Shindaiwa DGW600DM-AC Generator User Manual
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Shindaiwa DGW600DM-AC Generator User Manual

Diesel engine generator & welder
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OWNER'S AND OPERATOR'S MANUAL
DGW600DM-AC
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.
DGW600DM-AC/RT
X753-009 14 0
X753803-590 0

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Summary of Contents for Shindaiwa DGW600DM-AC

  • Page 1 OWNER’S AND OPERATOR’S MANUAL DGW600DM-AC 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. DGW600DM-AC/RT X753-009 14 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 ■The following explanatory symbols will be used throughout the manual and on the product itself. Please make sure to understand fully what each symbol stands for. Symbol form / shape Symbol description / application Read and understand instructions Safety / Alert Beware of exhaust fumes.
  • Page 5 Symbol form / shape Symbol description / application FALLING EQUIPMENT can injury.

  • Page 6: Table Of Contents

    Table of Contents 1. Safety Precautions ................... 2 2. Specifications ....................6 3. Applications ...................... 7 4. Part Names ......................7 5. Equipment ....................... 10 5-1. Spill Containment .................. 10 5-2. Idle Control ..................... 10 5-3. Weld Output Control ................11 5-4.

  • Page 7: 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 8 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 9 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 10 ■ Location of Warning/Caution Labels Replace warning or caution 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.

  • Page 11: Specifications

    2. Specifications (50 / 60Hz) Model DGW600DM-AC/RT Generating Method Rotating Field Operation Single Dual Rated Current (A) Rated Voltage (V) 42.8 32.0 Duty Cycle Current Adj. Range (A) 30 – 600 30 – 340 DROOP Welding Rod (Φ) 2.0 – 8.0 2.0 –...

  • Page 12: Applications

    3. Applications  Shielded Metal Arc Welding  Semi-automatic Arc Welding (MIG, MAG, Self-Shielded)  Gouging  Lift Start TIG, Scratch Start TIG  Power Source for Light, Electric Tools, Appliances and Air Tools Caution: Physical and Secondary Damage  Do not use the equipment for any applications not listed above.
  • Page 13 380/415V Breaker Earth Leakage Circuit Breaker (ELCB) Main Breaker 220/240V Breaker Weld Terminals A Bonnet Grounding Weld Terminals B 220/240V Receptacle Terminal 380/415V Receptacle (Inside ※Left Side) (Inside) Frequency Selector Air Cleaner Fuel Filter VRD Switch Sub Tank Right Door Oil Filter Battery Isolator Oil Gauge...
  • Page 14 Roping Lug Lifting Lug Top Plate Muffler Accessories Owner’s and Operator’s Manual Terminal Cap Terminal Cap Tail Pipe Pipe Band (Black/For [ (Red/For [ + ]) 1 part 1 part 2 parts 2 parts - 9 -...

  • Page 15: 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 16: Weld Output Control

    5-3. Weld Output Control (1) Weld Mode Selector Output Control You can select a weld mode of "CV- Dial WIRE", "DROOP-STICK", "GOUGING", "LIFT START TIG" or "CC-STICK" in Weld Mode accordance with the type of welding being Selector performed.  CV (Constant Voltage) -WIRE Arc Control You can use the equipment as a Dial...

  • Page 17: Remote Control (9-Pin Connector)

    5-4. 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 18: Error Code Display

    (2) Hour Meter When the RUN / STOP SWITCH is set to "RUN" while the engine is stopped, the display indicates operating time. Refer to the table below for the display 10,000 hours or more. (Maximum indication up to 49,999 hours) Operating Time Guide Display Operating Time...

  • Page 19: Monitor Lamp

    5-8. 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 20: Earth Leakage Circuit Breaker And Grounding

    5-9. Earth Leakage Circuit Breaker and Grounding Warning: Electric Shock  Always be sure to repair the corresponding earth leakage location when earth leakage circuit breakers operate. Warning: Fire  Do not ground wiring of earth leakage circuit breakers of the equipment to piping that passes through flammable material.

  • Page 21: Emergency Stop Switch

    5-10. Emergency Stop Switch Stop Press the emergency stop switch to stop the engine immediately. After pressing the emergency stop switch, securely return the RUN/STOP switch to the "STOP" position and turn the emergency stop switch clockwise to reset the switch. Reset 5-11.

