Table of Contents
Contents
1. and Select the polarity according to the operation referring to the table below lt Caution gt Follow the instruction of the welding rods the polarity of which is specified Application Connection Normal Polarity General welding Negative to holder Rod for construction material Positive to the earth Material Reverse Polarity Thin plate Cladding Negative to the Build up Stainless Steel earth Material Positive to holder Rod 8 3 Connection Welding Cable Danger Electric Shock Before connecting or disconnecting a welding cable from welding output terminals stop the engine and remove the engine key A person performing should always keep the key 8 3 1 Stop the engine Welding Rod Holder Welding Cable 8 3 2 Connecting a welding cable to a crimping Criping Terminal terminal and a welding rod holder and connect the other cable to a crimping terminal and a material SD holder 8 3 3 Connect the welding cables to the welding output terminals Material Holder lt Caution gt Be sure to crimp a crimping terminal to a cable and connect the cable to welding output terminal Otherwise welding output terminals may burn out by the heat caused by insufficient connections Do not use a cable without a crimping terminal If you use the cable the insulation is peeled off partly to bind to an output terminal the output terminal may burn out by the heat caused by insufficient connectio2. Contact cables securely 4 Change cables according to Selection Welding Cable 5 Contact securely 6 Refer to Simultaneous use of Welding and AC output 7 Clean air element Excessive welding arc 1 The setting of current adjustment dial 1 Turn the dial counterclockwise No AC output AC output is weak 1 The breaker to OFF 1 Wrong frequency 2 The current in the load exceeds the rated current 3 The loads used simultaneously exceed the rated output 1 Set the breaker to ON 1 Change the frequency to the correct one 2 Refer to the article of Output Limitation 3 Refer to Simultaneous use of Welding and AC output Slow Down does not activate Short circuit of welding cable 2 The power consumption of the load is 0 5A or below 1 Repair the short circuit 2 Turn the Slow Down switch to OFF Engine does not stop 1 Stop solenoid disorder 2 Fuse burnt Turn the fuel valve lever to CLOSE to stop and repair 2 Repair Black and white smoke exhaust from the muffler 1 Overloaded use 1 Keep the duty cycle of 50 and the rated output Refer to Output Limitation Page 33
3. Fuel Strainer 6 4 Checking Fuel Engine Oil and Water Leakage Caution Fire Always wipe any drip of Diesel fuel or oil Never use this equipment when a leak is found Repair the equipment before use Be sure to check for any fuel leak at hose connection and oil and coolant water by opening side doors When checking for fuel leak open a fuel lever and be sure to close the fuel lever after checking Page 15 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 in contact especially with eyes flush with a lot of water and contact to your physician immediately Caution Explosion When the liquid level is below the LOWER level never use the equipment nor recharge battery Battery may emit some combustible gas so keep it away form fire and sparks 6 5 1 Check the fluid level If the level is near or lower than the LOWER level add distilled water until the fluid level reaches the UPPER level 6 5 2 Make sure that the battery cables are firmly secured to the posts Tighten the clamps if necessary lt Caution gt Lower Limit Check the hydrometer of the battery fluid If it falls below 1 23 the battery requires recharging Please consult with our authorized distributor or our engineering section H Replacing battery 1 Remove the clamps and cable from negative post in the battery Remove always ne
