Pure-Wave DG-1500W User manual

IMPORTANT ─ Please make certain that persons who are to use this equipment
thoroughlyread and understand this user’s manualprior to operation

1
C O N T E N T S
1 . S A F E T Y I N F O R M A T I O N ………………………………………………2
2 . C O N T R O L F U N C T I O N ……………………………………………3
3 . P R E - O P E R A T I O N C H E C K ……………………………………………5
4 . O P E R A T I O N …………………………………………………………6
5 . P E R I O D I C M A I N T E N A N C E …………………………………………9
6 . T R O U B L E S H O O T I N G ………………………………………………1 2
7 . S T O R A G E …………………………………………………………1 3
8 . S P E C I F I C A T I O N S …………………………………………………1 4
9 . W I R I N G D I A G R A M … … … … … … … … … … … … … … … … … … … 1 6

2
! WARNING ──────────────────────────────────
PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MATCHINE.
────────────────────────────────────────
1．SAFETY INFORMATION
1）EXHAUST FUMES ARE POISONOUS
Never operate the engine in a closed area or it may cause unconsciousness and death within a short time. Operate
the engine in a well ventilated area.
2）FUEL IS HIGHLY FLAMMABLE AND POISONOUS
Always turn off the engine when refueling
Never refuel whilesmoking or in the vicinity of an open flame.
Take care not to spill any fuel on the engine or muffler when refueling.
If you swallow any fuel, inhale fuel vapor, or allow any to get in your eyes, see your doctor immediately. If any fuel
spills on your skin or clothing, immediately wash with soap and water and change your clothes.
When operating or transporting the machine, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or
fuel tank.
3）ENGINE AND MUFFLER MAY BE HOT
Place the machine in a place where pedestrians or children are not likely to touch the machine.
Avoid placing any flammable materials near the exhaust outlet during operation.
Keep the machine at least 1 m ( 3 ft ) from buildings or other equipment, or the engine may overheat.
Avoid operating theengine with a dust cover.
Be sure to carry the generator only by its carrying handle.
Put the machine on the flat ground, for the machine eliminating heat
freely.
4）ELECTRIC SHOCK PREVENTION
Never operate the engine in rain or snow.
Never touch the machine with wet hands or electrical shock will occur.
Be sure to ground (earth) the generator.
NOTE: ───────────────
Use ground (earth) lead of sufficient current capacity.
Diameter: 0.12mm (0.005 in)/ampere
EX: 10 Ampere --1.2mm (0.055 in)
──────────────────
hot
cool air

3
5）CONNECTION NOTES
Avoid connecting the generator to commercial power outlet.
Avoid connecting the generator in parallel with any other generator.
2．CONTROL FUNCTION
DESCRIPTION
(1) Economy control switch
(2) Engine switch
(3) Fuel tank
(4) Spark plug
(5) Muffler
(6) Carrying handle
(7) Choke lever
(8) AC pilot light
(9) Overload indicator light
(10) Oil warning light
(11) Ground (earth)terminal
(12) DC protector
(13) DC receptacle
(14) AC receptacle
(15) Frequency Transfer Switch
(16) Fuel filter
(17) Fuel tank cap
(18) Fuel pump
(19) Recoil starter
(20) Fuel cock
(21) Oil filler cap
(22) Air filter cover
1 2 3 4 5 6
8 9 10 11 12 13 14
16 17
19 20
7
15 18
21 22

4
1）OIL WARNING SYSTEM
When the oil level falls below the lower level, the engine stops automatically.
Unless you refill with oil, the engine will not start again.
2）ENGINE SWITCH
The engine switch controls the ignition system.
①ON (run)
Ignition circuit is switched on. The engine can be started.
②OFF (stop)
Ignition circuit is switched off. The engine will not run.
3）ECONOMY CONTROL SWITCH
When the economy control switch is turned “ON”, the economy control unit
control the engine speed according to the connected load. The results are
better fuel connection and less noise.
4）DC CIRCUIT PROTECTOR
The DC circuit protector turns off automatically when the load exceeds the
generator rated output.
CAUTION: ──────────────────────
Reduce the load to within specified generator rated output if the DC circuit
protector turn off.
───────────────────────────
5）FUEL TANK CAP AIRVENTKNOB
The fuel tank cap is provided with an air vent knob to stop fuel flow. The air
vent knob must be turned once clockwise from the closed position. This will
allow fuel to flow to the carburetor and the engine to run.
When the engine is not in use, tighten the air vent knob counterclockwise until it
is finger-tight to stop fuel flow.
6）FUEL COCK
The fuel cock is used to supply fuel from the tank to thecarburetor.
2
1
2
1
CLOSE
OPEN
CLOSEOPEN
ONOFF
DC PROTECTOR
ON OFF

