Shindaiwa DGW311DM User's Manual
Contents
1. Model DGW311DM DGW311L W 220B W 220B W 380A W 400A Generating Method Brushless Rotating Field Synchronous AC Generator Rated Current 280 260 Rated Voltage V 31 2 30 4 Duty Cycle 96 50 Rated Speed min 3600 3000 5 No Load Voltage MAX 85 5 Current Adj Range A ECO 30 160 5 3 2 0 4 0 o S Welding Rod Current Adj Range A Single 85 310 45 310 35 280 2 Welding Rod 2660 2 0 6 0 2 0 6 0 Current Adj Range A Dual 45 160 Welding Rod 2 0 4 0 Phase 3 Phase 1 Phase Rated Voltage V 220 110 380 220 400 230 415 240 3 Frequency Hz 60 50 5 Rated Output kVA 3 Phase 10 2 1 Phase 6 8 Rated Speed min 3600 3000 Power Factor 3 Phase 0 8 1 Phase 1 0 Rating Continuous Model Yanmar 3TNE68 USW2 Type Vertical Water cooled 4 Cycle Diesel Engine Displacement L 0 784 Rated Output KW PS min 15 1 20 5 3600 12 9 17 5 3000 5 Fuel Diesel Fuel ASTM No 2 D or Equivalent 2 Lubricant Oil API Class CD or Higher Lubrication Oil Volume L 3 5 Cooling Water Volume L 3 1 Starting Method Starter Motor Battery 46B24L Fuel Tank Capacity L 37 Length mm 1428 Bonnet Length 1293 Width 700 Height mm 760 870 with wheels Dry Weight kg 370 380 with wheels 3 Use Arc Welding Power Source for Electric Tool2. ts ie als Gye iR TATE h th 43111938 gt oo ao oe e 8 8 po 40151538 40151634 a WNIWUJI Indi no 59712 40151538 3 d ug um 301 INOW 91043105 anao ce H OWoss VH ET a Hliva g DIL BE IE YZ HOLIAS NHOQ MO 1S av I 32 ITI TE 71 YSTIONLNOD U3MOd 5 i 5 Sg s 274 Wid 88 8 t iN3MiSsnrav er i Lh B 1N3H8NI A zm Ceo 3 WEZ OR B 8 t ANALNO 3svHd l n BSVHd E ae 1 8 E HER 5 4 NN 8739 qr EHI awina 339134 170A 1084170 011 ASVHd 1 Ya a 31T0Y1d323u 3SVHd t y 1534 WNIWU3L Tt zH09 M W0 L LEM9Q 31 YOLSTYAHL 530105 3818 3 331511934 HOLINOH dl 01043705 ag Tees O NMOQ MO IS HOLINS z NMOGQ MO 15 2120 299 83711081802 U3MOd Zz z z8 b Wid Sm 30 ove 579 578 119 inawisnray 1 1NdiNO 1 3GVHd E O TVNI NYAL 114100 1 indino 331311984 Em 8 3 10v1d
3. Caution 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 5 2 2 Battery Charge Monitor Lamp When the battery is unable to be charged during operation the battery charge monitor lamp will flash and the automatic shutoff will be engaged In the event it will happen consult with the au thorized distributor or our engineering section Caution e The battery charge monitor cannot detect the degradation of battery life nor the battery fluid 8 level Check the battery fluid level periodically Refer to No 6 5 Checking Battery 5 2 3 Coolant Water Temperature Monitor Lamp Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by uninten tionally touching cooling fan and fan belt Danger Burns e Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor A Caution Burns e Do not touch the engine 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 c
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5. the table shown below The welding capacity is reduced if the small gauge cable is used lt Caution gt e Welding cables should be used unstrained e When the welding cables are used in swirl the welding capacity is reduced 16 Size of Cable Unit mm Welding Cur Return Length 20m 30m 40m 60m 80m 100m rent 300A 30 38 50 80 100 125 250A 22 30 38 60 80 100 200A 22 30 30 50 60 80 150A 22 22 22 38 50 60 100A 22 22 22 30 30 38 8 2 Polarity There are two kinds of welding output terminals and Select the polarity according to the operation referring to the table below Caution e Follow the instruction of the welding rods the polarity of which is specified Application Connection Normal Polarity General Welding Plus to the Earth Material such as construction Minus to holder Rod Reverse Polarity Thin Plate Build up Plus to holder Rod Welding Stainless Minus to the Earth Material Steel 8 3 Connection Welding Cable Danger Electric Shock e 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 Stop the engine Connect a welding cable to a crimping terminal and a welding rod holder and connect the other cable to a crimping terminal and a material holder Connect the w
6. 11 3 Cleaning Changing Air Filter Element Clean Every 200 hours Replace Every 400 hours Unfasten clips in the cleaner cap and remove the air AIR CLEANER cleaner cap Unscrew the wing bolt and remove the air filter ele ment Clean or replace the air filter element and reinstall it in reverse order lt Caution gt e Clean more frequently if used in dusty environment e Air Filter Element No 121465 12510 Yanmar B How to clean air filter element CLEANER If the element has dried contaminants It may be cleaned by blowing compressed air from the inside If the element has carbon or oil gt It should be replaced to a new one 11 4 Cleaning Changing Fuel Filter Clean Every 200 hours Replace Every 400 hours Turn the fuel line valve lever to CLOSE Q Unscrew the retaining ring by turning counterclockwise and remove the cup and fuel filter element Discard any dust or water inside the cup and clean the filter element by blowing compressed air or replace if necessary When you replace the filter element be sure to replace a o ring 26 as well Reassemble it back lt Caution gt Be sure to check for any contaminants on the packing whenever reinstalling the cup e Turn the fuel line valve lever OPEN after assembling and check for any leak Confirming no lea