4. SS so 90 Shindaiwa CERTIFIED OWNER S AND OPERATOR S MANUAL SOUND PROOF DIESEL ENGINE GENERATOR WELDER DGW201M Water cooled 4 Cycle Diesel Engine Table of Contents Page 1 Safety Guidelines 2 2 Specifications 6 3 Use 7 4 Parts 7 5 Equipment 9 5 1 Monitor Lamp 9 5 2 Throttle 11 5 3 Circuit Breaker 11 5 4 Slow Down 12 6 Initialization and Pre check 12 6 1 Checking Engine Oil 12 6 2 Checking Coolant Water 13 6 3 Checking Fuel 15 6 4 Checking Fuel Engine Oil and 15 Water Leakage 6 5 Checking Battery 16 7 Operation 17 7 1 Start up 17 7 2 Stopping 19 8 Welding Operation 20 8 1 Selection Welding Cable 20 8 2 Polarity 20 8 3 Connection Welding Cable 21 8 4 Duty Cycle 21 8 5 Welding 22 9 Generator Operation 23 9 1 Operation 25 9 2 Output Limitation 25 10 Simultaneous Use of Welding and 26 Generating 11 Checking and Maintenance 26 12 Long term Storage 31 13 Troubleshooting 32 CAUTION Do not operate the Generator Welder or any other appliance before you have read and understood the instructions for use Shindaiwa Corporation Introduction Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator Welder This user manual is 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
5. a a ES Exhaust gas Ee outlet Page 8 5 Equipment 5 1 Monitor Lamp The equipment is equipped with monitoring function EE EE of Oil Pressure Battery Charge and Water Coolant Monitor Lamp Monitor Lamp Monitor Lamp Temperature When it is started by the starter switch from STOP to RUN under normal condition Oil Pressure and Battery Lamps will flash and then the lamps will go OFF immediately after the engine starts When abnormality is detected either in water temperature or in oil pressure the correspondent monitor lamp will flash and the automatic shutoff shall be engaged to the engine When the automatic shutoff is engaged turn the starter switch to STOP position and then restart the engine In the event the automatic shutoff is engaged next time check all parts of the correspondent alarm 5 1 1 Oil Pressure Monitor Lamp Danger Injuries Close all doors and place locks during operation 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 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 injury When the engine oil pressure monitor drops during operation the oil pressure monitor lamp w
6. Induction Motor 1 2 1 4 Note Series motor with brush type Induction Motor brushless type The value shown above is Output Power in induction motor and Consumption Power in Other equipment Be sure to use the frequency designated in the load incorporated in mercury bulb or induction motor The load incorporated in motor may require bigger power than the rated power consumption Therefore consult with our authorized distributor or our engineering section When connecting 2 sets or more to use start the load one by one not to start them simultaneously When switching a Mercury Bulb again wait for 15 minutes about until it cools down A mercury bulb may flicker Page 25 10 Simultaneous use of Welding and Generating The circuit breaker reacts on the AC power supply circuit only In the simultaneous use of welding and generating there sometimes happens overload to the engine Refer to the following Supply in the simultaneous use of welding and generating For reference only as a kind of rod may require more current Welding Output AC Output Welding rod Current 50Hz 60Hz 2 0mm 60A 3 0kVA or below 3 5kVA or below 2 6mm 100A 2 5kVA or below 3 0kVA or below 03 2mm 140A 1 0kVA or below 1 5kVA or below 4 0mm 170A 0 5kVA or below 0 5kVA or below 11 Checking and maintenance Danger Electric Shock Injuries Before performing any equipment check or maintenance stop the engine and
7. aftero 13 Air Element change o 14 Adjust Tension V belt e e or after 15 V Belt change e or 2 years 16 Clean radiator fin outer e 17 Clean radiator fin inner e 18 Check carbon brush e 19 Change hoses fuel water and e or 2 oil also vibration absorbing years rubber 20 Adjust polish engine valve eadjust epolish clearance 21 Check Adjust injection nozzle e 22 Check Adjust injection pump e lt Caution gt When changing a part be sure to use genuine parts only Page 27 11 1 Oil Change Fist time 50 hours mark 2 or after Every 100 hours 11 1 1 Remove the oil plug 11 1 2 Loosen the oil drain plug and allow the oil to drain fully 11 1 3 Reinstall the oil drain plug 11 1 4 Checking the oil level by the oil level gauge add oil into the oil filler inlet to fill up to the max level about 2 0 liter max 11 1 5 Reinstall the oil plug hand tight lt Caution gt Refer to 6 1 Checking Engine Oil to select engine oil Whenever changing oil change packing as well Packing No Kubota 6C090 58961 11 2 Oil Filter Change Oil Drain Plug Fist time 50 hours mark 2 or after Every 200 hours 11 2 1 Drain the engine oil entirely as described in 11 1 Oil Change Side Cover 11 2 2 Remove the side cover 11 2 3 Loosen and remove the oil filter using oil filter wrench 11 2 4 Smear engine oil a little