  • Page 22: Wire Feeder Control

    5-13. Wire Feeder Control A wire feeder with a 14-pin plug can be used Wire Feeder with this equipment. (1) 14-Pin Connector Connecting the 14-pin plug of a wire feeder to the 14-pin connector of the equipment allows you to adjust the output voltage by using the wire feeder.

  • Page 23: Pre-Operation Inspection

    Caution: Injury  Do not move the equipment during operation.  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 24: 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.

  • Page 25: Fuel Inspection

    <Note>  Use a long-life coolant (LLC) in order to prevent Radiator Cap Top Plate freezing and rust. (An LLC with a 30% mixing ratio is used when shipped from the factory.)  Use an LLC mixing ratio in the range 30% to 50% in accordance with the outdoor air temperature.

  • Page 26: Spill Containment Inspection

    7-4. Spill Containment Inspection Warning: Fire  Spilled fuel and oil accumulates in the spill containment. Do not operate the equipment with liquid accumulated in the spill containment. Open the right door, check inside of the spill containment, and drain any liquid that has accumulated.

  • Page 27: Operating Procedures

     Battery Replacement Procedures Hold-Down Clamp 1) Remove the " " (negative) cable. – ]Post (Always be sure to first remove the " " (negative) ]Post side.) 2) Remove the battery hold-down clamp. 3) Remove the “+” (positive) cable. 4) Remove the battery. * Install the battery by performing the above procedures in reverse order.

  • Page 28: Starting The Engine

    8-1. Starting the Engine 1) Turn all breakers (Main, ELCB, 3-P 380/415V and 1-P 220/240V) to "OFF". 2) Turn the fuel valve (on the water separator) to "OPEN". 3) Set the idle control switch to "AUTO". 4) Check that the emergency stop switch has been released. 5) If the temperature is 5℃...

  • Page 29: Emergency Stop

    8-3. Emergency Stop The equipment includes an emergency stop device. Press the emergency stop switch if you want to immediately stop the engine when an emergency occurs in the work area, the equipment suffers an operating fault, and similar circumstances. <Note>...

  • Page 30: Welding Cable Connection

    (1) Shielded Metal Arc Welding, Gouging, Lift Start TIG, Scratch Start TIG Polarity Applications Connecting Method Indication + (positive) terminal Shielded metal arc welding of : Earth (Base material) Straight structures and similar items DC– Polarity Lift Start TIG Welding - (negative) terminal Scratch Start TIG Welding : Holder (welding rod)

  • Page 31: Duty Cycle

    Amount of Welding Personnel and Welding Cable Connection Locations Shielded Metal Arc Welding / Gouging Semi-automatic Arc Welding Single Dual Single Dual Welding Rod Welding Rod Welding Wire Welding Wire 2.0 - 8.0 2.0 - 6.0 : 0.6 - 1.2 MIG/MAG : 0.6 - 1.2 MIG/MAG Gouging Rod...
  • Page 32 Caution: Burn  Always be sure to wear leather gloves, apron, shoe covers, arc-proof glasses (face shield), safety shoes, hard hat and long-sleeve clothing to protect against the scattering of weld spatter that occurs during welding. Caution: Injury to Eyes and Skin ...
  • Page 33 Semi-automatic Arc Welding Not Using a Remote Controller  Not Using a 14-Pin Connector Output Control Dial 1) Set the weld mode selector to "CV-WIRE". Equipment 2) Switch the single/dual selector in Work Clip Lead accordance with the amount of welding Wire personnel and desired weld output.

  • Page 34: Using As A Generator

    10. Using as a Generator 10-1. Output Types and Ranges (1) 3-Phase 380/415V 3-P 380/415V Receptacle The equipment includes one 3-phase 380/415V receptacles. The total maximum output available from the receptacles is 18.0/21.5kVA. (2) 1-Phase 220/240V The equipment includes three 1-phase 220/240V receptacles.