7. 2 Replace Battery Engine does not start 1 Fuel lever to CLOSE 1 Fuel lever to OPEN 2 Insufficient Fuel 2 Replenish fuel 3 Drain water or clean fuel tank 3 Water or contaminants in fuel fuel filter and water sediments Engine starts but stalls imme 1 Insufficient oil 1 Replenish oil diately 2 Insufficient coolant water 2 Replenish coolant water Welding Arc is weak 1 Output selector switch is to 1 Turn to SINGLE or RATED or DUALI SPEED 2 Wrong current adjustment dial set 2 Turn the dial clockwise ting 3 Poor contacts of cables 3 Connect securely 4 Improper Cable Diameter 4 Change cables according to Selection Welding Cable 5 Insufficient connection to material 5 Connect securely 6 Dual Use 6 Stop using AC Power 7 Engine output is down 7 Keep 50 duty cycle Excessive Welding Arc 1 Output selector switch is to 1 Turn to ECOD or SINGLE or RATED OUTPUTT 2 Wrong current adjustment dial po 2 Turn the dial counterclockwise sition 28 No AC output 1 Circuit breaker is to OFFO 2 Output selector switch is tol ECO 1 Turn to OND 2 Turn to SINGLE or DUALO AC Output is Weak 1 The power consumption of the load exceeds the rated output 2 Dual Use 1 Adjust according to OUTPUT LIMITATION 2 Stop welding Slow Down does not activate 1 Short circuit of welding cable 2 Th
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9. Before performing any equipment check or maintenance stop the engine and remove the engine key A person performing the check or 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 Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Caution Suffocation from exhaust fume e Do not point the exhaust fume toward pedestrians or building A Caution Suffocation from welding fume 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 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 e 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 to your physician immediately A Caution Electric shock Do not flush water onto the equipment nor operate it in the rain A Caution Explosion When the liquid level is below the LOWER level never use the equipment n
10. ING TERMINAL HOUR METER 3 PHASE 1 PHASE OUTPUT TERMINAL U V W O BONNET GROUNDING TERMINAL WELDING OUTPUT TERMINAL DGW311DM DGW311L El SIDE DOOR FUSE AIR CLEANER __ RADIATOR OIL PLUG 4 s ENGINE OIL FILLER BATTERY le GAUGE et RESERVOIR TANK FUEL LEVER STRAINER 7 A P OIL FILTER OIL DRAIN PLUG WATER COOLANT DRAIN PLUG FUEL DRAIN PLUG FUEL INLET LIFTING LUG MUFFLER HANDLE 177 HANDLE EXHAUST OUTLET TOP PLATE 5 Equipment 5 1 ECO Welding DGW311DM only 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 4 0mmq welding rod at the Slow Down speed lt Caution gt When welding is performed do not turn the output selector switch which causes the burnout of the switch e is designed for welding only The circuit breaker trips when ECO is used for AC power supply 5 2 Monitor Lamp The equipment is equipped with monitoring function of oil pressure battery charge and water coolant Temperature When it is started by the starter switch from STOP to RU
11. ISO 9001 CERTIFIED OMERS AND CPERATCRS MANUAL SOUND PROOF ESEL ENG GENERATOR WELLER UD UU 000000 Water cooled 4 Cycle Diesel Engine Table of Contents Safety Guidelines Specifications Use Parts Equipment 5 1 ECO Welding DGW311DM only 5 2 Monitor Lamp 5 3 Earth Leakage Breaker 5 4 Slow Down Initialization and Pre check 6 1 Checking Engine Oil 6 2 Checking Coolant Water 6 3 Checking Fuel 6 4 Checking Fuel Engine Oil and water Leakage 6 5 Checking Battery Operation 7 1 Initializing Preparation 7 2 Stopping Generator Welder Welding Operation 8 1 Selection Welding Cable 8 2 Polarity 8 3 Connection Welding Cable 8 4 Duty Cycle 8 5 Welding Generator Operation 9 1 Output Range 9 2 Output Limitation 9 3 Operation Simultaneous Use of Welding and Generating Checking and Maintenance Long term Storage Troubleshooting Engine Wiring Diagram Generator Wiring Diagram Do not operate the Generator V l der or any other appli ance bef ore you have read and understood the i nstructi ons for use Shindaiwa Kogyo Co Introduction 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 instru
12. N D 5 PRESSURE MONITOR LAMP under normal condition Oil Pressure and Battery lamps will EON RIN Ji TEE COOLANT WATER TEMPERATURE flash and then the lamps will go off immediately after the MONITOR LAMP eee engine starts When abnormality is detected either in water temperature or in oil pressure the corresponding monitor lamp will flash and the automatic shutoff shall be engaged to the engine When the automatic shutoff is engaged turn the starter switch to STOP position and then restart the engine In the event the automatic shutoff is engaged next time check all parts of the corresponding alarm 5 2 1 Oil Pressure Monitor Lamp Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by uninten tionally touching cooling fan and fan belt A Caution Burns e Do not touch the engine muffler during operation and immediately after stopping the equipment for the temperature can reach extremely 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
