Shindaiwa DGW300MS/UK User manual

OPERATOR’S MANUAL
DGW300MS/UK
Water-Cooled
4-Cycle Diesel Engine
Table of Contents Page
1.Safety Guidelines
2.Specifications
3.Use
4.Parts
5.Equipment
5-1. Eco Welding
5-2. Display
5-3. Monitor Lamp
5-4. Remote Control
5-5. Earth Leakage Relay
and Grounding
5-6. Auto Idle Feature
5-7. Emergency Stop Switch
6.Initialization and Pre- operation check
6-1.Checking Engine Oil
6-2.Checking Coolant/Water
6-3.Checking Fuel
6-4.Checking Fuel, Engine Oil
and Water Leakage
6-5.Checking Battery
7.Operation
7-1.Starting
7-2.Stopping
7-3.Emergency Stop
8.Welding Operation
8-1.Selection-Welding Cable
8-2.Polarity
8-3.Connection-Welding Cable
8-4.Duty Cycle
8-5.Welding
9.Generator Operation
9-1.Output Range
9-2.Output Limitation
9-3.Operation
10.Simultaneous Use of Welding and
Generating
11.Checking and Maintenance
12.Long-term Storage
13.Troubleshooting
14.Engine Wiring Diagram
15.Generator Wiring Diagram
2
5
5
6
8
8
8
8
10
10
12
12
12
12
13
14
14
14
15
16
17
17
18
18
18
18
19
19
20
20
21
21
23
23
28
28
30
31
SOUND PROOF
DIESEL ENGINE
GENERATOR/WELDER
CAUTION: Do not operate the Welder-Generator, or any other appliance, before you
have read and
understood
the instructions for use.
DGW300MS/UK
X750803-4302

- 1 -
Introduction
Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Welder/Generator.
This operation manual has been 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.
Please operate this equipment after thoroughly reviewing and understanding
the contents of this manual.
Please supply this manual with the equipment.
■
■■
■ The following conventions will be used throughout the manual to indicate
the degree of caution.
Danger Can cause serious injuries or death.
Caution
Can cause minor injuries or damage to the equipment or
other properties.
<Caution> Other types of caution
Even some of the items noted in 『 Caution 』 may lead to serious injuries.
Please read all items and follow all the safety guidelines.
The following statement refers to the noise level data contained in the EC
Declaration of Conformity attached to this manual
“The figures quoted are emission levels and are not necessarily safe working levels.
Whilst there is a correlation between the emission and exposure levels, this cannot be used
reliably to determine weather or not further precautions are required. Factors that influence the
actual level of exposure of work-force include the characteristics of the work place, the other
source of noise etc. i.e. the number of machines and other adjacent processes, and the length
of time for which an operator is exposed to the noise. This information, however, will enable the
user of the machine to make a better evaluation of the hazard and risk”

- 2 -
1. Safety Guidelines
Danger: Suffocation from exhaust fumes
Exhaust fumes from the engine contain 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
Close and lock all equipment doors during operation.
Do not touch the output terminals during operation.
Do not insert metal objects (such as pin or wire) into plug-in receptacles.
Do not touch wiring or electric parts inside the equipment during operation.
Ground the grounding terminal to the earth as set out in the manual. If left
disconnected, it may cause injury.
Even though all the terminals of the loads have been grounded to the earth,
the canopy grounding terminal should also be grounded to the earth.
Before connecting or disconnecting a plug from output receptacle, always turn
the circuit breaker to the OFF position.
Before connecting or disconnecting a welding cable from output terminals, stop
the engine, and remove the engine key.
Before performing any equipment check or maintenance, stop the engine, and
remove the engine key. The person performing the maintenance must always
keep the key.
This machine is rated to IP23.
Danger: Burns
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid the possibility of sustaining burns from
hot water.
Danger: Injuries
Close and lock all equipment doors during operation of this equipment, to
avoid injuries by unintentional touching cooling fan and fan belt.
Caution: Suffocation from exhaust fumes
Do not direct the exhaust fumes toward pedestrians or buildings.
Caution: Suffocation from welding fumes
Be sure to wear a fume proof mask during operation, as welding fumes
contain poisonous gases and dust. Pay attention to the airflow direction and
ensure there is sufficient ventilation in order to prevent from inhaling fumes.
Caution: Injuries to eyes and skin
Be sure to wear spark protection glasses/mask, long-sleeve shirts, gloves, etc.
in order to protect eyes and skin from harmful sparks during welding.
Battery fluid contains diluted sulphuric acid. Avoid contact with eyes, skin or
clothing. If the acid comes in contact, especially with eyes, flush with a lot of
water, and contact your physician immediately.
Caution: Electric Shock
Do not flush water onto the equipment nor operate it in the rain.

