Shindaiwa DGW500DM Owner'S And Operator'S Manual Download Page 10

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Single/Dual
Selector

DC Meter

Emergency

Stop Switch

AC Meter

Weld Mode
Selector

VRD
Lamp

Output

Control
Dial

Rod Selector

Arc Control
Dial

Hour
Meter

Fuel
Meter

Remote
Control Connector

Idle

Control
Switch

VRD
Switch

Starter

Switch

Monitor
Lamps

Remote
Control

Cover

Ground Fault Circuit Interrupter
(GFCI) Receptacle

Main Breaker

Bonnet Grounding

Terminal

Forklift Skid

1-P Breaker

3-P/1-P
Output Terminal

4. Part Names

Weld Terminals A

Weld Terminals B

Operation Panel

Terminal Cover

Summary of Contents for DGW500DM

Page 1: ...ical Water Cooled 4 Cycle Diesel Engine DGW500DM 200 X750 023 04 0 X750803 680 2 CAUTION Do not operate the Generator Welder or any other appliance before you have read and understood the instructions for use and keep near for ready use ...

Page 2: ......

Page 3: ...ily accessed at all times to order parts or arrange for repair Contact the retail outlet where this equipment was purchased if any parts are lost the equipment becomes soiled or is otherwise damaged in any manner Consult with the retail outlet where the equipment was purchased if any of the points are unclear or you would like further information Be sure to note the model name and serial number of...

Page 4: ...ter Inspection 16 6 3 Fuel Inspection 17 6 4 Inspection for Fuel Oil Cooling Water Leakage 18 6 5 Battery Inspection 18 7 Operating Procedures 19 7 1 Starting the Engine 20 7 2 Stopping the Engine 21 7 3 Emergency Stop 21 8 Using as a Welder 21 8 1 Welding Cable Selection 21 8 2 Welding Polarity 22 8 3 Welding Cable Connection 23 8 4 Duty Cycle 24 8 5 Welding Work 24 9 Using as a Generator 26 9 1 ...

Page 5: ... to repair the corresponding ground fault location when ground fault circuit interrupters operate Always be sure to stop the engine and remove the starter key before performing any equipment check or maintenance Warning Fire Always be sure to stop the engine when inspecting fuel or refueling and absolutely never perform such tasks near fire or other open flame Wait until the engine has completely ...

Page 6: ...ause the battery generates ignitable gas Warning Electromagnetic Interference Persons using a heart pacemaker are not allowed near the welder or welding work area while welding is being performed without the permission of a doctor The welder generates a magnetic field while energized that can negatively affect pacemaker operation Caution Suffocation from Exhaust Fume Do not direct the engine exhau...

Page 7: ...t and lift slowly and directly straight above Wear a helmet safety shoes gloves and similar protective gear when performing lifting work Do not stand or get under the equipment while it is suspended Securely fix the equipment with rope or similar item so that it cannot move when transporting by truck or other vehicle Caution Injury to Eyes and Skin Always be sure to wear arc proof glasses clothes ...

Page 8: ...s by numbers in parentheses 1 Suffocation from Exhaust Fume No X505 007590 2 Suffocation from Welding Fume No X505 007600 3 Electric Shock No X505 007610 4 Fire No X505 007650 5 Injury No X505 007630 6 Injury No X505 007690 7 Injury No X505 007550 8 Burn No X505 007640 9 Burn No X505 007620 10 Burns No X505 007660 11 Electric Shock No X505 007680 1 2 3 5 6 7 4 8 9 10 5 6 11 ...

Page 9: ...ed 4 Cycle Diesel Engine Displacement L 1 498 Rated Output kW min 1 24 5 3000 27 0 3600 Fuel ASTM No 2 D Diesel Fuel or Equivalent Lubricant Oil API Class CD or better Lubrication Oil Volume L 6 0 Effective 2 0 Cooling Water Volume L 5 6 Sub Tank Capacity 0 8 L included Starting Method Starter Motor Battery 75D31R Japanese Industrial Standard Fuel Tank Capacity L 63 Dimen sion Length mm 1680 Width...

