DGW500DM/ANZ
Contents
1. Bey 22 LEAKAGE RELAY HAIN 3 PHASE n HAGUNET BREAKER BREAKER SWITCH 2 3 PHASE REACTOR CA i RECEPTACLE iw 7 7 THYRISTOR CHA IN 2 2 dici e n 8 t a CURRENT d STATOR SENSOR T MAGUNET SWITCH AU ny 4 E at WELDING REACTOR a E i OUTPUT ON OFF CA 1 TERMINAL un 1 dan 613 1611 611 R THYRISTOR VRD M TEMP ROTOR A A R L RESISTOR SENSOR 04 2 1 60 4 L 14 OO CIRCUIT H 4 eg PROTECTOR ur 61 2 1847 1927 EWR t1 5 STATOR 8 8 8 8 8 8 8 8 9 8 ftis i i4 FRONT COVER L B n wy CONTROL PLATED n a a THYRISTOR CHA TN PLATE CONTROLLER 1 PHASE uu t RECEPTACLE CURREN CURRENT SENSOR B BU 8 WELDING PEE TL 8 ort OUTPUT 8 8 5 TERMINAL MAGUMET SWITCH3 MAGUNET SWITCH2 A B ape BG REACTOR ol a SINGLE DUAL ON OFF LL 161 THYRISTOR VRD TEMP 8 RESISTOR SENSOR 0 82 J 4 i B TEMP TEMP TEMP TEMP TEMP SENSOR SENSOR SENSOR SENSOR SENSOR S13B V 18118 A A Grr GZBA 15218 e MAGUNET SWITCH4 L 8 8 9 BC i CXBONHET GROUNDING TERMINAL S INGLE DUAL sees 811007 1 2 e Gf vj L INSULATION2. SINGLE DUAL_ CHANGE 4 pz SINGLE DUAL b roe 1 OPERATION MODE 9 1 i footie SINGLE DUAL Se NEU M MAGUNET LT ES 4 1 T 0244 covey LIRE COLORS 0 8 CELLULOSE OTHERS A COLOR CODE L M GEN GEN WELDER REACTOR A ON OFF or ejej 3 7 1 TRANSFORMER eS 8 BLack B ONLY WELDER ONLY e SE oy eve CELLULOSE OTHERS White W pis M ON OFF ELECTOR 1 DIAL ADJUSTMENT DIAL GENERATOR Nes IDLE CONTROLE Red R SWITCH 1 ADJUSMENT 37e VRO eneen 5 gt e A Yellow Y E NC REACTOR ON OFF Hz PHASE MODE SELECT CONNECTOR CIRCUIT CIRCUIT T2 2 s Brown Br w ON OFF PROTECTOR PROTECTOR PM Blue k c2 2 Ci MAGUNET 6 2 7 SA 7 SWITCH 2 6778 LightGreen 9 N02 N01 8 Orange Or CELLULOSE MODE 7983321 OTHERS MODE ch connector Grey Nel J 4 PRINTED CIRCUIT OPERATION HODE d LED DISPLAY B SELECTOR SWITCH E MAINTENANCE MODE CONNECTOR Or Gr G6 8 1 L V B t t gat z 1 4 0 8r ENG INE WIRING NOI KOZ 1 DIAGRAM hun 5 om 4 Or ec i 2 Lie Bel GL Bel L W ER iei TAA T a R LI GEW 73710 12 1314 27
3. Caution Fire Burns Keep the equipment far away from fire the key AC Power Output 1 Phase 1 0 10 8kW 10 8kW 10 8kW 8 0kW 10 0kW amp 1 Phase When checking engine always stop the engine and keep away from fire Wait until the engine cools down before performing any checks Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor Do not open the side door during operation and immediately after stopping the equipment because some parts components flexible tube resistors etc can reach very high temperature inside the equipment lt Caution gt The authorized technicians should perform all checking and maintenance work except for the pre startup checks Request for the maintenance item with mark to the authorized distributor or our engineering section Always use our genuine parts of replacement When draining waste fluid from the equipment catch it by tray When disposing of oil fuel coolant LLC fuel filter battery and or other harmful disposal please follow the international federal regulations Please do not dispose the harmful items or waste fluid to the ground to a river pond and ocean to keep our environment clean and neat To optimize the use of this generator welder we recommend the periodical equipment checks and maintenance based on the following matrix Use
4. Do not attempt to turn to STOP position while actual welding or utilizing AC power source it may cause the serious damage on the unit 7 3 Emergency Stopping The Emergency Stop feature is incorporated in the equipment Push the Emergency Stop Switch in case of an emergency or equipment abnormality during operation D Push the Emergency Stop Switch to stop engine in an emergency case Caution Be sure to return the Starter Switch to STOP after the engine stops Never hit the Emergency Stop Switch by any tool such as a hammer Never use the Emergency Stop Switch except an emergency case Turn the Fuel Lever on Fuel Strainer or Water Separator to CLOSE to stop in the case the Emergency Stop Switch does not function 19 2 Turn the Emergency Stop Switch to arrow mark clockwise to release the feature lt Caution gt sure to re start the engine after releasing the Emergency Stop feature The engine does not start again though the starter motor is running without releasing the emergency stop feature EMERGENCY STOP STARTER SWITCH SWITCH Mey 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 lt Caution gt Welding cables should be used unstrained When the welding cables are used swirl the
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6. Filling to the Radiator D Open the top plate 2 Remove the radiator cap 3 Fill the radiator up to the top Install the cap back and tighten 5 Close the top plate lt Caution gt Use Long Life Coolant LLC for prevent freeze RADIATOR CAP and rust 30 mixture LLC is filled when shipped TOP PLATE from factory Mixture ratio of the coolant should be 30 45 depending on the ambient temperature Replace LLC at every year 2000 hours Lowest Ambient Temperature Mixture Ratio 6 3 Checking Fuel A Caution Fire 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 lt Caution gt Use Diesel fuel ASTM D975 No 2 D in the event ambient temperature reaches down to 5 C The engine is designed to use either No 1 D No 2 D Diesel fuel However for better economy use No 2 D Diesel Fuel whenever possible At temperatures less than 7 C 20T 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 fue
7. Ground every grounding terminal to the earth as set out in the manual If even one of all is disconnected by mistake or accidents it will be much more dangerous for human body than the NO RELAY case because leaking current inevitably goes through the body Even though all the terminals of the loads have been grounded to the earth the bonnet canopy grounding terminal should be grounded to the earth Before connecting or disconnecting a plug from output receptacle always turn the circuit breaker to OFF position 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 Q 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 4 Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentional touching cooling fan and fan belt Caution Suffocation from exhaust fume Donot point the exhaust fume toward pedestrians or building Caution Suffocation from welding fume 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