- 3 -
Caution: Explosion
Do not use the equipment or charge the battery, if the battery fluid level is
below the LOWER level.
Battery may emit combustible gas, so keep it away from fire and sparks.
Caution: Fire
The equipment uses Diesel as a fuel. When inspecting the equipment or
refueling, always stop the engine and keep away from fire, always wait until the
engine cools down before refueling.
Always wipe away any drip of Diesel fuel or lubrication oil. Do not use this
equipment if a leak is found. Repair the equipment before use.
Temperature around muffler and exhaust can get extremely high. Keep any
inflammable items (such as fuel, gas, paint, etc.) away from the equipment.
Keep any inflammable items and combustible items away from the welding
area, as welding causes hot sparks.
Always operate this equipment on flat surface and, at least 1 metre away from
any objects (wall, box, etc.).
Do not connect AC output to any indoor wiring.
Always wait until the equipment cools down, before placing any covering
materials for storage.
Keep children at a safe distance from the machine at all times.
Caution: Burns
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature could reach extremely high.
When checking engine oil or changing oil, always stop the engine, and wait
until the engine cools down. If you open either the oil gauge or the oil plug
during operation, hot oil may cause some injury.
Be sure to wear leather gloves, apron, shoe covers, eye protection
glasses/mask, safety shoes, safety cap, and long sleeve shirts, to protect from
sparks.
Do not open the side door during operation and immediately after stopping the
equipment, because some parts/components (flexible tube, resistors, etc.) can
reach very high temperatures inside the equipment.
Caution: Injuries
When lifting the equipment, always use a top-mounted lifting lug. Do not lift
using the positioning handle.
Always use appropriate lifting gear & secure adequately during transportation.
Always place the equipment on a flat and stable surface, and fix the wheels to
prevent equipment movement.
When starting the engine, turn off the connected equipment and set the circuit
breaker to OFF position.
Do not move the equipment during operation.
When performing equipment check and maintenance, always stop the engine.
Do not operate the equipment, if it is faulty or if there are missing parts.

- 4 -
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 labels, use the following part numbers.
① Suffocation from exhaust fumes (No. X505-006400)
② Positioning handle (No. X505-006430)
③ Electric shock (No. X505-004930)
④ Fire (No. X505-004880)
⑤ Injury (No. X505-004940)
⑥ Hot surface (No. X505-006420)
⑦ Burns (No. X505-006410)
⑧ Lifting eye （ No. X505-xxxxxx ）
⑨ Earth Grounding terminal （ No. X505-xxxxxx ）
①
③
⑤
⑦
④
②
⑥
②
⑧
⑨

- 5 -
2. Specifications
Model DGW300MS/UK
Generating Method Rotating Field
Rated Current (A) 280
Duty Cycle (%) 50
Current Adj. Range (A) 30 – 200
ECO Welding Rod (mm) 2.0 – 4.0
Current Adj. Range (A) 40 – 300
AUTO
/ HIGH Welding Rod (mm) 2.0 – 6.0
Rated Speed (min
-1
) 3000
Welding Generator
No Load Voltage (V) MAX 85
Rated Frequency (Hz) 50
Rated Speed (min
-1
) 3000
Phase 1-Phase 3-Phase
Rated Voltage (V) 110 CTE 415
Rated Current (A) 30 9.8
Power Factor 1.0 0.8
Rated Output (kVA) 3.3 7
AC Generator
Rating Continuous
Model Kubota D722
Type Water-Cooled 4-Cycle Diesel Engine
Displacement (L) 0.719
Rated Output (kW/min
-1
) 14.9 / 3600 (Gross Intermittent)
Fuel ASTM No.2 Diesel Fuel or Equivalent
Lubricant Oil API Class CD or Higher
Lubrication Oil Volume (L) 3.8 (Effective 1.4)
Cooling Water Volume (L) 3.0 (Sub Tank Capacity 0.6 L included)
Engine
Starting Method Starter Motor
Battery 46B24L
( Japan Industrial Standard)
Fuel Tank Capacity (L) 37
Length (mm) 1410
Width (mm) 566
Dimen
-sion
Height (mm) 760
Dry Weight (kg) 348
Generating Set: ISO 8528-8/G2
EMC Group 2 Class A
Rating Plate label is attached to the equipment
3. Use
Arc Welding
Power Source for Lights, Electric Tools and Home Appliances
Voltage classification G2
EMC classification Group 2 Class A
Caution: Damage to the equipment or other properties
Consult with your dealer or authorized distributor when utilizing this equipment
around devises with microcomputer control or ultra-precision items, which are
very sensitive to voltage fluctuation.
Keep the equipment away from those devises to avoid influence from
electromagnetic noise.
Consult with hospital or medical equipment companies before using this
equipment on medical apparatus.
It is recommended you follow this instruction manual strictly, to avoid
unnecessary accidents, repairs, and damage.

