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Summary of Contents for Shindaiwa DGW500M
- Page 1 S MANUAL DGW 500M 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. DGW500M-S2 X753-008 35 0 X753803-350 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.
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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. Idle Control ................9 5-2. Weld Output Control .............. 9 5-3. Monitor Lamp ..............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.
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Page 9: Specifications
2. Specifications (50/60Hz) Model DGW500M-S2 Generating Method Rotating Field Operation Single Rated Current Rated Voltage 39.2 Duty Cycle Current Adj. Range 60 – 500 Welding Rod (mm) φ2.6 – φ8.0 Gouging Rod (mm) φ3.2 – φ9.5 Rated Speed (min 3000/3600... -
Page 10: Part Names
4. Part Names Operation Panel Terminal Cover Bonnet Grounding Terminal Weld Terminals AC Output Terminals AC Output Hour Control Dial Meter Monitor Weld Output Lamp Control Dial Starter Switch Fuel Meter Idle Arc Control Control Dial Breaker Frequency Switch Selector (Inside) - 7 -... - Page 11 Oil Plug Air Cleaner Right Door Oil Inlet Sub Tank Fuse (60A, 20A) Fuel Inlet Battery Oil Gauge Fuel Lever (Water Separator) Oil Filter Fuel Lever (Fuel Filter) Water Drain Plug Fuel Drain Plug Oil Drain Plug Lifting Lug Muffler Roping Lug Top Plate Accessories...
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Page 12: Equipment
5. Equipment 5-1. Idle Control Idle Control Switch The equipment includes an idle control function. You can use the idle control switch to select an engine speed setting of "AUTO","HIGH". (1) Auto Idle The equipment includes an auto idle function in order to reduce noise, save fuel, and reduce exhaust gas emission. -
Page 13: Monitor Lamp
5-3. 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 14: Frequency Selector
<Note> • The oil pressure monitor cannot detect oil deterioration. Change the engine oil periodically. (Refer to section "12. (1) Changing the Engine Oil".) • The charge monitor cannot detect battery deterioration or insufficient battery fluid. Inspect the battery fluid level periodically. (Refer to section "7-5. Battery Inspection".) •... -
Page 15: Pre-Operation Inspection
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. Do not stand or get under the equipment while it is suspended. •... -
Page 16: Engine Oil Inspection
7-1. Engine Oil Inspection Caution: Burn • Always be sure to stop the engine and allow it to cool before inspecting or changing the engine oil. Opening the oil gauge or oil plug during operation will result in hot oil spurting out. Situate the equipment on a level surface and completely insert the oil gauge to inspect the oil level. -
Page 17: Fuel Inspection
(1) Adding Water to the Sub Tank Remove the sub tank cap. Sub Tank Cap Pour cooling water into the sub tank Sub Tank until it reaches the "FULL" level. Install the sub tank cap. (2) Adding Water to the Radiator Open the top plate. -
Page 18: Inspection For Fuel/Oil/Cooling Water Leakage
<Note> Do not use any fuel other than the specified light oil type. Doing so may lead to the problems described below. • This machine complies with the exhaust gas regulations. If you use any type of fuel other than the specified light oil type, the machine will be a product not conforming to the exhaust gas regulations. -
Page 19: Operating Procedures
■Battery Replacement Procedures Ins Cap " - " Post Remove the " " (negative) cable. "+" Post (Always be sure to first remove the " " (negative) side.) Remove the battery hold-down Hold-Down clamp. Clamp Remove the "+" (positive) cable. Remove the battery. -
Page 20: 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 21: Stopping The Engine
■Restarting after Stopping due to Running Out of Fuel The equipment includes an automatic air-bleeding device. You can easily restart the engine according to the following procedures even if the engine stops due to running out of fuel. Turn the breaker (1-P) to "OFF". Turn the starter switch to the "STOP"... -
Page 22: Welding Polarity
Proper Cable Cross-Sectional Area (Unit: mm Return Length 100m Weld Current 500A 450A 400A 350A 300A 250A 200A 150A 100A 9-2. 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 23: Duty Cycle
