Shindaiwa DGW420DM Owner's And Operator's Manual
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Shindaiwa DGW420DM Owner's And Operator's Manual

Shindaiwa DGW420DM Owner's And Operator's Manual

Diesel engine generator & welder
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OWNER'S AND OPERATOR'S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
CAUTION
Do not operate the Generator/Welder, or any other appliance, before you have
read and understood the instructions for use and keep near for ready use.
DGW420DM/ANZ
X750-022 87 0
X750803-640 0

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Summary of Contents for Shindaiwa DGW420DM

  • Page 1 OWNER’S AND OPERATOR’S MANUAL Vertical, Water-Cooled 4-Cycle Diesel Engine CAUTION Do not operate the Generator/Welder, or any other appliance, before you have read and understood the instructions for use and keep near for ready use. DGW420DM/ANZ X750-022 87 0 X750803-640 0...
  • Page 3 Introduction We would like to thank you very much for purchasing this Shindaiwa Soundproof Diesel Engine Generator & Welder. • This manual has been created in order to ensure safe and proper use of this equipment. Be sure to thoroughly read this manual before operating the equipment as the improper operation of this equipment can result in an accident or malfunction.

  • Page 4: Table Of Contents

    Table of Contents 1. Safety Precautions ................2 2. Specifications ..................6 3. Applications ..................6 4. Part Names .................... 7 5. Equipment ..................... 9 5-1. Spill Containment................9 5-2. VRD (Voltage Reduction Device) ..........9 5-3. Idle Control ..................9 5-4.

  • Page 5: Safety Precautions

    1. Safety Precautions Warning: Suffocation from Exhaust Fume • Do not operate the equipment in a poorly-ventilated area such as indoors or within a tunnel because the engine exhaust fume includes components that are harmful to humans. Warning: Suffocation from Welding Fume •...
  • Page 6 Warning: Injury • Do not operate the equipment with any doors or covers open. There is a danger of hair, body parts and other items being caught up in moving parts such as cooling fans and belts. • Do not modify the equipment and do not operate with parts removed. •...
  • Page 7 Caution: Injury • Use this equipment with it situated on a stable level surface so that it is prevented from moving. • Do not move the equipment during operation. • Always be sure to turn off the switches of all devices using the equipment and turn off the equipment breakers before starting the engine.
  • Page 8 Location of Warning Labels Replace warning labels when they become difficult to see or damaged by affixing new labels in the specified locations. Order the necessary labels by numbers in parentheses. (1) Suffocation from Exhaust Fume (No. X505-007590) (2) Suffocation from Welding Fume (No. X505-007600) (3) Electric Shock (No.

  • Page 9: Specifications

    2. Specifications Model DGW420DM Generating Method Rotating Field Operation Single Dual Rated Current (A) Rated Voltage (V) 35.6 28.0 Duty Cycle Current Adj. Range (A) 95 – 400 50 – 210 DROOP Welding Rod (φ) 2.6 – 8.0 2.0 – 4.0 Gouging Rod (φ)

  • Page 10: Part Names

    4. Part Names Operation Panel Terminal Cover Weld Terminals Weld Terminals VRD Lamp Single/Dual Idle Control Switch ECO Drive Display DC Meter Selector VRD Switch Starter Switch AC Meter Monitor Lamp Hour Meter AC Meter Selector Fuel Meter Operation Mode Selector Emergency Stop...
  • Page 11 Air Cleaner Right Door Oil Gauge Fuse Oil Plug (50A,20A) Oil Inlet Battery Sub Tank Battery Isolator Oil Filter Fuel Lever (Fuel Strainer) Spill Containment Oil Drain Plug Spill Containment Drain Fuel Drain Plug Water Drain Plug Fuel Inlet Fuel Inlet Cover Lifting Lug Muffler (Tail Pipe)

  • Page 12: Equipment

    5. Equipment 5-1. Spill Containment Warning: Fire • Always be sure to wipe up any spilled fuel or oil. • Spilled fuel and oil accumulates in the spill containment. Do not operate the equipment with liquid accumulated in the spill containment. •...

  • Page 13: Weld Output Control

    <Note> • The engine speed optimization function of eco drive is only for ECO Drive Display "DROOP" and "CC" welding. (It does not function if "CV-WIRE" is selected using the weld mode selector.) • If using as an AC power source during eco drive (including when welding and using as an AC power source at the same time), the engine operates at high speed and the eco drive display turns off.