8. frequency designated in the load Refer to 5 2 Throttle otherwise the load may be damaged Page 23 lt Caution gt Maximum output current from 15A receptacle is 15A Maximum output current from 30A receptacle is 30A Total output current from 3 receptacles is as follows Rated Output 50Hz 30A 60Hz 35A 9 1 Operation After engine is started Refer to No 7 1 Initialization Preparation operate as per the following procedures 9 1 1 Turn the Slow Down Switch ON 9 1 2 Select the frequency 50Hz Pull the throttle and turn 60Hz Push the throttle and turn AC Output Receptacle Breaker Current Adjut Dial Slow down switch Preheat Lamp Starter Switch poet Throttle High Speed 60Hz aan th Push the throttle and turn Throttle 9 1 3 Turn the breaker ON By the above procedures you can use 100V AC power from receptacles 9 2 Output Limitation Please refer to the following table because electric tools and home appliances cannot be judged only by the rated output or the power consumption due to the efficiency and characteristic of the components Applicable Load For reference only Load Capacity kW 50Hz 60Hz Electric Bulb Heater etc 3 0 3 5 Electric Tools Series Motor etc 1 5 1 7 Mercury Bulb High Power Factor Type 1 2 1 4 Submersible Pump Compressor etc
9. on the rubber gasket in a new oil filter 11 2 5 Screw the new filter into place and tighten by hand until the gasket contact onto the seat Then give it additional 1 1 4 Turn to seat the filter using oil filter wrench 11 2 6 Supply oil and install the oil cap Gasket lt Caution gt f an oil filter wrench is not available to get contact our authorized distributor or our engineering section Oil Filter Part No Kubota 15833 32433 11 3 Cleaning Changing Air Element Cleaning 50 hours mark 2 or after every 100 hours Changing Every 400 hours 11 3 1 Loosen the wing bolt to remove the cleaner cap Air Cleaner 11 3 2 Remove the air element 11 3 3 Clean or replace the air element and reinstall in reverse order lt Caution gt Clean more frequently if used in dusty Cleaner Cap environment Air Element Part No Kubota 67980 82632 Air Element Wing Nat H How to clean air element lf the element has dried contaminants gt It may be cleaned by blowing compressed air from the inside lt If the element has carbon or oil gt It should be replaced to a new one Page 29 11 4 Cleaning Changing Fuel Strainer Cleaning 50 hours mark 2 or after every 100 hours Changing Every 400 hours 11 4 1 Turn the fuel valve lever to CLOSE 11 4 2 Unscrew the retaining ring by turning counterclockwise and remove the cup and fuel element 11 4 3 Discard any
10. remove engine key A person performing the maintenance should always keep the key Danger Burns Do not open the radiator cap while operating this equipment or immediately after stopping the equipment to avoid sustaining burns from hot vapor Caution Fire Burns When checking the engine always stop the engine and keep away from fire Wait until the engine cools down before performing any check Do not touch the engine and muffler immediately after stopping the equipment for the temperature can reach extremely high Wait until the engine cools down before performing any checks To optimize the use of this equipment we recommend the periodical equipment checks and maintenance based on the following matrix Page 26 lt Caution gt Request for the maintenance item with e mark to the authorized distributor or our engineering section Checking item Start Checking Time Check At Every Every Every Every Every 50hrs 100hrs 200hrs 400hrs 1000hrs 2000hrs 1 Check and supply fuel o 2 Check and supply engine oil 3 Engine oil change da St or aftero A Oil filter change 1 s 2 or aftero 5 Check Add water coolant o 6 Water coolant change o or 2 years 7 Clean fuel strainer 1o Loft or aftero 8 Fuel element change o 9 Drain Clean fuel tank o 10 Check Leakage fuel oil water 11 Check Add battery water o 12 Clean air element 14o 2 or
