Shindaiwa EGW165M-I/UKV User manual

Original instructions
OWNER’S AND
OPERATOR’S MANUAL
Air-Cooled, 4 Cycle OHV Engine
EGW165M-I/UKV
X750-031 03 2
X750804-430 2
CAUTION: Do not operate the Generator/Welder, or any other appliance, before
you have read and understood the instructions for use.

Introduction
Thank you for purchasing Shindaiwa Sound Proof Petrol Engine Generator/Welder.
This Operator’s 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.
Warning
Can cause serious injuries or death.
Caution
Can cause minor injuries or damage to the equipment or other
property.
<Caution>
Other types of caution
The following explanatory symbols will be used throughout the manual and on the
product itself. Please make sure that you fully understand what each symbol means.
Symbol form/shape
Symbol description/application
Read and understand instructions
Safety/Alert
Do not operate this equipment in poorly ventilated areas
Beware of fire
Beware of electric shocks
Beware of suffocation from welding fumes

Symbol form/shape
Symbol description/application
Do not use for Indoor wiring
Do not use in the rain
Beware of eyes and skin
Beware of hot surface
Beware of high voltage
Guaranteed sound power level
Some of the items noted in [ Caution] may also lead to serious injuries.
Please read all items and follow all the safety guidelines.
This product is solely for professional use. Please follow international regulations (if any)
for the education/training in relation to welding works, the engine driven machine/fuel
handling qualification, first aid, etc.
The following statement refers to the noise level data contained in the EC Declaration of
Conformity contained on the next page 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 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”

Declaration of Conformity
The undersigned manufacturer: YAMABIKO CORPORATION
1-7-2 Suehirocho
Ohme, Tokyo 198-8760
JAPAN
declares, under the sole responsibility thereof, that the hereunder specified new unit:
SOUND PROOF PETROL ENGINE GENERATOR/WELDER
Brand: Shindaiwa
Type: EGW165M-I/UKV
Serial Number M03301000055 to M03301999999
complies with:
ʀthe requirements of Directive 2006/42/EC (use of harmonized standard EN 60974-1:2012)
ʀthe requirements of Directive 2014/30/EU (use of harmonized standard EN 60974-10:2014
EN 55012:2007/A1:2009
EN 61000-6-2:2005)
ʀthe requirements of Directive 2009/125/EC (use of other technical standard EN 60974-1:2012, Annex M)
and Regulation (EU) 2019/1784 (as its implementing measure)
ʀthe requirements of Directive 2011/65/EU (use of harmonized standard EN IEC 63000:2018)
ʀthe requirements of Directive 2000/14/EC
Noise measurements have been made in accordance with 2000/14/EC
annex 3 part B(57) with supervision by Notified Body No.0036
(TUV SUD Industrie Service GmbH Westendstrasse 199 80686 Munchen)
The declared noise values are as follows:
Measured sound power level Guaranteed sound power level
94dB LwA 95dB LwA
Tokyo, August 16th, 2021
YAMABIKO CORPORATION
the person in Europe who is authorized to compile the technical file.
Company: Shindaiwa Limited
Address: 6 The Dell, Enterprise Drive, Four Ashes, Wolverhampton WV 10 7DF United Kingdom
Hisashi Kobayashi
General Manager
Quality Assurance Dept.
YAMABIKO CORPOR
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Table of Contents
1. Safety Guidelines·································································1
2. Specifications ·····································································5
3. Use····················································································6
4. Parts··················································································7
5. Equipment··········································································8
5-1. Earth Grounding Terminal·············································8
5-2. Frequency Changeover Switch ······································8
5-3. Engine Speed Control Switch (Eco-mode)························8
5-4. Weld Mode Selector····················································9
5-5. AC Output Switch ·······················································9
5-6. Overload/Overheat Protection Devices ····························9
5-7. Oil Sensor······························································· 10
5-8. Display··································································· 10
5-9. Wheel Brake···························································· 11
5-10. Earth Leakage Circuit Breaker and Grounding ··············· 12
6. Operation ········································································· 13
6-1. Initialization/Pre-check ··············································· 13
6-2. Starting··································································· 17
6-3. Stopping································································· 19
7. Welding Operation····························································· 19
7-1. Selection–Welding Cable············································ 19
7-2. Polarity··································································· 19
7-3. Connection–Welding Cable········································· 20
7-4. Duty Cycle ······························································ 20
7-5. Welding·································································· 21
8. Generator Operation ·························································· 22
8-1. Operation································································ 23
8-2. Output Limitation ······················································ 23
9. Checking and Maintenance ················································· 24
10. Long-term Storage ··························································· 28
11. Troubleshooting ······························································ 29
12. Wiring Diagram································································ 31

