Shindaiwa DGW300MS User manual

OWNER
’
S AND OPERATOR
’
S MANUAL
Vertical, Water-Cooled 4-Cycle Diesel Engine
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 readily use.
DGW300MS/ANZ
X750803-5400

Introduction
Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator & Welder.
• This user manual was 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. Do not operate the equipment while under the influence of
alcohol, medication, or other drugs, or while fatigued.
• Must be compliant with all applicable regulations for the area in which the equipment
is operated.
• Please attach this manual and explain how to operate and have them read this
manual, if the equipment will be sub-leased.
• Please store this manual near the equipment for easy reference. Replace damaged
or missing the manual with new manual from authorized distributor.
• For service, contact the authorized distributor. Please be prepared to give them the
model name and serial number.
• Observe the relevant environmental protection regulations when disposing of
equipment.
■ Following convention will be used throughout the manual to indicate the
degree of cautions.
• Even some of the items noted in 『 Caution 』 may lead to serious injuries.
Please read all item and follow all the safety guidelines.
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.

- 1 -
Table of Contents
1. Safety Guidelines ･････････････････････････････････････ 2
2. Specifications ････････････････････････････････････････ 5
3. Usage ･･･････････････････････････････････････････････ 5
4. Names of Parts ･･･････････････････････････････････････ 6
5. Equipment ･･････････････････････････････････････････ 8
5-1. Eco Welding ･･････････････････････････････････････ 8
5-2. Welding Output Control ･･･････････････････････････ 8
5-3. VRD(Voltage Reduction Device) ･･･････････････････ 9
5-4. Output Remote Control ･･･････････････････････････ 9
5-5. Operation Mode Selector ････････････････････････ 10
5-6. Meter ･･･････････････････････････････････････････ 10
5-7. Monitor Lamp ････････････････････････････････････ 11
5-8. Earth Leakage Circuit Breaker and Grounding ････････ 12
5-9. Auto Idle Feature ･････････････････････････････････ 13
5-10. Emergency Stop Switch ･･････････････････････････ 14
5-11. Battery Isolator ･････････････････････････････････ 14
6. Initialization and Pre-operation check ･････････････････ 14
6-1. Checking Engine Oil ･････････････････････････････ 14
6-2. Checking Coolant/Water ･･････････････････････････ 15
6-3. Checking Fuel ･･･････････････････････････････････ 15
6-4. Checking Fuel, Engine Oil and Water Leakage ･･････ 16
6-5. Checking Battery ････････････････････････････････ 16
7. Operation the Engine ･･･････････････････････････････ 17
7-1. Starting ･････････････････････････････････････････ 17
7-2. Stopping ････････････････････････････････････････ 18
7-3. Emergency Stop Switch ･･････････････････････････ 18
8. Welding Operation ･･･････････････････････････････････ 19
8-1. Selection-Welding Cable ･･････････････････････････ 19
8-2. Polarity ･････････････････････････････････････････ 19
8-3. Connection-Welding Cable ････････････････････････ 19
8-4. Duty Cycle ･･････････････････････････････････････ 20
8-5. Welding ････････････････････････････････････････ 20
9. Generator Operation ･････････････････････････････････ 21
9-1. Output Range ･･･････････････････････････････････ 21
9-2. Output Limitation ････････････････････････････････ 22
9-3. Operation ･･･････････････････････････････････････ 22
10. Simultaneous Use of Welding and Generating ････････ 23
11. Checking and Maintenance ･････････････････････････ ･
･･
･ 24
12. Long-term Storage ････････････････････････････････ ･
･･
･ 28
13. Troubleshooting ･･･････････････････････････････････ ･
･･
･ 29
13-1. Symptom and Countermeasures ･･････････････････ 29
13-2. Error Code Display ･････････････････････････････ 31
14. Engine Wiring Diagram
････････････････････････････ ･
･･
･ 32
15. Generator Wiring Diagram ･････････････････････････ ･
･･
･ 33