8. breakers Main 3 P 1 P In the case the ELCB activates and the ELCB lever positions at OFF refer to 5 7 Earth Leakage Relay When any breaker has tripped restore the circuit breaker as per the following procedure D Turn OFF all the power switches in the loads 2 Turn push up the breaker to ON Caution e Take care for overload referring to 9 2 Output Limitation 25 circuit breakers Main 3 1 P react 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 B Limitation of AC Power Supply in the simultaneous use of welding and generating Welding Output perators 1 Person MODE SINGLE or DUAL 2 Persons MODE DUAL lt Caution gt Avoid the simultaneous use in the case high quality result in welding is required Simultaneous Use of Welding and Generating can be utilized only the Operation Amperage 80A 500A PLUS 3 Phase 0 8 15 0kVA 15 0kVA 14 5kVA 12 5kVA 10 0kVA 7 5 1 5 0 15 0kVA 13 5kVA 9 5kVA 5 5 1 Mode Selector Switch is set as WELDER Danger Electric Shock Injuries Before performing any equipment check or maintenance stop the engine and remove engine key A person performing the maintenance should always keep
9. carbon or oil Replace to a new one Reinstall them in reverse order Caution Clean more frequently if it is used in dusty environment Element Part No R1401 42271 Kubota 29 4 Clean Change Fuel Strainer Clean 1 50 hours and Every 100 hours afterwards Every 400 hours RIGHT DOOR FUELLEVER RETAINER ELEMENT Turn the fuel lever to CLOSE Unscrew the retainer ring counterclockwise and remove the cup and the filter element Discard any dust or water inside the cup and clean the filter element by blowing compressed air or replace if necessary Reassemble it back lt Caution gt Be sure to check for any contaminants on the packing whenever reinstalling the cup Turn the fuel lever to OPEN after assembling and check for any leak Having confirmed no leak without fail turn the fuel lever to CLOSE Element Part 15521 43161 Kubota 5 Drain Water from Water Separator Drain Every 400 hours When the Float red is coming up to Drain Water Drain Line drain the water Turn the fuel lever to CLOSE Unscrew the retainer ring counterclockwise and remove the cup and the gauze filter Dispose water or dirt inside the cup When dirt is adhered to the gauze filter clean the filter by compressed air 4 Reassemble it back RIGHT DOOR PUBL LEVER RETAINER RING GAUZE FILTER DRAIN WATER WATER SEPARATOR
10. firmly secured to the posts Tighten the clamps if necessary Caution e Make sure to turn to OFF the Battery Isolator Switch before attempting to maintain the battery terminal 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 D Turn the Battery Isolator Switch to OFF INS CAP 2 Remove the clamp and cable from negative post POST on the battery Remove always negative side first BATTERY 3 Remove the hold down clamp from the battery ISOLATOR Remove the clamp and cable from positive post on the battery 5 Remove battery from seat HOLD DOWN CLAMP Reinstall a new battery in the reverse order Install always the cable to the positive post in the new battery first lt Caution gt Use the following battery 75D31R lt gt Danger Suffocation from exhaust fume Exhaust fume from the engine contains many elements harmful to human Do not operate this equipment in poorly ventilated area such as inside a room or in a tunnel Caution Suffocation from exhaust fume Do not point the exhaust fume toward pedestrians or building Caution Fire Temperature around muffler and exhaust can get extremely high Keep any inflammable items such as fuel gas paint etc away from t
11. high speed whenever welding operation or electric supply starts A Caution Damage to the equipment or other properties e Turn always the Idle Control Switch to HIGH when the load is incorporated with any magnet switch Caution When the load of less than 0 5A is connected to use the Auto Idle feature does not function sometimes Therefore turn the switch to HIGH When welding operation or electric supply performs alternately or intermittently turn the switch to HIGH 5 9 Emergency Stop Switch The Emergency Stop Switch is used to stop the engine in emergency By pushing the switch the engine stops Be sure to restore the Starter Switch to STOP and reset the Emergency Stop Switch turning clockwise after using the switch 5 10 Battery Isolator When turning the Battery Isolator Switch to OFF position the engine electric circuit does not get battery power OFF position ON position Caution Do notturn the Battery Isolator position while in operation it may cause the serious damage on the unit 14 Caution Fire Burns Injuries 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 UP
12. induction motor 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 When connecting to use 2 or more sets start the load one by one not to start them simultaneously e When switching a Mercury bulb ON again wait for 15 minutes about until it cools down 9 3 Operation Danger Electric Shock Before connecting or disconnecting a load cable from the receptacles always turn the circuit breakers Main 3 P 1 P to OFF position And always stop engine and remove the engine key A person performing the maintenance should always keep the key Ground the every grounding terminal to the earth as set out in the manual 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 7 Earth Leakage Relay 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 Grounding should be made after the engine is stopped Whenever the current leakage breaker activates you should repair the leaking place first of all 24 Caution Injuries sure to connect to output terminals or insert a plug to a receptacle after confirming that all the s
