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OWNER'S AND
OPERATOR'S MANUAL
SOUND PROOF DIESEL
ENGINE
GENERATOR/WELDER
DGW500DM
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.
Table of Contents
and Water Leakage
Generating
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DGW500DM/ANZ
X750-027 88 0
X750803-780 2
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Table of Contents
Related Manuals for Shindaiwa DGW500DM/ANZ
Summary of Contents for Shindaiwa DGW500DM/ANZ
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Page 1: Table Of Contents
12.Long-term Storage 13.Troubleshooting 13-1.Symptom and Countermeasures 13-2.Error Code Display 14.Engine Wiring Diagram 15.Generator Wiring Diagram CAUTION: Do not operate the Generator/Welder, or any other appliance, before you have read and understood the instructions for use. DGW500DM/ANZ X750-027 88 0 X750803-780 2... - Page 2 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 instructions herein, to avoid unnecessary accidents and repairs.
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Page 3: Safety Guidelines
1. Safety Guidelines Danger : Suffocation from exhaust fume 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 ... - Page 4 Caution : Explosion Do not use the equipment or charge the battery, in the case the battery fluid level is lower than the LOWER level. Battery may emit some combustible gas, so keep it away from fire and sparks. Caution : Fire ...
- Page 5 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. ① Suffocation from exhaust fume (No. X505-004900) ②...
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Page 6: Specifications
2. Specifications Model DGW500DM Generating Method Rotating Field OPERATION SINGLE DUAL Rated Current (A) Rated Voltage (V) 39.2 29.2 Duty Cycle CC MODE Current Adj. Range (A) 60 – 500 30 – 280 Welding Rod (φ) 2.6 – 8.0 2.0 – 6.0 Gouging Rod (φ) 3.2 –... -
Page 7: Parts
4. Parts CONTROL PANEL WELDING TERMINAL A WELDING TERMINAL B DC METER AC METER VRD LAMP OPERATION MODE SELECTOR SWITCH OUTPUT CONTROL DIAL EMERGENCY STOP SWITCH SINGLE/DUAL ROD SELECTOR SELECTOR SWITCH SWITCH CV/CC SELECTOR SWITCH ARC CONTROL DIAL IDLE CONTROL HOUR METER STARTER SWITCH MONITOR LAMP... - Page 8 1-P RECEPTACLE 3-P RECEPTACLE MAIN BREAKER EARTH LEAKAGE CIRCUIT BREAKER (ELCB) 1-P BREAKER 3-P BREAKER BONNET GROUNDING TERMINAL HOLES FOR THE FORKLIFT RIGHT DOOR AIR CLEANER OIL PLUG BATTERY OIL INLET ISOLATOR SUB TANK FUSE (60A, 20A) FUEL INLET BATTERY FUEL COVER OIL GAUGE FUEL LEVER...
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Page 9: Equipment
5. Equipment 5-1. Welding Output Control (1) CV/CC The equipment incorporates CV (Constant Voltage) and CC (Constant Current) characteristic feature. Connecting a wire feeder and then turning the CC/CV Selector Switch to [CV-WIRE], semi-automatic welding such as MIG, MAG, SS, etc. is available to perform. -
Page 10: Vrd
5-2. VRD The equipment incorporates VRD (Voltage Reduction Device) feature, for the purpose of protecting an operator from electric shock with welding current. When the VRD Switch is turned to [ON], the voltage changes to 35V or lower during no welding period. The equipment is incorporated in monitoring function of VRD. -
Page 11: Remote Controller
(5) Circuit Protector for Wire Feeder When the over current (more than 5A) is flown into 14-Pin Connector for wire feeder, the Circuit Protector will be activated to shut off the current. <Caution> Resolve the over current issue to proceed the necessary maintenance when the Circuit Protector was activated, with reset the trip button. -
Page 12: Monitor Lamp
(2) AC Meter The meter displays the 3-Phase voltage (U-V) and the frequency in AC output. <Caution> While Operation Mode Selector Switch is [GEN. WELDER] or [GEN. ONLY], AC Meter displays 3-Phase voltage and frequency. When the Operation Mode Selector Switch is [WELDER ONLY], AC Meter display will goes off. - Page 13 (2) Battery Charge Monitor Lamp When the battery turns unable to be charged during operation, the battery charge monitor lamp will flash and the automatic shutoff will be engaged. In the event this occurs, consult with the authorized distributor or our engineering section.
