tools, etc
(Series Motor),
Mercury Bulb
4.8
(High Power Factor Type)
Submersible Pump,
Compressor, etc
(Induction Motor)
1.2
3.6
4.8
6.0
※ Series Motor : Motor with brush
※ Induction Motor : Brushless Motor
※ The value described is 『OUTPUT』 for Induction Motor loads and 『POWER
CONSUMPTION』 for the other equipment.
<Caution>
z Be sure to use the frequency designated in the equipment incorporated in
mercury bulb or induction motor.
z The load incorporated in motor may require bigger power than the rated power
consumption. Therefore, consult with our authorized distributor or our
engineering section to clarify.
z When connecting to use 2 or more sets, start the load one by one, not to start
them simultaneously.
z When switching a Mercury bulb ON again, wait for 15 minutes (about) until it
cools down.
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9-3 Operation
Danger : Electric Shock
z Before connecting or disconnecting a load cable from output terminals,
always turn the circuit breakers (3-P and 1-P) to『OFF』position. And always
stop engine, and remove the engine key. A person performing the
maintenance should always keep the key.
z Ground the every 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 than the NO-RELAY case, because leaking current
inevitably goes through the body. (Refer to『5-4 Frequency Change』.)
z Even though all the current leakage relays in the loads have been grounded
to the earth, the earth grounding terminal and the bonnet (canopy) should
be grounded to the earth.
z Grounding should be made after the engine is stopped.
z Whenever the current leakage breaker activates, you should repair the
leaking place first of all.
Caution : Injuries
z Be sure to connect to output terminals or insert a plug to a receptacle, after
confirming that all the switches in the loads are positioned to 『OFF』.
z Be sure to select the correct frequency, designated in the loads. (Refer to『5-4
Frequency Change』.)
Caution : Damage to the property・Aftermath
z Whenever connecting to use medical equipment or appliances, be sure to
consult with the medical equipment company, doctor or hospital personnel.
z Be sure to select the correct frequency, designated in the loads. Otherwise,
the loads may be damaged. (Refer to『5-4 Frequency Change』.)
<Caution>
z The 3-Phase Volt meter reads 380-415V, apart from the circuit breakers (3-P
and 1-P) positions to『ON』or『OFF』, when the engine is driving.
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After the engine starts (Refer to 『7-1 Starting』), operate the equipment as per the
following procedures.
① Turn the power switch OFF in the load, and then turn the circuit breaker to
『OFF』.
② Check to confirm that the breakers (3-P and 1-P) position 『OFF』.
③ Connect the load to the output terminals or receptacles.
④ Close the output terminal cover, after finishing connections and screw up the
bolts to fix the cover.
⑤ Turn the circuits breakers (3-P and 1-P) to 『ON』.
„ The Circuit Breaker has activated due to overload
Caution: Injuries
z Be sure to turn the power switch 『OFF 』in the load when turning the circuit
breaker to 『ON』again, when the circuit breaker has activated.
When the electric supply exceeds the rated output (overload), the circuit breaker
activates to trip off in order to shut down the circuit. When the load operation stops
during operation, check the circuit breakers (3-P and 1-P).
In the case the 3-P breaker trips, the current leakage breaker lamp should have
turned to OFF. If the lamp remains ON, refer to 『5-5 Earth Leakage Relay』.
When any breaker has tripped, restore the circuit breaker as per the following
procedure.
① Turn OFF all the power switches in the loads.
② Turn (Push) down the circuit breakers (3-P and 1-P) to『OFF』once. And then turn
(push) up the circuit breakers to『ON』.
<Caution>
z Take care for overload, referring to 『9-2 Output Limitation』.
z When the output selector switch is positioned to Eco and AC power is used,
the 3-P circuit breaker trips off to shut down the circuit. Stop using AC power
and follow the above procedure to restore the circuit breaker.
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10. Simultaneous Use of Welding and Generating
The circuit breakers (3-P and 1-P) react on the AC power supply circuit only. In the
simultaneous use of welding and generating, there sometimes happens overload to the
engine. Refer to the following table and limit the AC power use.
Limitation of AC Power Supply in the simultaneous use of welding and generating (60Hz)
Welding Output
AC Power Output
Welding Rod
Output
Select
3-Phase 380-415V Output
(P.F. 0.8)
1-Phase
Output
/ Amperage
φ2.0mm/60A
Dual
9.0kVA
10.5kVA
φ2.6mm/120A
φ3.2mm/140A
φ4.0mm/170A
φ5.0mm/240A
φ6.0mm/300A
φ8.0mm/380A
Dual
Dual
8.5kVA
8.0kVA
7.5kVA
2.5kVA
2.0kVA
0kVA
9.0kVA
8.5kVA
7.5kVA
5.0kVA
2.5kVA
0kVA
Dual
Single
Single
Single
In order to secure stable AC output, the output selector switch should be positioned
to DUAL in operation as long as possible.