- 2 -
Danger : Suffocation from exhaust fume
Exhaust fume from the engine contains 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 all doors and place locks during operation.
Do not touch the output terminals or external body while the unit or your body is
wet.
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 every 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 bonnet (canopy) grounding terminal
should be grounded to the earth.
Before connecting or disconnecting a plug from output receptacle, always turn
the circuit breaker to 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. A person performing the maintenance should always
keep the key.
Danger : Electromagnetic Interference
Person with a pacemaker of the heart, do not approach the equipment and
welding around the work site during work. May adversely affect the operation of
the pacemaker.
Danger : Injuries
Close and lock all equipment doors during operation.
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 fume
Do not direct the exhaust fume toward pedestrians or buildings.
Caution : Suffocation from welding fume
Be sure to wear a fume proof mask during operation, as welding fumes
contain poisonous gas 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 sulfuric 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.
1.
. .
. Safety Guidelines

- 3 -
Caution : Explosion
Do not use the equipment or charge the battery, in the case the battery fluid
level is below the LOWER level.
Battery may emit some 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 when 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 flammable items and combustible items away from the welding area,
as welding causes hot spatters.
Always operate this equipment on flat surface and, at least 1 meter 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.
Caution : Burns
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid sustaining burns from hot vapor.
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
spatters.
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 temperature inside the equipment.
Caution : Injuries
Always utilize lifting lug and proper slings to lift the equipment then move the
equipment carefully .
 When lifting the equipment, always wear helmet, safety shoes, and gloves.
Never enter the position under the equipment.
When carrying the equipment by trucks, fix it strongly to keep the equipment
from sliding.
Always place the equipment on a flat and stable surface, to keep the equipment
from sliding.
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 the equipment is being modified or if the parts
are removed.

- 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 the new label, use the following part numbers.
① Suffocation from exhaust fume (No. X505-004900)
② Suffocation from welding fume (No. X505-004910)
③ Electric shock (No. X505-004930)
④ Fire (No. X505-004880)
⑤ Injury (No. X505-004940) ⑧ Burns (No. X505-004960)
⑥ ELCB (No. X505-004980) ⑨ Burns (No. X505-004950)
⑦ Injury (No. X505-004630) ⑩ Burns (No. X505-004990)
①
②
③ ⑤
⑦
④
⑧
⑨
⑩
⑥

- 5 -
Model DGW300MS/ANZ
Generating Method Rotating Field
Rated Current (A) 260
Duty Cycle (%) 80
ECO 30 – 300
Current Adj. Range (A) AUTO/HIGH 35 – 300
Welding Rod (mm) 2.0 –6.0
Rated Speed (min
-1
) 3000
Welding Generator
No Load Voltage (V) MAX 95
Rated Frequency (Hz) 50
Rated Speed (min
-1
) 3000
Phase 1-Phase
Rated Voltage (V) 240
Rated Current (A) 30
Power Factor 1.0
Rated Output (kVA) 7.2
AC Generator
Rating Continuous
Model Kubota D722
Type Water-Cooled 4-Cycle Diesel Engine
Displacement (L) 0.719
Rated Output (kW/min
-1
) 11.7 / 3000 (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) 38
Length (mm) 1395
Width (mm) 566
Dimen
-sion
Height (mm) 760
Dry Weight (kg) 365
CC Power for Stick Welding
CV Power for Wire Feeder
Arc Gouging
Power Source for Lights, Electric Tools and Home Appliances
Caution : Damage to the equipment or other properties
Do not use other than the above purpose. When used for the microcomputer
controlled devices or for the ultra-precision devices, the load may be
malfunctioned.
Whenever connecting to use medical equipment or appliances, be sure to
consult with the medical equipment company, doctor or hospital personnel.
3.
. .
. Usage
2.
. .
. Specifications

- 6 -
4.
. .
. Name of Parts
CONTROL PANEL
WELDING TERMINAL
14-PIN CONECTOR
9-PIN CONECTOR
HOUR METER
MONITOR LAMP
IDLE CONTROL
SWITCH
WELD TERMINAL
SWITCH
WIRE FEEDER
VOLT METER
SWITCH 42V/115V SELECTOR
SWITCH
CIRCUIT PROTECTOR
FOR WIRE FEEDER
FUEL METER
STARTER SWITCH
AC METER DC METER
OPERATION MODE
SELECTOR SWITCH
EMERGENCY
STOP SWITCH
CC/CV SELECTOR SWITCH
ARC CONTROL DIAL
ROD SELECTOR
SWITCH
VRD SWITCH
OUTPUTCONTROL
DIAL
VRD LAMP
ECO LAMP

