OWNER S AND OPERATOR S MANUAL
Contents
1. 28 14 Wiring Diagram ee ee ee 30 15 Generator Wiring Diagram 31 1 Safety Guidelines Danger Suffocation from exhaust fume e 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 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 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 all doors and place lock2. e 6 L EX TWHYON 023 5 ius Ell E 3 NOLL23NNOO HOLINS 31903 ce HOLS HAH 82121125 104100 z z t r E N 31411234 a 7 3 T 40151534 6 E By JOE PEE 1 ux Nj WATT IaH 5 m 4 m BEDS XN 5 wka J B EA wousisae 818 qu Y H sh a u F Er EE aN ZO mn id m 8 oa g unm Ez 2s 30115 ge A ow ucl SE qw m ix 4 te pt 1 iu a 25 s ii E i gw EE s 1 2 aQ 5 S a fa 1 E HOLIME 13 I erm m 1 012145 2 wg 2 oe 4 109170 n i 1 fal TWNIWYEL 1 109100 t m Ka 1 NITAN el fella PE E n 40151539 MEGN3CNOO g E Ps c 5 9 IC NS E EZ Wid 1091405 Xd IN3k1entQY e eg A E DNV_ 1903 2 1 7 vi SIS mmm NR VA Vm AE 1 oO HOL NS MEZ WA lt r Yi SONWHO e 9 0g E 6 77 31241432384 9 10499 uo 2 135 2 e 7611 T t us 5 EIE ALES E
3. OIL FILTER FUEL INLET LIFTING LUG MUFFLER il O e LC AE e LJL pe HANDLE TOP PLATE HANDLE ACCESSORIES OWNER S AND OPERATOR S MANUAL a peg ENGINE KEY 1PAIR ay Dy E v M6 BOLT x1 GROUNDING ROD x1 5 1 Eco Welding The equipment is incorporated in Eco Welding feature that are aimed at performing the lower noise the lower fuel consumption and the lower gas emission than conventional models When you turn the output selector switch to ECO you will be able to weld with Max 4 0mm welding rod at the low speed lt Caution gt eWhen welding is performed do not turn the output selector switch which causes the burnout of the switch ECO is designed for welding only When AC output power is used by mistake the breaker activates to TRIP 5 2 Display The equipment incorporates in digital display It displays AC VOLTAGE HOUR SPEED successively by changin
4. OWNER S AND OPERATOR S MANUAL DieselEngine Generator Welder DGW310MC 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 DGW310MC RS X750 021 46 0 X750803 570 0 Introduction Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator amp 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 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
5. 13 6 1 Checking Engine Oil ee 13 6 2 Checking Coolant Water 5 0 806 13 6 3 Checking Fuel wo 9o BOB BON 33 3 3 3 8 2 8 8 8 3 3 3 3 3 3 3 3 3 B 14 6 4 Checking Fuel Engine Oil and Water 15 6 5 Checking Battery ee ee 15 7 Operation the Engine o 83 8 3 8 8 8 27 8 8 8 2 8 2 3 3 3 3 3 3 3 9 B BOB 16 7 1 Starting wo BOB BOB 3 8 3 3 3 35 35 3 3 3 8 8 3 3 23 3 3 3 3 3 3 3 BOB BOB 16 7 2 Stopping ee 8 3 872 737 3 2 33 333 17 8 Welding Operation wo 9 3 8 8 8 8 8 373 2 2 2 2 2 2 23 3 3 3 3 3 17 8 1 Selection Welding Cable 17 8 2 Polarity ODD 18 8 3 Connection Welding Cable 18 8 4 Welding er 19 9 Generator Operation ee ee ee 20 9 1 Output Range re ee ee ee 20 9 2 Output Limitation ssscsssnanssunsuanusuassssassatsusnusnuss 20 9 3 Operation ee ee ee 21 10 Simultaneous Use of Welding and 22 11 Inspection and 23 12 Long term Storage Set AOE ea AC ee 27 13 Troubleshooting ee ee ee ee
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7. Every Every 50hrs 100 200 400 1000 2000 hrs hrs hrs hrs hrs Check Adjust Injection Nozzle 21 Check Adjust Injection e Pump 1 Oil Change First Time 50 hour mark 2 after Every 100 hours Remove the oil plug Loosen the oil drain plug and allow the oil to drain fully Reinstall the oil drain plug Checking the oil level by the oil level gauge add oil into the oil filler to fill up to the max level Approx 3 8L Reinstall the oil plug hand tight Caution gt Refer to 6 1 Checking Engine Oil to select engine oil eChange the packing whenever changing oil e Packing No 66090 58961 Kubota OIL PLUG OIL INLET OIL DRAIN PLUG e After reinstalling the oil drain plug tightly keep the engine drive for a while to check no engine oil leakage and then stop the engine 2 Cil Filter Change First Time 50 hour mark 219 or after Every 200 hours Drain the engine oil completely as described in 11 1 Oil Change Loosen and remove the oil filter using an oil filter wrench Smear a little engine oil on the rubber gasket of a new filter Screw the new filter into place and tighten it by hand until the gasket contact the seat Then
