Shindaiwa DGW400DML User manual

OWNER’S AND OPERATOR’S MANUAL
DGW400DML
Vertical, Water-Cooled 4-Cycle Diesel Engine
DGW400DML-D2V
X753-008 19 0
X753803-330 5
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.
California Proposition 65
WARNING
Breathing diesel engine exhaust exposes you to chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.
 Always start and operate the engine in a well ventilated area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING
Cancer and reproductive Harm-
www.P65Warnings.ca.gov
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead
compounds, and other chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm. WASH HANDS AFTER
HANDLING.

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.
Danger: Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
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. Specificaons ................................................................................................. 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. Remote Control (9-Pin Connector)........................................................ 12
5-5. Meter .................................................................................................... 12
5-6. Error Code Display ............................................................................... 13
5-7. Monitor Lamp ....................................................................................... 13
5-8. Ground Fault Circuit Interrupter (GFCI) and Grounding ........................ 14
5-9. Emergency Stop Switch (Option) .......................................................... 15
5-10. VRD (Voltage Reduction Device) ........................................................ 16
5-11. Wire Feeder Control ........................................................................... 16
6. Transporting ............................................................................................... 17
7. Pre-Operation Inspection ........................................................................... 18
7-1. Engine Oil Inspection ............................................................................ 18
7-2. Cooling Water Inspection ...................................................................... 19
7-3. Fuel Inspection ..................................................................................... 19
7-4. Spill Containment Inspection ................................................................ 20
7-5. Inspection for Fuel/Oil/Cooling Water Leakage ..................................... 20
7-6. Battery Inspection ................................................................................. 20
8. Operating Procedures ................................................................................ 21
8-1. Starting the Engine ............................................................................... 22
8-2. Stopping the Engine ............................................................................. 23
8-3. Emergency Stop (Option) ..................................................................... 23
9. Using as a Welder ...................................................................................... 24
9-1. Welding Cable Selection ....................................................................... 24
9-2. Welding Polarity ................................................................................... 24
9-3. Welding Cable Connection ................................................................... 25
9-4. Duty Cycle ............................................................................................ 26
9-5. Welding Work ....................................................................................... 26
10. Using as a Generator ............................................................................... 29
10-1. Output Types and Ranges .................................................................. 29
10-2. Usable Device Capacities ................................................................... 29
10-3. Operation ........................................................................................... 30
11. Simultaneously Welding and Using as AC Power Source ..................... 31
12. Inspection/Maintenance ........................................................................... 32
13. Long-Term Storage .................................................................................. 38
14. Troubleshooting ....................................................................................... 39
15. Engine Wiring Diagram ............................................................................ 42
16. Generator Wiring Diagram ....................................................................... 43

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1. Safety Precautions
Danger: Using a generator indoors CAN KILL YOU MINUTES
 Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.
 NEVER use inside a home or garage, EVEN IF doors and windows are open.
 Only use OUTSIDE and far away from windows, doors, and vents.
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, into AC 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 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.

- 3 -
Warning: Fire
 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.
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 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.

- 4 -
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.
 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
 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 an AC 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.
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 the AC 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.

- 5 -
 Location of Danger/Warning/Caution Labels
Replace danger, 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.
⑴
Suffocation from Exhaust Fume (No. X505-007590)
⑵
Suffocation from Welding Fume (No. X505-007600)
⑶
Electric Shock (No. X505-007610)
⑷
Injury (No. X505-007630)
⑸
Burn (No. X505-007620)
⑹
Fire (No. X505-007650)
⑺
Injury (No. X505-007550)
⑻
Burns (No. X505-007660)
⑼
EPA Regulation Complied Notice (No. X505-008400)
⑽
Warning / California / Operating
･･･
(No. X505-010400)
⑾
Warning / California / Batteries
･･･
(No. X505-010410)
⑿
Bonnet Grounding Terminal (No. M708-000890)
⒀
Danger: Using a generator
･･･
(No. X505-011430)
⑻
⑷
⑸
⑶
⑺
⒀
⑵
⑾
⑽
⑹
⑼
⑿
⑴