13. never turn the starter switch to START 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 DONO Turn the Starter Switch to STOP Fill the fuel Turn the Idle Control Switch to AUTO Turn the Starter Switch to START and drive the starter motor for about 10 seconds Release the Starter Switch as promptly as the engine started Wait for about 1 minute to vacuum the air out The engine speed becomes stable when the air is extracted lt Caution gt Never turn the engine HIGH speed or connect the loads until the air is extracted completely the engine speed becomes stable 7 2 Stopping 9 9 Turn Push down the breakers Main 3 P 1 P to OFF Turn the Idle Control Switch to AUTO Keep the engine idle cooling down for about 5 minutes Turn the Starter Switch to STOP After the engine has stopped turn the every Fuel Lever to CLOSE Turn the Battery Isolator Switch to OFF position Caution When the engine does not stop in spite of turning the Starter switch to STOP Turn the Fuel Lever on Fuel Strainer or Water Separator 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
14. suitable arc performance Stable Mild welding arc can be obtained with Arc Control Dial negative dial side and Strong Crisp welding arc can be obtained with Arc Control Dial dial side 4 ROD SELECTOR for CC mode The equipment incorporates Rod Selector feature When the CV CC Selector Switch is positioned at CC STICK GOUGING the welding characteristics can be switched by changing Rod Selector Switch CELLULOSE mode is suitable for the Cellulose Rods and OTHERS mode is suitable for the Gouging Rods and ordinal rods except cellulose 5 2 VRD equipment incorporates VRD Voltage Reduction Device feature for the purpose of protecting an operator from electric shock with welding current When the VRD Switch is turned to ON the voltage changes to 35V or lower during no welding period The equipment is incorporated in monitoring function of VRD When the VRD Switch is turned to ON Green VRD Lamp will be automatically turned on at BELOW 35V side When the Red VRD lamp will be turned on at AT OR ABOVE 35V side the welding voltage is exceeded more than 35V accidentally or while the VRD switch is at TEST mode VRD LAMP 5 3 Output Remote Control The equipment incorporates Output Remote Control feature 1 14 Pin Connector Wire Feeder Control Wire Feeder Control operation is available by connecting the Wire Feeder to the 14 Pin Connector 2 Weld Terminals Swit
15. ventilation also in order to prevent from inhaling the fume A Caution Injuries to eyes and skin 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 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 Dd Caution Explosion Do not use the equipment or charge the battery in the case the battery fluid level is lower than the LOWER level Battery may emit some combustible gas so keep it away from fire and sparks Caution Fire 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 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 obj
16. 5 7 8 7 1 15167 Li 4 S 57 167111 14 188 8 3 4 S 7 8 I3 17 14 1516 1820 iQ 1 4111 1 37 CNB CHF CNA PRINTED CIRCUIT MAIN CONTROLLER CNE des CHL 10 connector CHS 5 La 9 156 17 18 2 5 1 4 3611 1410131215 1 2 3455 7 8 9 5431 8101 POLARITY Or 6r Ts sf eT d WEL tier Be ta Gel Gr R 5 B Y U Y Bel 8r 8 5 R R W SWITCH 4 8 eR Y R Y R WIRE FEEDER v8 z ENGINE VOLT HETER 8 D NUES WIRING eb 2 eae ee L B 8 DIAGRAM BE a ee ee ae UN 42 E xS cepe sd DENN ee eee E ENG INE 2 1 WIRING WIRE FEEDER VOLT METER A PRINTED CIRCUIT CHYRISTOR CONTROLLER
17. ISO 9001 CERTIFIED OWNER S AND Table of Contents Page 1 Safety Guidelines 2 OPERATOR S MANUAL 2 Specifications 5 3 Use 5 4 Parts 6 5 Equipment 8 5 1 Welding Output Control 8 SOUND PROOF DIESEL 5 2 VRD 9 5 3 Output Remote Control 9 5 4 Operation Mode Selector 10 5 5 Meter 10 GENERATOR WELDER 5 6 Monitor Lamp 1 5 7 Earth Leakage Relay 13 5 8 Auto Idle Feature 14 DGW500DM 5 9 Emergency Stop Switch 14 14 5 10 Battery Isolator 6 Initialization and Pre check 15 6 1 Checking Engine Oil 15 Vertical Water Cooled 6 2 Checking Coolant Water 15 4 Cycle Diesel Engine 6 3 Checking Fuel 16 6 4 Checking Fuel Engine Oil 17 and Water Leakage 6 5 Checking Battery 17 7 Operation 18 7 1 Starting 18 7 2 Stopping 19 7 3 Stopping 19 8 Welding Operation 20 8 1 Selection Welding Cable 20 8 2 Polarity 20 8 3 Connection Welding Cable 21 8 4 Duty Cycle 22 8 5 Welding 22 9 Generator Operation 23 9 1 Output Range 23 9 2 Output Limitation 24 9 3 Operation 24 10 Simultaneous Use of Welding and 26 Generating 11 Checking and Maintenance 26 12 Long term Storage 31 13 Troubleshooting 32 13 1 Symptom and Countermeasures 32 13 2 Error Code Display 34 14 Wiring Diagram 35 15 Generator Wiring Diagram 36 CAUTION Do not operate the Generator Welder or any other appliance before you have read and understood the instructions for use DGW500DM ANZ X750803 3700 Introduct
18. LINE FLOAT RED lt Caution gt sure to check for any contaminants on the packing whenever reinstalling the cup Turn the fuel to OPEN after assembling and check for any leak Having confirmed no leak without fail turn the fuel lever to CLOSE 30 6 Drain Water from Fuel Tank Every 200 hours Unscrew the fuel drain plug 2 Reinstall the drain plug after draining water completely 222 lt Caution gt Change the packing whenever changing oil FUEL DRAIN PLUG Packing Part No 6 090 58961 Kubota 7 Changing Coolant Water Every 2 years or 2000 hours Total Coolant Water Capacity about 5 6 L including sub tank cap 0 8 L RADIATOR CAP RIGHT DOOR TOP PLATE ry zT 2 L1 ui Ld x To Ant i 12 1 3 ET CD Open the top plate 2 Remove the radiator cap 8 Loosen the water drain plug After draining all the water reinstall the water drain plug Caution Change the packing whenever changing oil 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 Close the top plate 69 9 Danger Electric Shock Before performing any equipment check or maintenance stop the engine and remove the engine key A person perfor