5
3. PRE-OPERATION CHECK
NOTE: ────────────────────────
Pre-operation checks should be made each time the generator is used.
───────────────────────────
1）CHECK ENGINE FUEL
Make sure there is sufficient fuel in the tank.
If fuel islow, refill with unleaded automotive gasoline.
Be sure to use the fuel filter screen on the fuel filter neck.
Recommended fuel: Unleaded gasoline.
Fuel tank capacity: (see page 14-15)
WARNING: ──────────────────────
Do not refill tank while engine is running or hot.
Close fuel cock before refueling with fuel.
Be careful not to admit dust, dirt, water or other foreign objects into fuel.
Do not fill above the top of the fuel filter or it may overflow when the fuel
heats up later and expands.
Wipe off spilt fuel thoroughly before starting engine.
Keep openflames away.
──────────────────────────
2）CHECK ENGINE OIL
Make sure the engine oil is at the upper level of the oil filler hole. Add oil as
necessary.
Remove oil filler cap and check the engine oil level.
If oil level is below the lower level line, refill with suitable oil to upper level
line. Do not screw in the oil filler cap when checkingoil level.
Change oil if contaminated.
Oil capacity: (see page 14-15)
Recommended engine oil:
API Service SJ
3）GROUND (Earth)
Make sure to ground (earth) the generator.
32¡ã
F F
80¡ã
25¡ã
CC
0¡ã
or 10W-30
SAE #30
or 10W-40
SAE #20
or 10W-30
or 10W-40or 10W-40
or 10W-30
SAE 10W
UPPER
LEVEL

6
4. OPERATION
NOTE: ────────────────────────
The generator has been shipped without engine oil. Fill with oil or it will
not start.
Do not tilt the generator when adding engine oil. This could result in
overfilling and damage to the engine
───────────────────────────
1）STARTING THE ENGINE
NOTE: ─────────────────────
Before starting the engine, do not connect the electric apparatus.
─────────────────────────
1. Open the fuel tank air vent to the OPENposition.
2. Turn the fuel cock lever to the ON position.
3. Turn the engine switch to the ON position
4. When first time to use the generator sets, pressing the primer bulb 6 times
after refuel gasoline
5. Turn the choke lever to the ││CHOKE position. Not necessary if
the engine is warm.
6. Pull the starter handle slowly until resistance is felt. This is the
Compression point. Return the handle to its original position and pull
swiftly. Do not fully pull out the rope. After starting, allow the starter handle
to return to its original position while still holding the handle. Grasp the
carrying handle firmly to prevent the generator from falling over when
pulling the recoil starter.
7. Warm up the engine.
8. Turn the choke leverback to the ││RUN position.
9. Warm up the engine without a loadfor a few minutes.
2）USING ELECTRIC POWER
1. AC APPLICATION
(a) Check the AC pilot lamp for proper voltage.
(b) Turn off the switch(es) of the electrical appliance(s) before connecting to
the generator.
CLOSE
OPEN
OPEN
ON
ON
STOP
ENGINE
SWITCH

7
(c) Insert the pulg(s) of the electrical appliance(s)into the receptacle.
CAUTION: ─────────────────────
Be sure the electric apparatus is turned off before plugging in.
Be sure the total load is within generator rated output.
Be sure the socket load current is within socket rated current.
The economy control switch must be turned to OFF when using electric
devices that require a large starting current, such as a compressor or a
submergible pump.
──────────────────────────
2．OVERLOAD INDICATOR LIGHT
The overload indicator light comes on when an overload of a connected
electrical device is detected, the inverter unit overheats, or the AC output
voltage rises. The electronic breaker will then activate, stopping power to the
generation in order to protect the generator and any connected electric devices.
The output pilot light (green) will flicker and the overload indicator light (red) will
turn on, then the engine will stop running.If so please follow the following steps:
(a) Turn off any connectedelectric devices and stop the engine
(b) Reduce the total wattage of connected electric devices within the
application range.
(c) Check for blockages in the cooling air inlet and around the control unit. If
any blockages are found, remove.
(d) Afterchecking, restart the engine.
CAUTION: ─────────────────────────────────────
The generator AC output automatically resets when the engine is stopped and then restarted.
The overload indicator light may come on for a few seconds at first when using electric devices that require a large
starting current, such as a compressor or a submergiblepump. However, this is not a malfunction.
──────────────────────────────────────────
ON
OFF
ECON.
SWITCH