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2. Specificaons
Model DGW400DML-D2V
Generating Method Rotating Field
Welding Generator
Operation Single Dual
CC
DROOP
Rated Current (A) 380 200
Rated Voltage (V) 35.2 28.0
Duty Cycle (%) 60 100
Current Adj. Range (A) 30 – 390 30 – 210
Welding Rod (in.) 5/64 – 5/16 5/64 – 5/32
Gouging Rod (in.) 1/8 – 5/16 1/8 – 3/16
CV
Rated Current (A) 340 200
Rated Voltage (V) 32.0 21.0
Duty Cycle (%) 100 100
( Current Adj. Range (A) ) ( 60 – 400 ) ( 60 – 210 )
Voltage Adj. Range (V) 14 – 35 14 – 28.5
Welding Wire (in.) .025 - 5/64 .025 - 1/16
Rated Speed (rpm) 3600
No Load Voltage (V) MAX 85
AC Generator
Rated Frequency (Hz) 60
Rated Speed (rpm) 3600
Phase 1 Phase 3 Phase
Rated Voltage (V) 120 120 / 240 240
Rated Current (A) 20Ax2 40Ax1 36A×1
Rated Output (kVA) 4.8 4.8 / 9.6 15
Power Factor 1.0 0.8
Rating Continuous
Engine
Model (Manufacturer) D902 (Kubota)
Type Vertical, Water-Cooled 4-Cycle Diesel Engine
Displacement (cu.in. / liters) 55 / 0.898
Rated Output (hp / rpm) 23.6 / 3600
Fuel ASTM No.2-D,S15 EPA regulation
Lubricant Oil API Class CF or better (CJ excluded)
Fuel Tank Capacity (gal. / liters) 11.4 / 43
Lubrication Oil Volume (gal. / liters) 0.95 / 3.6 (Effective 0.45 / 1.7)
Cooling Water Volume (gal. / liters) 1.06 / 4.0 (Sub Tank Capacity 0.16 / 0.6 included)
Starting Motor Capacity (V - kW) 12 - 1.2
Charging Alternator Capacity (V - W) 12 - 150
Battery Capacity (V - Ah) 12 - 36 (46B24L)
Dimension
Length (in. / mm) 56.5 / 1435
Width (in. / mm) 27.6 / 700
Height (in. / mm) 33.4 / 848
Dry Weight (lbs. / kg) 1045 / 474
Net Weight (lbs. / kg) 1149 / 521

- 7 -
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 and Appliances
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.
4. Part Names
Weld Terminals A
Weld Terminals B
Operation Panel
Terminal Cover
Start
er Switch Cover
9
-
Pin
Connector
Hour Meter
Fuel Meter
Monitor Lamp
Starter Switch
AC Meter
DC Meter
Output Control
Dial
ECO Drive Display
Single/Dual
Selector
Weld Mode
Selector
Arc Control
Dial
AC Meter
Selector
Circuit Protector
for Wire Feeder
Wire Feeder
Voltmeter Selector
Weld Terminal
Switch
RUN/STOP Switch
14
-
Pin
Connector
VRD Lamp Idle Control Switch

- 8 -
Right Door
Fuse
(60A,20A)
Oil Gauge
Battery
Fuel Lever
(Fuel Strainer)
Fuel Drain Plug
Oil Drain Plug
Wat
er Drain Plug
Spill Containment
Fuel Filter
Sub Tank
Oil Plug
Oil Inlet
Air Cleaner
Spill Containment Drain
M
a
in
Breaker
1
-
P
120/
240
V Breaker
Bonnet Grounding
Terminal
1
-
P
120/240
V Receptacle
VRD Switch
(
Inside)
3
-
P
240
V Receptacle
Ground Fault Circuit Interrupter
(GFCI) Receptacle
1
-
P
1
2
0V Break
er
Forklift
Skid

- 9 -
Muffler
Top Plate
Fuel Inlet Cover
Fuel Inlet
Lifting Lug
Owner’s and
Operator’s
Manual
Accessories
Tail Pipe
1 part
Pipe Band
1 part
Terminal Cap
(Black/For [
-
])
2 parts
Terminal Cap
(Red/For [ + ])
2 parts
Product
Warranty
Manual
Engine
Warranty
Manual

- 10 -
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.