19. PER line through the oil inlet OIL INLET OIL PLUG OIL DRAIN PLUG lt Caution gt 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 Selecting proper engine oil 2 UPPER LEVEL lt Caution gt EFFECTIVE Use the API class CD or higher 22222 LOWER LEVEL 4 0L Viscosity and Temperature Temperature Over 20 C 10 20 10 40 Viscosity SAE30 5 20 5 10 30 6 2 Checking Coolant Water Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt 4 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 Caution Burns 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 345 RIGHT DOOR 1 Filling to the Reservoir Tank D Remove the sub tank cap Vs TN 2 Fill up the sub tank to the FULL level 3 Install the cap back 2
20. S 540505 55344 710 YILYM 4015 35 oj jaj 3 3 DIAGRAM 14P INCA 14PINCD IPINIA SPIN B CIRCUIT OUTPUT WORK 1 42V CIRCUIT OUTPUT WORK REMOTE REMOTE tc m TRIGGER CONTROL EARTH TRIGGER CONTROL EARTH CONTROLLER CONTROLLER EXG 9 eoo 000060 THYRISTOR MAIN orf Bef EE 40 Or 8 40 THYRISTOR VRD T Y in GIKI 63 i 5 th prm eco ix a e fe 515 Bri l2 Uu 8 y Yi 6 Or 872 Y MP GU j ory B 8 77 OUTPUT MAGUNET at WELD TERMINAL gt SWITCH CONNECTION e 0 6 3 REMOTELY 2 IE CONTROLLED
21. TERMINAL 36 7 2 SUEHIROCHO 1 TOKYO 198 8760 JAPAN PHONE 81 428 32 6118 FAX 81 428 32 6145 2009 YAMABIKO CORPORATION Printed in Japan
22. ce always stop the engine Do not operate the equipment if the equipment is being modified or if the parts are removed B 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 CD Suffocation from exhaust fume No 19402 00194 2 Suffocation from welding fume No 19402 00195 3 Electric shock No 19402 00193 4 Fire No 19402 00166 Injury No 19402 00199 Burns No 19402 00200 6 Injury No 19402 00207 S Burns No 19402 00201 2 Injury No 19402 00210 Burns No 19402 00256 Model DGW500DM Generating Method Rotating Field OPERATION SINGLE DUAL Rated Current A 480 23 Rated Voltage V 292 0 30 280 60 500 20 60 480 0 Gouging Rod 3 2 9 5 3 2 5 0 Rated Current A 480 230 CVMODE DuyOyde W 14 29 06 20 L MES Welding Generator N N Phase Phase ais 10 10 8 15 Lubrication Oil Volume 1 6 0 Effective 2 0 Starting Method 750318 63 Length mm 1680 Width mm 700 Height mm Dry Weight kg CC Power for Stick Welding CV Power for Wire Feeder Arc Gouging Power Source for Lights Electric Tools and Home Appliances Caution Damage to the equipment or other proper
23. ch Wire Feeder Control operation is available by turning the Weld Terminals Switch to REMOTE CONTROL When the Weld Terminals Switch to WELD TERMINALS ON the welding voltage is always supplied at machine s welding terminal When the Weld Terminals Switch to REMOTE CONTROL the welding voltage will be supplied at machine s welding terminal by pressing the wire feeder torch trigger 3 Wire Feeder Voltmeter Selector Selecting Wire Feeder Voltmeter Switch can be switched the voltmeter indication polarity which is equipped on the wire feeder unit 4 42V 115V Selector Selecting 42V 115V Selector Switch can be switching the supply voltage for the required output voltage based on the wire feeder specification lt Caution gt e 42V 115V Selector Switch is available only for A side Output Remote Control B side Output Remote Control is set as 42V only due to the regulation 9 5 Circuit Protector for Wire Feeder When the over current more than 5A is flown into 14 Pin Connector for wire feeder the Circuit Protector will be activated to shut off the current lt Caution gt Resolve the over current issue to proceed the necessary maintenance when the Circuit Protector was activated with reset the trip button 6 9 Pin Connector Remote Control Remote Control operation is available by connecting the compatible Remote Controller to the 9 Pin Connector You can adjust the welding current in CC condition or welding voltag
24. ch of the SINGLE DUAL CV CC Selector switch OUTPUT CONTROL DIAL SINGLE DUAL WELD TERMINALS SELECTOR SWITCH CV CC SELECTORS SWITCH E 42VA15V DIAL 9 L LEM SELECTOR SWITCH ROD SELECTOR SWITCH WIRE FEEDER VOLTMETER SWITCH 1 Welding Rod include Gouging Rod Turn the Weld Terminals Switch to WELD TERMINALS Turn the SINGLE DUAL Selector Switch to SINGLE or DUAL according to the operation Turn the CV CC Selector Switch to CC STICK GOUGING Turn the Rod Selector Switch to CELLLOSE on cellulose rod welding or to OTHERS on gouging or ordinal welding rods except cellulose rod Set the current amperage by the Output Control Dial Adjust the arc strike current by turning the Arc Control Dial 2 Semi Automatic Wire Feeder Weld Terminal While not using 14 Pin Connector Turn the Weld Terminals Switch to WELD TERMINALS Turn the SINGLE DUAL Selector Switch to SINGLE or DUAL according to the operation Turn the CV CC Selector Switch to CV WIRE Set the voltage by the Output Control Dial ee m Oo While using 14 Pin Connector Turn the 42V 115V Selector Switch to 42V or 115V according to the applicable Wire Feeder Connect the Wire Feeder plug into 14 Pin Connector Turn the Weld Terminals Switch to REMOTE CONTROL Synchronize the polarity of unit with Wire Feeder display by selecting Wire Feeder Voltmeter Sw
25. control panel Corrective Actions Possible Causes Error No Turn the Idle Control Switch to AUTO and cool down the unit with no load operation until OVERHEAT Monitor Lamp blinking will be stopped Stop the engine after the OVERHEAT Monitor Lamp blinking will be stopped then restart the engine E01 Alternator and or control parts Overheat OVER HEAT Monitor Lamp is also blinking gt lt Operate the unit properly based on the operation manual to avoid overload over duty cycle unclosed door and or intake exhaust clogging etc Shut off the engine immediately and resolve the malfunction components Control parts Malfunction X Consult your dealer for necessary inspection Shut off the engine immediately and confirm if there is short circuit on the welding output Start the engine after resolving the troubled area for recovery Welding output Short Circuit Shut off the engine immediately and resolve the malfunction components Incorrect Welding Mode Selector 3X Consult your dealer for necessary inspection Shut off the engine immediately and resolve the malfunction components Incorrect Operation Mode Selector 3 Consult your dealer for necessary inspection Digital Meter Error Code Displa Y f E T R OUTRUT ONTPUT 2