- 6 -
4. Parts
STARTER SWITCH
IDLE CONTROL SWITCH
DISPLAY
DISPLAY CHANGE SWITCH
REMOTE CONTROL
RECEPTACLE
WELDING OUTPUT
TERMINAL
FUEL METER
MONITOR LAMP
CURRENT
ADJUSTMENT
DIAL
1-PHASE ELCB
3-PHASE ELCB
(BREAKER)
1-PHASE BREAKER
EMERGENCY
STOP SWITCH
UNDER PLATE
BATTERY
FUSE
(10A ， 50A)
SIDE DOOR
AIR CLEANER
OIL GAUGE
COOLANT
SUB TANK
OIL PLUG
OIL INLET
OIL
DRAIN PLUG
FUEL
DRAIN PLUG WATER
DRAIN PLUG
FUEL LEVER
(FUEL STRAINER)
3-PHASE
RECEPTACLE
1-PHASE
RECEPTACLE
SIDE B
1-PHASE
RECEPTACLE
SIDE A
BONNET
GROUNDING
TERMINAL

- 7 -
OIL FILTER
FUEL INLET
TOP
MOUNTING
LIFTING EYE EXHAUST
TOP PLATE POSITIONING
HANDLE
(NOT TO BE USED
FOR LIFTING)
POSITIONING
HANDLE
(NOT TO BE USED
FOR LIFTING)
FIXED SIDE PANEL REMOVED

- 8 -
5. Equipment
5-1. Eco Welding
The equipment is incorporates an Eco welding feature that provides lower noise
levels, lower fuel consumption and lower gas emissions than conventional
welder-generators.
When you turn the idle control switch to Eco, you will be able to weld at Max. with a
4.0mm welding rod at the low speed.
<Caution>
Eco is designed for welding only. The engine automatically moves to high speed,
if it is used for AC Output.
5-2. Display
The equipment incorporates in Digital Display. It displays 『 AC Voltage 』 , 『 Hours
worked 』 , 『 Speed 』 successively, by changing the display selector switch.
<Caution>
During operation, the AC voltage meter always displays the voltage in 415V,
3-Phase both at the breaker position 『 ON 』 and 『 OFF 』 .
5-3. Monitor Lamp
The equipment incorporates a monitoring function and shut off for WATER TEMP,
BATTERY CHARGING, and OIL PRESSURE.
Under normal conditions, when the starter key is turned from [STOP] to [RUN], the
BATTERY CHARGING, and OIL PRESSURE monitor lamps will be illuminated.
When the engine starts, all the monitor lamps will goes OFF. When fault occurs in
running, the corresponding monitor lamp will flash, and the engine will be
automatically shut-off.
When the automatic shut-off is engaged, turn the starter key to [STOP] position.
Find and fix the fault, and then restart the engine. In the event the automatic
shut-off is engaged repeatedly, check which monitor lamp turns ON or OFF and
investigate further the related malfunction.
(1) Coolant/Water Temperature Monitor Lamp
Danger: Injuries
Close and lock all equipment doors when operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to prevent burns from hot steam or water.
BATTERY
CHARGE
OIL
PRESSURE
WATER
TEMP

