Shindaiwa DGW500DM Owner's And Operator's Manual
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Shindaiwa DGW500DM Owner's And Operator's Manual

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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.
DGW500DM-200
X750-023 04 0
X750803-680 2

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Summary of Contents for Shindaiwa DGW500DM

  • Page 1 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. DGW500DM-200 X750-023 04 0 X750803-680 2...
  • 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. VRD (Voltage Reduction Device) ......... 9 5-2. Idle Control ................9 5-3. Weld Output Control ............10 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 ■Locations 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 DGW500DM-200 Generating Method Rotating Field Operation Single Dual Rated Current Rated Voltage 39.2 29.2 Duty Cycle Current Adj. Range 60 – 500 / 65 – 500 30 – 280 / 35 – 280 Welding Rod (mm) φ2.6 –φ8.0 φ2.0 –φ6.0...

  • Page 10: Part Names

    4. Part Names Operation Panel Terminal Cover Weld Terminals A Weld Terminals B Idle AC Meter Hour DC Meter Monitor Control Lamp Meter Switch Lamps Switch Output Control Starter Dial Switch Emergency Fuel Stop Switch Meter Remote Single/Dual Control Selector Cover Remote Weld Mode...
  • Page 11 Frequency Selector Air Cleaner Oil Plug Side Door Oil Inlet Sub Tank Fuse (60A, 20A) Fuel Inlet Battery Fuel Inlet Cover Oil Gauge Fuel Lever (Water Separator) Fuel Lever Oil Filter (Fuel Filter) Water Drain Plug Fuel Drain Plug Oil Drain Plug Muffler Lifting Lug Roping Lug...

  • Page 12: Equipment

    5. Equipment 5-1. VRD (Voltage Reduction Device) The equipment includes a voltage reduction device VRD Lamp VRD Switch on the weld output side. The voltage reduction device reduces the output voltage of the welder when welding is paused in order to further increase safety when welding in locations with high humidity, elevated locations, extremely confined spaces near possible hazards, and...

  • Page 13: Weld Output Control

    5-3. Weld Output Control (1) Weld Mode Selector Output You can select a weld mode of Control "CV-WIRE" or "CC-STICK" in Dial accordance with the type of welding being performed. Weld Mode CV (Constant Voltage) -WIRE Selector You can use the equipment as a Arc Control power source for semi-automatic arc Dial...

  • Page 14: Meter

    <Note> • The output control dial on the remote controller connection side of the equipment does not function when a remote controller is connected. • If the remote controller is disconnected from the remote control connector while welding, the equipment output control dial becomes functional, possibly resulting in an increase or decrease in weld current.

  • Page 15: Error Code Display

    5-6. Error Code Display The equipment includes an error code Error Code Display display function that notifies the operator of (Also used as DC and AC meters) any errors during operation. If an error is detected during operation, error codes are displayed by the DC and AC meters.
  • Page 16 (2) Battery Charge Monitor Lamp The battery charge monitor lamp ("CHARGE") lights up and the engine is automatically stopped if battery charge fails during operation. If this occurs, it is probable that there is fan belt damage or a wiring fault. Request repair at the retail outlet where the equipment was purchased.

  • Page 17: Frequency Selector

    This equipment can operate at either 50Hz or 60 Hz. Frequency Set the frequency selector located Selector inside the side door to change the frequency in accordance with the devices using the equipment. 5-9. Ground Fault Circuit Interrupter (GFCI) and Grounding Warning: Electric Shock •...

  • Page 18: Emergency Stop Switch

    <Note> • Connect using a plug with a grounding pole. • If using a plug without a grounding pole, perform grounding work and check that used devices are connected to ground. • Securely ground the bonnet grounding terminal to the metal frame of the vehicle if transporting the equipment by truck or trailer.

  • Page 19: Engine Oil Inspection

    Caution: Burn • The engine, muffler and similar parts are extremely hot during operation and immediately after stopping the equipment. Never touch hot parts. 6-1. Engine Oil Inspection Caution: Burn • Always be sure to stop the engine and allow it to cool before inspecting or changing the engine oil.

  • Page 20: Fuel Inspection

    • Use a cold-weather fuel that conforms to Strainer 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 1,000 ppm. - 17 -...

  • Page 21: Inspection For Fuel/Oil/Cooling Water Leakage

    • 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 10,000 ppm) fuel. • Do not use a fuel with a sulfur content of 10,000 ppm or more. Ultra-low sulfur fuel must be used if using the equipment in a region subject to EPA exhaust gas regulations.

  • Page 22: Operating Procedures

    ■Battery Replacement Procedures " - " Post " + " Post Ins.Cap Remove the " " (negative) cable. (Always be sure to first remove the " " (negative) side.) Remove the battery hold-down clamp. Hold-Down Remove the "+" (positive) cable. Clamp Remove the battery.

  • Page 23: Starting The Engine

    7-1． ． ． ． Starting the Engine Turn all breakers (main and 1-P) to "OFF". Turn the fuel lever (on the fuel filter and water separator) to "OPEN". Set the idle control switch to "AUTO". Check that the emergency stop switch has been released. If the temperature is 5°C or less, turn the starter switch to the "PREHEAT"...