8. DIAL EARTH LEAKAGE CIRCUIT BREAKER OUTPUT SELECTOR SWITCH 3 P OUTPUT TERMINAL EARTH GROUNDING TERMINAL FUSE 10A FUSE 50A BONNET GROUNDING TERMINAL DISPLAY MONITOR LAMP JOL trie 2 FUEL METER IDLE CONTROL SWITCH STARTER SWITCH DISPLAY SELECTOR SWITCH 1 PHASE RECEPTACLE X RECEPTACLE COVER REMOTE CONTROL UNDER PLATE COICO S44 FUEL DRAIN PLUG BATTERY 451 WELDING OUTPUT RECEPTACLE TERMINAL FRONT DOOR FREQUENCY CHANGE SWITCH AC VOLTAGE ADJUSTMENT DIAL OIL DRAIN PLUG SIDE DOOR AIR CLEANER OIL GAUGE COOLANT SUB TANK FUEL LEVER FUEL STRAINER OIL PLUG OIL INLET WATER DRAIN PLUG SIDE DOOR
9. please observe the relevant environmental protection regulations e Please do not dispose the harmful items or waste fluid to the ground to a river pond and ocean to keep our environment clean and neat eCheck to see if it is safe around the equipment before open the door Close all doors and place locks if you leave from the equipment for a while 23 Checking Time Checking Items Every Every Every Every Every 85 sohrs 100 200 400 1000 2000 hrs hrs hrs hrs hrs 1 Check and Supply Fuel O Check and Supply Engine Oil O 19 219 Engine Oil Change 4s 27 or 4 Oil Filter Change Check Add 3 Water Coolant O 6 Water Coolant Change O or 274 or 7 Clean Fuel Strainer after 8 Change Fuel Filter Drain Water Clean Fuel 9 Check Leakage Fuel 10 Oil Water o Check Add Battery Water O st 274 or 12 Clean Air Element after O 13 Change Air Element 274 or 14 Adjust V Belt Tension e after e 15 Change V Belt 2year 16 Clean Radiator Fin 17 Clean Radiator inside Change 18 Fuel Hose Oil Hose or Vibration Absorbing 2year Rubber 19 Adjust Engine Valve Clearance Adjust Plane 24 Checking Time 1 Startup Checking Items Check Every Every Every
10. start the load one by one not to start them simultaneously eWhen switching a Mercury bulb ON again wait for approximately 15 minutes until the bulb cools down 9 3 Operation Danger Electric Shock Before connecting or disconnecting a terminal always turn the earth leakag Ground the every grounding terminal plug from output receptacle or circuit breaker to OFF position 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 than the NO RELAY case because leaking current inevitably goes through the body Even though all the current leakage relays in the loads have been grounded to the earth the earth grounding term be grounded to the earth Grounding should be made after the engine is stopped inal and the bonnet canopy should Whenever the current leakage breaker activates you should repair the leaking place first of all Caution Injuries Be sure to connect to output terminals or insert a plug to a receptacle after confirming that all the switches in the loads are positioned to OFF Be sure to select the correct frequency designated in the loads A Caution Damage to the property Aftermath Whenever connecting to use medical equipment or appliances be sure to consult with the medical equipment company doctor or hospital personnel Be sure to select the correct frequency des
11. engine inside the cylinders NEC LOWER LEVEL E Selecting proper engine oil lt Caution gt eUse the API class CD or higher Temperature Over 20 C 10 C 20 C 10 C 40 C Viscosity SAE30 SAE20 SAE10W 30 6 2 Checking Coolant Water Q Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentional contact with 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 could reach extremely high temperature 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 13 1 Filling to the Coolant Sub Tank Remove the coolant sub tank cap Fill up the coolant sub tank to the COOLANT FULL level F ot the cap back 2 Filling to the Radiator Open the top plate Remove the radiator Fill the radiator up to the top 4 Install the cap back and tighten COOLANT Close the top pla