Page 10: ...Hour Meter Fuel Meter Remote Control Connector Idle Control Switch VRD Switch Starter Switch Monitor Lamps Remote Control Cover Ground Fault Circuit Interrupter GFCI Receptacle Main Breaker Bonnet Grounding Terminal Forklift Skid 1 P Breaker 3 P 1 P Output Terminal 4 Part Names Weld Terminals A Weld Terminals B Operation Panel Terminal Cover ...

Page 11: ...tor s Manual Fuel Lever Water Separator Frequency Selector Oil Plug Oil Inlet Fuel Inlet Cover Fuel Drain Plug Oil Drain Plug Water Drain Plug Oil Filter Fuel Inlet Side Door Air Cleaner Battery Fuse 60A 20A Fuel Lever Fuel Filter Sub Tank Oil Gauge Lifting Lug Muffler Roping Lug Top Plate ...

Page 12: ...n for AC generated output voltage 5 2 Idle Control The equipment includes an idle control function You can use the idle control switch to select an engine speed setting of AUTO HIGH 1 Auto Idle The equipment includes an auto idle function in order to reduce noise save fuel and reduce exhaust gas emission You can set the idle control switch to AUTO so that the engine operates at low speed when not ...

Page 13: ...ctor is set to CC STICK you can pre set the output current using the output control dial 3 Arc Control for CC STICK mode The equipment includes an arc control function that adjusts the arc strength You can adjust the setting of the arc control dial of the short circuit current of the weld output Note The arc control function is only for CC STICK mode It does not function if using CV WIRE Always tu...

Page 14: ...nerated output 1 DC Ammeter Voltmeter The DC ammeter and voltmeter display the weld output for both outputs A and B separately If the single dual selector is set to SINGLE the DC meter for output B does not display current or voltage Note If the weld mode selector is set to CV WIRE the set voltage that has been pre set using the output control dial is displayed by the voltmeter when not welding Th...

Page 15: ...sult in hot oil spurting out The equipment includes monitor lamps for WATER TEMP CHARGE OIL PRESS and OVERHEAT If the equipment is normal the CHARGE and OIL PRESS monitor lamps light up when the starter switch is switched from STOP to RUN and all monitor lamps turn off when the engine is started If any error besides that of overheating occurs during operation the corresponding monitor lamp lights ...

Page 16: ...tor lamps WATER TEMP CHARGE and OIL PRESS light up Refer to section 4 Part Names for fuse location If a fuse has blown it is probable that there is a fault in an electric part or the wiring Request repair at the retail outlet where the equipment was purchased 4 Overheat Monitor Lamp The overheating monitor lamp OVERHEAT flash and the equipment cuts the output if the equipment is used excessively o...

Page 17: ...erminal is not protected by the ground fault circuit interrupters 1 Operation Check of Ground Fault Circuit Interrupters Be sure to always check the ground fault circuit interrupters before starting operation according to the following procedures 1 Start the engine Refer to section 7 1 Starting the Engine 2 Set the idle control switch to HIGH 3 Turn all breakers main and 1 P to ON 4 Press the GFCI...

Page 18: ... the GFCI receptacle reset button until it stays in Note There is a fault in the ground fault circuit interrupters if the GFCI receptacle LED lamp flush and reset button pop out Request repair at the retail outlet where the equipment was purchased 5 10 Emergency Stop Switch Press the emergency stop switch to stop the engine immediately After pressing the emergency stop switch securely return the s...

Page 19: ... at an angle Operating the equipment when the oil has been filled above the maximum level can result in engine cylinder internal damage Engine Oil Selection Use a diesel type engine oil with a viscosity that is appropriate for the outdoor air temperature refer to the table Note Use oil with a quality of CD class or better API classification Temperature Engine Oil Relationship Temperature 20 C or m...

Page 20: ...ide Min Temp 15 C 20 C 30 C Mixing Ratio 30 35 45 6 3 Fuel Inspection Warning Fire Always be sure to stop the engine when inspecting fuel or refueling and absolutely never perform such tasks near fire or other open flame Wait until the engine has completely cooled before inspecting fuel or refueling Check that there is sufficient fuel and add fuel if insufficient After refueling securely tighten t...