11. repairs Please operate this equipment after thoroughly reviewing and understanding the contents of this manual Please attach this manual if the equipment will be sub leased Please store this manual near the equipment for easy reference Following convention will be used throughout the manual to indicate the degree of cautions Danger Can cause severe injuries or death Caution Can cause minor injuries or damage to the equipment or other properties lt Caution gt Other types of caution Even some of the items noted in Caution may lead to severe injuries Please read all items and follow the safety guidelines 1 Safety Guidelines Danger Suffocation from exhaust fume Exhaust fume from the engine contains many elements harmful to human Do not operate equipment in poorly ventilated area such as inside a room or in a tunnel Danger Electric Shock Do not 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 wirings or electric parts inside the equipment during operation Before connecting or disconnecting a load 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 check or maintenance should always keep the key Danger Burns Do not open the radiator cap while operatin
12. 1 Initialization Preparation operate as per the following procedures 8 5 1 Turn the Slow Down Switch ON 8 5 2 Turn the throttle either to Low Speed Welding 50Hz or High Speed Welding 60Hz AN _ __ Pull the throttle and turn Throttle 8 5 3 Adjust the current by the current adjustment dial The adjustable current range is different from the throttle position Low Speed Welding 50Hz and High Speed Welding 60Hz Welding Current Adjustable Range Throttle Position Current Adjustable Range Welding Rod Low Speed Welding 50Hz 60 180A 02 0 64 0 High Speed Welding 60Hz 50 200A 02 0 64 0 AC Output Receptacle Breaker Current Adjut Dial Slow down switch Preheat Lamp Starter Switch Throttle d 9 Generator Operation Caution Electric Shock Do not operate the equipment if the equipment or you are wet Caution Injuries Before connecting or disconnecting a load cable from output terminals always turn a circuit breaker to OFF position Be sure to use the frequency designated in the load Refer to 5 2 Throttle Caution Damage to the equipment or other properties Inthe event using the equipment to computers microcomputers incorporated loads and precision equipment there is a possibility for them to be mal functioned or break down Be sure to use the
13. bota 2482 B Type Vertical In lined Water cooled 2 Cylinders Diesel Displacement L 0 479 Rated Output kw PS min 7 8 10 6 3000 9 2 12 5 3600 Fuel Diesel Fuel ASTM No 2 D or Equivalent Lubricant Oil API Class CC or Higher Lubricant Oil Volume L 2 05 E Cooling Water Volume L 2 8 Sub tank capacity 0 6L included W Starting Method Starter Motor Battery 44B19L Fuel Tank Capacity L About 15 Dimension Length mm 998 Width mm 603 Height mm 773 Dry Weight kg 212 Page 6 3 Usage Arc welding Power source for electric tools and home appliances Power source for lighting Caution Damage to the equipment or other properties The equipment is designed for the above purpose only Do not use it for the other purposed When it will be used for the equipment with the microcomputer control or the ultra precision devices the load may be malfunctioned 4 Parts Current Adjust Dial Breaker AC Output Receptacle Starter Switch Monitor Lamp Slow down Switch Dee GER Throttle Handle DC Output Receptacle Bonnet Grounding Tarminal Page 7 Hour Meter Oil gauge Cleaner Oil Plug Oil Inlet Option Side Door SN its UEAN rm VFA Sub Tank Oil Drain Plug Fuel Drain Plug Oil Drain Plug Fuel Level Strainer Caster Side Cover Handle Oil Filter Lifting Lug Muffler Top Plate Fuel Inlet Sa Ki Cap Ba d D X 5 Fuel Meter e ee
14. ce to keep the equipment from sliding Be sure to lock the wheels for the wheeled models When stating 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 Page 4 DOV E 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 Suffocation from exhaust fume No 19402 00106 Suffocation from welding fume No 19402 00107 Burns No 19402 00112 Electric shock No 19402 00103 Injuries No 19402 00109 Page 5 2 Specifications Model DGW201M Generating Method Rotating Field Synchronous AC Generator _ Rated Current A 170 190 2 Rated Voltage V 26 8 27 6 o Duty Cycle 50 Rated Speed min 3000 3600 No Load Voltage V MAX 80 Current Adjustable Range A 60 180 50 200 Welding Rod mm 2 0 4 0 Phase 1 Phase Rated Voltage V 220 Frequency Hz 50 60 o Rated Output kVA 3 0 3 5 Rated Current A 14 16 S Rated Speed min 3000 3600 7 Power Factor 1 0 lt Rating Continuous Model Ku