12. give it additional 1 1 4 Turn to seat the filter using an oil filter wrench Supply oil and install the filler cap Caution e f an oil filter wrench is not available contact with authorized distributor Oil Filter Part No 15241 32090 Kubota e After the engine oil supply keep the engine drive for a while to check no engine oil leakage and then stop the engine 25 3 Clean Change Air Filter Element Clean 1 50 hours and Every 100 hours afterwards Change Every 400 hours AIR CLEANER SH cue AIR CLEANER CAP Disconnect the air cleaner cap by releasing the clips Remove the air element Clean or change the air element The element is adhered with dried contaminants Blow up compressed air from inside the element The element is adhered with carbon or oil gt Replace to a new one Reinstall them in reverse order Caution gt eClean more frequently if it is used in dusty environment e Element Part No 19659 11221 Kubota 4 Clean Change Fuel Strainer Clean 1 50 hours and Every 100 hours afterwards Change Every 400 hours DTurn the fuel lever to CLOSE RETAINER Unscrew the retainer ring counterclockwise and remove the cup and the filter element Discard any dust or water inside the cup and clean the filter element by blowing compressed air or change if necessary Reassemble it back lt Cautio
13. oil filter cap during operation hot oil may spilled out When the engine oil pressure drops during operation the oil pressure monitor lamp will flash and the automatic shutoff will be engaged When this symptom occurs check the engine oil level and replenish to the maximum level if needed Caution gt The engine oil pressure monitor cannot detect the deterioration of engine oil itself Check the engine oil periodically and change if needed Refer to 11 Inspection and Maintenance e Check the fuse next when the abnormality other than WATER TEMP CHARGE or OIL PRESS is detected If the fuse is burned out consult with authorized distributor as there may be an abnormality of electrical components or wiring which would be inspected 5 4 Remote Control Option The equipment incorporates with remote REMOTE control receptacle feature CONTROL BOX Remote control boxes are the optional parts Remote control operation is available by connecting the compatible remote controller to the receptacle zs Adjust the welding current at the remote area from the machine Attach the remote control receptacle removing the receptacle cover M4 Screw 2 pieces RECEPTACLE COVER ENE COMOL P SIG Ex CONTROL RECEPTACLE REMOTE 7 MO AS CONTROL Zaje RECEPTACLE
14. switch according to the operation Set the current amperage by the current adjustment dial per the table below CURRENT OUTPUT SELECTOR ADJUSTMENT SWITCH DIAL Welding Current at the dial position MIN 1 2 3 4 5 MAX ECO 30 45 70 95 120 145 160 50Hz 35 60 110 160 205 255 280 60Hz 45 70 125 180 230 285 310 The values shown in the table are for reference only The length and the ambient temperature affect the value When the remote control box is used the values change to some degree 19 Position Freq NORMAL 9 Generator Operation 9 1 Output Range 1 3 Phase 400V 440V 3 Phase 4 Wire Maximum output by the 3 Phase output U V 9 terminal is 9 9kVA Max 9 9kVA 2 1 Phase 400V 440V 1 Phase 400V 440V output is available through 1 pair out of 3 terminals Maximum output by the 1 pair of 3 terminals is 6 0 6 6 50 2 60 2 Maximum output by the 3 pair of 3 terminals is total 8 You should connect the load for 3 pairs evenly as possible to terminals Max 6 0 6 6kVA Total 8 0kVA max 3 1 Phase 230V 250V 1 Phase 230V 250V Output is available through 2 receptacle sets Maximum output by 1 receptacle set is 3 45 3 75 50 2 60 2 Maximum output by 2 receptacle set is 6 9 7
15. wall box etc Caution Injuries e Always place the equipment on a flat and stable surface to keep the equipment from sliding Before starting the engine be sure to disconnect the loads and set the breaker to OFF position Caution Burns Do not touch the engine and muffler during operation and immediately after stopping the equipment for the temperature could reach extremely high temperature lt Caution gt eCheck to see if it is safe around the equipment before starting eWhen working is performed together by two or more persons take care to perform all work safely e Do not use the location of dusty hot and humid Close all doors and place locks during operating this equipment to damage the equipment by decrease of cooling performance eWhen the equipment is noisy it use additional hearing protection item to prevent the abnormal auditory PREHEAT STARTER LAMP SWITCH 7 1 Starting Turn the breaker to OFF Turn the fuel lever OPEN Turn the idle control switch to AUTO gt When the temperature is below 5 a laa turn and keep the Starter switch to PREHEAT until the preheat lamp turns off about 5 seconds BREAK