- 9 -
Caution: Burns
Do not touch the engine or exhaust during operation or immediately after
stopping the equipment, as the temperature will be extremely high.
When the water temperature rises abnormally, the coolant/water temperature
monitor lamp will flash, and the automatic engine shut-off will be engaged.
When this symptom occurs, check the coolant sub tank, and replenish if needed.
(Refer to 『 6-2. Checking coolant/water 』 )
If the water level is normal, there may be a possibility of overloading. Always
connect equipment within the rated duty cycle and output power.
(2) Battery Charge Monitor Lamp
When the battery is unable to be charged during operation, the battery charge
monitor lamp will flash and the automatic shut-off will be engaged.
<Caution>
The battery charge monitor cannot detect the degradation of the battery nor the
battery fluid level. Check the battery fluid level periodically.
(Refer to 『 6-5. Checking Battery 』 )
(3) Oil Pressure Monitor Lamp
Danger: Injuries
Close and lock all equipment doors when operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Caution: Burns
Do not touch the engine and exhaust during operation or immediately after
stopping the equipment, as the temperatures will be extremely high.
When checking engine oil, always stop the engine, and wait until the engine
cools down. Do not open the oil gauge or the oil filter cap during operation
If the engine oil pressure drops during operation, the oil pressure monitor lamp will
flash, and the automatic shutoff will be engaged.
When this symptom occurs, check the engine oil level, and replenish to maximum
level.
<Caution>
The engine oil pressure monitor cannot detect the degradation of engine oil itself.
Please check the engine oil periodically, and change if needed.
(Refer to 『 11. Checking and Maintenance 』 )
Check the fuse next, when the abnormality, other than WATER TEMP, BATTERY
CHARGED OR OIL PRESSURE is detected. If the fuse is burned out, consult
with our dealer or authorized distributor, as there may be an abnormality of
electrical components or wiring which should be inspected.

- 10 -
5-4. Remote Control
The equipment incorporates a Remote Control receptacle.
Remote control box is an optional part.
Remote Control operation is available by connecting the compatible Remote
Controller to the receptacle.
5-5. Earth Leakage Relay and Grounding
Danger: Electric Shock
Ground the grounding terminal to the earth as set out in the manual.
Failure to do so could result injury.
Even though all the load terminals have been grounded to the earth, the
canopy grounding terminal should also be grounded to the earth.
Grounding should be made whilst the engine is stopped.
Whenever the earth leakage relay has been activated, you should always
repair the fault before re-using the machine.
The equipment is provided with an earth leakage relay (ELR) with in the Main
Circuit Breaker (MCB) to detect any earth leakage due to problems such as
insulation failure of the load whilst the generator is running. When activated ELR
will automatically switch the MCB to the OFF position.
The specifications of the earth leakage relay:
Rated Sensitive Current: 30mA (or below)
(Grounding resistance: 500 Ω or below)
(1) Grounding Work
A qualified electrician should perform the grounding work at the 2 points
(500 Ω or below).
The Canopy of this equipment (canopy grounding terminal)
The Canopy of the load
<Caution>
In the event you cannot ground
the generator to the earth,
consult with our dealer or
authorized distributor.
CANOPY
GROUNDING
TERMINAL
GROUNDING
ROD
REMOTE CONTROL RECEPTACLE
REMOTE CONTROL BOX

- 11 -
(2) Operation Check
Before operating the equipment, always check if the safety shut-down device
works as shown in the following procedure.
① Ensure that the circuit breakers and load switches are positioned to
[OFF].
② Start engine after turning the Idle Control Switch to [HIGH].
③ Push-up the 1-Phase and 3-Phase ELCB (lever) to the [ON] position.
④ Push the test button on 3-Phase ELCB. The earth leakage indicator button
protrudes and the lever is in between the [ON] and [OFF] position.
⑤ Push down the lever [OFF] on 3-Phase ELCB.
⑥ Push the test button on 1-Phase ELCB. The ELCB (White lever and Black
lever) turns to OFF.
⑦ Proceed with engine start procedure after returning a starter switch to [STOP].
In the event you cannot correctly complete all steps in the above procedure, the
machine is out of order. Consult with our dealer or authorized distributor to repair.
(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.
If the 3-Phase earth leakage relay has been activated, the leakage indication button
will protrude and the lever is between [ON] and [OFF] position.
If the 1-Phase earth leakage relay has activated, The ELCB (White lever and Black
lever) turns to [OFF].
In the case, stop the engine promptly and find each leakage fault.
After repairing the fault, return (push up) the ELCB (lever) to [ON].
For 3-Phase ELCB, push breaker lever down to 『 OFF 』 and push lever up to 『 ON 』 .
<Caution>
If the 3-Phase ELCB Leakage indication button does not protrude or the
1-Phase ELCB (only Black lever) turns to OFF, it means AC Output over load.
5-6. Auto Idle Feature
The Auto Idle feature sets the engine speed automatically to low(in approximately 8
seconds) for the purpose of reducing noise and fuel consumption, whenever
welding operation or electric supply is not being used.
To use the Auto Idle feature, turn the Idle Control Switch to [ECO] or [AUTO].
The engine automatically moves to high speed, whenever welding operation or
electric supply starts.
Caution: Damage to the equipment or other properties
Always switch the Idle Control Switch to [HIGH], when the load is incorporated
with any magnet switch.
3-PHASE ELCB
1-PHASE ELCB
TEST BUTTON
LEAKAGE
INDICATION
BUTTON
TEST BUTTON
WHITE LEVER
AND
B
LACK
LEVER