15. ck 6 2 2 Filling to the radiator 6 2 2 1 Remove the top plate 6 2 2 2 Remove the radiator cap 6 2 2 3 Fill up the coolant water to the top 6 2 2 4 Install the cap back and tighten 6 2 2 5 Reinstall the top plate lt Caution gt Use soft water such as tap water Ifthe ambient temperature is near freezing use Long Life Coolant LLC 30 mixture LLC is filled when shipped from factory Maximum ratio of the coolant should be between 30 to 45 depending on the ambient temperature Use the same LLC to the sub tank Page 14 Side Door D gt DOOCUIOOOUo Uu OUR Top Plate V i ug HAA ANA Radiator Cap III Sub Tank LLC Maximum Mixture Ratio Lowest Ambient 15 C 20 C 30 C Temperature Max Mix Ratio 30 35 45 6 3 Checking Fuel Caution Fire Always wipe any drip of fuel Do not use this equipment when a leak is found Repair the equipment before use Check for the fuel level in the tank Add if necessary lt Caution gt Use Diesel fuel ASTM No D975 No 2 D in the event ambient temperature reaches down to 5 C At the temperature less than 7 C No 2 D fuel may pose operating problem At colder temperature use No 1 D fuel if available or use winterized No 2 D a blend of No 1 D and No 2 D Always use the Diesel fuel strainer Fill the fuel tank slightly less than the ring level a aS
16. engine cools down before refueling Always wipe 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 inflammable items and easily burning items away from the place in welding because welding splashes 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 touch the engine and muffler during operation an immediately after stopping the equipment for the temperature can reach extremely high Page 3 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 filter cap during operation hot oil may cause some injury Be sure to wear leather gloves apron shoe covers eye protection glassed es mask safety shoes safety cap and long sleeve shirts because welding splashes spatters Caution Injuries When lifting the equipment always sue a lift hook Do not lift a handle for it may cause equipment to drop due to handle breaking off Always place the equipment o a flat and stable surfa
17. g this equipment or immediately after stopping equipment to avoid sustaining burns from hot vapor Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentionally touching cooling fan and fan belt Caution Suffocation from exhaust fume Do not point the exhaust fume toward pedestrians or building Caution Suffocation from welding fume Be sure to wear a fume proof mask in operation because welding fume contains poisonous gas and dust Pay attention to the airflow direction and sufficient ventilation also in order to prevent from inhaling the fume Caution Injuries to eyes and skin Be sure to wear spark protection glass es long sleeve shirts gloves etc in order to protect and skin from harmful spark in welding Page 2 Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or on clothing If the acid comes in contact especially with eyes flush with a lot of water and contact to your physician immediately Caution Electric Shock Do not flush water onto the equipment nor operate it in the rain Caution Explosion When the liquid level is below the LOWER level never use the equipment nor recharge the batter Battery may emit some combustible gas so keep it away from fire and sparks Caution Fire The equipment uses Diesel fuel as a fuel When refueling always stop the engine and keep away from fire Moreover always wait until the
18. gative side first 2 Remove the hold down clamp from the battery 3 Remove the clamp and cable from positive post in the battery 4 Remove the battery from the seat Reinstall a new battery in the reverse order Install always the cable to the positive in the new battery first lt Caution gt Use the Yuasa 44B19L battery Page 16 7 Operation 7 1 Initializing Preparation Danger Suffocation from exhaust fume e Caution e Caution e Caution e Exhaust fume from the engine contains many elements harmful to human Do not operate this equipment in poorly ventilated area such as a room or in a tunnel Suffocation from exhaust fume Do not point the exhaust fume toward pedestrians or building Fire Temperature around muffler and exhaust can get extremely high Keep any inflammable 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 Injuries Always place the equipment on flat and stable surface to keep the equipment from sliding Be sure to lock the wheels for the wheeled models When starting the engine turn off the connected equipment and set the circuit breaker to OFF position 7 1 1 Turn the circuit breaker to OFF position 7 1 2 Turn the fuel lever to OPEN 7 1 3 Turn the Slow Down switch to ON 7 1 4 When the ambient temperature is below 5 C turn the sta