Page 21: ... inspection and close it after inspection has been completed 6 5 Battery Inspection Warning Injury to Eyes and Skin Use protective gear such as rubber gloves when inspecting or replacing the battery due to the dilute sulfuric acid in the battery fluid Be sure that fluid does not get into eyes or on skin or clothing If battery fluid gets into the eyes or on the skin or clothing immediately wash wit...

Page 22: ...ine exhaust towards passersby private homes or similar persons locations because the engine exhaust fume includes components that are harmful to humans Caution Burn The engine muffler and similar parts are extremely hot during operation and immediately after stopping the equipment Never touch hot parts Caution Injury Use this equipment with it situated on a stable level surface so that it is preve...

Page 23: ...gine starts do not turn the starter switch to START during operation Restarting after Stopping due to Running Out of Fuel The equipment includes an automatic air bleeding device You can easily restart the engine according to the following procedures even if the engine stops due to running out of fuel 1 Turn all breakers main and 1 P to OFF 2 Turn the starter switch to the STOP position 3 Add fuel ...

Page 24: ...etail outlet where the equipment was purchased 7 3 Emergency Stop The equipment includes an emergency stop device Press the emergency stop switch if you want to immediately stop the engine when an emergency occurs in the work area the equipment suffers an operating fault and similar circumstances Note After stopping the engine using the emergency stop device turn the starter switch to STOP Do not ...

Page 25: ...between the 2 holders could become high and there may be a danger 1 Shielded Metal Arc Welding Gouging Scratch Start TIG 2 Semi automatic Arc Welding MIG MAG Self shielded Polarity Rod Indication Applications Connecting Method Straight Polarity DC Shielded metal arc welding of structures and similar items Scratch Start TIG Welding positive terminal Earth Base material negative terminal Holder weld...

Page 26: ...Gouging Rod φ3 2 φ9 5 mm Gouging Rod φ3 2 φ5 0 mm Weld Terminals A Weld Terminals A or B Weld Terminals A Weld Terminals A or B Note Securely crimp the crimped terminals and securely connect the welding cables Using insufficiently crimped terminals or loosely connected cables can result in heat generation from poor connection thereby causing burnout of the weld output terminals Be sure to always s...

Page 27: ...rsons using a heart pacemaker are not allowed near the welder or welding work area while welding is being performed without the permission of a doctor The welder generates a magnetic field while energized that can negatively affect pacemaker operation Caution Injury to Eyes and Skin Always be sure to wear arc proof glasses refer to the table below clothes that completely cover the skin and other p...

Page 28: ...each type of welding work being performed The range of weld output that can be adjusted using the output control dial varies depending on the positions of the single dual selector and weld mode selector Refer to section 2 Specifications 1 Semi automatic Arc Welding 1 Set the weld mode selector to CV WIRE 2 Switch the single dual selector in accordance with the amount of welding personnel and desir...

Page 29: ...e DC meter During welding both the DC ammeter and voltmeter display the actual output values When welding is completed both meters display the actual output values for approximately 8 seconds after which display returns to the set values The arc control function is only for CC STICK mode It does not function if using CV WIRE 9 1 Output Types and Ranges 1 Output Types 3 Phase 200 220V Output 1 Phas...

Page 30: ...utator motor and similar devices 1 2 1 3 2 3 2 5 2 9 2 9 4 0 4 0 Mercury lamps high power factor types 0 9 1 0 1 8 2 0 2 3 2 3 3 2 3 2 Submerged pump compressor and similar devices Induction motors 0 9 1 0 1 8 2 0 2 3 2 3 3 2 3 2 4 0 4 0 Commutator motors Motors with brushes Induction motors Motors without brushes Capacity values are displayed under OUTPUT for induction motors and under POWER CONS...

Page 31: ...ance with the devices using the equipment 1 Switch the frequency selector in accordance with the devices using the equipment Refer to section 5 8 Frequency Selector 2 Turn off the switches of devices being used 3 Turn all breakers main and 1 P to OFF 4 Start the engine Refer to section 7 1 Starting the Engine 5 Connect the power plug s of device s being used to the AC output receptacle s or the lo...