The 1-Phase output is the total of 1-Phase from the receptacle and 1-Phase from
terminals.
<Caution>
z The simultaneous use of Eco welding and AC power is NOT available.
z Avoid the simultaneous use in the case high quality result in welding is
required.
11. Checking and Maintenance
Danger : Electric Shock・Injuries
z Before performing any equipment check or maintenance, stop the engine, and
remove engine key. A person performing the maintenance should always keep
the key.
Caution: Fire・Burns
z Keep the equipment far away from fire.
z When checking engine, always stop the engine, and keep away from fire. Wait
until the engine cools down, before performing any checks.
<Caution>
z The authorized technicians should perform all checking and maintenance work,
except for the pre-startup checks.
z Request for the maintenance item with ● mark to the authorized distributor or
our engineering section.
z Always use our genuine parts of replacement.
To optimize the use of this generator/welder, we recommend the periodical equipment
checks and maintenance based on the following matrix.
Use the hour meter as a guide for the operating time.
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Checking Time
Every Every
Startup
Check
At
Every
Every Every
1000 2000 hrs
hrs
Checking Items
200
hrs
400
hrs
50hrs 100
hrs.
1
2
Check and Supply Fuel
Check and Supply Engine
Oil
○
○
2nd or
1st
3
4
Engine Oil Change
Oil Filter Change
after
○
○
2nd or
after
○
1st
○
5
6
Check/Add Water/Coolant
Water/Coolant Change
○
○ or one
year
2nd or
after
○
1st
7
Clean Fuel Strainer
○
8
9
Change Fuel Filter
Drain Water/Clean Fuel
Tank
○
○
Check Leakage Fuel, Oil,
Water
10
○
○
○
○
11 Check/Add Battery Water
change
Clean
1st
2nd or
12 Clean Air Element
13 Change Air Element
14 Adjust Tension V-Belt
○
after○
○
1st
2nd or
●
after●
● or 2
15 Change V-Belt
years
16 Clean Radiator Fin
●
●
17 Clean Radiator (inside)
Change Fuel Hose,
● or 2
Oil Hose, Vibration-Absorbing
Rubber
18
years
Adjust Engine Valve
Clearance
●
●
19
20
21
Adjust
Plane
Check/Adjust Injection
Nozzle
●
Check/Adjust Injection
Pump
●
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(1) Oil Change
First Time
2nd or after
50 hour mark
Every 100 hours
1
2
3
4
Remove the oil plug.
Loosen the oil drain plug and allow the oil to drain fully.
Reinstall the oil drain plug.
Checking the oil level by the oil level gauge, add oil into the oil filler to fill up to
the max level (about 5.0 liter).
5
Reinstall the oil plug hand tight.
<Caution>
z Refer to 『6-1 Checking Engine Oil』to select engine oil.
z Change the packing, whenever changing oil.
z Packing No. : 6C090-58961 (Kubota)
(2) Oil Filter Change
First Time
2nd or after
50 hour mark
Every 200 hours
① Drain the engine oil completely, as described in 『11-1 Oil Change』.
② Loosen and remove the oil filter, using an oil filter wrench.
③ Smear a little engine oil on the rubber gasket of a new filter.
④ Screw the new filter into place and tighten it by hand until the gasket contact the
seat. Then, give it additional『1.1/4 Turn』to seat the filter, using an filter wrench.
⑤ Supply oil and install the filler cap.
<Caution>
z If an oil filter wrench is not available, contact our authorized distributor or our
engineering section.
z Oil Filter Part No.: 16271-32092 (Kubota)
(3) Clean/Change Air Filter Element
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Clean
1st 50 hours and Every 100 hours afterwards
Every 400 hours
Replace
① Loosen the wing bolts in the air cleaner and remove the air element.
② Clean or replace the air element.
<The element is adhered with dried contaminants>
Blow up compressed air from inside the element.
<The element is adhered with carbon or oil>
Replace to a new one.
③ Reinstall it in reverse order.
<Caution>
z Clean more frequently, if it is used in dusty environment.
z Element Part No. 15471-11083 (Kubota)
(4) Clean/Change Fuel Strainer
Clean
1st 50 hours and Every 100 hours afterwards
Replace
Every 400 hours
① Turn the fuel lever to 『CLOSE』.
② Unscrew the retainer ring counterclockwise, and remove the cup and the filter
element.
③ Discard any dust or water inside the cup, and clean the filter element by blowing
compressed air, or replace if necessary.
④ Reassemble it back.
<Caution>
z Be sure to check for any contaminants on the packing, whenever reinstalling
the cup.
z Turn the fuel line valve lever『OPEN』after assembling, and check for any leak.
Having confirmed no leak without fail, turn the fuel line valve 『CLOSE』.
z Element Part No.: 15521-43161 (Kubota)
(5) Drain Water from Fuel Tank
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Drain Water
Every 200 hours
① Unscrew the fuel drain plug.