19. ill flash and the automatic shutoff will be engaged When this occurs check the engine oil level and replenish to the maximum level if needed Page 9 The oil pressure monitor cannot detect the degradation of engine oil itself Please check the engine oil periodically and change if needed Refer to No 11 Maintenance 5 1 2 Battery Charge Monitor Lamp When the battery is unable to be charged during operation the battery charge monitor lamp flash and the automatic shutoff will be engaged In the event it will happen consult with the authorized distributor or our engineering section lt Caution gt The battery charge monitor cannot detect the degradation of battery life nor the battery fluid level Check the battery fluid level periodically Refer to No 6 5 Checking Battery 5 1 3 Coolant Water Temperature Monitor Lamp Danger Injuries Close all doors and place locks during 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 avoid sustaining burns from hot vapor 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 t
20. ment leveled and insert the oil gauge all the way in oe Prior to starting the equipment make sure to fill the engine oil to HIGH level through the oil inlet Oil Volume about 2 0L Total Effective Oil Volume about 0 7L from the lower limit to higher limit Page 12 lt Caution gt Ifthe equipment is not leveled you cannot obtain accurate oil level Do not overfill over H line the engine oil The excessive volume of engine oil may damage the engine H Selecting proper engine oil Use the engine oil for Diesel engine in proper viscosity in compliance with the ambient temperature Refer to the chart Upper Limit Level H Effective Oil Volume lt Caution gt wae Lower Limit Level L Use the API class CC or higher 6 2 Checking Coolant Water Danger Injuries Close all doors and place locks during operating the 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 avoid sustaining burns from hot vapor Page 13 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 radiator accordingly 6 2 1 Filling to the sub tank 6 2 1 1 Remove the sub tank cap 6 2 1 2 Fill up the sub tank to the FULL level 6 2 1 3 Install the cap ba
21. ming any equipment check or maintenance stop the engine and remove the engine key A person performing the maintenance should always keep the key Page 31 WE nanana DCD DU _ Eege DOUD mut UI Radiator Cap Fuel Drain Plug Caution Injuries 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 Caution Fire Burns When checking the engine always stop the engine and keep away from fire Wait until the engine cools down before performing any check Do not touch the engine and muffler immediately after stopping the equipment for the temperature can reach extremely high Wait until the engine cools down before performing any checks In the generator welder will not be used for more than two months perform the following maintenance and storage procedures 12 1 Remove battery 12 2 Change engine oil 12 3 Drain fuel from fuel tank and fuel strainer 12 4 Clean all parts cover the generator welder and keep it in the storage Away from dust and humidity lt Caution gt Recharge the removed battery once a month 12 Troubleshooting Danger Electric Shock Do not operate the equipment if the equipment or you are wet Before performing any equipment check or maintenance stop the engine Caution Injuries When performing equipment check and main
22. ns and also a bare part of the cable may touch the bonnet to short circuit 8 4 Duty Cycle Duty cycle means the welding time ratio for 10 minutes The duty cycle of the equipment is 50 namely the welding time is 5 minutes or less in continuous 10 minutes Be sure to take 5 minutes recess after 5 minutes welding lt Caution gt The equipment may be damaged due to overheat if welding in more than successive 5 minutes or short time recess Page 21 8 5 Welding Caution Suffocation from welding fume Be sure to wear a fume proof mask in operation because welding fume contains poisonous gas and dust Pay attention to the airflow direction and sufficient ventilation also in order to prevent from inhaling the fume Caution Injuries to eyes and skin Be sure to wear protection glass es Refer to the table below long sleeve shirts gloves etc in order to protect eyes and skin from harmful spark in welding Light Shielding Standard Japan Industrial Standard Light Shielding Degree No 7 8 9 lio In 12 13 Welding Current A 30 75 76 200 201 400 Caution Fire Keep any inflammable items and easily burning items away from the place in welding because welding splashes spatters Caution Burns Be sure to wear leather gloves apron shoe covers eye protection glass es mask shoes and safety cap and long sleeve shirts because welding splashes spatters After engine is started Refer to No 7