- 1 -
1. Safety Guidelines
Warning: 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.
Warning: Electric Shock
Close all equipment doors during operation.
Do not touch the output terminals during operation.
Do not touch or operate the equipment, if the equipment or you are 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.
Even though all the terminals of the loads have been grounded to the earth, this
equipment grounding terminal should be grounded to the earth.
Before connecting or disconnecting a welding cable from output terminal, stop the
engine, and remove the starter key.
Before performing any equipment check or maintenance, stop the engine and remove
the starter key. The person performing the check or maintenance must always keep
the key.
Warning: Electromagnetic Interference
Persons using a heart pacemaker are not allowed near the Generator work area while
the Generator is in operation without the permission of a doctor. The welder generates
a magnetic field while energized that can negatively affect pacemaker operation.
This product may cause interference if used in residential areas.
Such use must be avoided unless the user takes special measures to reduce
electromagnetic emissions to prevent interference to the reception of radio and
television broadcasts.
Warning: 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.
Warning: Injuries to eyes and skin
Battery fluid contains diluted sulphuric acid. Avoid contact with eyes, skin and clothing.
If the acid comes in contact with eyes, flush with lots of water, and contact your
physician immediately.
Warning: Explosion
The battery may emit some combustible gas. Keep it away from fire and sparks.
Do not use this equipment for the purpose of thawing pipes.

- 2 -
Warning: Fire
The equipment uses Petrol as a fuel. When inspecting the equipment or refueling,
always stop the engine, remove static electricity and keep away from sparks or naked
flames. Always wait until the engine cools down before refueling.
Never fill fuel above the upper level.
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
flammable items (such as fuel, gas, paint, etc.) away from the equipment.
Always operate the equipment on a flat surface and with at least 1 metre clearance
from all objects.
Never operate the equipment covers with the flammable products.
Keep any flammable items and combustible items away from the welding area as
welding creates hot sparks.
Always set up extinguishers near the welding area.
Always drain fuel before transporting by vehicle.
Do not operate the equipment when it is stored in a vehicle.
Warning: Injuries
When performing equipment checks and maintenance, always stop the engine, and
remove the starter key.
Do not operate the equipment, if the equipment has been modified or if parts have
been removed.
Caution: Suffocation from exhaust fumes
Do not point exhaust fume outlet pipe in the direction of pedestrians or buildings.
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.
Caution: Electric shock
Do not sprinkle water on the equipment and do not use where exposed to rain and
thunder.
This machine is rated to IP23.
Do not touch the spark plug, plug cap or high-voltage wiring during operation.

- 3 -
Caution: Fire
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.
Starting this product in an explosive atmosphere may cause an explosion even with
the extremely weak sparks generated by the switch of the equipment. Do not carry
this equipment into an explosive atmosphere as well as not start.
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 and 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 any connected equipment and set the AC output
switch to the [OFF] position.
Do not move the equipment during operation.

- 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 label, use the following part numbers.
1. Suffocation from Exhaust Fumes (X505-011481)
2. Electric Shock (X505-011470)
3. Hot Surface (X505-011490)
4. High Voltage (X505-011500)
5. Lifting Point (X505-006430)
1
2
4
3
5
X505-006430
Positioning handle.
Do not use as lifting point
2
1
3
4
5
5