  • Page 14: Wire Feeder Control

    (2) Weld Output Pre-Set The equipment includes a weld output pre-set function. If the weld mode selector is set to "CV", you can pre-set the output voltage using the output control dial. If the weld mode selector is set to "DROOP" or "CC", you can pre-set the output current using the output control dial.

  • Page 15: Remote Control (9-Pin Connector)

    5-6. Remote Control (9-Pin Connector) You can connect a compatible remote controller to 9-Pin Connector the 9-pin connector to enable remote operation of weld output adjustment. <Note> • The output control dial for the remote control connection side of the equipment does not function when a remote controller is connected.

  • Page 16: Monitor Lamp

    5-9. Monitor Lamp Warning: Injury/Electric Shock • Do not operate the equipment with any doors or covers open. There is a danger of hair, body parts and other items being caught up in moving parts such as cooling fans and belts. Caution: Burn •...

  • Page 17: Earth Leakage Circuit Breaker And Grounding

    (4) Spill Containment Monitor Lamp The spill containment monitor lamp ("SPILL CONTAINMENT") lights up if the level of liquid in the spill containment is approximately 70% full (approx. 43 L) in order to ensure that liquid accumulated in the spill containment does not spill out of the equipment.

  • Page 18: Emergency Stop Switch

    (2) Bonnet Grounding Terminal The equipment includes a bonnet grounding terminal in order to connect bonnet ground wire. A neutral point of the AC power source is connected to the bonnet grounding terminal. <Note> Bonnet Grounding • Connect using a plug with a grounding pole. Terminal •...

  • Page 19: Pre-Operation Inspection

    6. Pre-Operation Inspection Warning: Injury/Electric Shock • Do not operate the equipment with any doors or covers open. There is a danger of hair, body parts and other items being caught up in moving parts such as cooling fans and belts. •...

  • Page 20: Cooling Water Inspection

    • Use a cold-weather fuel that conforms to Fuel Inlet ASTM standards if using the equipment in a cold weather region. • Shindaiwa recommends using a fuel with a sulfur content of less than 1,000ppm. - 17 -...

  • Page 21: Spill Containment Inspection

    • Change the engine oil and oil filter after a shorter period than normal (approximately one-half the normal period) if using a high-sulfur (sulfur content of between 5,000 to 10,000ppm) fuel. • Do not use a fuel with a sulfur content of 10,000ppm or more. •...

  • Page 22: Operating Procedures

    1) Turn the battery isolator to "OFF". 2) Inspect the battery fluid level. If it is near the lower Terminal level, add distilled water until it reaches the upper UPPER level. LEVEL 3) Inspect for loose terminals and retighten if loose. <Note>...

  • Page 23: Starting The Engine

    <Note> • Check that the surrounding area is safe before starting the engine. • When there are multiple workers who are working together, they must mutually signal each other before starting the engine. • Do not use in an area with high temperature or humidity, or an area with a large amount of dust.

  • Page 24: Stopping The Engine

    7-2. Stopping the Engine 1) Turn all breakers (main, 3-P and 1-P) to "OFF". 2) Set the idle control switch to "ECO" or "AUTO". 3) Allow the engine to cool down for approximately 5 minutes. 4) Set the starter switch to "STOP". 5) After the engine stops, turn the fuel lever to "CLOSE".

  • Page 25: Welding Polarity

    8-2. Welding Polarity There are "+" (positive) and " " (negative) weld output terminals. Refer to the table below to select a polarity corresponding to the work you are performing. <Note> • Use the polarity indicated for the welding rods being used if so indicated. •...

  • Page 26: Duty Cycle

    1) Stop the engine. 2) Install the welding cables, crimped terminals, welding rod holders (or wire feeder) and earth fittings. 3) Pass the welding cables through the terminal caps. 4) Connect the welding cables to the weld terminals and cover with the terminal caps. (Refer to the table below for cable connection locations.) 5) Close the terminal covers.
  • Page 27 Caution: Injury to Eyes and Skin • Always be sure to wear arc-proof glasses (refer to the table below), clothes that completely cover the skin and other protective gear when welding to protect the eyes and skin from harmful light rays generated during welding. Standards for Arc-Proof Glasses (Japanese Industrial Standard) Filter No.
  • Page 28 (1) Semi-automatic Arc Welding Not Using a Remote Controller Not Using a 14-Pin Connector Output Control Dial 1) Set the operation mode selector to either Equipment "GEN.WELDER" or "WELDER ONLY". Work Clip Lead 2) Set the weld mode selector to "CV-WIRE". Wire 3) Switch the single/dual selector in Feeder...