13. aution gt gt Use soft water such as tap water Ba e lf the ambient temperature is near freezing use Long AN Life Coolant LLC 80 mixture LLC is filled when Se shipped from factory E e Mixture ratio of the coolant should be between 30 to 4596 depending on the outside temperature Er p Use the same LLC in identical mixture ratio to the res ervoir tank ED N TANK e Replace LLC at every year or 1000 hours Mixture Ratio for reference only C Lowest Ambient 15 C 20 C 30 C Temperature Mixture Ratio 30 35 45 6 3 Checking Fuel A Caution Fire e Always wipe any drip of fuel Do not use this equipment when a leak is found Repair the equipment before use Check for the fuel level in the tank Add if necessary Caution 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 or No 2 D Diesel fuel However for better economy use No 2 D Die sel Fuel whenever possible At the temperature less than 7 C 20F No 2 D fuel may pose operating problems see Cold Weather Operation which follows At colder tem peratures use No 1 D fuel if available or use a winter ized No 2 D a blend of No 1 D and No 2 D e TANK CAP FUEL INTAKE FUEL STRAIN NET This blended fuel is usually called No 2 D also but can be used in colder temperature
14. ctions 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 M Following convention will be used throughout the manual to indicate the degree of cautions Danger Can cause severe injuries or death A Caution Can cause minor injuries or damage to the equipment or other prop erties lt Caution gt Other types of caution Even some of the items noted in Caution may lead to severe injuries Please read all items and follow all the safety guidelines 1 Safety Guidelines 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 e Do not touch the output terminals during operation e 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 Before connecting or disconnecting a welding cable from output terminals stop the engine and remove the engine key
15. ding 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 Turn the circuit breaker to OFF position Turn the fuel lever to OPEN Turn the Slow Down switch to ON When the temperature is below 5 C turn the starter switch to PREHEAT The preheating lamp flashes 15 seconds The lamp comes off when the PREHEAT fin ishes Turn the starter switch to START to start the engine by the starter motor lt Caution gt FUEL LEVER e 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 Release the starter switch as soon as the engine is started lt Caution gt e Once the engine is started do not turn the starter switch to START Make sure the frequency to the monitor on the control panel Keep the engine idle for about 5 minutes DGW311DM CIRCUIT BREAKER Qo db SWITCH STARTER SWITCH PREHEAT 15 DGW311L CIRCUIT BREAKER STARTER SWITCH SLOW DOWN SWITCH PREHEAT LAMP Restart after stopping due to fuel shortage This equipment is equipped with automatic air vacuuming feature Therefore even though the engine stops due to running out of fuel you can restart the engine easily by the fol
16. djust 16 Check Adjust Injection Nozzle e 17 Check Adjust Injection Pump e 11 1 Oil Change First Time 50 hour mark 2 or after Every 200 hours Remove the oil plug Reinstall the oil drain plug e into the oil filler to fill up to the max level 3 5 liter Max Reinstall the oil plug hand tight lt Caution gt Loosen the oil drain plug and allow the oil to drain fully Checking the oil level by the oil level gauge add oil EA OIL PLUG YELLOW OIL DRAIN PLUG Bi e Referto 6 1 Checking Engine Oil to select engine oil 11 2 Oil Filter Change First Time 50 hour mark 274 or after Every 200 hours Drain the engine oil fully as describe 11 1 Oil 25 Loosen and remove the oil filter using an oil filter wrench EE za SA IL GAUGE YELLOW Smear a little engine oil on the rubber gasket of a new OIL FILTER filter Screw the new filter into place and tighten it by hand until the gasket contact the seat Then give it additional jo 1 1 4 to seat the filter using an filter wrench GASKET Supply oil and install the filler cap lt Caution gt e f an oil filter wrench is not available contact our au thorized distributor or our engineering section e Oil Filter Part No 119305 35151 Yanmar
17. e Range Selector Position Current Adjustable Range Welding Rod Single ECO 30 160A 2 0 4 0 Single Use 85 310A 2 6 6 0 Dual Dual Use 45 160A 2 0 4 0 After the engine is started Refer to No 7 1 Initializing Preparation operate as per the proce dures in the following table CURRENT ADJUSTMENT CURRENT ADJUSTMENT DIALA DIAL B fa pe e qp OUTPUT SELECTOR SCH WELDING OUTPUT WELDING OUTPUT TERMINAL TERMINAL A Welding Operation Procedure Procedure Operation ECO Single Single Welding Dual Welding Welding Rod Welding Rod Welding Rod 2 0 4 0 2 6 6 0 2 0 4 0 Selector ECO O SINGLE 0 DUALO Current Current Adjust Current Adjust Current Adjust Adjustment Dial Dial DialA B 8 5 2 DGW311L Start the engine Refer to No 7 1 Initializing Preparation Q Adjust the current by the current adjustment dial Welding Current Adjustable Range BEEN Current Adjustable Range ES 50Hz 60Hz Welding Rod 35 280A 45 310A 2 0 6 0 oo 9 Generator Operation 9 1 Output Range 9 1 1 DGW311DM W 220B DGW311L W 220B 9 1 1 1 3 Phase 220V Output Terminals Maximum ou
