Shindaiwa 1 Series User manual

OPERATOR’S MANUAL
165/UK
Series 1
Original Instructions
CAUTION: Do not operate the Welder-Generator, or any other appliance, before you
have read and understood the instructions for use.

Introduction 1
EC Declaration of Conformity 2
1. Safety Guidelines 3
2. Specifications 6
3. Use 7
4. arts 8
5. Equipment 10
5-1. Display 10
5-2. Oil Sensor 10
5-3. Overload/Overheat Protection Devices 11
5-4. Eco-mode Engine speed control) 11
5-5. Earth Leakage Circuit Breaker and Grounding 12
5-6. Wheel Brake 13
6. Operation 14
6-1. Initialisation/Pre-check 14
6-2. Starting 18
6-3. Stopping 19
7. Welding Operation 20
7-1. Selection – Welding Cable 20
7-2 Polarity 20
7-3. Connection – Welding Cable 20
7-4. Duty Cycle 21
7-5. Welding 22
8. Generator Operation 23
8-1. Operation 24
8-2. Output Limitation 24
9. Simultaneous Use of Welding and Generating 25
10. Checking and Maintenance 25
11. Long-term Storage 29
12. Troubleshooting 30
13. Wiring Diagram for Shindaiwa 165/UK 31

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 1 -
165/UK
Series 1
OOM-165UK
001-05-2010
Introduction
Thank you for purchasing a Shindaiwa Sound Proof Petrol Engine Welder-Generator.
This user 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 include this manual, if the equipment is to be on-sold or rented out.
Please store this manual with the equipment for easy reference.
■
■■
■The following convention 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
property.
<Caution> Other types of caution
Some of the items noted in [ Caution] may also 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 contained on page 2 of 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 whether or not further precautions are required. Factors that influence the actual
level of exposure of work‐force include the characteristics of the work room, the other sources of
noise, etc. i.e. the number of machines and other ad acent processes, and the length of time for
which an operator is exposed to the noise. Also the permissible exposure level can vary from
country to country. This information, however, will enable the user of the machine to make a
better evaluation of the hazard and risk”.

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 2 -
165/UK
Series 1
OOM-165UK
001-05-2010
EC Declaration of Conformity
In accordance with EN ISO 17050-1:2004
MANUFACTURER :
EUROPEAN CONTACT:
YAMABIKO CORPORATION SHINDAIWA LTD
6-2-11 Ozuka-Nishi
Asaminami-KU
HIROSHIMA 731-3167, JAPAN
6, The Dell, Enterprise Drive
Four Ashes Ind. Est.
WOLVERHAMPTON WV10 7DF, UK
in accordance with the following Directive(s):
2004/108/EC The Electromagnetic Compatibility Directive
2006/42/EC The Machinery Directive
2000/14/EC The Noise Emission in the Environment by Equipment for Use Outdoors Directive
hereby declare that:
Equipment Petrol engine driven welding set
Model number 165/UK
is in conformity with the applicable requirements of the following documents
Ref. No. Title Edition/date
BS EN 60974-10 Arc welding equipment. Electromagnetic compatibility (EMC) requirements 2007
EN 12601 Reciprocating internal combustion engine driven generating sets. Safety 2001
EN 60974-1 Arc welding equipment. Welding power sources 2005
Noise measurements have been made in accordance with 2004/14/EC annex III section B(57) with
supervision by Notified Body No. 1942 (CEM International Ltd, The Atrium Business Centre, Curtis
Road, Dorking, Surrey, RH4 1XA) (Schedule 9/Annex V1). The declared noise values are as follows:
Measured sound power level
Guaranteed sound power level
93
dB L
WA
93
dB L
WA
I hereby declare that the equipment named above has been designed to comply with the
relevant sections of the above referenced specifications and is in accordance with the
requirements of the Directive(s)
Signed by: ....................................................................................................................
Name
s
:
MARK STANSFIELD
Position:
DIRECTOR
Conducted at: WOLVERHAMPTON
On
:
21
st
April 2010
Document ref. No.
2960/1050467
The technical documentation for the machinery is available from:
Shindaiwa Limited, 6 The Dell, Enterprise Drive, FourAshes, Wolverhampton, WV10 7DF