- 7 -
FUEL LEVER
(WATER SEPARATOR)
BATTERY
ISOLATOR
OIL PLUG
OIL INLET
FUEL DRAIN PLUG
OIL DRAIN PLUG
WATER DRAIN PLUG
RIGHT DOOR
AIR CLEANER
BATTERY
FUSE
(60A, 10A)
FUEL LEVER
(FUEL STRAINER)
SUB TANK
OIL GAUGE
1
-
P RECEPTACLE
EARTH LEAKAGE
CIRCUIT BREAKER
(ELCB)
1
-
P BREAKER
BONNET
GROUNDING
TERMINAL
FORKLIFT
SKIDS
OIL FILTER
LEFT DOOR
LIFTING LUG
MUFFLER
TOP PLATE
FUEL INLET COVER
FUEL INLET

- 8 -
ECO LAMP IDOL CONTROL
SWITCH
5-1. Eco Welding
The equipment is incorporates in Eco Welding features that are aimed at performing
the lower noise, the lower fuel consumption and the lower gas emission than
conventional models. When you turn the idle control switch to 『 ECO 』 , the optimum
engine speed will be adjusted automatically by load with green “ECO DRIVE”
indicator lamp turned on.
< Caution >
•The optimum engine speed will be adjusted
automatically while using welding output only.
•The engine speed will be set as rated speed while
using generating output only.
•The engine speed will be set as rated speed while
using simultaneous use of welding and
generating.
•The engine speed will be set automatically low speed at no load.
•Turn always the idle control switch to 『 HIGH 』 , when using motor with large capacity
or the load is incorporated with any magnet switch.
•When the load of less than 1A is connected to use, the feature does not function
sometimes. Therefore, turn the idle control switch to 『 HIGH 』 .
•When welding operation or electric supply performs alternately or intermittently, turn
the idle control switch to 『 HIGH 』 .
5-2. Welding Output Control
(1) CV/CC
The equipment incorporates CV (Constant Voltage) and CC (Constant Current)
characteristic feature.
Connecting a wire feeder and then turning the CC/CV Selector Switch to [CV-WIRE],
semi-automatic welding such as MIG, MAG, SS, etc. is available to perform.
Connecting the welding cables and then turning the CV/CC Selector Switch to
[CC-STICK, GOUGING], stick welding or arc gouging is available to perform.
When the CV/CC Selector Switch is positioned at [CV-WIRE], the current from the
terminals becomes Constant Voltage Characteristic. Therefore, Adjust the voltage by
the Output Control Dial.
When the CV/CC Selector Switch is positioned at [CC-STICK, GOUGING], the
current from the terminals is set as Constant Current Characteristic. Adjust current
by Output Control Dial.
(2) Welding Output Pre-Set
The equipment incorporates Welding Output Pre-Set feature.
When the CV/CC Selector Switch is positioned at [CV-WIRE], CV Output voltage
can be Pre-Set by the Output Control Dial
When the CV/CC Selector Switch is positioned at [CC-STICK, GOUGING], CC
Output current can be Pre-Set by the Output Control Dial.
<Caution>
The applicable remote controller with 9-Pin Connector has an Output control dial
which can be adjusted the output current in the remote area prior to the dial on
the machine.
(3) ARC CONTROL (for CC mode)
The equipment incorporates Arc Control feature.
Arc Control can be adjusted by turning the Arc Control Dial for suitable arc
performance. Stable (Mild) welding arc can be obtained with Arc Control Dial
5.
. .
. Equipment