23. o No 6 2 Checking coolant water temperature If the water level is normal there may be a possibility of overloading and always use equipment within the rated amperage Page 10 lt Caution gt In the event coolant water level is too low to detect the sensor does not monitor temperature Be sure to check the level in the sub tank before operation Check the fuse next after oil pressure battery charge and water temperature will be found normal 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 5 2 Throttle The device is to select the output in conformity with the application You can save fuel consumption and lower noise by selecting low speed welding 50Hz Low Speed Welding Welding 170A Duty Cycle 50 2 50Hz AC 100V 50Hz 3 0kVA 2 High Speed Welding Welding 190A Duty Cycle 50 60Hz AC 100V 60A 3 5kVA lt Caution gt Before turning the throttle be sure to confirm that engine has stopped or at the slow down speed where the slow down switch positions ON 5 3 Circuit Breaker Danger Injuries Be sure to turn off the power switch in the load when re turning the circuit breaker to ON in case the circuit breaker has activated In case the electric supply exceeds the rated output overload the circuit breaker activated to trip off in o
24. r switch to START 7 Wait for about 1 minute to vacuum the air out The engine speed becomes stable when the air is extracted lt Caution gt Keep the Slow Down switch ON until the air is completely extracted out until the engine speed becomes stable otherwise the engine may disorder 7 2 Stopping 7 2 1 Turn Push down the breaker to OFF 7 2 2 Turn the Slow Down switch to ON gt 7 2 3 Keep the engine idle cooling down for about 5 minutes 7 2 4 Turn the starter switch to STOP 7 2 5 After the engine stops turn the fuel lever to CLOSE lt Caution gt When the engine does not stop in spite of turning the starter switch to STOP turn the fuel lever to CLOSE the engine will stop in a few minutes In this case consult with our authorized distributor or our engineering section and ask repair Page 20 8 Welding Operation 8 1 Selection Welding Cable Select the cable at proper gauge based on the allowable amperage and distance per the table shown below The welding capacity is reduced if the small gauge cable is used lt Caution gt Welding cables should be used unstrained When the welding cables are used in swirl the welding capacity is reduced Proper size of cable Unit mm Welding Return 20m 30m 40m 60m 80m 100m Current Length 200A 22 30 30 50 60 80 150A 22 22 22 38 50 60 100A or below 22 22 22 22 30 38 8 2 Polarity There are two kinds of welding output terminal
25. rder to shut off the circuit When the load stops during operation check the breaker first of all If you will find the breaker positions at OFF recover it by the following procedures 5 3 1 Turn off all the power switches in the loads 5 3 2 Return the breaker to ON lt Caution gt Refer to 9 2 Output Limitation and be careful not to use overloaded over current Page 11 5 4 Slow Down The slow Down feature is to set the engine speed low automatically for the purpose of reducing noise and fuel consumption whenever welding operation or generating operation is not performed In case of using the slow down feature turn the slow down switch to ON The engine automatically moves to high speed when welding or electric supply starts Caution Damage to the equipment or other properties Always turn the slow down switch to OFF in case the load is incorporated with electro magnetic switch lt Caution gt Incase the load of less than 0 5A is connected to use the slow down feature does not function sometimes Therefore turn the switch to OFF When welding operation or electric supply is used intermittently turn the switch to OFF 6 Initialization and Pre check Caution Fire Burns Injuries When checking the engine always stop the engine and keep away from fire Wait until the engine cools down before performing any check 6 1 Checking Engine Oil When checking for engine oil be sure to keep the oicauge Oil Plug equip