18. e power consumption of the load is 0 5A or below 1 Repair the short circuit 2 Turn the Slow Down switch to OFFO Engine does not stop 1 Stop Solenoid disorder 1 Turn the fuel lever to CLOSE to stop and repair Black and white smoke exhaust from muffler successively 1 Overloaded use 1 Keep the duty cycle 2 Adjust according to OUTPUT LIMITATION 29 14 Engine Wiring Diagram Ad3LLv8 UJMOd HOLIKS m 9NIINVIS i en 2 3 7 r l HO IMS i i A HAMAS rags NMOG HO7S d a gt 8 8 HOLINS 7 UNOH 318915 9 IF a z A 30010 Ex Mid uw m z 5 x w m gt lt FE LIT i AL34VS L PIS T d ua 2 BE EH 9NIOuYH2 D 9155344 110 to ve us mE 7 up rym aza 479 AYT38 1 ia 0314189 css p 1 7 wait HOLIAS HOLIMS 710 dW3l UJLYM CTT TS IWS SETA Mii a sot 30 15 Generator Wiring Diagram
19. e the switch to STOP lt Caution gt Inthe event you cannot complete every step of the above procedure to the end the device is out of order Consult with our authorized distributor or our engineering section to repair 10 When the engine is to start there may be a case that the engine will not start unless the starter switch is restored to STOP once 5 3 3 The Earth Leakage Breaker has activated When the earth leakage breaker has activated the earth leakage indication lamp turns ON and the breaker lever trips to the middle of ON and OFF positions 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 Push the reset button or stop the engine Q Restore push down the breaker lever to OFF position By the above procedures you can reset the breaker to ON position Caution When the breaker trips to the middle but the lamp does not turn RED simultaneously the cause is Over loaded or the output selector switch is positioned to ECO Restore as per the procedures No 9 3 Operation 5 4 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 welding operation or electric supply is not performed In the case of using the Slow Down feature turn the Slow Down switch to ON The engine automatically moves to h
20. e welding splashes spatters A Caution Injuries 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 po sition 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 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 Suffocation from exhaust fume Suffocation from welding fume Electric shock Electric shock Injuries Burns Burns Fire DGW311DM DGW311L W 220B No 19402 00194 No 19402 00195 No 19402 00192 No 19402 00193 No 19402 00199 No 19402 00201 No 19402 00200 No 19402 00166 DGW311L W 380A W 400A W 415A 2 Specifications
21. ecking engine always stop the engine and keep away from fire e Temperature around muffler and exhaust can get extremely high Wait until the engine cools down before performing any checks 27 If the generator welder will not be used for more than two months perform the following maintenance and storage procedures Remove battery Change engine oil Drain fuel from fuel tank and fuel filter Clean all parts cover the generator welder and keep it in the storage away from dust and humidity lt Caution gt e Recharge the removed battery once a month 13 Troubleshooting Danger Electric Shock e Do not operate the equipment if the equipment or you are wet Before performing any equipment check or maintenance stop the engine A Caution Injuries e When performing equipment check and maintenance always stop the engine A Caution Fire Burns When checking engine always stop the engine and keep away from fire e Temperature around engine muffler and exhaust can get extremely high Wait until the en gine 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 sec tion to request the repair Symptoms Possible Cause Corrective Actions Starter motor does not start 1 Weak Battery 1 Recharge Battery 2 Dead Battery
22. elding cables to the output terminals In terms of DGW311DM connect cables to the welding output terminals referring to the table below WELDING CABLE WELDING ROD HOLDER CRIMPING TERMINAL MATERIAL HOLDER ECO Single Single Dual Welding Rod Welding Rod Welding Rod p 2 0 4 0 p 2 6 6 0 p 2 0 4 0 Welding Output Terminal A Welding Output Terminal A Welding Output Terminal A and Welding Output Terminal B Close the output terminal cover after finishing connections and fix the cover with bolts lt Caution gt Be sure to crimp a crimping terminal to a cable and connect the cable to welding output ter 17 minal Otherwise welding output terminals may burn out by the heat caused by insufficient connections e 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 welding time ratio for 10 minutes This equipment is the rated duty cycle is 50 namely the welding time is 5 minutes or less Be sure to take 5 minutes recess after 5 minutes welding lt Caution gt The equipment may be damaged due to overheat if welding more than 5 minutes succes sively or short time recess after the weldi