- 9 -
negative( － ) dial side and Strong (Crisp) welding arc can be obtained with Arc
Control Dial positive( ＋ ) dial side.
(4) ROD SELECTOR (for CC mode)
The equipment incorporates Rod Selector feature.
When the CV/CC Selector Switch is positioned at [CC-STICK, GOUGING], the
welding characteristics can be switched by changing Rod Selector Switch.
[CELLULOSE] mode is suitable for the Cellulose Rods and [OTHERS] mode is
suitable for the Gouging Rods and ordinal rods except cellulose.
5-3. Voltage Reduction Device
The equipment incorporates VRD (Voltage Reduction Device) feature, for the
purpose of protecting an operator from electric shock with welding output.
When the VRD Selector Switch is turned to [ON], the voltage changes to 35V or less
during no welding period.
The equipment is incorporated with
monitoring function of VRD.
When the VRD Selector Switch is turned to
[ON], Green VRD Lamp will be automatically
turned on at [BELOW 35V] side.
When the Red VRD lamp will be turned on at [AT OR ABOVE 35V] side, the welding
voltage is exceeded more than 35V or while the VRD Selector switch is at [TEST]
mode.
5-4. Output Remote Control
The equipment incorporates Optional Output Remote Control feature.
(1) 14-Pin Connector (Wire Feeder Control)
Wire Feeder Control operation is available by connecting the Optional Wire Feeder
to the 14-Pin Connector
(2) Welding Terminals Switch
Wire Feeder Control operation is available by turning the Weld Terminals Switch to
[REMOTE CONTROL] position.
When the Weld Terminals Switch to [WELD TERMINALS ON] position, the welding
voltage is always supplied from machine’s welding terminal.
When the Weld Terminals Switch to [REMOTE CONTROL] position, the welding
voltage will be supplied from machine’s welding terminal by pressing the wire feeder
torch trigger.
(3) Wire Feeder Voltmeter Selector
The Wire Feeder Voltmeter Switch can change the voltmeter indication polarity
which is equipped on the optional wire feeder.
(4) 42V / 115V Selector
The 42V / 115V Selector Switch can change the supply voltage for the required
output voltage based on the optional wire feeder specification.
VRD
LAMP
WIRE FEEDER
14-PIN
CONECTOR

- 10 -
(5) Circuit Protector for Wire Feeder
When the over current (more than 5A) is flown into 14-Pin Connector for wire feeder,
the Circuit Protector will be activated to shut off the current.
<Caution>
Resolve the over current issue to proceed the necessary maintenance when the
Circuit Protector was activated, with reset the trip button.
(6) 9-Pin Connector (Remote Control)
Remote Control operation is
available by connecting the
compatible Remote Controller
to the 9-Pin Connector. Adjust
the welding current (in CC
condition) or welding voltage (in
CV condition) in the remote
area from the machine.
< Caution >
•When the remote control box is
connected, the current adjustment dial of the equipment’s front panel will not work.
•When the plug of remote control box has disconnected while welding, the current
adjustment dial of the equipment will work. It may affect to increase or decrease the
current accidentally.
5-5. OPERATION MODE SELECTOR
The equipment incorporates Operation Mode Select feature.
Below three modes can be selected by the Operation Mode Selector Switch position.
[GEN. WELDER] ： Both Welder and Generator mode
[WELDER ONLY] ： Only welding function mode
[GEN. ONLY] ： Only generating function mode
5-6. Meter
The equipment incorporates digital meters, voltage & amperage of welding output
and also 1-Phase Voltage & frequency of AC output.
(1) DC Ampere Meter ・
・・
・ Volt Meter
Each meter displays welding voltage and amperage.
<Caution>
While operating at no-load, if the CV/CC Selector Switch is set as [CV-WIRE], DC
Volt Meter is indicating desired voltage by Output Control Dial.
(There is no display at DC Ampere Meter while no-load.)
While operating at no-load, if the CV/CC Selector Switch is set as [CC-STICK,
GOUGING], DC Ampere Meter is indicating desired amperage by Output Control
Dial. (There is no display at DC Volt Meter while no-load.)
During actual welding work, both DC Volt Meter ・ Ampere Meter displays actual
output. Both displays will be back to the pre-set value after counting about
8seconds with blinking dot on the DC Volt meter.
(2) AC Meter
The meter displays the 1-Phase voltage and the frequency in AC output.
<Caution>
While Operation Mode Selector Switch is [GEN. WELDER] or [GEN. ONLY],
AC Meter displays 1-Phase voltage and frequency. When the Operation Mode
Selector Switch is [WELDER ONLY], AC Meter display will goes off.
9
-
PIN CONNECTOR
REMOTE
CONTROLLER
(Compatible)