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.
The equipment includes a spill containment (structure that collects leaking liquid) in order
to prevent leaking liquid from getting outside of the equipment if oil, fuel or other liquid
should leak. Before starting operation, check if there is any fluid accumulated in the spill
containment and drain any accumulated liquid. (Refer to section "12.(7) Draining Liquid
from the Spill Containment".)
<Note>

It is necessary to periodically drain the liquid from within the equipment because any
rainwater that leaks into the equipment also accumulates in the spill containment.

Although the fluids that can leak internally consist of oil, fuel and cooling water, the spill
containment does not have a function that can separate rainwater that has leaked into the
equipment from these internally leaked fluids. Properly dispose of liquid drained from the
spill containment in a manner according to the applicable laws and regulations.
5-2. Idle Control
The equipment includes an idle control function.
You can use the idle control switch to select an engine
speed setting of "ECO", "AUTO" or "HIGH".
(1) ECO Drive
The equipment includes an eco drive function in order
to reduce noise, save fuel, and reduce exhaust gas
emission.
When the idle control switch is set to "ECO" and only welding is being performed, the
engine operates at an optimal speed corresponding to the weld output and it automatically
returns to low speed when welding is stopped.
The eco drive display lights up during eco drive to indicate that operation is
environmentally considerate.
<Note>

The engine speed optimization function of eco drive is only for
"DROOP-STICK", "GOUGING", "LIFT START TIG" and "CC-
STICK" welding. (It does not function if "CV-WIRE" is selected
using the weld mode selector.)

If using as an AC power source during eco drive (including when
welding and using as an AC power source at the same time), the
engine operates at high speed and the eco drive display turns off.

Set the idle control switch to "AUTO" or "HIGH" if welding or using as an AC power
source in an intermittent manner.

Set the idle control switch to "HIGH" if using a high capacity motor, precision instruments
or AC load with an attached magnetic switch.

Set the idle control switch to "HIGH" if using as an AC power source of a device of 0.5A
or less because the engine might not reach a high speed as speed control does not
operate at that level.
ECO Drive Display
Idle Control
Switch

- 11 -
(2) Auto Idle
The equipment includes an auto idle function in order to reduce noise, save fuel, and
reduce exhaust gas emission.
You can set the idle control switch to "AUTO" so that the engine operates at low speed
when not welding or using the equipment as a power source.
When you start to weld or use as an AC power source, the engine automatically increases
to high speed. When in a no-load condition, the engine automatically returns to low speed
after approximately 8 seconds of high-speed operation.
<Note>

Set the idle control switch to "HIGH" if using a high capacity motor, precision instruments
or AC load with an attached magnetic switch.

Set the idle control switch to "HIGH" if using as an AC power source of a device of 0.5A
or less because the engine might not reach a high speed as speed control does not
operate at that level.
(3) High Idle
You can set the idle control switch to "HIGH" to maintain the engine constantly at high
speed.
5-3. Weld Output Control
(1) Weld Mode Selector
You can select a weld mode of "CV-WIRE",
"DROOP-STICK", "GOUGING",
"LIFT START TIG" or "CC-STICK" in
accordance with the type of welding being
performed.
 CV (Constant Voltage) -WIRE
You can use the equipment as a power
source for semi-automatic arc welding
(MIG, MAG and self-shielded).
 DROOP (Drooping Characteristic)–STICK, GOUGING
The weld current can be adjusted by manipulating the welding rod due to being able to
increase or decrease the current for changing the arc length, thereby allowing you to
adjust the arc status and weld beads.
The arc start is good and the arc is strongly felt.
This mode is optimal for welding work such as pipe welding or when using special
welding rods.
 LIFT START TIG
The (DC) TIG welding (Lift Start) is available in this mode. The arc is generated by
bringing the tungsten electrode into contact with the base material once and then lifting
it up.
 CC (Constant Current) -STICK
Welding can be performed at a constant uniform current even if the arc length changes
due to a shaky hand or similar cause to provide a stable arc that is not easily
extinguished.
Welding can be performed at a specified current value without being affected by the
length or thickness (thinness) of the welding cable.
This mode is optimal for general welding as the stable arc reduces the amount of
spatter.
(2) Weld Output Pre-Set
The equipment includes a weld output pre-set function.
If the weld mode selector is set to "CV-WIRE", you can pre-set the output voltage using
the output control dial.
Arc Control
Dial
Output Control
Dial
Weld Mode
Selector