26. e in CV condition in the remote area from the machine 9 PIN CONNECTOR REMOTE CONTROLLER Compatible 5 4 OPERATION MODE SELECTOR The equipment incorporates Operation Mode Select feature Below three modes can be selected by the Operation Mode Selector Switch position GEN WELDER Both Welder and Generator mode WELDER ONLY Only welding function mode GEN ONLY Only generating function mode 5 5 Meter The equipment incorporates digital meters voltage amp amperage of welding output and also 3 Phase Voltage amp frequency of AC output 1 DC Ampere Meter Volt Meter Each meter displays welding voltage and amperage in Side A or Side B terminals When the SINGLE DUAL Selector Switch is positioned at SINGLE the meters do not display the amperage or the voltage in Side B terminals Caution While operating at no load if the CV CC Selector Switch is set as CV WIRE DC Volt Meter is indicating desired voltage by Output Control Dial There is no display at DC Ampere Meter while no load While operating at no load if the CV CC Selector Switch is set as CC STICK GOUGING DC Ampere Meter is indicating desired amperage by Output Control Dial There is no display at DC Volt Meter while no load During actual welding work both DC Volt Meter Ampere Meter displays actual output Both displays will be back to the pre set value after counting about 8seconds with blinking d
27. ects wall box etc 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 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 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 Do not open the side door during operation and immediately after stopping the equipment because some parts components flexible tube resistors etc can reach very high temperature inside the equipment Caution Injuries When lifting the equipment always use a lifting lug Do not lift the roping lug for it may cause equipment to drop due to roping lug breaking off When carrying the equipment by trucks fix it strongly to keep the equipment from sliding 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 Do not move the equipment during operation When performing equipment check and maintenan
28. firm the coupler for proper connected properly connection 2 Circuit protector is activated 2 Reset the circuit protector Unable to operate 3 Improper power input for the 3 Select the correct power input the wire feeder wire feeder 42 115 for designated wire properly feeder 4 CC mode is selected 4 Select the CV mode properly incorrectly Mode selector 1 Use of Welding or Generating 1 Stop using the machine load switch can not be and keep idling for selecting selected the switches The breaker MAIN or 3 P or 1 Turn to ON 1 P or ELCB positions to OFF No AC Output Operation Mode Selector 2 Turn to GEN WELDER or Switch is selected incorrectly as GEN ONLY WELDER ONLY The rated current of the load 1 Adjust according to AC Output is exceeds the rated output OUTPUT LIMITATION weak Use of Welding and 2 Stop Welding Generating Welding cables short circuit 1 Repair the short circuit Unable to activat IDEE The power consumption of the 2 Set the Idol Control to HIGH mode load is 0 5A or below mode Engine does not 1 Stop Solenoid malfunction 1 Turn the fuel lever to CLOSE stop to stop and repair Excessive Black 1 Overloaded use 1 Operate the machine within the smoke exhaust rated output from muffler d 33 13 2 Error Code Display Inspect the following items accordingly when the Error Code E01 E05 are displayed on the
29. he 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 Be sure to lock the wheels for the wheeled models Before starting the engine be sure to disconnect the loads and set the breakers Main 1 P 3 P to OFF position 7 1 Starting Turn the breakers Main 3 P 1 P to OFF Turn the every Fuel lever on Fuel Strainer and Water Separator to OPEN Turn the Battery Isolator Switch to ON Turn the Idle Control Switch to AUTO Ensure the Emergency Stop Switch is positioned to release MAIN BREAKER OO When the temperature is below 5 turn and keep the Starter switch to PREHEAT until the preheat lamp turns off about 5 seconds 7 the Starter Switch to START and then the engine starts by the starter motor Release the Starter Switch as soon as the engine has started 9 Keep the engine idle for about 5 minutes BATTERY ISOLATOR ON position EMERGENCY STOP STARTER FUEL WATER SWITCH SWITCH STRAINER SEPARATOR IDLE CONTROL SWITCH lt Caution gt Do not drive the starter motor for more than 15 seconds successively If you need to restart wait for 30 seconds or more before retry Once the engine has started
30. id sustaining burns from hot vapor Caution Burns 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 6 2 Checking coolant water 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 11 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 engineering section lt Caution gt The battery charge monitor cannot detect the degradation of the battery nor the battery fluid level Check the battery fluid level periodically Refer to 6 5 Checking Battery 3 Oil Pressure Monitor Lamp Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt A Caution Burns Do touch the engine and muffler during operation and immediately after stopping the equipment for the temperature can reach extremel