- 11 -
5-7. Monitor Lamp
The equipment is incorporated in Monitoring function of WATER TEMP,BATTERY
CHARGING, OIL PRESSURE, OVERHEAT.
Under normal condition, when the starter
switch changes from [STOP]to [RUN],all the
lamps of BATTERY CHARGING, OIL
PRESSURE and OVERHEAT turn ON. When
the engine starts, all the lamps turn OFF. When
abnormality is detected on other than
OVERHEAT, the corresponding monitor lamp will flash, and the engine automatically
shutoff. When the automatic shutoff is engaged, turn the starter switch to [STOP]
position once, and then restart the engine. In the event the automatic shutoff is
engaged next time, check which lamp turns ON or OFF and point out where is the
abnormality.
(1) Coolant/Water Temperature Monitor Lamp
Danger: Injuries
Close and lock all equipment doors during operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Caution: Burns
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid sustaining burns from hot vapor.
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
When the water temperature rises abnormally, the coolant/water temperature
monitor lamp will flash, and the automatic shutoff will be engaged.
When this occurs, check the coolant/water reservoir 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 use the
equipment within the rated duty cycle and output power.
(2) Battery Charge Monitor Lamp
When the battery turns unable to be charged during operation, the battery charge
monitor lamp will flash and the automatic shutoff will be engaged. In the event this
occurs, consult with the authorized distributor or our engineering section.
<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 during operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Caution : Burns
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
When checking engine oil, always stop the engine, and wait until the engine
cools down. If you open either the oil gauge or the oil filter cap during
operation, hot oil may cause some injury.
BATTERY
CHARGE
WATER
TEMP
OVERHEAT
OIL PRESSURE

- 12 -
When the engine oil pressure drops during operation, the oil pressure monitor lamp
will flash, and the automatic shutoff will be engaged.
When this occurs, check the engine oil level, and replenish to the maximum level if
needed.
<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 authorized distributor or our engineering section, because there may be
an abnormality of electric/electronic parts or wiring and repairing may be required.
(4) Overheat Monitor Lamp
OVERHEAT monitor lamp may flash in the case the machine is used excessively
over the duty cycle or over load.
When the OVERHEAT monitor lamp is blinking, this equipment cuts the out put off.
When this overheat occurs, there may be a possibility of overloading. Always use
the equipment within the rated duty cycle and output power.
<Caution>
There may be a case that the lamp will not flash, depending on the welding type
or the weather condition.
5-8. Earth Leakage Circuit Breaker and Grounding
Danger : Electric Shock
Ground every grounding terminal to the earth as set out in the manual.
If even one of all is unconnected by mistake or accident, it will be much more
dangerous for human body than the NO RELAY case, because leaking current
inevitably goes through the body.
Even though all the terminals of the loads have been grounded to the earth, the
bonnet (canopy) grounding terminal should be grounded to the earth.
Grounding should be made after the engine is stopped.
Whenever the earth leakage relay has activated, always repair the leaking
circuit first.
The equipment is provided with the earth leakage relay in the Circuit Breaker to
detect any leakage arisen due to the troubles as insulation failure of the load while
the generator is running. And cutting off the circuit for protection against any
accident such as electrical shock resulting from the trouble.
The specifications of the earth leakage relay:
Rated Sensitive Current: 30mA (or below)
(Grounding resistance: 500 Ω or below)
(1) Grounding Work
The qualified electrician should perform the
grounding work of the following 2 points
(500 Ω or below).
The Outer Bonnet of this equipment (bonnet grounding terminal)
The Outer Bonnet of the load
<Caution>
In the event you cannot ground the generator to the earth, consult with the
authorized distributor or service dealers.
GROUNDING
ROD
BONNET
GROUNDING
TERMINAL