- 12 -
<Caution>
When the load of less than 0.5A is connected, the Auto Idle feature may not
function. In this case, turn the switch to [HIGH].
When welding operation or electric supply performs alternately or intermittently,
turn the switch to [HIGH].
5-7. Emergency Stop Switch
The Emergency Stop Switch is used to stop the engine in
emergency. The engine stops immediately after pressing
the button.
Be sure to restore the Starter Switch to [STOP] and reset
the Emergency Stop Switch, turning clockwise after using
the switch.
6. Initialization and Pre- operation check
Caution : Fire ・
・・
・ Burns ・
・・
・ Injuries
When checking engine, always stop the engine. Wait until the engine cools
down, before performing any inspection.
6-1. Checking Engine Oil
When checking for engine oil, be sure
to keep the equipment leveled, and
insert the oil gauge firmly.
Prior to starting the equipment, make
sure to fill the engine oil to the
UPPER line through the oil inlet.
<Caution>
If the equipment is not level, you cannot
obtain an accurate oil level reading.
Do not overfill (over UPPER line)
the engine oil. Excessive amounts
of engine oil may damage the
engine.
Selecting proper engine oil
<Caution>
Use the API class CD or higher.
Viscosity and Temperature
Temperature Over +20
℃ +10 ～ +20 ℃ -10 ～ +40 ℃
Viscosity SAE30 SAE20 SAE10W/30
6-2. Checking Coolant / Water
Danger: Injuries
Close and lock all equipment doors during operating this equipment, to avoid
injuries by unintentionally touching moving parts.
RESET
STOP
UPPER LEVEL
EFFECTIVE
LOWER LEVEL
OIL
GAUGE
OIL DRAIN PLUG
OIL PLUG
INLET

- 13 -
Danger: Injuries
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to prevent burns from hot steam or water.
Caution: Burns
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature could reach extremely high
temperature.
Check to see if the coolant/water level is between FULL and LOW levels in the
coolant sub tank. If the coolant/water is below the LOW level, fill the tank and the
radiator accordingly.
(1) Filling to the Coolant Sub Tank
① Remove the coolant sub tank cap.
② Fill up the coolant sub tank to the FULL level.
③ Install the cap back.
(2) Filling the Radiator
① Open the top plate.
② Remove the radiator cap.
③ Fill the radiator up to the top.
④ Install the cap back and tighten.
⑤ Close the top plate.
<Caution>
Use Long Life Coolant (LLC), for prevent freezing
and corrosion. (30%mixture LLC is filled when
shipped from factory)
Mixture ratio of the coolant should be 30%-45%,
depending on the ambient temperature.
Replace LLC at every year or 2000 hours.
Mixture Ratio (for reference only)
Lowest Ambient
Temperature -15
℃ -20 ℃ -30 ℃
Mixture Ratio 30% 35% 45%
6-3. Checking Fuel
Caution: Fire
Always wipe away any drip of fuel. Do not use this equipment if a leakage is
found. Repair the equipment before use.
Check for the fuel level in the tank. Add if necessary.
LOW
FULL
COOLANT
SUB TANK
CAP
COO-
LANT
SUB
TANK
TOP PLATE
WATER INLET
RADIATOR
CAP