- 5 -
2. Specifications
Model
EGW165M-I/UKV
Generating Method
Rotating Field, Synchronous AC Generator
Welding Generator
Recommended
Rated Current (A)
145
Rated Load Voltage (V)
25.8
Duty Cycle (%) @ 40°C
50
Rated Speed (min-1)
3600
No Load Voltage (V)
75 (3800 min-1)
54 (EN 60974-1:2012 Fig. 4, 3800 min-1)
Current Adjustable Range (A)
30-165 (3400-3700 min-1)
Welding Rod (φ)
2.0-4.0
Power source efficiency (%)
92
Idle state power consumption (W)
4
AC Generator
Voltage Regulation System
Inverter
Phase
1-Phase
Rated Voltage (V)
110
Frequency (Hz)
50/60
Rated Speed (min-1)
3600
Rated Output (kVA)
3.2
Rated Current (A)
29
Power Factor
1.0
Rating
Continuous
Engine
Model
Yamaha MZ300
Type
Air-cooled, 4-Cycle OHV Gasoline
Displacement (L)
0.296
Rated Output (kW/min-1 )
5.8/3600
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 BPR4ES
Battery
Yuasa YTX9-BS
Fuel Tank Capacity (L)
15 (approx.)
Noise (dB(A))
Sound pressure level LpA
80 (2006/42/EC, d = 1 m, h = 1.6 m, I2 = 165 A)
Measured sound power level LWA
94(2000/14/EC, r = 4 m)
Uncertainly KWA
1
Guaranteed sound power level LWA
95 (2000/14/EC, r = 4 m)
95 (declared)(2000/14/EC, r = 4 m)
Dimension
L x W x H (mm)
730 x 545 x 647
Dry Weight (kg)
87
WELDING GENERATOR EN 60974-10 EMC Group 2 Class A

- 6 -
3. Use
Arc welding (Manual welding only)
Power source for electric tools
Power source for lights
EMC classification Group 2 Class A
Caution: Damage to the equipment or other properties
This product may cause interference if used in residential areas. Such use must be
avoided unless the user takes special measures to reduce electromagnetic
emissions to prevent interference to the reception of radio and television
broadcasts.
Consult with our dealer or authorized distributor when utilizing 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.
This product is solely for manual welding. Even if some ancillary equipment (such as
a wire-feeder) can connect with this product, do not use this product in conjunction
with them because they may cause malfunctions.
It is recommended you follow this instruction manual strictly, to avoid any
unnecessary accidents, repairs and damage.

- 7 -
4. Parts
1. Choke
2. AC Output Switch
3. Frequency Changeover Switch
4. Display
5. Current Adjusting Dial
6. Engine Speed Control Switch
7. Starter Switch
8. Weld Mode Selector
9. AC Output Receptacle (16 A)
10. AC Output Receptacle (29 A)
11. Welding Output Terminal
12. Earth Leakage Circuit Breaker (ELCB)
13. Battery
14. Earth Grounding Terminal
15. Plug Cap (Spark Plug)
16. Fuel Valve
17. Air Cleaner (Cleaner Cover)
18. Recoil Knob
19. Fuel Inlet
20. Front Door
21. Side Door
22. Plug Maintenance Cover
23. Handle
24. Lifting Lug
25. Wheel Stopper
26. Muffler (with Exhaust Wire Mesh)
27. Exhaust Outlet
28. Oil Maintenance Cover
29. Oil Gauge/Oil Inlet
30. Oil Drain Plug
31. Wheel
32. Grip for Lifting
Accessories
Owner’s and
Operator’s
Manual
Starter Key 2 pcs
Plug Wrench 1 set
Engine
Operator’s
Manual
Technical
Data Sheet

- 8 -
5. Equipment
5-1. Earth Grounding Terminal
The grounding terminal of this equipment.
Even though all the terminals of the loads have
been grounded to the earth, this machine
grounding terminal should be grounded to the
earth.
(Grounding resistance: 500 Ω or below)
<Caution>
In the event you cannot ground the generator
to the earth, consult with the authorized
distributor or our dealer.
5-2. Frequency Changeover Switch
This Frequency Changeover Switch changes the
frequency either 50 Hz or 60 Hz.
Change the frequency:
50 Hz: Turn the frequency changeover switch
to [50 Hz].
60 Hz: Turn the frequency changeover switch
to [60 Hz].
5-3. Engine Speed Control Switch (Eco-mode)
The Eco mode is designed to control the engine
speed based on the required current to minimize
the noise level and fuel consumption. Turn the Idle
control switch to [ECO] position to use this
function.
(1) Welding
When welding current output is detected, the
engine turns to appropriate speed and returns to
idling rpm approximately 8 seconds after welding
has finished.
(2) Generator
While utilizing AC output, the engine turns to appropriate speed and returns to idling rpm
when not utilizing AC output. [HIGH] mode will always turn the engine to high rpm.
<Caution>
Always select [HIGH] mode while utilizing high load equipment to ensure constant
output.
Earth Grounding Terminal
Earth Grounding Terminal
Grounding Rod
Frequency Changeover Switch
Engine Speed Control Switch