31. ing lamp is blinking equipment cools down the lamp 4 Malfunction of the Operation to OFF Mode Selector Switch 4 Repair 32 Symptoms Possible Cause Corrective Actions 1 SINGLE DUAL Selector Switch 1 Turn to SINGLE mode position is incorrectly selected to DUAL mode 2 Wrong Output Control Dial position 3 Arc Control Dial is set to negative side for CC mode 4 Improper connection of cables 5 Improper Cable Diameter 2 Turn the dial clockwise 3 Turn the Arc Control Dial clockwise to positive side 4 Connect securely 5 Replace the cables based on the Welding Cable Selection 6 Connect securely Welding Arc is weak Improper connection to the base material 7 Simultaneous Use of Welding and Generating Engine output is down SINGLE DUAL Selector Switch is to SINGLE mode 2 Wrong Output Control Dial position 3 Arc Control Dial is set to positive side for CC mode 4 CV CC Selector Switch is selected for CC Mode Unable to weld 1 OTHERS mode is selected 1 Select CELLULOSE mode the Cellulose rods for rod selection 7 Stop using AC Power output Keep duty cycle Turn to DUAL mode Turn the dial counterclockwise Excessive Welding Arc 3 Turn the dial counterclockwise to negative side 4 Turn to CC mode 1 Wire feeder coupler is not 1 Con
32. ion Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator Welder This user manual was created to ensure the safe operation of this equipment Therefore the manufacturer of this equipment strongly recommends that the user follow the instructions herein to avoid unnecessary accidents and repairs Please operate this equipment after thoroughly reviewing and understanding the contents of this manual Please attach this manual if the equipment will be sub leased Please store this manual near the equipment for easy reference Following convention will be used throughout the manual to indicate the degree of cautions Can cause serious injuries or death Can cause minor injuries or damage to the equipment A Caution other properties Other types of caution Even some of the items noted in Caution may lead to serious injuries Please read all item and follow all the safety guidelines 4 Danger Suffocation from exhaust fume e 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 Close all doors and place locks during operation Do not touch the output terminals during operation 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
33. itch Turn the SINGLE DUAL Selector Switch to SINGLE or DUAL according to the operation Turn the CV CC Selector Switch to CV WIRE Set the voltage by the Output Control Dial lt Caution gt The wire feeder will not work properly if the 42V 115V Selector Switch is selected incorrectly compare to the wire feeder rated voltage 9 1 Output Range 1 3 Phase 415V Output Receptacle Maximum output from the receptacle is 15KVA 3 P RECEPTACLE 2 1 Phase 240V Output Receptacles Phase 240V Output is available through 3 receptacle sets Maximum output is 10 8kVA for 3 receptacle sets 1 P RECEPTACLE Dg 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 Load For reference purpose only kW T 1 WEM UN 3 Phase NEL MM V 415 V Receptacle Receptacle Electric Bulb Heater etc _ ERE E Series Motor High Power Factor Type Compressor etc Induction Motor 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 Be sure to use the frequency designated in the equipment incorporated in mercury bulb or
34. l 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 e Always use the fuel strainer Fill the fuel tank slightly less than the FULL tank FUEL STRAINER TANK CAP 4 FUEL COVER FUEL INLET 5465 6 4 Checking Fuel Engine Oil and Water Leakage Caution Fire Do not use this equipment when a leak is found Repair the equipment before use Be sure to check 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 Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or clothing e acid comes to contact especially with eyes flush with a lot of water and contact your physician immediately A Caution Explosion Do not use the equipment or charge the battery in the case the battery fluid level is lower than the LOWER level e Battery may emit some combustible gas so keep it away from fire and sparks Caution Fire e Battery may emit some combustible gas so keep it away from fire and sparks D Check the fluid level If the level is near or lower TERMINAL than LOWER level add distilled water until the fluid level reaches UPPER level 2 Make sure that the battery cables are
35. le to a crimping terminal welding rod holder Wire Feeder and a material holder 3 After connecting cables be sure to close output terminal covers 1 Welding Rod Gouging Rod WELDING ROD HOLDER or GOUGING TORCH CRIMPING MATERIAL HOLDER TERMINAL 2 Semi automatic Wire Feeder WIRE FEEDER CRIMPING TERMINAL MATERIAL 2 Semi automatic Wire Feeder 1 Welding Rod Gouging Rod Dual Single Dual Wening Rog Welding Wire Welding Wire 2 6 8 0 2 0 6 0 MIG MAG 0 6 1 6 MIG MAG 0 6 1 2 Gouging Rod Self Shield 0 9 4 2 4 Self Shield 0 9 2 0 Gouging Rod 3 2 9 5 3 2 5 0 Welding Terminal Welding Terminal A A amp B A A amp B lt Caution gt 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 e Do notuse 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 21 8 4 Duty Cycle Duty cycle is the percentage of time the load is being applied in a 10 minutes period For example a 60 duty cycle rep
36. line 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 Symptoms Possible Cause Corrective Actions Battery Isolator Lever is OFF 1 Turn Battery Isolator Lever to Starter motor does position ON position not start Weak Battery Recharge Battery Dead Battery Replace Battery 1 Fuel lever on fuel strainer or 1 Open the fuel lever for both water separator to CLOSE fuel strainer and water separator 2 Insufficient Fuel 2 Replenish fuel 3 Emergency Stop Switch keeps 3 Release the Emergency Stop Switch 4 Fuse burnt Repair the fuse gt 5 Fuel is contaminated by the Drain water or clean fuel tank water or dust fuel strainer and fuel separator 6 Fuel pump malfunction 6 Repair the fuel pump 1 Insufficient oil 1 Replenish oil Engine starts but 2 High Water Temperature 2 Replenish coolant water stalls immediately Insufficient coolant water 3 Unable to charge 3 Repair 1 Weld Terminals Switch is 1 Turn to WELD TERMINALS ON selected incorrectly as for either terminal A or B directly REMOTE CONTROL 2 Operation Mode Selector 2 Turn to WELDER ONLY or Switch is selected incorrectly as GEN WELDER for welding No Welang IGEN ONLY function 3 Exceeding Duty Cycle 3 Stop the operation until the The warn