- 14 -
<Caution>
Use Diesel fuel, ASTM D975 No.2-D in the event ambient temperature reaches
down to -5 ℃ .
The engine is designed to use either No.1-D or No.2-D Diesel fuel. However, for
better economy, use No. 2-D Diesel Fuel whenever possible. At temperatures
less than -7 ℃ (20 ℉ ), No.2-D fuel may pose operating problems (see “Cold
Weather Operation which follows). At colder temperatures, use No.1-D fuel (if
available) or use a “winterised” No.2-D (a blend of No.1-D and No.2-D). This
blended fuel is usually called No.2-D also, but can be used in colder temperature
than No.2-D fuel which has not been “winterised”. Check with the services
station operator to make sure you can get the properly blended fuel. Note that
Diesel fuel may foam during a fill-up. This can cause the automatic pump nozzle
to shut off even though your tank is not full.
Always use the fuel strainer.
Fill the fuel tank slightly less than the
FULL.
6-4. Checking Fuel, Engine Oil and Water Leakage
Caution: Fire
Do not use this equipment if a leakage is found. Repair the equipment before
use.
Be sure to check for any leakage for fuel, oil and coolant/water at the hose
connections by opening side doors. Whenever checking any fuel leakage, turn the
fuel lever [OPEN] and be sure to close the fuel lever after checking.
6-5. Checking Battery
Caution: Injuries to eyes and skin
Battery fluid contains diluted sulphuric acid. Avoid contact with eyes, skin or
clothing.
If acid comes into contact, with eyes, flush with lots of water, and contact your
physician immediately.
Caution: Explosion
Do not use the equipment or charge the battery, if the battery fluid level is lower
than the LOWER level.
The battery may emit some combustible gas, so keep away from frames and
sparks.
Caution: Fire
Battery may emit some combustible gas, so keep away from frames and
sparks.
TANK CAP
FUEL INLET
FUEL
STRAINER

- 15 -
① Check the fluid level. If the level is near or lower
than LOWER level, add distilled water until the fluid
level reaches UPPER level.
② Make sure that the battery cables are firmly secured
to the posts. Tighten the clamps if necessary.
<Caution>
Check the specific gravity of the battery fluid. If it falls below 1.23, the battery requires
recharging. Please consult with our dealer or authorized distributor.
Replacing battery
① Remove the under plate. (M6 bolt x 2)
② Remove the clamp and cable from
negative [ - ] post on the battery. (Remove
always negative side first)
③ Remove the hold-down clamp from the
battery.
④ Remove the clamp and cable from
positive [+] post on the battery.
⑤ Remove the battery from the base.
※ Reinstall a new battery in the reverse order.
(Install always the cable to the positive [+] post in the new battery first.)
<Caution>
Use the following battery.
＜ 46B24L ＞
7. Operation
Danger: Suffocation from exhaust fumes
Exhaust fumes from the engine contains many elements harmful to humans.
Do not operate this equipment in poorly ventilated areas, such as inside a
room or in a tunnel.
Caution: Suffocation from exhaust fumes
Do not redirect the exhaust outlet toward pedestrians or building.
Caution: Fire
Temperatures around muffler and exhaust can reach extremely high levels.
Keep inflammable items (such as fuel, gas, paint, etc.) away from the
equipment.
Always operate this equipment on a flat surface and, at least 1 metre away
from any objects (wall, box, etc.)
Caution: Injuries
Always place the equipment on a flat and stable surface, and fix any wheels
with suitable brakes, to prevent the equipment moving.
Before starting the engine, be sure to disconnect the loads and set the
breakers (1-P, 3-P) to [OFF] position.
[ － ] POST
HOLD
DOWN
CLAMP
UNDER PLATE
INS CAP
[+] POST