- 13 -
(2) Operation Check
Before operating the equipment, check always if the device can work duly as
shown in the following procedure.
① Start engine after turning the Idle Control
Switch to [HIGH].
② Turn (Push-up) the ELCB (lever) to ON
position.
③ Push the test button(Gray color) in the
ELCB. While test button is pressed,
the ELCB indicator (White) must be popped up and the lever positions will be
moved in between [ON] and [OFF].
④ Turn (Push-down) the ELCB (lever) to OFF position.
⑤ Return the ELCB (lever) to [ON] position.
(The ELCB indicator (white) will be returns to original position)
⑥ Restore the switch to STOP once, when starting the engine.
In the event you cannot complete all steps in the above procedure to the end, the
device is out of order. Consult with our authorized distributor or service dealers.
(3) The Earth Leakage Relay has activated
Caution: Electric Shock/Injuries
Be sure to disconnect all the loads to the equipment when turning the ELCB ON
again, after the earth leakage relay has activated.
When the earth leakage relay has activated, the ELCB indicator button (White)
popped up and the ELCB (lever) positions has moved to the position in between
[ON] and [OFF]. In the case, stop the engine promptly and find the leakage point to
repair. After repairing leakage point(s), reset the ELCB by following procedure.
① Push the ELCB lever down to [OFF].
② Then the ELCB lever will be able to be [ON] position.
<Caution>
When the ELCB has tripped to the middle but the indicator button is not popped
up simultaneously, the cause to have tripped is OVER-LOAD.
Restore as per the procedures No. 9-3 Operation.
5-9. Auto Idle Feature
The Auto Idle feature is to set the engine speed low automatically (in about 8
seconds) for the purpose of reducing noise and fuel consumption, whenever no
welding operation or electric supply is performed.
In the case of using the Auto Idle feature, turn the Idle Control Switch to [AUTO].
By the condition, the engine automatically moves to high speed, whenever welding
operation or electric supply starts.
Caution : Damage to the equipment or other properties
Turn always the Idle Control Switch to [HIGH], when the load is incorporated
with any magnet switch.
<Caution>
When the load of less than 0.5A is connected to use, the Auto Idle feature does
not function sometimes. Therefore, turn the switch to [HIGH].
When welding operation or electric supply performs alternately or intermittently,
turn the switch to [HIGH].
ELCB
INDICATOR
TEST
BUTTON
ELCB
(MAIN
BRAKER)

- 14 -
5-10. Emergency Stop Switch
The Emergency Stop Switch is used to stop the engine in
emergency. By pushing the switch, the engine stops.
Be sure to restore the Starter Switch to [STOP] and reset
the Emergency Stop Switch, turning clockwise after using
the switch.
5-11. Battery Isolator
When turning the Battery Isolator Switch to
[OFF] position, the engine electric circuit
does not get battery power.
<Caution>
Do not turn the Battery Isolator position
while in operation, it may cause the
serious damage on the unit.
Danger : Electric Shock ・
・・
・ Injuries
Before performing any inspection or maintenance, always stop the engine, and
remove engine key. A person performing the maintenance should always keep
the key.
Close and lock all equipment doors during operating this equipment, to avoid
injuries by unintentional touching cooling fan and fan belt.
Caution : Fire ・
・・
・ Burns ・
・・
・ Injuries
When checking engine, always stop the engine, and keep away from fire. 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 all the way in. 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 leveled, it is
difficult to check the accurate oil level.
Do not overfill (over UPPER line) the engine oil.
The excessive Amount of engine oil may damage
the engine (inside the cylinders)
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.
. .
. Initialization and Pre-operation check
RESET
STOP
UPPER LEVEL
EFFECTIVE
LOWER LEVEL
OFF position ON position
OIL
GAUGE OIL DRAIN
PLUG
OIL INLET
OIL PLUG
RIGHT
DOOR