23. ff the circuit for protection against any accident such as electrical shock resulting from the trouble The specifications of the earth leakage breaker e Rated Sensitive Current 30mA or below Grounding resistance 5000 below e Sensitive time Within 0 1second 5 3 1 Grounding Work The qualified electrician should perform the grounding work of the following 3 points 5000 or below The earth grounding terminal in the output terminals e The Outer Bonnet Canopy of the generator The Outer Bonnet of the load Caution Inthe event you cannot ground the generator to the earth consult with the authorized dis tributor or our engineering section DGW311DM DGW311L BONNET GROUNDING TERMINAL BONNET GROUNDING TERMINAL s GROUNDING ROD ij GROUNDING ROD 5 3 2 Operation Check Before operating the generator check always if the device can work reset BUTTON EARTH LEAKAGE Turn the starter switch from STOP to Run Turn Push up the circuit breaker lever to ON position Push the test button When the button is pushed the earth leakage indication lamp turns ON and the circuit breaker is po sitioned in the middle of ON and OFF positions the device can TEST BUTTON work normal Push the reset button The earth leakage indication lamp red turns OFF subsequently Turn push down the circuit breaker lever to OFF position Restor
24. igh speed when welding operation or electric supply starts A Caution Damage to the equipment or other properties e Turn always the Slow Down switch to OFF when the load is incorporated with a electro magnetic switch Caution When the load of less than 0 5A is connected to use the Slow Down feature does not func tion sometimes Therefore turn the switch to OFF When welding operation or electric supply is used intermittently turn the switch to OFF When the output selector switch is positioned to ECO the engine does not turn to high speed DGW311DM only 6 Initialization and Pre check A Caution Burns Injuries When checking engine always stop the engine and keep away from fire Wait until the en gine cools down before performing any checks 6 1 Checking Engine Oil When checking for engine oil be sure to keep the equipment OIL GAUGE YELLOW OIL FILLER leveled and insert the oil gauge all the way in Prior to starting the equipment make sure to fill the engine oil to the HIGH level through the oil inlet 11 lt Caution gt e Ifthe equipment is not leveled you cannot obtain accurate oil level e Do not overfill over H line the engine oil The excessive volume of engine oil may damage the engine inside the cylinders M Selecting proper engine oil Use the engine oil for Diesel engine in proper viscosity in compliance with the ambient temperatu
25. k turn the fuel line valve CLOSE Fuel Element Part No 124550 55700 Yanmar 11 5 Draining Water from Fuel Tank Drain Water Every 200 hours 4 Unscrew the fuel drain plug u fr Q Reinstall the drain plug after draining the water entirdy 7 IS gt FUEL DRAIN WATER DRAIN 009 0 59 PLUG 11 6 Changing Coolant Water ZNAD Replace Every 1 year or 1000 hours Remove the top plate Remove the radiator G Loosen the water drain plug SE After draining all the water reinstall the water drain plug amp Remove the reservoir tank and replace all the water WATER FILLER Install the reservoir tank back and fill the radiator with coolant water up to radiator filler neck Total cool ant water Capacity is 3 1 liter AES EA Reinstall the radiator cap DN Mid Install the top plate back 2 M Ss SZEJ RESERVOIR TANK 12 Long Term Storage Danger Electric Shock e 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 A Caution Injuries e 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 A Caution Fire Burns When ch
26. low 7 6 or below 2 6mm 80A 8 6kVA or below 6 8kVA or below 3 2mm 120A 7 2kVA or below 5 7kVA or below 4 0mm 2 0mmx2 170A 5 2kVA or below 4 1kVA or below 5 0mm 2 6mmx2 220A 3 0kVA or below 2 4kVA or below 6 0mm 3 2mmx2 280A OKVA or below OKVA or below indicates 2 Persons Dual Use DGW311DM only Caution e The simultaneous use of ECO welding and AC power is not available DGW311DM only DGW311L W 380A DGW311L W 400A DGW311L W 415A Limitation of AC Power Supply in the simultaneous use of welding and generating 50Hz Welding Output AC Power Output Welding Rod Current 3 Pase Power use only 1 Phase Power Use only 2 0mm 50A or below 8 5kVA or below 6 8kVA or below 2 6mm 80A 7 6 or below 6 0kVA or below 3 2mm 120A 6 2kVA or below 4 9kVA or below 4 0mm 170A 4 2kVA or below 3 3kVA or below 5 0mm 220A 2 0kVA or below 1 6kVA or below 6 0mm 260A OKVA or below OkVA or below 11 Checking and Maintenance Danger Electric Shock Injuries Before performing any equipment check or maintenance stop the engine and remove en gine key A person performing the maintenance should always keep the key A Caution Fire Burns When checking the engine always stop the engine and keep away from fire Wait until the engine cools down before performi