- 16 -
7-1. Starting
① Turn the breakers (1-P, 3-P) to [OFF]
② Turn the Fuel lever to [OPEN].
③ Turn the Idle Control Switch to [ECO] or [AUTO].
④ Ensure the Emergency Stop Switch is in released position.
⑤ When the temperature is below -5 ℃ , turn and keep the Starter switch to
PREHEAT until the preheat lamp turns off (about 5 seconds).
⑥ Turn the Starter Switch to [START] and then the engine starts by the starter
motor.
⑦ Release the Starter Switch, as soon as the engine has started.
⑧ Keep the engine idle for approximately 5 minutes
before use.
<Caution>
Do not turn the starter motor for more than 15 seconds successively.
If you need to restart, wait for 30 seconds or more before reattempt.
Once the engine has started, never turn the starter switch to [START].
Restart after stopping due to fuel shortage
This equipment has a self-bleed system. Therefore, even though the engine stops
due to running out of fuel, you can restart the engine easily using the following
steps.
① Turn the Starter Switch to [STOP].
② Fill the fuel.
③ Turn the Idle Control Switch to [ECO] or [AUTO].
④ Turn the Starter Switch to [START]
⑤ Release the Starter Switch, once the engine has started.
⑥ Wait for about 1 minute to bleed the air out. The engine speed becomes
stable when the air is extracted.
<Caution>
Never turn the engine HIGH speed or connect the loads until the air is extracted
completely (the engine speed becomes stable)
7-2. Stopping
① Turn the breakers (1-P, 3-P) to [OFF].
② Turn the Idle Control Switch to [ECO] or [AUTO].
③ Keep the engine idling (cooling down) for approximately 5 minutes.
④ Turn the Starter Switch to [STOP].
⑤ After the engine has stopped, turn the every Fuel Lever to [CLOSE].
IDLE CONTROL
SWITCH
FUEL LEVER
CLOSE
OPEN
EMERGENCY
STOP
SWITCH
STARTER
SWITCH
BREAKER

- 17 -
<Caution>
Do not attempt to turn to [STOP] position while actual welding or utilizing AC
power source, it may cause the serious damage on the unit.
7-3. Emergency Stop
An Emergency Stop feature is incorporated in the equipment.
Push the Emergency Stop Switch in case of an emergency or if an equipment
fault develops during operation.
① Push the Emergency Stop Switch to stop engine in an emergency.
<Caution>
Be sure to return the Starter Switch to [STOP] after the engine stops.
Never use the Emergency Stop Switch except in case of an emergency.
② Turn the Emergency Stop Switch to arrow mark (clockwise) to release the
feature.
8. Welding Operation
8-1. Selection – Welding Cable
Ensure adequate lighting is available. If ambient light is insufficient, use additional
lights.
Select the correct cable, based on the allowable amperage distance, as per the
table shown below.
The welding capacity is reduced if the small gauge cable is used.
<Caution>
Welding cables should be used uncoiled. When the welding cables are used
coiled, the welding capacity is reduced.
Correct Size of Cable (Unit: mm
2
)
Return Length
Welding Current
20m 30m 40m 60m 80m 100m
300A 30 38 50 80 100 125
250A 22 30 38 60 80 100
200A 22 30 30 50 60 80
150A 22 22 22 38 50 60
100A 22 22 22 30 30 38
RESET
STOP
STARTER
SWITCH
EMERGENCY
STOP
SWITCH

- 18 -
8-2. Polarity
There are two welding output terminals, 『 ＋
＋＋
＋ 』 and 『 －
－－
－ 』 .
Select the polarity according to the operation, referring to the table below.
<Caution>
Follow the instruction of the welding rods, the polarity of which is specified.
8-3. Connection – Welding Cable
Danger: Electric Shock
Always examine welding cables, power cables and plug etc., to ensure there
are no defects present, prior to operation.
Before connecting or disconnecting a welding cable from welding output
terminals, stop the engine, and remove the engine key. A person performing
this task must always keep the key.
① Stop the engine.
② Connect the welding cables to the DINZE connectors, a welding rod holder
and a material holder.
<Caution>
Always fit the correct size DINZE connectors.( Recommended parts ： DIX SK70)
Ensure the welding cables connections are made correctly.
Be sure to connect the cables tightly to welding output terminal. Otherwise,
welding output terminals may burn due to the heat caused by poor connections.
Do not use a cable without the DINZE connectors. Personal injury or damage to
the machine may result as a consequence.
8-4. Duty Cycle
Duty cycle is the percentage of time the load is being applied in a 10 minutes period.
For example, a 50% duty cycle represents 5 minutes of load and 5 minutes of no
load in a 10 minutes period. Be sure to take 5minutes break after each 5minutes of
continuous welding time.
<Caution>
The equipment may become damaged due to overheating, if continuous welding
periods exceed 5minutes or if break period is reduced.
This machine produces drooping characteristics to EN60974-1.
Application Connection
Normal Polarity Generals Welding, such as
Construction
[+]Plus to the Earth (Material)
[-]Minus to holder (Rod)
Reverse Polarity Thin Plate, Build-Up Welding,
Stainless Steel
[+]Plus to holder (Rod)
[-]Minus to the Earth (Material)
DINZE
CONNECTOR
MATERIAL HOLDER
WELDING ROD HOLDER