- 9 -
5-4. Weld Mode Selector
You can select a weld mode of [DROOP] or [CC]
in accordance with the type of welding being
performed.
DROOP (Drooping Characteristic)
The weld current can be adjusted by
manipulating the welding rod due to being able
to increase or decrease the current for
changing the arc length, thereby allowing you to adjust the arc status and weld beads.
The arc start is good and the arc is strongly felt.
This mode is optimal for welding work such as pipe welding.
CC (Constant Current)–STICK
Welding can be performed at a constant uniform current even if the arc length changes
due to a shaky hand or similar cause to provide a stable arc that is not easily
extinguished.
Welding can be performed at a specified current value without being affected by the
length or thickness (thinness) of the welding cable.
This mode is optimal for general welding as the stable arc reduces the amount of
spatter.
5-5. AC Output Switch
This AC Output Switch changes between
connecting and disconnecting of AC power
source. This switch does not have function to
automatically shut off the output like a breaker
does.
5-6. Overload/Overheat Protection Devices
This device is designed to protect the welding machine by tripping the AC output when the
overload or extreme temperatures are detected in the inverter circuit.
Display will indicate the following abbreviations when the device is activated.
[OC]: Overload (over current)
[OH]: Overheat (high temperature at inverter circuit)
Follow the instructions below to reset the device after protection has been activated.
Shut off any connected equipment and change the AC output switch to [OFF] position.
Allow the unit to cool down during idling mode for a minimum of 5 minutes.
Shut off the engine.
Caution: Injuries
Be sure to turn off any connected equipment before restarting the engine after the
overload and/or overheat protection devices are activated.
Weld Mode Selector
AC Output Switch

- 10 -
After checking the engine has stopped completely, turn the engine on again, and then
change the AC output switch to [ON] position.
<Caution>
Refer to 8-2 Output Limitation (P. 23) for a table showing maximum currents from the
circuit.
There is no automatic shut off function with AC output switch.
Insufficient air cooling may cause Overheating [OH].
5-7. Oil Sensor
If the engine oil sensor is activated during operation, the display of the control panel will
indicate [OIL], and the automatic shutoff will be engaged in order to protect engine from
failure, this is the function of the oil sensor unit.
After the engine has stopped automatically, the display on the control panel shows [OFF].
In this instance, you should re-start the engine to check the cause of engine shutoff. If the
engine stops again and the display shows [OIL], check the engine oil level and replenish to
the maximum level if needed. Please refer to 6-1 (1) Checking Engine Oil (P. 13).
<Caution>
The engine oil sensor cannot detect degradation of engine oil. Please check the engine
oil periodically, and change if required. Refer to 9. Checking and Maintenance (1)
Change Engine Oil (P. 25).
Always operate the equipment on a flat and stable surface, as the engine can stop after
operating the oil sensor.
5-8. Display
This equipment has a multi display which
indicates operation status on the control panel,
while the engine is running.
(1) Digital hour meter
Total operation hours will be indicated for 5
seconds only, after the engine has started.
(Maximum indication up to 9,999 hours) Then
the display will alternate between pre-set/actual
welding current.
Caution: Injuries
When re-starting the engine in order to check oil sensor activation, turn off the
connected equipment and set the AC output switch to [OFF] position.
Caution: Injuries
When checking engine 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.
Do not touch the engine immediately after stopping the equipment, as temperatures
can reach extremely high levels.
AC Output Lamp
Display
Actual Welding Current Lamp
Eco Lamp
Frequency Lamp
Pre-set Welding
Current Lamp

- 11 -
(2) Welding current (pre-set/actual)
Default display mode indicates pre-set welding current.
(The pre-set welding current lamp turns on.)
The display indicates actual welding current while welding.
(The actual welding current lamp turns on.)
(3) Oil warning
If the engine oil sensor is activated during operation, the display will indicate [OIL].
Please refer to 5-7 Oil Sensor (P. 10).
(4) Overload warning
When the AC output current exceeds the machine rating, the display will indicate [OC].
Please refer to 5-6 Overload/Overheat Protection Devices (P. 9).
(5) Overheat warning
When extreme high temperature is detected at the inverter circuit, the display will indicate
[OH]. Please refer to 5-6 Overload/Overheat Protection Devices (P. 9).
(6) AC Output
When the AC output switch is ON, the AC output lamp will turn on green. And when the
AC output switch is OFF, the AC output lamp will turn off.
(7) Frequency
The lamp turns RED in accordance with the position of the Frequency Switch.
(8) Eco-mode
When the engine speed control switch is in the [ECO] position, the eco lamp will turn on
green. And when the engine speed control switch is in the [HIGH] position, the eco lamp
will turn off.
5-9. Wheel Brake
The wheel brake is designed to lock the wheels to avoid unnecessary movement of the
equipment when operating on a flat surface. It is recommended you secure additional
stoppers and/or ropes to fix the position during transportation or when operating the
machine on uneven ground.
(1) Lock the wheel
1. Lift the brake arm upward to position 1.
2. Move the equipment back and forth gently to
allow the brake arm to slide into position 2
with a clicking noise.
3. Confirm the equipment is now locked.
Caution: Injuries
Be sure to place this equipment on a flat surface and lock the wheel by lifting the
brake arm as shown below.
Wheel Lock