27. lowing steps Turn the starter switch to STOP Fill the fuel Turn the Slow Down switch to ON Turn the starter switch to RUN O 0 Turn the starter switch to START and drive the starter motor lt Caution gt e Do not drive the starter motor for more than 15 seconds successively e f you need restart wait for 30 seconds or more before retry Release the starter switch as soon as the engine started lt Caution gt Once the engine is started do not turn the starter switch to START Wait for about 1 minute to vacuum the air out The engine speed becomes stable when the air is extracted Caution Keep the Slow Down switch ON unit the air is completely extracted out unit the engine speed becomes stable otherwise the engine may disorder 7 2 Stopping Generator Welder Turn Push down the breaker to OFF Turn the Slow Down switch to ON Keep the engine idle cooling down for about 5 minutes Turn the starter switch to STOP After the engine stops turn the fuel lever to CLOSE Q lt Caution gt e 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 consult with our authorized distributor or our engineering section and ask to re pair 8 Welding Operation 8 1 Selection Welding Cable Select the cable with proper gauge based on the allowable amperage and distance per
28. ng 8 5 Welding A Caution Suffocation from welding fume sure to wear 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 A 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 Light Shielding Degree No 7 8 9 10 11 12 13 Welding Current A 30 75 76 200 201 400 A Caution Fire Keep any inflammable items and easily burning items away from the place in welding be cause welding splashes spatters A 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 lt Caution gt Never turn the output selector switch during welding because it causes burnout of the switch DGW311DM only 8 5 1 DGW311DM The equipment can be welding by 2 persons simultaneously Each person can adjust the welding current individually The current adjustable range by the current adjustable dial depends on the position each of the 18 welding output selector switch ECO Single Dual Welding Current Adjustabl
29. ng any checks To optimize the use of this equipment we recommend the periodical equipment checks and maintenance based on the following matrix lt Caution gt e The authorized technicians should perform all checking and maintenance work except for the pre startup checks e Request for the maintenance item with mark to the authorized distributor or our engi neering section This table only covers the simple checks and maintenance for the engine For more detailed guide please refer to the User s Manual for the engine e Always use our genuine replacement parts 24 Use the hour meter as a guide for the operating time Checking Items Startup Checking Time Check At Every Every Every Every 50hrs 200hrs 400hrs 1000 hrs 2000 hrs 1 Check and Supply Fuel O Check and Supply Engine Oil O 3 Engine Oil Change 1o or after O 4 Oil Filter Change 6 7 after O 5 Check Add Water Coolant O 6 Water Coolant Change O or one year 7 Clean Change Fuel Filter O O Clean change 8 Drain Water from Fuel Tank 9 Check Leakage Fuel Water O 10 Check Add Water Battery O 11 Clean Change Air Cleaner Element O O Clean change 12 Adjust Tension V Belt 20 aftere 13 Clean Radiator Fin e 14 Change Hose Fuel Radiator e o Change Vibration Absorbing Rubber years 15 Adjust Engine Valve Clearance Adjust A
30. oad the circuit breaker activates to trip off in order to shut off the circuit When the load in operation stops check the breaker When the circuit breaker is positioned intermediary ON and check if the earth leakage indication lamp turns ON or not In the case the lamp turning ON refer to 5 3 Earth Leakage Breaker In the case the lamp NOT turning ON follow the next procedures to restore the circuit breaker Turn off all the power switches in the loads Turn Push down the circuit breaker OFFI once and then turn push up the circuit breaker to ONI lt Caution gt Take care for overload referring to 9 2 Output Limitation When the output selector switch is positioned to ECO and AC power is used the circuit breaker trips off to shut down the circuit Stop using AC power and follow the above proce dures to restore the circuit breaker DGW311DM only 10 Simultaneous Use of Welding and Generating The circuit breaker reacts 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 DGW311DM W 220B DGW311L W 220B Limitation of AC Power Supply in the simultaneous use of welding and generating 60Hz 23 Welding Output AC Power Output Welding Rod Current 3 Pase Power use only 1 Phase Power Use only 2 0mm 50A or below 9 5kVA or be
31. oolant water temperature If the water level is normal there may be a possibility of overloading and always use equipment within the rated amperage lt Caution gt Check the fuse next after oil pressure battery charge and water temperature will be found normal when you have checked them in the first place 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 5 3 Earth Leakage Breaker Danger Electric Shock e All the grounding terminals must be grounded If one of them is not grounded human body may get a serious electric shock by leaked current e Even though all the terminals of the loads have been grounded to the earth the earth grounding terminal and the outer bonnet canopy grounding terminal should be grounded to the earth Grounding should be made after the engine is stopped Whenever the earth leakage breaker has activated you should always repair the leaking place first of all lt Caution gt The earth leakage breaker activates only for AC power supply The circuit breaker trips to protect the loads whenever AC power is used if the selector switch is in the ECO position DGW311DM only The equipment is provided with the earth leakage breaker to detect any leakage arisen due to such the troubles as insulation failure of the load while the generator is running and to cut o