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Page 14: Earth Leakage Relay
5-7. Earth Leakage Relay Danger : Electric Shock Ground every grounding terminal to the earth as set out in the manual. If even one of all is unconnected by mistake or accident, it will be much more dangerous for human body than the NO RELAY case, because leaking current inevitably goes through the body. -
Page 15: Auto Idle Feature
(3) The Earth Leakage Relay has activated Caution : Electric Shock / Injuries Be sure to disconnect all the loads to the equipment when turning the breakers ON again, after the earth leakage relay has activated. When the earth leakage relay has activated, the ELCB (lever) turns to [OFF]. In the case, stop the engine promptly and find the leakage point to repair. -
Page 16: Initialization And Pre-Check
6. Initialization and Pre-check Caution : Fire・Burns・Injuries When checking engine, always stop the engine, and keep away from fire. Wait until the engine cools down, before performing any checks. 6-1. Checking Engine Oil When checking for engine oil, be sure to keep the equipment leveled, and insert the oil gauge all the way in. -
Page 17: Radiator Cap
(1) Filling to the Reservoir Tank RIGHT DOOR ① Remove the sub tank cap. SUB TANK CAP ② Fill up the sub tank to the FULL level. ③ Install the cap back. SUB TANK (2) Filling to the Radiator ① Open the top plate. ②... -
Page 18: 6-4.Checking Fuel, Engine Oil
6-4. Checking Fuel, Engine Oil and Water Leakage Caution : Fire Do not use this equipment when a leak is found. Repair the equipment before use. Be sure to check any leakage for fuel, oil and coolant/water at the hose connections by opening side doors. -
Page 19: Operation
7. Operation Danger : Suffocation from exhaust fume 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. Caution : Suffocation from exhaust fume ... -
Page 20: 7-2.Stopping
<Caution> 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. Once the engine has started, never turn the starter switch to [START]. ... -
Page 21: Welding Operation
② Turn the Emergency Stop Switch to arrow mark (clockwise) to release the feature. <Caution> Be sure to re-start the engine after releasing the Emergency Stop feature. The engine does not start again though the starter motor is running, without releasing the emergency stop feature. -
Page 22: 8-3.Connection-Welding Cable
(1) Welding Rod (include Gouging Rod) Application Connection Generals Welding, such as Plus to the Earth (Material) Normal Polarity Construction Minus to holder (Rod) Thin Plate, Build-Up Welding, Plus to holder (Rod) Reverse Polarity Stainless Steel , Gouging Minus to the Earth (Material) (2) Semi-automatic wire feeder Application Connection... -
Page 23: 8-4.Duty Cycle
8-4. Duty Cycle Duty cycle is the percentage of time the load is being applied in a 10 minutes period. For example, a 60% duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minutes period. <Caution>... -
Page 24: Generator Operation
(1) Welding Rod (include Gouging Rod) ① Turn the Weld Terminals Switch to [WELD TERMINALS ON]. ② Turn the SINGLE/DUAL Selector Switch to [SINGLE] or [DUAL], according to the operation. ③ Turn the CV/CC Selector Switch to [CC-STICK, GOUGING]. ④ Turn the Rod Selector Switch to [CELLLOSE] on cellulose rod welding or to [OTHERS] on gouging or ordinal welding rods except cellulose rod. -
Page 25: 9-2.Output Limitation
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 character of the components. Applicable Load (For reference purpose only) Capacity (kW) 1-Phase 3-Phase... -
Page 26: Main Breaker
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]. Caution : Damage to the property・Aftermath Whenever connecting to use medical equipment or appliances, be sure to consult with the medical equipment company, doctor or hospital personnel. -
Page 27: Simultaneous Use Of Welding And
10. Simultaneous Use of Welding and Generating The circuit breakers (Main, 3-P, 1-P) react 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. ... - Page 28 <Caution> The authorized technicians should perform all checking and maintenance work, except for the pre-startup checks. Request for the maintenance item with ● mark to the authorized distributor or our engineering section. Always use our genuine parts of replacement. ...
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Page 29: Right Door
Checking Time Startup Every Every Every Every Every Checking Items Check 50hr 1000 2000 Check/Add Battery ○ ○ ○ Water Clean Change after 14 Clean Air Element ○ ○ 15 Change Air Element ○ after Adjust Tension V-Belt ● ● ●... -
Page 30: Oil Filter
(2) Oil Filter Change First Time 50 hour mark or after Every 200 hours RIGHT DOOR OIL FILTER ① Drain the engine oil completely, as described in『11 (1) Oil Change』. ② Loosen and remove the oil filter, using an oil filter wrench. ③... - Page 31 (4) Clean/Change Fuel Strainer Clean 50 hours and Every 100 hours afterwards Replace Every 400 hours RETAINER FUEL LEVER RING RIGHT DOOR CLOSE OPEN ELEMENT FUEL STRAINER ① Turn the fuel lever to [CLOSE]. ② Unscrew the retainer ring counterclockwise, and remove the cup and the filter element.
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Page 32: Long-Term Storage
(6) Drain Water from Fuel Tank Drain Water Every 200 hours ① Unscrew the fuel drain plug. ② Reinstall the drain plug, after draining water completely. <Caution> FUEL DRAIN PLUG Change the packing, whenever changing oil. Packing Part No. ： 6C090-58961 (Kubota) (7) Changing Coolant/Water Replace Every 1 year or 2000 hours... -
Page 33: Troubleshooting
If the generator/welder will not be used for more than two months, perform the following maintenance and storage procedures. ① Remove the battery. ② Change the engine oil. ③ Drain fuel from the fuel tank, the Fuel Strainer and the Water Separator. ④... -
Page 34: Output Limitation
Symptoms Possible Cause Corrective Actions 1. SINGLE/DUAL Selector Switch 1. Turn to [SINGLE] mode position is incorrectly selected to [DUAL] mode 2. Wrong Output Control Dial 2. Turn the dial clockwise position 3. Arc Control Dial is set to 3. Turn the Arc Control Dial negative(－) side for CC mode clockwise to positive(＋) side Welding Arc is... -
Page 35: 13-2.Error Code Display
13-2. Error Code Display Inspect the following items accordingly when the Error Code E01－E05 are displayed on the control panel. Error No. Possible Causes Corrective Actions Turn the Idle Control Switch to [AUTO] and cool down the unit with no-load operation until [OVERHEAT] Monitor Lamp blinking will be stopped. -
Page 36: Engine Wiring Diagram
14. Engine Wiring Diagram - 35 -... -
Page 37: Generator Wiring Diagram
15. Generator Wiring Diagram - 36 -... - Page 38 - 37 -...
- Page 39 - 38 -...
- Page 40 ©2023...
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