  • Page 24: Stopping The Engine

    <Note> • Do not switch the engine to high speed or apply any loads to it until all the air has been bled from the fuel pipes (until speed is stable). Doing so can cause a malfunction. 7-2. Stopping the Engine Turn all breakers (main and 1-P) to "OFF".

  • Page 25: Welding Polarity

    Proper Cable Cross-Sectional Area (Unit: mm Return Length 100m Weld Current 500A 450A 400A 350A 300A 250A 200A 150A 100A 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.

  • Page 26: Welding Cable Connection

    8-3. Welding Cable Connection Warning: Electric Shock • Be sure to stop the engine whenever touching Weld output terminals such as when installing or removing welding cables. • Do not connect welding cables to any part other than weld output terminals. Welding Rod Semi-automatic Wire Feeder Welding Rod Holder...

  • Page 27: Duty Cycle

    8-4. Duty Cycle The duty cycle is the percentage of time the load is being applied in a 10-minute period. For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no-load in a 10-minute period. <Note>...
  • Page 28 You can select from among 3 weld modes in accordance with the type of welding being performed. Select a weld mode by referring to the recommended modes in the table below. Weld Modes Table (Recommended) Welding Mode Name Applications Position Semi-automatic Arc Welding -WIRE (MIG, MAG, self-shielded,...

  • Page 29: Using As A Generator

    (2) Shielded Metal Arc Welding, Gouging, Scratch Start TIG 1) Switch the single/dual selector in accordance with the amount of welding personnel and desired weld output. 2) Switch the weld mode selector and the rod selector in accordance with the work being performed.

  • Page 30: Usable Device Capacities

    (2) Output Ranges It can be used to the following output. (Units: kVA) (50/60Hz) 1-Phase 200/220V 1-Phase 115/127V 3-Phase Receptacle 200/220V L1-L2 L2-L3 L1-L3 5.7 / 5.7 5.7 / 5.7 5.7 / 5.7 2.3 / 2.5 2.3 / 2.5 9.9 / 9.9 total：8.0 / 8.0 total：4.6 / 5.1 9-2．...

  • Page 31: Operation

    9-3. Operation Warning: Electric Shock • Always be sure to turn off all breakers before installing or removing devices using AC output receptacles and AC output terminals. • Always be sure to repair the corresponding ground fault location when ground fault circuit interrupters operate.

  • Page 32: Simultaneously Welding And Using As Ac Power Source

    Follow the following procedures to recover operation when breakers operate due to overcurrent. Turn off all switches of devices using the equipment as an AC power source. Push up the breaker lever that has operated to the "ON" position. <Note> •...

  • Page 33: Inspection/Maintenance

    11. Inspection/Maintenance Warning: Electric Shock/Injury • Do not touch the equipment during operation if the equipment or your body is wet. • Always be sure to stop the engine and remove the starter key before performing any equipment check or maintenance. •...
  • Page 34 • When removing waste liquid from the equipment, place some container to collect the liquid and prevent it from spilling on the ground. Dispose of such oil, fuel, cooling water (LLC), filters, batteries and other harmful substances as industrial waste in accordance with applicable laws and regulations. Consult with the retail outlet where the equipment was purchased if you have any inquiries regarding proper disposal.
  • Page 35 Inspection Period Pre- Every Every Inspection Item Operation 50th Every 100 Every 200 Every 400 1,000 2,000 Inspection hour hours hours hours hours hours Replace Fuel/Cooling Water/Oil Hoses and Anti-Vibration Rubber 2 years Adjust/Lap Clearance of Air Intake/Release Adjust- Lapping Valves ment Inspect/Adjust...
  • Page 36 <Note> • Contact the retail outlet where the equipment was purchased if you do not have a filter wrench. • Oil filter part no.: 16271-32093 (Kubota part no.) • After adding engine oil, operate the engine for a short period and check that there is no oil leakage.
  • Page 37 (5) Draining Water from the Water Separator Draining Every 200 hours Water When the float (red) is coming up to drain water line, drain the water. 1) Turn the fuel lever to "CLOSE". 2) Turn the retainer ring to the left and remove the Water Separator cup and gauze filter.

  • Page 38: Long-Term Storage

    <Note> • Replace the packing with a new part each time you change the cooling water. • Packing part no.: 6C090-58961 (Kubota part no.) • Operate the engine for a short period and check that there is no cooling water leakage.

  • 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 Starter motor does 1.
  • Page 41 Symptom Possible Causes Remedy 1. Current of device using the 1. Set the idle control switch to Engine cannot obtain equipment as AC power source "HIGH". high speed. is 0.5A or less. 1. Idle control switch is set to 1. Set to "AUTO". Engine cannot obtain "HIGH".

  • Page 42: Engine Wiring Diagram

    14. Engine Wiring Diagram - 39 -...

  • Page 43: Generator Wiring Diagram

    15. Generator Wiring Diagram - 40 -...
  • Page 44 ©2014...

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