Page 32: ... Simultaneously 50 60Hz Weld Output AC Power Output Amount of Personnel Current PLUS 3 phase Output Power factor 0 8 OR 1 phase Output Power factor 1 0 Used by 1 Person SINGLE or DUAL 70A 9 9 9 9 kVA 8 0 8 0 kW 100A 9 9 9 9 kVA 8 0 8 0 kW 150A 9 9 9 9 kVA 8 0 8 0 kW 200A 9 9 9 9 kVA 8 0 8 0 kW 250A 9 9 9 9 kVA 8 0 8 0 kW 300A 7 5 8 0 kVA 6 0 7 0 kW 350A 4 5 5 5 kVA 3 5 4 5 kW 400A 1 5 2 5 kVA 1 0 ...

Page 33: ...ng the battery due to the dilute sulfuric acid in the battery fluid Be sure that fluid does not get into eyes or on skin or clothing If battery fluid gets into the eyes or on the skin or clothing immediately wash with a large amount of water and always be especially sure to seek medical attention if it gets into the eyes Warning Explosion Do not operate the equipment or recharge the battery when t...

Page 34: ...quipment can be operated in optimal condition Use the hour meter as a general indicator for the operating time Inspection Item Pre Operation Inspection Inspection Period 50th hour Every 100 hours Every 200 hours Every 400 hours Every 1 000 hours Every 2 000 hours 1 Inspect Add Fuel 2 Inspect Add Engine Oil 3 Change Engine Oil 1st time 2nd time and after 4 Change Oil Filter 1st time 2nd time and af...

Page 35: ...efer to section 6 1 Engine Oil Inspection for the types of engine oil Replace the packing of the oil drain plug with a new part each time the oil is changed Packing part no 6C090 58961 Kubota part no After tightening the oil drain plug operate the engine for a short period and check that there is no oil leakage Stop the engine when completed 2 Changing the Oil Filter 1 Drain the engine oil accordi...

Page 36: ...al Note Clean sooner than scheduled if using the equipment in a dusty location Element part no R1401 42271 Kubota part no 4 Cleaning Replacing the Fuel Filter Cleaning 1st time 50th hour 2nd time and after Every 100 hours Replacement Every 400 hours 1 Turn the fuel lever to CLOSE 2 Turn the retainer ring to the left and remove the cup and element 3 Remove any water or foreign material from the cup...

Page 37: ... fuel drain plug 2 Drain the water and tighten the fuel drain plug Note Replace the packing with a new part each time you drain the water Packing part no 6C090 58961 Kubota part no Always be sure to check that there is no fuel leakage after tightening the fuel drain plug 7 Changing the Cooling Water Change Every 2 000 hours or 1 year Cooling Water Total Capacity Approximately 5 6 L Including the s...

Page 38: ... sure to wipe up any spilled fuel or oil Caution Burn The engine muffler and similar parts are extremely hot during operation and immediately after stopping the equipment Never touch hot parts Always be sure to stop the engine and allow it to cool before inspecting or changing the engine oil Opening the oil gauge or oil plug during operation will result in hot oil spurting out Perform the followin...

Page 39: ...es and Skin Use protective gear such as rubber gloves when inspecting or replacing the battery due to the dilute sulfuric acid in the battery fluid Be sure that fluid does not get into eyes or on skin or clothing If battery fluid gets into the eyes or on the skin or clothing immediately wash with a large amount of water and always be especially sure to seek medical attention if it gets into the ey...

Page 40: ... Weak welding arc 1 Single Dual selector is set to DUAL 2 Frequency selector is set to 50Hz 3 Wrong Output control dial position 4 Faulty cable connection 5 Improper cable excessively thin 6 Faulty connection with base material 7 Using simultaneously as AC power source 8 Welding cable short circuit 1 Set to SINGLE 2 Set to 60Hz 3 Turn the output control dial clockwise 4 Connect securely 5 Replace ...

Page 41: ...e under no load until the display changes from E01 to 888 Then stop and restart the engine The idle control switch does not operate when this failure happens E02 Fault Malfunction of control parts for welding Stop the engine and repair the location of the fault DO NOT restart the engine unless the fault is repaired E03 Short circuit of the weld output Stop the engine Return the short circuit of th...

Page 42: ... 39 14 Engine Wiring Diagram ...

Page 43: ... 40 15 Generator Wiring Diagram ...

Page 44: ... 2014 ...

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