32. or recharge the battery Battery may emit some combustible gas so keep it away from fire and sparks A Caution Fire The equipment uses Diesel fuel 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 objects 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 A Caution Burns Do not touch the engine and muffler during operation and immediately after stopping the equip ment 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 filter cap 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 becaus
33. re lt Caution gt Use the API class CD grade or higher Viscosity and Temperature Temperature Over 20 C 10 20 C 10 40 C Viscosity SAE30 SAE20 SAE10W 30 6 2 Checking Coolant Water Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by uninten tionally touching cooling fan and fan belt Danger Burns e Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor A Caution Burns e 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 reservoir tank If the coolant water is below the LOW level fill the tank and the radiator accordingly 6 2 1 Filling to the Reservoir Tank Take out the reservoir tank to remove the cap RE RA WE Fill up the reservoir tank to the FULL level TNR SE Install the cap back and tighten and reinstall the tank to 2 equipment 6 2 2 Filling to the Radiator 3 RESERVOIR TANK Remove the top plate Remove the radiator cap 12 Fill up the radiator up to the top Install the cap back and tighten Reinstall the top plate TOP PLATE Re lt C
34. rminal Terminal 1 set 3 sets 1 set 3 sets Total Total Electric Bulb Heater etc 3 0 6 0 6 0 8 0 Electric Tools Series Motor 1 5 3 0 3 0 4 0 etc Mercury Bulb High Power 1 2 2 4 2 4 3 2 Submersible Pump Com 1 2 2 4 2 4 3 2 4 0 pressor etc Induction Mo tor Series Motor Motor with brush Induction Motor Brushless Motor value described is OUTPUTI for Induction Motor loads and POWER CON SUMPTION for the other equipment Caution sure to use the frequency designated in the equipment incorporated in mercury lamp or induction motor e 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 2 or more sets to use start the load one by one not to start them simulta neously When switching a Mercury bulb ON again wait for 15 minutes about until it cools down A Mercury bulb may flicker sometimes 9 3 Operation Danger Electric Shock Before connecting or disconnecting a load cable from output terminals always turn a circuit breaker to OFF position All the grounding terminals must be grounded If one of them is not grounded human body may get a serious electric shock by leaked current Refer to 5 3 Earth Leakage Breaker Grounding should be made after the engine is stopped Whenever
35. s and Home Appliances Power Source for Lighting Caution Damage to the equipment or other properties e 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 microcomputer control or for the ultra precision devices the load may be malfunctioned 4 Parts DGW311DM CURRENT CURRENT ADJUSTMENT ADJUSTMENT DIALA DIALB CIRCUIT BREAKER SLOW DOWN SWITCH STARTER SWITCH 3 PHASE VOLT METER MONITOR LAMP OUTPUT SELECTOR SWITCH FUEL GAUGE 1 PHASE OUTPUT RECEPTACLE HOUR METER WELDING OUTPUT TERMINAL A WELDING OUTPUT TERMINAL B Bee 1 OUTPUT TERMINAL 3 PHASE 1 PHASE OUTPUT TERMINAL EARTH GROUNDING TERMINAL BONNET GROUNDING TERMINAL DGW311L p W 220B CURRENT ADJUSTMENT DIAL CIRCUIT BREAKER SLOW DOWN SWITCH STARTER SWITCH 3 PHASE VOLT METER MONITOR LAMP 1 PHASE OUTPUT RECEPTACLE FUEL GAUGE EARTH GROUNDING TERMINAL HOUR METER 3 PHASE 1 PHASE OUTPUT TERMINAL WELDING OUTPUT TERMINAL 1 PHASE OUTPUT TERMINAL BONNE GROUNDING TERMINAL DGW311L W 380A W 400A W 415A CURRENT ADJUSTMENT DIAL CIRCUIT BREAKER SLOW DOWN SWITCH 3 PHASE VOLT METER STARTER SWITCH MONITOR LAMP FUEL GAUGE EARTH GROUND
36. s and the other terminal O Maximum output available for the one set of terminals is 3kVA but the total output for 3 sets is 8kVA which please note W O DGW311L W 380A W 400A lcs Output voltage 220V 230V 240V TOTAL 8kVA Caution When using 1 Phase output connect the loads evenly to each terminal set as much as pos sible 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 characteristic of the components DGW311DM W 220B DGW311L W 220B Applicable Load For reference purpose only 60Hz Capacity kW 1 Phase 110V 1 Phase 220V 3 Phase Loads 220V Receptacle Terminal Receptacle Terminal Terminal Terminal 1 unit 1 set 8 Terminal 1 set 3 sets Total Total Electric Bulb Heater etc 1 5 3 0 6 0 6 0 8 0 Electric Tools Series Motor 0 7 1 5 3 0 3 0 4 0 etc Mercury Bulb High Power 0 6 1 2 2 4 2 4 3 2 Submersible Pump Com 0 6 1 2 2 4 2 4 3 2 4 0 pressor etc Induction Mo tor 21 DGW311L W 380A DGW311L W 400A DGW311L W 415A Applicable Load For reference purpose only 50Hz Capacity KW 1 1 Phase 3 Phase PANE O amp U V W U W U V W Terminal Terminal Terminal Te