- 12 -
If the weld mode selector is set to "DROOP-STICK", "GOUGING", "LIFT START TIG" or
"CC-STICK", you can pre-set the output current using the output control dial.
(3) Arc Control (for CC-STICK mode)
The equipment includes an arc control function that adjusts the
arc strength.
You can adjust the setting of the short-circuit current of the
weld output by turning the arc control dial.
<Note>

The arc control function is only for "CC-STICK" mode. It does
not function if using "CV-WIRE","DROOP-STICK",
"GOUGING" or "LIFT START TIG".

Always turn the arc control dial to "0"(zero) when the scratch start TIG welding is
functioned otherwise a welding current becomes unstable as the arc control is
functioned.
5-4. Remote Control (9-Pin Connector)
You can connect a compatible remote controller to 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.

If the remote controller is removed from the remote
controller receptacle while welding, the equipment
output control dial becomes functional, possibly
resulting in a sudden increase or decrease in weld
output.
5-5. Meter
The equipment includes a DC meter that provides digital display of both weld current and
voltage, and an AC meter that provides digital display of voltage, current and frequency of
three phase 240V generated output.
(1) DC Ammeter – Voltmeter
The DC ammeter and voltmeter display the weld output
for both outputs A and B separately.
If the single/dual selector is set to "SINGLE", the DC
meter for output B does not display current or voltage.
<Note>

If the weld mode selector is set to "CV-WIRE", the set
voltage that has been pre-set using the output control
dial is displayed by the voltmeter when not welding.
(The DC ammeter display is blank when not welding.)

If the weld mode selector is set to "DROOP-STICK",
"GOUGING", "LIFT START TIG" or "CC-STICK", the set current that has been pre-set
using the output control dial is displayed by the DC ammeter when not welding. (The
voltmeter display is blank when not welding.)

During welding, both the DC ammeter and voltmeter display the actual output values.
When welding is completed, both meters display the actual output values for
approximately 8 seconds, after which display returns to the pre-set values.
Arc Control Dial
Weaker
Stronger
DC Meter
Single/Dual Selector
Remote Controller
(Compatible)
9-Pin Connector

- 13 -
(2) AC Meter
The equipment includes an AC meter that displays the three
phase 240V generated output.
The AC meter is equipped with an AC meter selector that
can be switched to display voltage, current or frequency.
<Note>

During operation, the three phase 240V output voltage of
the AC power source is constantly displayed regardless
of whether the breaker is set to "ON" or "OFF".
5-6. Error Code Display
The equipment includes an error code
display function that notifies the operator of
any errors during operation. If an error is
detected during operation, error codes are
displayed by the DC and AC meters. If this
occurs, stop operation immediately, and
inspect and repair the location where the
error has occurred.
(Refer to section "14. Troubleshooting".)
5-7. 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

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.
The equipment includes monitor lamps for water
temperature, battery charge, oil pressure and spill
containment.
If the equipment is normal, the "CHARGE", "OIL PRESS"
and "PREHEAT(5 seconds)" monitor lamps light up when
the RUN/STOP switch is switched to "STOP" to "RUN",
and all monitor lamps turn off when the engine is started.
If any error besides that of spill containment occurs during
operation, the corresponding monitor lamp lights up and
the engine is automatically stopped. If the engine is
automatically stopped, return the RUN/STOP switch to
"STOP" and restart the engine. Watch the lit/unlit status of
the monitor lamps the next time an automatic stop occurs
and check the error contents.
AC Meter
AC Meter Selector
Error Code Display
(Also used as DC and AC meters)
Battery
Charge
Water Temp
Oil Press
Spill
Containment
Preheat