- 15 -
6-2. Checking Coolant / Water
Danger : Injuries
Close and lock all equipment doors during operating this equipment, to avoid
injuries by unintentionally touching cooling fan and fan belt.
Caution : Burns
Do not open the radiator cap while operating this equipment or immediately
after stopping the equipment, to avoid sustaining burns from hot vapor.
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
Check to see if the coolant/water level is between FULL and LOW levels in the sub
tank. If the coolant/water is below the LOW level, fill the tank and the radiator
accordingly.
(1) Filling to the Reservoir Tank
① Remove the sub tank cap.
② Fill up the sub tank to the FULL level.
③ Install the cap back.
(2) Filling to 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 freeze
and rust. (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 any drip of fuel. Do not use this equipment when any leak is found.
Repair the equipment before use.
The equipment uses Diesel as a fuel. When refueling, always stop the engine
and keep away from fire. Moreover, always wait until the engine cools down
before refueling.
Check for the fuel level in the tank. Add if necessary.
<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
WATER INLET
RADIATOR
CAP
TOP PLATE
LOW
FULL
SUB TANK
SUB
TANK CAP
SUB
TANK
FUEL INLET
FUEL
COVER
TANK CAP
FUEL
STRAINER

- 16 -
“winterized” 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 temperatures than No.2-D fuel
which has not been “winterized”. Check with the services stations operator to be
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 tank.
6-4. Checking Fuel, Engine Oil and Water Leakage
Caution : Fire
Do not use this equipment when a leak is found. Repair the equipment before
use.
Be sure to check 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 sulfuric acid. Avoid contact with eyes, skin or
clothing.
If the acid comes to contact, especially with eyes, flush with a lot of water, and
contact your physician immediately.
Caution : Explosion
Do not use the equipment or charge the battery, in the case the battery fluid
level is lower than the LOWER level.
Battery may emit some combustible gas, so keep it away from fire and sparks.
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>
Make sure to turn to [OFF] the Battery Isolator
Switch before attempting to check the battery
terminal.
Check the specific gravity of the battery by The
hydrometer.
Recharge the battery If it falls below 1.23. Please
consult with our authorized distributor or service
dealers .
Replacing battery
① Turn the Battery Isolator Switch to [OFF]
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 seat.
※ 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
TERMI
NAL
UPPER
LEVEL
LOWER
LEVEL
INS. CAP
[ + ] POST
HOLD
-
DOWN CLAMP
[
-
]
POST
BATTERY
BATTERY
ISOLATOR

- 17 -
Danger : Suffocation from exhaust fume
Exhaust fume from the engine contains many elements harmful to human.
Do not operate this equipment in poorly ventilated area, such as inside a room
or in a tunnel.
Caution : Suffocation from exhaust fume
Do not direct the exhaust fume toward pedestrians or building.
Caution : Fire
Temperature around muffler and exhaust can get extremely high.
Keep any flammable items (such as fuel, gas, paint, etc.) away from the
equipment.
Always operate this equipment on flat surface and, at least 1 meter away from
any objects (wall, box, etc.)
Caution : Injuries
Always place the equipment on a flat and stable surface, to keep the
equipment from sliding. Be sure to lock the wheels for the wheeled models.
Before starting the engine, be sure to disconnect the loads and set the
breakers (MAIN, 1-P) to [OFF] position.
Caution : Burns
Do not touch the engine and muffler during operation and immediately after
stopping the equipment, for the temperature can reach extremely high.
< Caution >
•Check to see if it is safe around the equipment before starting.
•When operating the equipment by two or more persons, ensure all work condition
are safe.
•Do not use the equipment on dusty , hot and humid location.
•Close and lock all equipment doors during operating this equipment, to avoid
damaging the equipment by decrease of cooling efficiency.
•Always close and lock all equipment doors during operating this equipment, to
prevent the hearing abnormality. Use additional hearing protection item.
7-1. Starting
① Turn the breakers (MAIN, 1-P) to [OFF]
② Turn the every Fuel lever (on Fuel Strainer and Water Separator) to [OPEN].
③ Turn the Battery Isolator Switch to [ON] Turn the Idle Control Switch to
[AUTO].
④ Ensure the Emergency Stop Switch is positioned to release.
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 about 5 minutes.
7．
．．
．Operating the Engine
FUEL
STRAINER
CLOSE
OPEN
WATER
SEPARATOR
OPEN
CLOSE
1-P
BREAKER
MAIN
BREAKER
BATTERY ISOLATOR
ON position