- 12 -
(2) Unlock the wheel
Slide the brake arm to position 1 and then down
to default position 2.
<Caution>
Be sure to unlock the brake, before attempting
to move the equipment to avoid a locking
system malfunction.
5-10. Earth Leakage Circuit Breaker and Grounding
(1) Grounding Work
A qualified electrician should perform the
grounding work of the following 2 points (500 Ω
or below).
The grounding terminal of this equipment.
The Outer Bonnet of the load.
<Caution>
In the event you cannot ground the generator
to the earth, consult with the authorized
distributor or our dealer.
(2) Operation Check
Before operating the equipment, please follow
the instruction below.
1. Start the engine as per starting procedure.
Please refer to 6-2 Starting (P. 17).
2. Turn the AC output switch to [ON] position.
3. Switch the ELCB to [ON] position.
4. Press the test button (Gray) in the ELCB.
(Once the test button is pressed, the ELCB indicator (White) must be out and the
switch in the middle position.)
5. Push down the ELCB switch [OFF] position.
6. Return the ELCB switch to [ON] position.
(The ELCB indicator (White) will return to its original position)
In the event you cannot complete all 6 steps in the above procedure, the ELCB is
faulty. Consult with our authorized distributor or our dealer to repair.
Warning: 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 circuit breaker has been activated, you should always
repair the fault before re-using the machine.
Wheel Unlock
ELCB
ELCB Indicator
Test Button
Earth Grounding Terminal
Grounding Rod

- 13 -
7. Be sure to set the AC output switch to [OFF] position before starting the engine.
(3) The Earth Leakage Circuit Breaker has activated
When the Earth Leakage Circuit Breaker has activated, the ELCB indicator button
(White) will be out and the ELCB switch will have moved to the middle position.
In this case, stop the engine, trace the earth leakage fault and repair.
After repairing the leakage fault, reset the ELCB using the following procedure.
Push the ELCB switch down to [OFF] position.
Lift the ELCB switch to return to the [ON] position.
6. Operation
6-1. Initialization/Pre-check
(1) Checking Engine Oil
Position the equipment on a flat and stable surface, Open the oil maintenance cover and
insert the oil gauge into oil inlet to check the engine oil level (do not screw the oil gauge
into the oil tank).
Before operation, ensure oil is to upper level.
Oil Capacity: approximately 1.0 litre (maximum)
Effective Oil Volume: approximately 0.5 litre (between the LOWER and UPPER)
Warning: Electric Shock/Injuries
Be sure to disconnect all the loads to the equipment before turning the ELCB ON
again, after the earth leakage circuit breaker has activated.
Caution: Fire/Burns/Injuries
When checking the equipment, always stop the engine, and wait until the engine
cools down.
Never place the equipment close to flammable products. Maintain a minimum
clearance of 1 metre around the equipment.

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<Caution>
You cannot measure the oil level accurately when the equipment is on an uneven
surface.
If the machine is placed on an uneven surface, it is still possible for the engine to run,
however, the oil sensor may not detect accurately the true level of oil and this may cause
engine failure.
Engine Oil Selection
Use the engine oil with the correct viscosity, based on the ambient temperature (Refer
to the chart below).
<Caution>
Use oil of Class SE or superior.
Check the remaining oil level more frequently when using a multi-grade type oil, as the
oil consumption rate increases under high ambient temperature.
Oil Selection Criteria
Oil Gauge
Upper Level
Lower Level
Oil Gauge
Oil Drain Plug
Oil Maintenance
Cover
Press the Click to
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direction