37. ming the maintenance should always keep the key Caution Injuries Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key Caution Fire Burns When checking engine always stop the engine and keep far away from fire 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 D Remove the battery 5 Change the engine 9 Drain fuel from the fuel tank the Fuel Strainer and the Water Separator Clean all parts cover the generator welder and keep it in the storage away from dust and humidity lt Caution gt Recharge the removed battery once a month Danger Electric Shock Do not operate the equipment if the equipment or you are wet Before performing any equipment check or maintenance stop the engine Caution Injuries When performing equipment check and maintenance always stop the engine Caution Fire Burns When checking engine always stop the engine and keep away from fire Temperature around engine muffler and exhaust can get extremely high Wait until the engine cools down before performing any checks 13 1 Symptom and Countermeasures Follow the guide
38. ot on the DC Volt meter 10 2 AC Meter The meter displays the 3 Phase voltage U V and the frequency AC output lt Caution gt While Operation Mode Selector Switch is GEN WELDER or GEN ONLY AC Meter displays 3 Phase voltage and frequency When the Operation Mode Selector Switch is WELDER ONLY AC Meter display will goes off 5 6 Monitor Lamp The equipment is incorporated in monitoring function of WATER TEMP BATTERY CHARGING OIL PRESSURE OVERHEAT WATER TEMP OIL PRESSURE BATTERY CHARGE OVERHEAT Under normal condition when the starter switch changes from STOP to RUN all the lamps of BATTERY CHARGING OIL PRESSURE and OVERHEAT turn ON When the engine starts all the lamps turn OFF When abnormality is detected on other than 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 Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Danger Burns Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avo
39. rain plug Checking the oil level by the oil level gauge add oil into the oil filler to fill up to the max level about 6 0L 5 Reinstall the oil plug hand tight lt Caution gt Referto 6 1 Checking Engine Oil to select engine oil Change the packing whenever changing oil Packing No 6C090 58961 Kubota 28 2 Oil Filter Change 274 or after Every 200 hours GASKET Drain the engine oil completely as described 11 1 Oil Change Loosen and remove the oil filter using an oil filter wrench Smear a little engine oil on the rubber gasket of a new filter 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 AONO lt Caution gt e If an ail filter wrench is not available contact our authorized distributor or our engineering section Oil Filter Part No 16271 32093 Kubota 3 Clean Change Air Filter Element Clean 1 50 hours and Every 100 hours afterwards AIR CLEANER THREE CLIPS AIR CLEANER ELEMENT D Disconnect the Air Cleaner Cap by releasing the three clips 2 Remove the air element 3 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
40. resents 6 minutes of load and 4 minutes of no load in a 10 minutes period lt Caution gt The equipment may be damaged due to overheat if welding more than duty cycle 8 5 Welding A Caution Suffocation from welding fume 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 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 Caution i Keep any inflammable items and easily burning items away from the place in welding because welding splashes spatters Caution Burns 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 Make sure to turn the Operation Mode Selector Switch to GEN WELDER or WELDER ONLY There would be no welding output while the Operation Mode Selector Switch is at GEN ONLY position 2 persons can weld simultaneously Each person can adjust the welding output individually The output adjustable range by the Output Control Dial depends on the position ea
41. rth Leakage Relay 4 Danger Electric Shock Ground every grounding terminal to the earth as set out 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 Even though all the terminals of the loads have been grounded to the earth the bonnet canopy grounding terminal should be grounded to the earth Grounding should be made after the engine is stopped 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 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 The specifications of the earth leakage relay Rated Sensitive Current 30mA or below Grounding resistance 5000 below 1 Grounding Work The qualified electrician should perform the grounding work of the following 2 points 500Q or below The Outer Bonnet of this equipment bonnet grounding terminal The Outer Bonnet of the load BONNET GROUNDING TERMINAL GROUNDING ROD Caution Inthe event you cannot ground the generator to the earth consult with the authorized distributor or our engineering
42. section 2 Operation Check Before operating the equipment check always if the TEST BUTTON device can work duly as shown in the following procedure D Start engine after turning the Idle Control Switch to HIGH Turn Push up the ELCB lever to ON position Li 3 Push the test button The device is found to be normal when the ELCB lever turns to OFF B Inthe 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 13 3 Earth Leakage Relay has activated Caution Electric Shock Injuries 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 ELCB lever turns to OFF In the case stop the engine promptly and find the leakage point to repair After repairing leakage point s return push up the ELCB lever to ON 5 8 Auto Idle Feature The Auto Idle 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 Auto Idle feature turn the Idle Control Switch to AUTO By the condition the engine automatically moves to