- 14 -
(1) Water Temperature Monitor Lamp
The water temperature monitor lamp ("WATER TEMP") lights up and the engine is
automatically stopped if the cooling water temperature becomes irregularly high during
operation. If this occurs, inspect the water level of the sub tank and add cooling water if
the water level is insufficient. (Refer to section "7-2 Cooling Water Inspection".)
If the cooling water in the sub tank is at the specified level, it is probable that overloading
is the cause. Use within the rated output.
(2) Battery Charge Monitor Lamp
The battery charge monitor lamp ("CHARGE") lights up and the engine is automatically
stopped if battery charge fails during operation. If this occurs, it is probable that there is
fan belt damage or a wiring fault. Request repair at the retail outlet where the equipment
was purchased.
(3) Oil Pressure Monitor Lamp
The oil pressure monitor lamp ("OIL PRESS") lights up and the engine is automatically
stopped if the engine oil pressure drops during operation. If this occurs, inspect the engine
oil level and fill with engine oil until it reaches the maximum level.
<Note>
 The oil pressure monitor cannot detect oil deterioration. Change the engine oil
periodically. (Refer to section "12. Inspection/Maintenance".)
 The charge monitor cannot detect battery deterioration or insufficient battery fluid. Inspect
the battery fluid level periodically. (Refer to section "7-6. Battery Inspection".)
 Inspect the fuses if the engine is automatically stopped and none of the monitor lamps
("WATER TEMP", "CHARGE" and "OIL PRESS") light up. (Refer to section "4. Part
Names" for fuse location.)
If a fuse has blown, it is probable that there is a fault in an electric part or the wiring.
Request repair at the retail outlet where the equipment was purchased.
(4) Spill Containment Monitor Lamp
The spill containment monitor lamp ("SPILL CONTAINMENT") lights up if the level of liquid
in the spill containment is approximately 70% full (approx. 38 L) in order to ensure that
liquid accumulated in the spill containment does not spill out of the equipment. If this
occurs, drain the accumulated liquid from the equipment. (Refer to section "12.(7) Draining
Liquid from the Spill Containment".)
<Note>
 The engine is not stopped if the spill containment monitor lamp lights up during operation.
 When the spill containment monitor lamp lights up during operation, stop the engine,
check for fuel, oil and cooling water leakage, and repair as necessary.
 Do not use the equipment with liquid accumulated in the spill containment. Drain the spill
containment before using. (Refer to section "12.(7) Draining Liquid from the Spill
Containment".)
5-8. Ground Fault Circuit Interrupter (GFCI) and Grounding
Warning: Electric Shock
 Always be sure to repair the corresponding ground fault location when ground fault
circuit interrupters operate.
Warning: Fire
 Do not ground wiring of ground fault circuit interrupters of the equipment to piping that
passes through flammable material.
The equipment is provided includes ground fault circuit interrupters (solidly grounded type)
in order to prevent electric shock. Immediately isolate the electrical circuit if ground fault
occurs due to insulation failure in devices using the equipment or similar reason.

- 15 -
<Note>

The GFCI receptacles are protected by the ground fault circuit interrupters.
(1) Operation Check of Ground Fault Circuit Interrupters
Be sure to always check the ground fault circuit interrupters before starting operation
according to the following procedures.
1) Start the engine.
(Refer to section "8-1. Starting the Engine".)
2) Set the idle control switch to "HIGH".
3) Turn all breakers (main and 1-P 120V) to "ON".
4) Press the GFCI receptacle test button. Operation is normal
if the GFCI receptacle reset button pop out this time.
5) Press the GFCI receptacle reset button
until it stays in.
There is a fault in the ground fault circuit interrupters if
operation cannot be checked according to the above
procedures. Request repair at the retail outlet where the
equipment was purchased.
(2) Bonnet Grounding Terminal
The equipment includes a bonnet grounding terminal in
order to connect bonnet ground wire.
A neutral point of the AC power source is connected to
the bonnet grounding terminal.
<Note>

Connect using a plug with a grounding pole.

