Shindaiwa 3 Series User manual

OPERATOR’S
MANUAL
ECO 300/UK
Series 3
Original Instructions

CAUTION: Do not operate the Welder-Generator, or any other appliance, before you
have read and understood the instructions for use.

TABLE OF CONTENTS
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Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T: [phone]
F: [phone]
- 1 - ECO 300/UK
Series 3
OOM-300UK
Vs.01- Aug 2011
Introduction
Thank you for purchasing a 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 contained on page 2 of this manual:
!              

 
‐
   
   
" 


Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 3 - ECO 300/UK
Series 3
OOM-300UK
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 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 outlet toward pedestrians or buildings.
Caution: Suffocation from welding fumes
Be sure to wear a fume proof mask in 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 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.

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 4 -
ECO 300/UK
Series 3
OOM-300UK
Caution: Electric shock
Do not flush water onto the equipment nor operate it in the rain.
Caution: Explosion
Do not use the equipment or charge the battery, if the battery fluid level is
Below the LOWER level.
The battery may emit combustible gas, so keep it away from fire and sparks.
Caution: Fire
This equipment uses Diesel as a fuel. When inspecting the equipment or
refuelling, always stop the engine and keep away from fire, always wait until the
engine cools down before refuelling.
Always wipe away any drips 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 a flat surface and at least 1 metre away from
any object (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 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 to
prevent equipment movement.
When starting the engine, turn off the connected equipment and set the circuit
breaker 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 it is faulty or if there are missing parts.

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 5 - ECO 300/UK
Series 3
OOM-300UK
Location of Warning labels
When the warning labels become unreadable or damaged, place new labels at
the appropriate locations, as specified in the following figure.
When ordering labels, use the following part numbers.
Suffocation from exhaust fumes (No. 19402-00194)-S6
Suffocation from welding fumes (No. 19402-00195)
Electric shock (No. 19402-00193)
Fire (No. 19402-00166)
Injury (No. 19402-00199)
Burns (No. 19402-00200)-S5
Burns (No. 19402-00201)-S16
Lifting Eye (S10)
Earth Symbol (S17)
 Positioning Handle (S3)























Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 6 - ECO 300/UK
Series 3
OOM-300UK
LABEL REPRODUCTION
Label (No. 19402-00194)-S6
Label (No. 19402-00200)-S5
Label (No. 19402-00201)-S16
Label (No. S10)
Label (No. S17)
Label (No. S3)

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 7 -
ECO 300/UK
Series 3
OOM-300UK
2. Specifications
Model ECO 300/UK
Generating Method Rotating Field
Rated Current (A) 280
Duty Cycle (%) 50
Current Adj. Range (A) 30 – 200
ECO Welding Rod (mm) 2.0 – 5.0
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
Dimensions Length x Width x Height (mm) 1410 x 566 x 760
Dry Weight (kg) 348
Generating Set ISO 8528-8/G2
EMC Group 2 Class A
Illustration of Rating Plate Label

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 8 - ECO 300/UK
Series 3
OOM-300UK
3. Use
Arc Welding
Power Source for Lights, Electric Tools and equipment.
Voltage classification G2
EMC classification Group 2 Class A.
Caution: Damage to the equipment or other properties
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.

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 9 - ECO 300/UK
Series 3
OOM-300UK
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
FRONT PANEL REMOVED

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 10 - ECO 300/UK
Series 3
OOM-300UK
OIL FILTER
FUEL INLET TOP-MOUNTED LIFTING LUG EXHAUST
TOP PLATE
POSITIONING HANDLE
POSITIONING HANDLE
NOT TO BE USED FOR LIFTING
FIXED SIDE PANEL REMOVED

Shindaiwa Limited
Four Ashes, Wolverhampton, UK
T:
+44
(
0
)
1902 791855
- 11 - ECO 300/UK
Series 3
OOM-300UK
5. Equipment
5-1. Eco Welding
This equipment 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
5.0mm

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 a Digital Display. It displays AC Voltage, Hours Worked
and Speed successively, by changing the display selector switch.
<Caution>
During operation, the AC voltage meter always displays the voltage in 415V,
3-Phase both with 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, the monitor lamps will go OFF. When a 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 the [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 further
investigate the related malfunction.
BATTERY
CHARGE
OIL
PRESSURE
WATER
TEMP

Shindaiwa Limited
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Series 3
OOM-300UK
(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.
Danger: Burns
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 or exhaust during operation or immediately after
stopping the equipment, as the temperatures 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
If 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 or 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 filler 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.
If this symptom occurs, check the engine oil level, and replenish to maximum level.