8
3. DC APPLICATION (option)
This usage is applicable to 12V battery charging only.
(a) Charging instruction for battery
Disconnect the leads for the battery.
Make the battery fluid filler cap loose fully.
Fill distilled water to the upper limit, if the battery fluid is low level.
Measure the specific gravity for the battery fluid by using the hydrometer,
and calculate the charging time in according with the table shown on right
side.
The specific gravity for the fully charged battery shall be within 1.26 to
1.28. It is recommended to confirm every hour.
(b) Connect between the DC output socket and the battery terminals using
the charging leads. The leads shall be connected making sure of the (+)
and (-) polarity.
(c) The DC circuit protectoris to be set to ON after confirming theconnection,
if the protector is in OFF position.
CAUTION: ──────────────────────
Be sure the economy control switch is turned OFF while charging the
battery.
───────────────────────────
3）STOPPING THE ENGINE
1. Turn off the power switch of the electric apparatus or disconnect any
electric devices.
2. Turn the engine switch to STOP position.
3. Turn the fuel cock lever to OFF.
4. Turn the fuel tank cap air vent knob counterclockwise to the CLOSED
position.
.
3
2
1
C
Specific gravity 20¡ã
3. 47AH 20HR
2. 35AH 20HR
1. 30AH 20HR
Battery capacity
chargong time Hr 810
4620
1.06
1.14
1.10
1.22
1.18
1.26
1.30
Aim for specific gravity and charging time
ON
STOP
ENGINE
SWITCH
OFF
CLOSE
OPEN
CLOSE

9
5. PERIODIC MAINTENANCE
1)MAINTENANCE CHART
Regular maintenance is most important forthe best performance and safe operation.
Item
Remarks
Pre-operation
check
(daily)
Initial
1 months
or 20 Hr
Every
3 months
or 50Hr
Every
6 months
or100Hr
Every
12 months
or 300Hr
Spark
Plug
Check condition adjust gap and
clean. Replace if necessary.

Engine
Oil
Check oil level

Replace


Oil filter
Clean oil filter

AirFilter
Clean. Replace if necessary.

Fuel Filter
Clean fuel cock filter. Replace if
necessary

Choke
Check choke operation

Valve
Clearance
Check and adjust when engine
is cold.

Fuel Line
Check fuel hose for crack or
damage. Replace if necessary.

Exhaust
System
Check for leakage. Retighten or
replace gasket if necessary

Check mufflerscreen.
Clean / replace if necessary.

Carburetor
Check choke operation

Cooling
system
Check fan damage.

Starting
system
Check recoil starter operation.

Idle speed
Check and adjust engine idle speed

Fittings /
Fasteners
Check all fittings and fasteners
correct if necessary.

Crankcase
breather
Check breather hose for cracks or
damage. Replace if necessary

Generator
Check the pilot light comes on


10
2）ENGINE OIL REPLACEMENT
1. Place the machine on a level surface andwarm up the engine for several
minutes. Then stop the engine and turn the fuel cock knob to OFF.
Turn the fuel tank cap air vent knob clockwise.
2. Loosen the screw and remove the cover.
3. Remove the oil filler cap
4. Place an oil pan under the engine. Tilt the generator to drain the oil
completely
5. Replace the generator on a level surface.
6. Add engine oil to the upper level.
7. Install the oil filler cap
8. Install the cover and tighten the screw
Recommended engine oil: (see page 14-15)
API Service “ SJ”
CAUTION: ──────────────────────
Be sure no foreign material enters the crankcase.
Do not tilt the generator when adding engine oil. This could result in
overfilling and damage to the engine
Clean the oil filter every other 100hr.
───────────────────────────
3）AIRFILTER
Maintaining an air cleaner in proper condition is very important. Dirt induced
through improperly installed, improperly serviced, or inadequate elements
damages and wears out engines. Keep the element always clean.
1. Remove the cover.
2. Remove the air filter cover and element.
3. Wash the element in solvent and dry.
4. Oil the element and squeeze out excess oil. The element should be wet but
not dripping.
5. Insert the element into the air filter.
6. Install the cover
UPPER
LEVEL

11
CAUTION: ──────────────────────
The engine should never run without the element; excessive piston and/or
cylinder wear may result.
───────────────────────────
4）CLEANING AND ADJUSTING SPARK PLUG
1. Removethe cover.
2. Check for discoloration and remove the carbon.
3. Check the spark plug type and gap.
4. Install the spark plug.
5. Install the cover
5）FUEL TANK FILTER
1. Removethe fuel tank capand filter.
2. Clean the filter with solvent. If damaged, replace.
3. Wipe the filter and insert it.
! WARNING ────────────
Be sure the tank cap is tightened securely.
─────────────────
6）MUFFLERSCREEN
! WARNING ─────────────────────
The engine and mufflerwill be very hot after the engine has been run.
Avoid touching the engine and muffler while they are still hot with any part
of your body orclothing during inspection or repair.
──────────────────────────
1. Remove the cover.
2. Remove the muffler screen.
3. Use the flathead screw driver to pry thespark arrester out from the muffler
Standard electrode color: Tan Color
Standard Spark Plug: see page 14-15
Spark Plug Gap: 0.6-0.7 mm (0.024-0.028 in)