If using a plug without a grounding pole, perform
grounding work and check that used devices are
connected to ground.

Securely ground the bonnet grounding terminal to the metal frame of the vehicle if
transporting the equipment by truck or trailer.
(3) If a Ground Fault Circuit Interrupter Operates
Caution: Electric Shock/Injury

Always be sure to turn off the power switches of all devices using the equipment when
turning on the equipment breakers after a ground fault circuit interrupters operates.
Leaving on the power switch of a device using the equipment when the equipment
breaker is turned on could result in the sudden operation of the corresponding device.
The GFCI receptacle reset button pop out when a ground fault circuit interrupters operate.
When this occurs, immediately stop the engine and repair the ground fault location.
After repairing all faults, press the GFCI receptacle reset button until it stays in.
<Note>

There is a fault in the ground fault circuit interrupters if the
GFCI receptacle LED lamp flush and reset button pop out.
Request repair at the retail outlet where the equipment was
purchased.
5-9. Emergency Stop Switch (Option)
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.
Idle Control
Switch
GFCI
Receptacle
LED Lamp
Bonnet
Grounding
Terminal
Stop
Reset
Test
Button
1-P 120V Breaker
Reset
Button
GFCI
Receptacle
Main
Breaker

- 16 -
5-10. VRD (Voltage Reduction Device)
The equipment includes a voltage reduction device on the
weld output side. The voltage reduction device reduces the
output voltage of the welder when welding is paused in order
to further increase safety when welding in locations with high
humidity, elevated locations, extremely confined spaces near
possible hazards, and similar conditions.
When the VRD switch is set to "ON" and not welding, the
voltage reduction device reduces the voltage of the Weld
output terminals to 35 V or less.
When welding is started, the voltage-reduction function is
cancelled and the equipment returns to the reduced voltage
status when welding is completed. Turning the VRD switch to
"OFF" also cancels the voltage-reduction function.
The green VRD lamp ("BELOW 35V" side) lights up when
weld output voltage is less than 35 V and the red lamp ("AT
OR ABOVE 35V" side) lights up when the voltage is 35 V
or more.
<Note>

The VRD is only for weld output. It does not function for AC generated output voltage.

The VRD lamp lights up only when the VRD switch is set to "ON".

The VRD does not function if using "CV-WIRE".
5-11. Wire Feeder Control
A wire feeder with a 14-pin plug can be used 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.
(2) Weld Terminal Switch
Voltage is constantly output from the equipment
weld terminals when the weld terminal switch is set
to "WELD TERMINALS
ON".
When the weld terminal switch is set to "REMOTE
CONTROL", voltage is output from the equipment
weld terminals only when the torch switch is set to
"ON".
(3) Wire Feeder Voltmeter Selector
By switching the wire feeder voltmeter selector,
you can select the polarity of the voltmeter display
equipped to the wire feeder.
(4) Circuit Protector for Wire Feeder
The circuit protector for the wire feeder operates to stop the current if the there is an
overcurrent of 5A or more in the wire feeder.
Circuit Protector
for Wire Feeder
14-Pin
Connector
Wire Feeder
Voltmeter Select
or
Weld Terminal
Switch
14-Pin
Connector
Wire Feeder
Left
Door
VRD Switch
(Inside)
VRD Lamp

- 17 -
<Note>

The wire feeder control function is only for output A.

When the circuit protector for the wire feeder operates due to an overcurrent fault, inspect
for the fault and press the circuit protector button after resolving the fault in order to reset
the system.
6. Transporting
Caution: Injury

Do not move the equipment during operation.

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.
Always be sure to fix the equipment securely when transporting the equipment.
<Note>

Tighten a rope from all four-directions to protect against unintended movement when this
equipment intends to transport.

Do not hook the rope in the shoulder area on the top cover as the metal plate may
become distorted if it is bent when this equipment is placed.

Handle the equipment with great care when raising, lowering and transporting. Rough
handling of the equipment can result in damage or malfunction.
Do not hook the rope
in the shoulder.
Tighten a rope from all
four-directions to prevent
the unintended movement.
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