② Reinstall the drain plug, after draining water completely
<Caution>
z Change the packing, whenever changing oil.
z Packing Part No.: 6C090-58961 (Kubota)
(6) Changing Coolant/Water
Replace
Every 2 years or 2000 hours
(Total Coolant/Water Capacity: 4.3 liter, including sub tank cap. 0.6 liter.)
1
Remove the top plate.
2
3
4
Remove the radiator cap.
Loosen the water drain plug.
After draining all the water, reinstall the water drain plug.
<Caution>
z Change the packing, whenever changing oil.
z Packing Part No.: 6C090-58961 (Kubota)
Replace all the water. In the sub tank.
Fill the coolant/water to the MAX level (to the upper edge of the inlet).
Reinstall the radiator cap.
5
6
7
8
Install the top plate back.
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12. Long-Term Storage
Danger : Electric Shock
z 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 : Injuries
z 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
z When checking engine, always stop the engine, and keep far away from fire.
z Temperature around muffler and exhaust can get extremely high. Wait until the
engine cools down, before performing any checks.
If the generator/welder will not be used for more than two months, perform the following
maintenance and storage procedures.
① Remove the battery.
② Change the engine oil.
③ Drain fuel from the fuel tank and the fuel strainer.
④ Clean all parts, cover the generator/welder, and keep it in the storage, away from
dust and humidity.
<Caution>
z Recharge the removed battery once a month.
13. Troubleshooting
Danger : Electric Shock
z Do not operate the equipment, if the equipment or you are wet.
z Before performing any equipment check or maintenance, stop the engine.
Caution : Injuries
z When performing equipment check and maintenance, always stop the engine.
Caution : Fire・Burns
z When checking engine, always stop the engine, and keep away from fire.
z Temperature around engine, muffler and exhaust can get extremely high. Wait
until the engine cools down, before performing any checks.
Follow the guideline below, when performing any troubleshooting. If you cannot resolve
the problems by this troubleshooting guide, contact the authorized distributor or our
engineering section to request the repair.
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Symptoms
Possible Cause
Corrective Actions
1. Recharge Battery
Starter motor does not 1. Weak Battery
start
2. Dead Battery
2. Replace Battery
Engine does not start
1. Fuel lever to CLOSE
2. Insufficient Fuel
1. Fuel lever to OPEN
2. Replenish fuel
3. Water or contaminants in fuel
4. Fuse burnt
3. Drain water or clean fuel tank and
fuel strainer
4. Repair
Engine starts, but stalls 1. Insufficient oil
1. Replenish oil
immediately
2.High
Water
Temperature, 2. Replenish coolant/water
Insufficient coolant/water
3. Unable to charge
3. Repair
Welding Arc is weak
1. Output selector switch positions 1. Turn to 『SINGLE』
to 『Eco』or 『Dual』
2. Frequency Switch is to 『50Hz』 2. Turn to 『60Hz』
3. Wrong current adjustment dial
position
3. Turn the dial clockwise
4. Poor contact of cables
5. Improper Cable Diameter
6. Poor Contact to material
7. Dual Use
4. Connect securely
5. Change cables according to
『Selection – Welding Cable』
6. Connect securely
8. Engine output is down
9.
Exceeding Duty Cycle (the 7. Stop using AC Power
warning lamp blinks)
8. Keep 60% duty cycle
9. Wait until the equipment cools down
(the lamp to OFF)
Excessive Welding Arc
No AC Output
1. Output selector switch is to 1. Turn to 『ECO』 or 『DUAL』
『SINGLE』
2. Turn the dial
2. Wrong current adjustment dial
position
counterclockwise
1. The breaker (3-P or 1-P) 1. Turn to 『ON』
positions to 『OFF』
2. Output selector switch
2. Turn to『SINGLE』
positions to 『ECO』
or 『DUAL』
AC Output is Weak
1. Wrong Frequency
1. Change to the load
frequency
2. The power consumption of the
load exceeds the rated output
3. The rated current of the load
exceeds the rated output
4. Dual Use
2. Correspond the frequency
of the lever to the bus bars
3. Adjust according to
『OUTPUT LIMITATION』
4. Stop welding
Slow-Down does not 1. Welding cables short circuit
1. Repair the short circuit
activate
2. The power consumption of the 2. Turn the slow-down switch to
load is 0.5A or below
『OFF』
Engine does not stop
1. Stop Solenoid disorder
1.Turn the fuel lever to 『CLOSE』to
stop and repair
Black and white smoke 1. Overloaded use
exhaust from muffler
1. Keep the duty cycle
successively
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14. Engine Wiring Diagram
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15. Generator Wiring Diagram
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Shindaiwa Corporation
Head Office : ６－２－１１，Ｏｚｕｋａ－Ｎｉｓｈｉ，
Ａｓａｍｉｎａｍｉ－Ｋｕ，Ｈｉｒｏｓｈｉｍａ，
７３１－３１６７，Ｊａｐａｎ
Telephone: +81-82-849-2220 FAX: +81-82-849-2481
71905-94310
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