Shindaiwa DGW400DMK User manual

OWNER’S AND OPERATOR’S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
DGW400DMK-S1
X753-005 84 0
X753803-070 0
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.

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.
This equipment should only be operated by persons who thoroughly understand the
contents of this manual and can safely operate the equipment. Persons who are ill,
taking medicine, or are in bad health should not operate this equipment if such
conditions will affect operation of the equipment and related work.
Operation and use of this equipment must be in strict compliance with the
applicable laws, as well as rules and regulations based on such laws.
Always be sure to include this manual with the equipment if it is loaned out to
another party, and instruct said party that they must thoroughly read this manual
before operating the equipment.
Store this manual securely in a predetermined location so that it can be readily
accessed at all times to order parts or arrange for repair. Contact the retail outlet
where this equipment was purchased if any parts are lost, the equipment becomes
soiled, or is otherwise damaged in any manner.
Consult with the retail outlet where the equipment was purchased if any of the
points are unclear or you would like further information.
Be sure to note the model name and serial number of your equipment, and provide
this information when making an inquiry.
If disposing of this equipment, dispose in a manner according to laws and
regulations applicable to industrial waste. Consult with the retail outlet where the
equipment was purchased if you have any inquiries regarding proper disposal.
The precautions used in this manual are divided into the following three ranks.
It is possible that items described under <Caution >or <Note >can result in a
serious accident depending on the circumstances. The contents of both of these
types of precautions are important. Be sure to always comply with all precautions.
Warning: Improper operation can result in death or serious personal injury.
Caution: Improper operation can result in moderate or minor personal injury, or
physical damage.
<Note>: Explanatory note in order to ensure that equipment protection and
performance are fully realized.

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Table of Contents
1. Safety Precautions...............................................................................2
2. Specifications .......................................................................................6
3. Applications ..........................................................................................6
4. Part Names............................................................................................7
5. Equipment.............................................................................................9
5-1. Spill Containment...........................................................................9
5-2. Idle Control....................................................................................9
5-3. Weld Output Control....................................................................10
5-4. Remote Control Receptacle........................................................ 11
5-5. Meter............................................................................................ 11
5-6. Error Code Display......................................................................12
5-7. Monitor Lamp...............................................................................12
5-8. Earth Leakage Circuit Breaker and Grounding...........................13
5-9. Emergency Stop Switch ..............................................................14
5-10. Frequency Selector...................................................................15
6. Transporting........................................................................................15
7. Pre-Operation Inspection...................................................................16
7-1. Engine Oil Inspection ..................................................................16
7-2. Cooling Water Inspection ............................................................17
7-3. Fuel Inspection............................................................................17
7-4. Spill Containment Inspection.......................................................18
7-5. Inspection for Fuel/Oil/Cooling Water Leakage ..........................18
7-6. Battery Inspection........................................................................18
8. Operating Procedures........................................................................19
8-1. Starting the Engine......................................................................20
8-2. Stopping the Engine....................................................................21
8-3. Emergency Stop..........................................................................21
9. Using as a Welder...............................................................................21
9-1. Welding Cable Selection.............................................................21
9-2. Welding Polarity...........................................................................22
9-3. Welding Cable Connection..........................................................22
9-4. Duty Cycle...................................................................................23
9-5. Welding Work ..............................................................................23
10. Using as a Generator .......................................................................25
10-1. Output Types and Ranges.........................................................25
10-2. Usable Device Capacities .........................................................25
10-3. Operation...................................................................................26
11. Simultaneously Welding and Using as AC Power Source...........27
12. Inspection/Maintenance...................................................................28
13. Long-Term Storage...........................................................................34
14. Troubleshooting ...............................................................................35
15. Engine Wiring Diagram....................................................................38
16. Generator Wiring Diagram...............................................................39

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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
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.
Warning: Electric Shock
Do not operate the equipment with any doors or covers open.
Do not touch wirings or any electric parts inside the equipment during operation.
Do not touch the equipment during operation if the equipment or your body is wet.
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.
Do not insert any metallic objects, such as pins or wires, intoAC output receptacles
or remote control receptacles.
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.
Always be sure to stop the engine and remove the engine key before performing any
equipment check or maintenance.
Warning: Fire
Always be sure to stop the engine when inspecting fuel or refueling, and absolutely
never perform such tasks near fire or other open flame. Wait until the engine has
completely cooled before inspecting fuel or refueling.
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.
Absolutely never use the equipment if there is a fuel, oil or cooling water leak, and be
sure to always repair the leak before using.
Absolutely never inspect or perform maintenance to the equipment near fire or other
open flame.
Keep any ignitable items (such as fuel, gas and paint) or inflammable items away
from the equipment because the muffler, exhaust fume and other parts attain high
temperatures.
Keep any ignitable items (such as fuel, gas and paint) or inflammable items away
from the work area due to the scattering of weld spatter that occurs during welding.
Provide at least 1 meter (3 feet) of distance between the equipment and walls and
other obstacles, and operate the equipment on a flat surface.
Allow the equipment to cool before covering with protective covers and similar items.
Do not ground wiring of earth leakage circuit breakers of the equipment to piping that
passes through flammable material.