Welding Rod Terminal Cover Welding Rod Holder Welding Cable Weld Terminals Earth Fitting Crimped Terminal Stop the engine. Install the welding cables, crimped terminals, welding rod holders and earth fittings. Connect the welding cables to the weld terminals. (Refer to the table below for cable connection locations.) Close the terminal cover. -
Page 24: Welding Work
9-5. Welding Work Warning: Suffocation from Welding Fume • Always be sure to wear a fume-proof mask when welding as the fumes generated during welding include harmful gases and dust. Also be careful that the wind direction is not such that it will cause fumes to be inhaled and always operate the equipment in a well-ventilated area. -
Page 25: Using As A Generator
10. Using as a Generator 10-1. Output Types and Ranges (1) 1-Phase 240V The equipment includes 1-phase 240V output terminals. The maximum output available from the output terminals is 3.6kVA. Terminal Cover AC Output Terminals Weld Terminals 1-P Breaker 10-2. Usable Device Capacities Usable capacity varies depending on the type and performance of the electrical tool or household appliance being used. -
Page 26: Operation
10-3．Operation Warning: Electric Shock • Always be sure to turn off the breaker before installing or removing devices using AC output receptacles. Caution: Injury • Always be sure to turn off the power switches of all devices using the equipment when turning on the equipment breaker. -
Page 27: Simultaneously Welding And Using As Ac Power Source
11. 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 28: Inspection/Maintenance
12. Inspection/Maintenance Warning: Electric Shock/Injury • Always be sure to stop the engine and remove the engine 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 29 • When performing maintenance with doors or covers open, be sure that no other persons can accidentally come close to the equipment. Close all doors and covers if momentarily leaving the equipment unattended. Perform periodic inspection and maintenance as indicated by the table below in order to ensure that this equipment can be operated in optimal condition.
- Page 30 (1) Changing the Engine Oil 1st time 50th hour 2nd time and after Every 100 hours 1) Remove the oil plug. Oil Plug 2) Remove the oil drain plug and drain the Oil Inlet engine oil. Oil Gauge 3) Tighten the oil drain plug. 4) Add oil through the oil inlet, while checking the oil level using the oil gauge, Oil Drain Plug...
- Page 31 (3) Cleaning/Replacing the Air Element 1st time: 50th hour / Cleaning 2nd time and after: Every 100 hours Replacement Every 400 hours Clips 1) Release the air cleaner clips and remove the cleaner cap. 2) Clean or replace the air element. <...
- Page 32 <Note> Retainer Fuel Lever • Check that no foreign material is adhering to Ring the packing then install the cup. CLOSE • After installation, turn the fuel lever to "OPEN" Gauze and check that there is no fuel leakage. After Filter checking, turn the fuel lever to "CLOSE".
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Page 33: Long-Term Storage
13. Long-Term Storage Warning: Electric Shock/Injury • Always be sure to stop the engine and remove the engine 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 34: Troubleshooting
14. Troubleshooting Warning: Electric Shock/Injury • Always be sure to stop the engine and remove the engine key before performing any equipment check or maintenance. • Do not touch the equipment during operation if the equipment or your body is wet. •... - Page 35 Symptom Possible Causes Remedy Starter motor does 1. Battery has a low charge. 1. Recharge the battery. not start. 2. Battery is deteriorated. 2. Replace the battery. 1. Fuel lever is "CLOSE". 1. Turn the fuel lever to "OPEN". (fuel filter or water separator) (fuel filter and water separator) 2.
- Page 36 <Note> • Maintenance of this equipment must be performed by specialized technicians. • When performing maintenance with doors or covers open, be sure that no other persons can accidentally come close to the equipment. Close all doors and covers if momentarily leaving the equipment unattended. •...
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Page 37: Engine Wiring Diagram
15. Engine Wiring Diagram - 34 -... -
Page 38: Generator Wiring Diagram
16. Generator Wiring Diagram - 35 -... - Page 39 - 36 -...
- Page 40 ©2020 - 37 -...
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