26. rter switch to PREHEAT The lamp comes off when the preheating finished in about 5 seconds Page 17 7 1 5 Turn the starter switch to START to start the engine by the starter motor lt Caution gt Do not drive the starter motor for more than 15 seconds successively If you need to restart wait for 30 seconds or more before retry 7 1 6 Release the starter switch as soon as the engine is started lt Caution gt Once the engine is started do not turn the starter switch to START 7 1 7 Keep the engine idle for about 5 minutes AC Output Receptacle Breaker Current Adjut Dial Fuel Lever en Slow down switch Preheat Lamp H Restart after stopping due to fuel shortage This equipment is equipped with automatic air vacuuming feature Therefore even though the engine stops due to out of fuel you can restart the engine easily by the following steps 1 Turn the starter switch to STOP 2 Fill the fuel 3 Turn the Slow Down switch to ON Page 18 4 Turn the starter switch to RUN Operation 5 Turn the starter switch to START and drive the starter motor in about 10 seconds lt Caution gt Do not drive the starter motor for more than 15 seconds successively If you need to restart wait for 30 seconds or more before retry 6 Release the starter switch as soon as the engine is started lt Caution gt Once the engine is started do not turn the starte
27. tenance always stop the engine Caution Fire Burns When checking engine always stop the engine and keep away from fire Temperature around engine muffler and exhaust can get extremely high Wait until the engine cools down before performing any checks Follow the guideline below when performing any troubleshooting If you cannot resolve the problems by the troubleshooting guide contact the authorized distributor or our engineering section to request the repair Symptoms Presumed Cause Corrective Actions Starter motor does not start 1 Batter Weak 1 Recharge Battery 2 Battery Dead 2 Change Battery Engine does not start 1 Fuel Lever to CLOSE 1 Fuel Lever to OPEN 2 Insufficient fuel 2 Replenish fuel 3 Water or contaminants 3 Drain water or clean fuel in fuel tank fuel strainer 4 Fuse burnt 4 Repair Engine starts but stalls 1 Insufficient oil 1 Replenish oil immediately 2 High water 2 Keep the duty cycle of 50 temperature Refer to the article of 3 Charging current is not Output Limitation censored 3 Repair Welding arc is weak 1 The throttle at Low Speed Welding 50HZ 2 Wrong setting of current adjustment dial 3 Poor contacts of cables 4 Improper cable diameter 5 Insufficient contact to material 6 The total loads exceed the rated simultaneous use output limit 7 Engine output is down 1 Turn the throttle to High Speed Welding 60Hz 2 Turn the dial clockwise 3
28. water and dust inside the cup and clean the filter by blowing compressed air or change if necessary 11 4 4 Reassemble it in reverse order lt Caution gt Be sure to check for any contaminants on the packing whenever reinstalling the cup Turn the fuel valve lever to OPEN after assembling and check for any leak After confirming no leak turn the fuel valve to CLOSE Fuel Element Part No Kubota 16271 43561 11 5 Draining Water from fuel tank Water Drain Every 200hours 11 5 1 Unscrew the fuel drain plug 11 5 2 Reinstall the drain plug after draining the water entirely lt Caution gt Whenever draining water change packing as well Packing No Kubota 6C090 58961 Fuel Drain Plug 11 6 Changing Coolant Water Change Every 2000hours or 2 years lt Total volume is about 2 8 Liter including the sub tank 0 6 Liter gt 11 6 1 Remove the top plate 11 6 2 Remove the radiator cap 11 6 3 Loosen the water drain plug 11 6 4 After draining all the water reinstall the water drain plug lt Caution gt Whenever draining water change packing as well Packing No Kubota 6C090 58961 11 6 5 Replace all the water in sub tank 11 6 6 Fill up the water to the neck of the water inlet 11 6 7 Reinstall the radiator cap 11 6 8 Install the top plate back 12 Long term Storage Danger Electric Shock Before perfor
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