37. s 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 e Always use the Diesel fuel strainer e Fill the fuel tank slightly less than the FULL tank 13 6 4 Checking Fuel Engine Oil and Water Leakage A Caution Fire e Always wipe any drip of Diesel fuel or oil Do not use this equipment when a leak is found Repair the equipment before use Be sure to check for any fuel leak at the hose connection and oil and coolant water by opening side doors When checking for any fuel leak open a fuel lever and be sure to close the fuel lever after checking 6 5 Checking Battery A Caution Injuries to eyes and skin e Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or clothing If the acid comes in contact especially with eyes flush with a lot of water and contact your physician immediately A Caution Explosion e When the liquid level is below the LOWER level never use the equipment nor recharge the battery e Battery may emit some combustible gas so keep it away from fire and sparks Check the fluid level If the level is near or lower than the LOWER level add distilled water until the fluid level reaches the UPPER level Q Make sure that the battery cables are firmly secured to the posts Tighten the clamps if necessary Caution Check the hydrometer of the battery fluid If it falls belo
38. the earth leakage breaker activates you should repair the leaking place first of all A Caution Injuries 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 22 A Caution Damage to the equipment or other properties e In event using the equipment to computers microcomputers incorporated loads and pre cision equipment there is a possibility for them to be mal functioned or broken down lt Caution gt sure to use the power cord with crimping terminal to connect to output terminals Volt meter reads the 3 Phase figures even if the circuit breaker is positioned td OFF when the engine is driving After the engine starts Refer to 7 1 Initializing Preparation operate the equipment as per the following procedures Turn off the power switch in the load and then turn the circuit breaker to OFF Connect the load to the output terminals or receptacles Close the output terminal cover after finishing connections and fix the cover with bolts Turn the circuit breaker to ONI When finishing the load operation always turn the circuit breaker OFF The Circuit Breaker A Caution Injuries Be sure to turn off the power switch in the load when turning the circuit breaker to ONI when the circuit breaker has activated When the electric supply exceeds the rated output overl
39. tput from the terminals U V W is 10kVA 9 1 1 2 1 Phase 220V Output Terminals using the terminals only 1 Phase 220V Output is available using the 3 phase output terminals Maximum output available for the one set of the terminals is 6kVA but the total output for the 3 sets is 8kVA which please note TOTAL 8kVA 9 1 1 3 1 110V Output Receptacles amp Terminals 1 Phase 110V Output is available through 2 receptacle sets and one terminal set Maximum output per one receptacle is 1 5kVA and one terminal set is 3kVA The total output for the receptacles and the terminal set is 6kVA 1 5 REGEPTAGLE 110V P 1 5 1 PHASE 110V OUTPUT TERMINAL O O t TOTAL 9 1 2 DGW311L W 380A DGW311L W 400A DGW311L W 415A 9 1 2 1 3 Phase Output Terminals Maximum output from the terminals U V W is 10kVA U v DGW311L Ww O O W 380A W 400A W 415A Output voltage 380V 400V 415V 9 1 2 2 1 Phase Output Terminals 1 Phase Output is available using the 3 Phase output terminals Maximum output available for the one set of the terminals is 6kVA but the total output for the sets is 8kVA which please note DGW311L Wj380A W 400A W15A Output voltage 380V 400V 415V TOTAL 8kVA 20 9 1 2 3 1 Phase Output Terminals 1 Phase Output is available using the 3 Phase output terminal
40. w 1 23 the battery requires recharg ing Please consult with our authorized distributor or our engineering section INS CAP TERMINAL m Replacing battery TERMINAL Remove the clamp and cable from negative post in the battery Remove always negative side first Remove the hold down clamp from the battery Remove the clamp and cable from positive post in the battery BATTERY 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 Use the following battery 46B24L 7 Operation 7 1 Initializing Preparation 14 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 A Caution Suffocation from exhaust fume e Do not point the exhaust fume toward pedestrians or building A Caution Fire e Temperature around muffler and exhaust can get extremely high Keep any inflammable items such as fuel gas paint etc away from the equipment Always operate this equipment on flat surface and at least 1 meter away from any objects wall box etc A Caution Injuries eo Always place the equipment on flat and stable surface to keep the equipment from sli
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