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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.
Always be sure to stop the engine and remove the engine key before performing any
equipment check or maintenance.
Warning: Injury to Eyes and Skin
Use protective gear, such as rubber gloves, when inspecting or replacing the battery
due to the dilute sulfuric acid in the battery fluid. Be sure that fluid does not get into
eyes, or on skin or clothing.
If battery fluid gets into the eyes, or on the skin or clothing, immediately wash with a
large amount of water, and always be especially sure to seek medical attention if it
gets into the eyes.
Warning: Explosion
Do not operate the equipment or recharge the battery when the battery fluid level is
below the lower level.
Do not generate any sparks near the battery and do not allow any fire or other open
flame near the equipment because the battery generates ignitable gas.
Warning: Electromagnetic Interference
Persons using a heart pacemaker are not allowed near the welder or welding work
area while welding is being performed without the permission of a doctor. The welder
generates a magnetic field while energized that can negatively affect pacemaker
operation.
Caution: Suffocation from Exhaust Fume
Do not direct the engine exhaust towards passersby, private homes or similar
persons/locations because the engine exhaust fume includes components that are
harmful to humans.
Caution: Electric Shock
Do not sprinkle water on the equipment and do not use where exposed to rain.
If wearing gloves, be sure to always wear gloves with dry insulation properties. Do
not wear gloves that are damaged or wet.
Caution: Burn
The engine, muffler and similar parts are extremely hot during operation and
immediately after stopping the equipment. Never touch hot parts.
Never open the radiator cap during operation or immediately after stopping the
equipment. Hot cooling water and steam will spurt out.
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.

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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.
Always be sure to turn off the power switches of all devices using the equipment
when turning on the equipment breakers. Leaving on the power switch of a device
using the equipment when the equipment breakers are turned on could result in the
sudden operation of the corresponding device.
Do not leave on the power switch of a device using the equipment and do not
connect a device to anAC output receptacle.
The lifting lug is designed to be used only for lifting the equipment. Do not lift the
equipment with any heavy items (such as a trailer, gas canister and additional fuel
tank) added to the equipment.
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.
Securely fix the equipment with rope or similar item so that it cannot move when
transporting by truck or other vehicle.
Caution: Injury to Eyes and Skin
Always be sure to wear arc-proof glasses, clothes that completely cover the skin and
other protective gear when welding to protect the eyes and skin from harmful light
rays generated during welding.
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: Physical and Secondary Damage
Do not use the equipment for any improper applications. Improper usage can result in
an accident or malfunction.
Do not connect theAC power source to indoor wiring.
If using the equipment as a power source for medical equipment, you must check
with the medical equipment manufacturer, doctor and hospital before using the
equipment.
Set the frequency in accordance with the devices using the equipment.

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Location 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. X505-007610)
(4) Injury (No. X505-007630)
(5) Burn (No. X505-007620)
(6) Fire (No. X505-007650)
(7) Injury (No. X505-007550)
(8) Burns (No. X505-007660)
(4)
(1)
(2)
(3)
(5)
(8)
(7)
(6)

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2. Specifications
Model
DGW400DMK-S1
Generating Method
Rotating Field
Welding Generator
Operation
Single
Dual
CC
DROOP
Rated Current (A)
370 / 390
180 / 200
Rated Voltage (V)
34.8 / 35.6
27.2 / 28.0
Duty Cycle (%)
60
100
Current Adj. Range (A)
95 –390 / 110 –400
50 –200 / 60 –210
Welding Rod ()
2.6 –8.0
2.0 –4.0
Gouging Rod ()
3.2 –8.0
3.2 –5.0
CV
Rated Current (A)
330 / 340
180 / 200
Rated Voltage (V)
31.5 / 32.0
20.0 / 21.0
Duty Cycle (%)
100
100
Voltage Adj. Range (V)
14 –34.5 / 14.5 –35
14 –21 / 14.5 –23.5
Welding Wire ()
0.6 –2.0
0.6 –1.6
Rated Speed (min-1 )
3000 / 3600
No Load Voltage (V)
MAX 85
AC Generator
Rated Frequency (Hz)
50 / 60
Rated Speed (min-1 )
3000 / 3600
Phase
1 Phase
Rated Voltage (V)
110 / 115
230 / 240
Rated Output (kVA)
3.3 / 3.5
6.9 / 7.2
Power Factor
1.0
Rating
Continuous
Engine
Model
Kubota D902
Type
Vertical, Water-Cooled 4-Cycle Diesel Engine
Displacement (L)
0.898
Rated Output (kW/min-1)
15.0 / 3000 17.6 / 3600
Fuel
ASTM No.2-D Diesel Fuel or Equivalent
Lubricant Oil
API Class CD or better
Lubrication Oil Volume (L)
3.6 (Effective 1.7)
Cooling Water Volume (L)
4.0 (Sub Tank Capacity 0.6 Lincluded)
Starting Method
Starter Motor
Battery
46B24L (Japanese Industrial Standard)
Fuel Tank Capacity (L)
37
Dimen-
sion
Length (mm)
1435
Width (mm)
700
Height (mm)
848
Dry Weight (kg)
453
3. Applications
Shielded MetalArc Welding
Semi-automatic Arc Welding (MIG, MAG, Self-Shielded)
Gouging
Scratch Start TIG
Power Source for Light, Electric Tools andAppliances
Caution: Physical and Secondary Damage
Do not use the equipment for any applications not listed above. Improper usage can
result in an accident or malfunction.
If using the equipment as a power source for medical equipment, you must check
with the medical equipment manufacturer, doctor and hospital before using the
equipment.

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4. Part Names
Weld Terminals A
Weld Terminals B
Operation Panel
Terminal Cover
Remote Control
Receptacle
Hour Meter
Fuel Meter
Monitor Lamp
Starter Switch
Idle Control Switch
AC Meter
DC Meter
Output Control
Dial
ECO Drive Display
Single/Dual
Selector
Weld Mode
Selector
Arc Control
Dial
AC Meter
Selector
Emergency
Stop
Switch
1-P
230/240V Receptacle
Earth Leakage Circuit
Breaker (ELCB)
1-P
230/240V Breaker
Bonnet Grounding
Terminal
1-P
110/115V Receptacle
1-P
110/115V Breaker