12
4. Remove the carbon deposits on the muffler screen and spark arrester
using a wire brush.
5. Install the muffler screen.
6. Install the cover
6．TROUBLE SHOOTING
1）Engine won’t start
1. Fuel systems
No fuel supplied to combustion chamber.
No fuel in tank….Supply fuel.
Fuel in tank….Fuel tank cap air vent knob to OPEN, fuel cock knob to ON.
Clogged fuel line….Clean fuel line.
Clogged carburetor….Clean carburetor.
2．Engine oil system
Insufficient
Oil level is low….Add engine oil.
3. Electrical systems
Poorspark
Spark plug dirty with carbon or wet….Remove carbon or wipe spark plug dry.
Faulty ignition system….Consult dealer.
4. Compression insufficient
Worn out piston and cylinder….Consult dealer.
2）Generator won’t produce power
Safety device (AC) to “OFF” …Stop the engine, then restart.
Safety device (DC) to “OFF” …Press to reset the DC protector

13
7. STORAGE
Long term storage of your machine will require some preventive procedures to guard against deterioration.
1）DRAIN THE FUEL
1. Remove the fuel tank cap, drain the fuel from the fuel tank
2. Remove the cover, drain fuel from the carburetor by loosening the drain screw.
2）ENGINE
1. Remove the spark plug, pour in about one tablespoon of SAE 10W30 or 15W40 motor oil into the spark plug hole
and reinstall the spark plug.
2. Use the recoil starterto turn the engine over several times (with ignition off).
3. pull the recoil starter until you feel compression.
4. Stop pulling.
5. Clean exterior of the generator and apply a rust inhibitor.
6. Store the generator in a dry, well-ventilated place, with the cover place over it.
7. The generator must remain ina vertical position.

14
8. SPECIFICATION
MODEL
950i
1500i
GENERATOR
Type
Inverter Generator
AC Voltage
50Hz
100V, 220V, 230V, 240V
60Hz
100V,110V, 120V,220V, 240V
Max. Output
0.80 kW
1.5kW
Rated Output
0.70 kW
1.2 kW
Power Factor
1.0
DC Output
12V / 4.0A (Option)
ENGINE
Model
PureWave DG-950
PureWave DG-1500
Type
Air-cooled,4 cycle, OHV, Gasoline Engine
Bore×Stroke mm×mm
39×33.5
44×39.5
Displacement
40 cc
60 cc
Max. Output
0.9KW / 5500rpm
1.5KW / 5500rpm
Fuel
Regular AutomobileGasoline
Fuel tank Capacity
2.1 liters
3.0 liters
Rated Continuous Operation
4.1 hr
4.8 hr
Lubricating oil
SAE 10W30
Lubricating oil Capacity
0.25 liter
0.27liter
Starting System
Recoil Starter
Ignition system
C.D.I.
Spark Plug: Type
CMR6A (TORCH)
A5RTC (TORCH)
DIMENSION
Net dimension L×W×H
395×209×355 mm
448×236×392 mm
Overall dimension L×W×H
425×230×380mm
480×255×425 mm
Net Weight
20 lb
30 lb
Gross Weight
22 lb
32 lb
Specifications subject to change without prior notice.

15
9．WIRING DIAGRAM
950i,1200i
BL
BL
BL
BL
BL
BL
W
W
INVERTER
UNIT
OVERLOAD
LOW OIL
R
PI
BL
BR
GR
P
Y/G
W
O
R
BU OUTPUT
R
SUB
WINDING
MAIN
WINDING
M
R
O Bu PI Br
IGNITION
WINDING
OIL SENSOR
DC
WINDING
SPARK PLUG
SPRING WINDING
CONTROL PANEL BLOCK
GENERATOR BLOCK
ENGINE BLOCK
GROUND
TERMINAL
GRAY
YELLOW/GREEN
PI Gr PINK
Y/G
ORANGE
YELLOW O
Y
BL
Bu
BLACK
BLUE
BROWN
RED
Br
R
W WHITE
G GREEN
P
ENGINE SWITCH
W
BL W P
BL O
RY/G
Y/G
Y/G
Bu
Bu
Bu
BL
R
BL
P PURPLE
DC OUTPUT
ECO. SWITCH
IGNITION CONTROLLER
STEPPER MOTOR ASSY.
RECTIFIER
IGNITION COIL
R
DC PROTECTOR 4.5A
+
FUSE 15A
R
BL
R
BL
Y/G
AC OUTPUT
R
R