  • Page 29: Using As A Generator

    <Note> • The wire feeder will not operate if the voltage selected using the 42V/115V selector is different from the rated voltage of the wire feeder being used. • The value selected using the output control dial is displayed by the DC meter. During welding, both the DC ammeter and voltmeter display the actual output values.

  • Page 30: Operation

    9-3. Operation Warning: Electric Shock • Always be sure to turn off all breakers before installing or removing devices using AC output receptacles. • Always be sure to repair the corresponding earth leakage location when earth leakage circuit breakers operate. Caution: Injury •...

  • Page 31: Simultaneously Welding And Using As Ac Power Source

    10. Simultaneously Welding and Using as AC Power Source Due to the fact that breakers only function for AC power output, the engine can become overloaded if simultaneously welding and using the equipment as an AC power source. Refer to the table below and limit the use of AC power accordingly. Overview of Capacities Usable Simultaneously Weld Output AC Power Output...

  • Page 32: Inspection/Maintenance

    11. Inspection/Maintenance Warning: Electric Shock/Injury • Always be sure to stop the engine and remove the starter key before performing any equipment check or maintenance. • Do not operate the equipment with any doors or covers open. There is a danger of hair, body parts and other items being caught up in moving parts such as cooling fans and belts.
  • Page 33 Perform periodic inspection and maintenance as indicated by the table below in order to ensure that this equipment can be operated in optimal condition. Use the hour meter as a general indicator for the operating time. Inspection Period Pre- Every Every Inspection Item Operation...
  • Page 34 (1) Changing the Engine Oil 1st time 50th hour Oil Plug Oil Gauge Oil Inlet 2nd time Every 100 hours and after 1) Remove the oil plug. 2) Remove the oil drain plug and drain the engine oil. 3) Tighten the oil drain plug. 4) Add oil through the oil inlet, while checking the oil level using the oil gauge, until it reaches the maximum level.
  • Page 35 (3) Cleaning/Replacing the Air Element 1st time: 50th hour / Crip Right Door Cleaning 2nd time and after: Every 100 hours Replacement Every 400 hours 1) Release the air cleaner clips and remove the cleaner cap. 2) Clean or replace the air element. <If dry dust is adhering>...
  • Page 36 (6) Changing the Cooling Water Change Every 2,000 hours or 1 year Cooling Water Total Capacity: Approximately 4.3 L (Including the sub tank capacity of approx. 0.6 L) Radiator Cap Sub Tank Water Inlet Water Drain Plug Top Plate 1) Open the top plate. 2) Remove the radiator cap.
  • Page 37 (8) Cleaning/Inspecting the Spill Containment Cleaning Every 400 hours or 1 year Caution: Injury • Always be sure to use the lifting lug when lifting the equipment, and lift slowly and directly straight above. • Wear a helmet, safety shoes, gloves and similar protective gear when performing lifting work.

  • Page 38: Long-Term Storage

    12. Long-Term Storage Warning: Electric Shock/Injury • Always be sure to stop the engine and remove the starter key before performing any equipment check or maintenance. • Do not operate the equipment with any doors or covers open. There is a danger of hair, body parts and other items being caught up in moving parts such as cooling fans and belts.

  • Page 39: Troubleshooting

    13. Troubleshooting Warning: Electric Shock/Injury • Always be sure to stop the engine and remove the starter key before performing any equipment check or maintenance. • Do not touch the equipment during operation if the equipment or your body is wet. •...
  • Page 40 Refer to the table below to perform inspection when the equipment is operating poorly. If you cannot resolve a problem after inspecting the equipment, request repair at the retail outlet where the equipment was purchased. Symptom Possible Causes Remedy 1. Battery isolator is "OFF". 1.
  • Page 41 Symptom Possible Causes Remedy 1. Idle control switch is set to "ECO". 1. Set to "HIGH" or "AUTO". Engine cannot obtain 2. Current of device using the 2. Set the idle control switch to "HIGH". high speed. equipment as AC power source is 0.5A or less.

  • Page 42: Engine Wiring Diagram

    14. Engine Wiring Diagram - 39 -...

  • Page 43: Generator Wiring Diagram

    15. Generator Wiring Diagram - 40 -...
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  • Page 45 MEMO MEMO MEMO MEMO - 42 -...
  • Page 46 MEMO MEMO MEMO MEMO - 43 -...
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  • Page 48 © © © © 2013 - 45 -...

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