43. t incorporates CV Constant Voltage and CC Constant Current characteristic feature Connecting a wire feeder and then turning the CC CV Selector Switch to CV WIRE semi automatic welding such as MIG MAG SS etc is available to perform Connecting the welding cables and then turning the CV CC Selector Switch to CC STICK GOUGING stick welding or arc gouging is available to perform When the CV CC Selector Switch is positioned at CV WIRE the current from the terminals becomes Constant Voltage Characteristic Therefore you have to adjust voltage by the Output Control Dial When the CV CC Selector Switch is positioned at CC STICK GOUGING the current from the terminals is Constant Current Characteristic Therefore you have to adjust current by Output Control Dial 2 Welding Output Pre Set The equipment incorporates Welding Output Pre Set feature When the CV CC Selector Switch is positioned at CV WIRE CV Output voltage can be Pre Set by the Output Control Dial When the CV CC Selector Switch is positioned at CC STICK GOUGING CC Output current can be Pre Set by the Output Control Dial lt Caution gt The applicable remote controller with 9 Pin Connector has an Output control dial which can be adjusted the output current in the remote area prior to the dial on the machine 3 ARC CONTROL for CC mode The equipment incorporates Arc Control feature Arc Control can be adjusted by turning the Arc Control Dial for
44. the hour meter as a guide for the operating time Checking Time Startup 100 200 400 1000 2000 hrs hrs hrs hrs hrs Checking Items Check and Supply Fuel 2 Check Supply Engine Oil At 50hrs 2 or 3 Engine Oil Change after O x 2 O e Oil Filter Change 214 or after 5 Check Add Water Coolant or Water Coolant Change one year 154 2 or 7 Clean Fuel Strainer 8 Change Fuel Filter O Check Water Separator Drain Water Clean _ Water Separator O Drain Water Clean Fuel 11 O Check Leakage Fuel Water O ARDO 27 Checking Time Checking Items Startup Every Every Every Check At 100 50hrs hrs 13 Check Add Battery Water Clean Air Element Change Air Element 16 Adjust Tension V Belt Change V Belt Clean Radiator Fin 19 Clean Radiator inside Change Fuel Hose 20 Oil Hose Vibration Absorbing Rubber Adjust Engine Valve Clearance Check Adjust Injection Nozzle 21 22 23 Check Adjust Injection Pump 1 Oil Change OIL INLET 274 or after Every 100 hours Remove the oil plug 2 Loosen the oil drain plug and allow neni to PLUG 9 Reinstall the oil d
45. ties 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 CONTROL PANEL WELDING TERMINAL A WELDING TERMINAL B AC METER DC METER VRD LAMP OPERATION MODE SELECTOR SWITCH 1 0 BETA OUTPUT CONTROL DIAL STOP SWITCH SINGLE DUAL ROD SELECTOR SELECTOR SWITCH SWITCH CV CC SELECTOR SWITCH ARC CONTROL DIAL IDLE CONTROL HOUR METER SRL STARTER SWITCH MONITOR LAMP VRD SWITCH FUEL METER WELD TERMINALS SWITCH WIRE FEEDER 1 VOLTMETER SWITCH 42V 115V SELECTOR CIRCUIT PROTECTOR SWITCH FOR WIRE FEEDER 3 P RECEPTACLE 1 P RECEPTACLE MAIN BREAKER EARTH LEAKAGE CIRCUIT BREAKER ELCB BONNET GROUNDING TERMINAL HOLES FOR THE FORKLIFT RIGHT DOOR AIR CLEANER nem ous ISOLATOR Bie SUB TANK A 60 20 FUEL INLET BATTERY FUEL COVER OIL GAUGE FUEL LEVER WATER SEPARATOR FUEL LEVER OIL FILTER FUEL STRAINER FUELDRAINPLUG OIL DRAIN PLUG WATER DRAIN PLUG LIFTING LUG MUFFLER ERR EXHAUST PORT EE TOP PLATE ROPING LUG 5 1 Welding Output Control 1 CV CC The equipmen
46. welding capacity is to reduce Size of Cable Unit mm m Return Length 20 30m 40m 60m 80m 100m Welding Current 500A 38 60 125 200 450A 38 60 80 350A 30 50 60 300A 38 50 250A 30 38 200A 22 30 30 150A 22 22 22 100A 22 22 22 30 30 38 8 2 Polarity There are two welding output terminals and 1 1 Select the polarity according to the operation referring to the table below Caution Follow the instruction of the welding rods the polarity of which is specified O02 1 Welding Rod include Gouging Rod 250000 Application Generals Welding such as Plus to the Earth Material Construction Minus to holder Rod Thin Plate Build Up Welding Plus to holder Rod Stainless Steel Gouging Minus to the Earth Material 2 Semi automatic wire feeder eee Application Self shield Weld Plus to the Earth Material Normal Polarity Small Diameter Minus to Torch Wire MIG MAG Welding Plus to Torch Wire Reverse Polarity cir Shield Big Diameter Minus to the Earth Material 8 3 Connection Welding Cable Danger Electric Shock 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 D Stop the engine 2 Connect a welding cab
47. witches in the loads are positioned to OFF Caution Damage to the property Aftermath Whenever connecting to use medical equipment or appliances be sure to consult with the medical equipment company doctor or hospital personnel Caution Turn the Operation Mode Selector Switch to WELDER or GEN ONLY while selecting AC generator output The AC output is not supplied when the Operation Mode Selector Switch is WELDER ONLY mode The AC Volt meter reads 3 P output voltage apart from the circuit breakers Main 3 P 1 P positions to ON or OFF when the engine is driving After the engine starts Refer to 7 1 Starting operate the equipment as per the following procedures D Turn the power switch to OFF in the load 2 Turn the breakers Main 3 P 1 P to OFF 3 Connect the load to the output receptacles the breakers Main 3 P 1 to ON Ensure the ELCB lever to be positioned at ON MAIN BREAKER ELCB 1 P BREAKER 3 P BREAKER Circuit Breaker has activated due to overload Caution Injuries 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
48. y high 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 engine oil pressure monitor cannot detect the degradation of engine oil itself Please check the engine oil periodically and change if needed Refer 111 Checking and Maintenance 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 Overheat Monitor Lamp OVERHEAT monitor lamp may flash in the case the machine is used excessively over the duty cycle or over load When the OVERHEAT monitor lamp is blinking this equipment cuts the out put off When this overheat occurs there may be a possibility of overloading Always use the equipment within the rated duty cycle and output power Caution There may be a case that the lamp will not flash depending on the welding type or the weather condition 12 5 7 Ea
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