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 3 -
165/UK
Series 1
OOM-165UK
001-05-2010
1. Safety Guidelines
Danger : Suffocation from exhaust fumes
Exhaust fumes from the engine contain many elements harmful to humans. Do
not operate this equipment in poorly ventilated areas, such as inside a room or in
a tunnel.
Danger : Electric Shock
Do not touch or operate the equipment, if the equipment or you are wet.
Do not insert metal objects (such as pins or wire) into plug-in receptacles.
Do not touch wiring or electric parts inside the equipment during operation.
Before connecting or disconnecting a welding cable from output terminal, stop
the engine, and remove the key.
Before performing any equipment check or maintenance, stop the engine and
remove the engine key. The person performing the check or maintenance should
always keep the key.
Caution : Suffocation from exhaust fumes
Do not point exhaust fume outlet pipe in the direction of 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
sufficient ventilation in order to prevent inhalation of the fumes.
Caution : Injuries to eyes and skin
Be sure to wear spark protection glasses/mask, long-sleeve shirts, gloves, etc. in
order to protect the eyes and skin from harmful sparks during welding.
Battery fluid contains diluted sulphuric acid. Avoid contact with eyes, skin &
clothing. If the acid comes into contact with eyes, flush with lots of water, and
contact your physician immediately.
Caution: Electric shock
Do not throw water onto the equipment or operate it in the rain.
This machine is rated to IP23.
Do not touch a spark plug, plug cap or high-voltage wiring during operation.
Caution: Explosion
Do not use the equipment or charge the battery when the battery fluid level is
below the lower level marker if applicable.
The battery may emit some combustible gas. Keep it away from fire and sparks.

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 4 -
165/UK
Series 1
OOM-165UK
001-05-2010
Caution: Fire
The equipment uses Petrol as a fuel. When inspecting the equipment or
refuelling, always stop the engine and keep away from sparks or naked flames.
Always wait until the engine cools down before refuelling.
Always wipe away any drips of fuel or lubrication oil. Do not use this equipment if
a leak is found. Repair the equipment before use.
Temperatures around the 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 creates hot sparks.
Always operate this equipment on a flat surface and with at least 1 metre
clearance from all objects.
Do not connect AC output to any indoor wiring.
Always wait until the equipment cools down, before covering for storage.
Do not allow children near the equipment. 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, as temperatures can reach extremely high levels.
When checking engine oil or changing oil, always stop the engine, and wait until
the engine cools down. Do not open the oil gauge/oil filler cap during operation
as hot oil may cause 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.
Caution: Injuries
When lifting the equipment, always use the top-mounted lifting lug. Do not lift
using the positioning handles.
Always use appropriate lifting gear & secure adequately during transportation.
Always place the equipment on a flat and stable surface and fix the wheels
using the brake, to prevent equipment movement.
When starting the engine, turn off all connected equipment and set the AC
Output Switch to the OFF position.
Do not move the equipment during operation.
When performing equipment checks and maintenance, always stop the engine.
Do not operate the equipment, if the equipment is faulty or if there are missing
parts.

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 5 -
165/UK
Series 1
OOM-165UK
001-05-2010
Location of Warning Labels
When the warning labels become unreadable or damaged, place new labels on
the appropriate locations, as specified in the following figure.
When ordering the label, use the following part numbers.
① Suffocation from exhaust fumes (No.X505-005930)/S7
② Electric shock (No.19402-00240)/S7
③ Injuries No.S3
④ Burns (No.19402-00200)/S5
⑤ High Voltage (No.19402-00139)/S7
S7 Electric Shock S3 Injuries
S5 Burns
①
③
②
⑤
④

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 6 -
165/UK
Series 1
OOM-165UK
001-05-2010
2. Specifications
Model 165/UK
Generating Method Rotating Field, Synchronous AC Generator
Welding Generat
or
Rated Current (A) 140
Duty Cycle (%) @ 40°50
Rated Speed (min
-
1
) 3600
No Load Voltage (V) MAX 75
Current Adjustable Range (A) 40-165
Welding Rod (φ) 2.0-4.0mm
AC Generator
Phase 1-Phase
Rated Voltage (V) 110
Frequency (Hz) 50/60
Rated Speed (min
-
1
) 3600
Rated Output (kVA) 2.5
Rated Current (A) 23
Power Factor 1.0
Rating Continuous
Engine
Model Subaru EX27DS
Type Air-cooled, 4-Cycle OHC Petrol
Displacement (L) 0.265
Rated Output (kW/min
-
1
) 5.1/3600
Fuel Unleaded Petrol
Lubricant Oil API Class SE or higher
Lubricant Oil Volume (L) 1.0(approx)
Starting Method Electric Start and Recoil Start
Spark Plug NGK BR6HS
Battery Yuasa YTX9-BS or 34A19L
Fuel Tank Capacity (L) 12
Dimensions L x W x H (mm) 706 x 494 x 625
Dry Weight (kg) 79
GENERATING SET ISO 8528-8/G2 EMC Group 2 Class A

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 7 -
165/UK
Series 1
OOM-165UK
001-05-2010
3. Use
Arc welding
Power source for electric tools
Power source for lights
Voltage classification G2
EMC classification Group 2 Class A.
Caution: Damage to the equipment or other property
Consult with our dealer or authorised distributor when utilising this equipment
around devices with microcomputer control or ultra-precision items, which are
very sensitive to voltage fluctuation.
Keep the equipment away from those devices 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.