Shindaiwa Limited
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Series 3
OOM-300UK
<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)
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 in 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) within 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 the 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or below)
Remote Receptacle
Remote Control Box

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Series 3
OOM-300UK
(1) Grounding Work
Aqualified electrician should perform the grounding work at the 2 points:
(500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 a qualified
electrician or Shindaiwa Ltd.
(2) Operation Check
Before operating the equipment, always check if the safety shut-down device
works as shown in the following procedure.
Ensure that the circuit breakers and load switches are positioned to
[OFF].
Start engine after turning the Idle Control Switch to [HIGH].
Push-up the 1-Phase and 3-Phase ELCB (lever) to the [ON] position.
Push the test button on the 3-Phase ELCB. The earth leakage indicator
button protrudes and the lever is between the [ON] and [OFF] position.
Push down the lever [OFF] on 3-Phase ELCB.
Push the test button on 1-Phase ELCB. The ELCB (White lever and Black
lever) turns to OFF.
In the event you cannot correctly complete all steps in the above procedure, the
machine is “out of order”. Consult with a qualified electrician.
(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 the [ON] and [OFF] position.
If the 1-Phase earth leakage relay has activated, The ELCB (White lever and Black
lever) turns to [OFF].
In this case, stop the engine 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.
CANOPY
GROUNDING
TERMINAL
GROUNDING
ROD
3-PHASE ELCB
1-PHASE ELCB
TEST BUTTON
LEAKAGE
INDICATION
BUTTON
TEST BUTTON
WHITE LEVER
AND
BLACK
LEVER

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Series 3
OOM-300UK
<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 property
Always switch the Idle Control Switch to [HIGH], when the load is incorporated
with any magnet switch.
<Caution>
When a 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.
RESET
STOP

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Series 3
OOM-300UK
6. Initialisation 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 level, 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 (above UPPER line)
the engine oil. Excessive amounts
of engine oil may damage the
engine.
Selecting correct 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 operation of this equipment, to
avoid injuries by unintentionally touching moving parts.
Danger: Burns
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 or exhaust during operation or immediately after
stopping the equipment, as the temperature will be extremely high.
UPPER
EFFECTIVE
LOWER LEVEL
OIL
GAUGE
OIL DRAIN PLUG
OIL FILLER
CAP

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Series 3
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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 the Coolant Sub Tank
Remove the coolant sub tank cap.
Fill the coolant sub tank to the FULL level.
Place the cap back.
(2) Filling the Radiator
Open the top plate.
Remove the radiator cap.
Fill the radiator up to the top.
Place the cap back and tighten.
Close the top plate.
<Caution>
Use Long Life Coolant (LLC), to 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 drips of fuel. Do not use this equipment if a leak is found.
Repair the equipment before use.
Check 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°F), 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
LOW
FULL
COOLANT
SUB
TANK
CAP
COOLANT
SUB
TANK
TOP PLATE
WATER INLET
RADIATOR
CAP

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Series 3
OOM-300UK
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 “winterised”. Check with the
service station operator to make sure you can get the correctly 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 to slightly less than
FULL.
6-4. Checking Fuel, Engine Oil and Water Leakage
Caution: Fire
Do not use this equipment if a leak is found. Repair the equipment before use.
Be sure to check for any leakage of fuel, oil and coolant/water at the hose
connections.
6-5. Checking Battery
Caution: Injuries to eyes and skin
Battery fluid contains diluted sulphuric acid. Avoid contact with eyes, skin and
clothing.
If acid comes into contact with eyes, flush with lots of water, and seek medical
attention 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 gases, so keep away from naked
flames and sparks.
Caution: Fire
Battery may emit combustible gases, so keep away from flames and sparks.
Check the fluid level. If the level is near or lower
than the LOWER level, add distilled water until the
fluid level reaches UPPER level.
Make sure that the battery cables are firmly secured
to the posts. Tighten the clamps if necessary.
TANK CAP
FUEL
STRAINER
FUEL INLET