  • Page 35: Operation

    10-3. 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 36: Using As A Compressor

    11. Using as a Compressor Warning: Exhaust gas poisoning  The engine exhaust gas contains substances harmful to the human body. Do not operate the machine indoors, in tunnels, or in other poorly ventilated areas. Warning: Fire  The muffler and exhaust gas will be hot. Keep combustible or flammable materials (e.g., fuel, gas, paint) at a safe distance from the machine.

  • Page 37: 11-2.Stopping The Compressor

    <Note>  Do not turn the compressor switch (breaker) on and off repeatedly within a short period of time.  Check to confirm that the hoses are properly connected. Check for safety before opening the compressor air valve. Pressure Gauge Compressor Switch Main (breaker)

  • Page 38: Simultaneously Welding And Using As Ac Power Source

    12. 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 (50/60Hz) Weld Output...

  • Page 39: Inspection/Maintenance

    13. Inspection/Maintenance Warning: Electric Shock/Injury  Always be sure to stop the engine 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 40 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 Every Every...
  • Page 41 Inspection Period Pre- Every Every Every Every Every Every Inspection Item Operation 50th 1,000 1,500 2,000 Inspection hour hours hours hours hours hours hours ● 25 Spill containment ○ 1year (Check/Clean) (Clean) (1) Changing the Engine Oil Oil Plug Oil Gauge 1st time 50th hour Oil Inlet...
  • Page 42 (3) Cleaning/Replacing the Air Element 1st time: 50th hour / Clip Cleaning 2nd time and after: Every 250 hours Replacement Once in 6 times cleaning or 1 year 1) Release the air cleaner clips and remove the cleaner cap. 2) Clean or replace the air element. <If dry dust is adhering>...
  • Page 43 (6) Draining Water from the Fuel Tank Draining Water Every 250 hours 1) Remove the fuel drain plug (R 3/8”) and open the valve lever. 2) Close the valve lever after the liquid has been flushed, and apply sealant coating to the plug or wrap it in seal tape.
  • Page 44 <Note>  Secure the drain valve body using a spanner or similar tool so that it does not loosen when removing/installing the plug by turning it.  It is possible that there is a fuel or oil leak if the drained fluid contains oily components.

  • Page 45: Compressor Maintenance And Inspection

    <Note>  Do not operate the equipment with the spill containment separated.  If liquid drained from the spill containment during cleaning contains oily components, dispose of it in a manner according to the applicable laws and regulations.  If the spill containment has a leak, request repair at the retail outlet where the equipment was purchased.
  • Page 46 Maintenance inspection interval Remarks See the table below for Amount / Every Every Inspection item Periodic Periodic the relationship process 500 hrs 2,500 hrs Daily inspection inspection between and or two or one maintenance months year inspection intervals. Clean / ○...

  • Page 47: 14-2.Air Filter Cleaning

    14-2.Air filter cleaning If the pressure gauge reading does not rise or if the flow of air appears inadequate, check whether the air filter is clogged. Clean periodically. <Note>  Remove the compressor inspection hatch and compressor panel to access the compressor.

  • Page 48: Long-Term Storage

    15. Long-Term Storage Warning: Electric Shock/Injury  Always be sure to stop the engine 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 49: Troubleshooting

    16. Troubleshooting Warning: Electric Shock/Injury  Always be sure to stop the engine before performing any equipment check or maintenance.  Do not touch the equipment during operation if the equipment or your body is wet.  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 50 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". 2. Emergency stop switch is "ON". 2.
  • Page 51 Symptom Possible Causes Remedy 1. VRD switch is set to "OFF". 1. Set to "ON". VRD does not work. 2. "CV-WIRE","LIFT START TIG" 2. Set to "CC-STICK". weld mode has been selected. Compressor does not 1. Breaker is OFF 1. Turn on the breaker work 2.

  • Page 52: Engine Wiring Diagram

    17. Engine Wiring Diagram - 47 -...

  • Page 53: Generator Wiring Diagram

    18. Generator Wiring Diagram P (1 / 3) - 48 -...
  • Page 54 P (2 / 3) - 49 -...
  • Page 55 P (3 / 3) - 50 -...
  • Page 56 MEMO - 51 -...
  • Page 57 MEMO - 52 -...
  • Page 58 MEMO - 53 -...
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