16. 5kVA 50Hz 60Hz 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 character of the components Applicable Load For reference purpose only Capacity Unit kW 3 Phase Loads 1 Phase 230V 250V 1 Phase 400V 440V 400V 440V Receptacle Receptacle 1 pair of 3 3 pair of 3 Terminal 1 set 2 sets use terminals terminals 3 45 50Hz 6 9 50Hz 6 0 50Hz Electric Bulb Heater etc 3 75 60Hz 7 5 60Hz 6 6 60Hz 8 0 Electric Tools Series Motor 1 7 50Hz 3 4 50Hz 3 0 50 2 40 1 8 60 2 3 7 60Hz 3 3 60Hz Mercury Bulb 1 3 50Hz 2 7 50Hz 2 4 50Hz 32 High Power Factor 1 5 60 2 3 0 60Hz 2 6 60Hz Submersible Pump Compressor etc 225 125 22 3 2 4 0 Induction Motor 5 60HZ 0 60 2 6 60 2 X Series Motor Motor with brush X Induction Motor Brushless Motor X The value described is OUTPUT for Induction Motor loads and POWER CONSUMPTION for the other equipment 20 lt gt sure to confirm the frequency designate mercury bulb or induction motor d in the equipment incorporated in load incorporated in motor may require bigger power than the rated power consumption Therefore consult with authorized distributor to clarify eWhen connecting to use 2 or more sets
17. 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 e Turn always the Idle Control Switch to HIGH when the load is incorporated with any magnet switch lt Caution gt eWhen 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 eWhen welding operation or electric supply performs alternately or intermittently turn the switch to HIGH eWhen the output selector switch is positioned to ECO the engine does not turn to high speed 5 7 AC Voltage Adjustment Dial Danger Injuries Electric Shock AC voltage adjust should be done only after stopping the engine Moreover close doors and place locks during operating this equipment to avoid injuries and electric shock A Caution Burns Do not touch the engine during operation and immediately after stopping the equipment for the temperature can reach extremely high Adjust the dial whenever the AC output voltage adjustment is necessary Caution gt When raising the voltage the current is AC VOLTAGE uu ADJUSTMENT DIAL decreasing Use the output w
18. E 4 eel d sje sla 48555483 i a E E i xod INO n m X 31038 ET a Leer se imE O 3 a v E a ia esee LINII 1 33710 INCO CAVTSIO gt 131414 3 73 4 al al c PP 6 TRY 3 3 EERBEMBEEBEREN se FEDERER E 5 4s PE T DS E To AJN3Cudd3 2 A Wya LO T YAMABIKO CORPORATION 7 2 SUEHIROCHO 1 CHOME OHME TOKYO 198 8760 JAPAN PHONE 81 428 32 6118 FAX 81 428 32 6145 2012 YAMABIKO CORPORATION Printed in Japan
19. ER IDOL CONTROL SWITCH 248 Turn the starter switch to START and then the engine starts by the starter ZEEV motor OPEN amp Release the starter switch as soon as ix a the engine has started Keep the engine idle for about 5 oe minutes ab lt Caution gt e Do not drive the starter motor for more than 15 seconds successively elf you need to restart wait for 30 seconds or more before reattempt Once the engine has started never turn the starter switch to START Restart after stopping due to fuel shortage This equipment is incorporated in automatic vacuuming air feature Therefore even though the engine stops due to running out of fuel you can restart the engine easily by the following steps DTurn the breaker to OFF Turn the Starter Switch to STOP Fill the fuel Turn the idle control switch to AUTO 5 Turn the starter switch to START and drive the starter motor for about 10 seconds Release the starter switch as soon as the engine has started Wait for about 1 minute to vacuum the air out The engine speed becomes stable when the air is extracted Caution gt e Never turn the engine high speed or connect the loads until the air is extracted completely the engine speed becomes stable 7 2 Stopping DTurn the breaker to OFF Turn the idle control switch to AUTO Keep the engine idle cooling down for about 5 min
20. d output Engine does not stop Stop solenoid malfunction Turn the fuel lever to CLOSE to stop and repair Welding arc is weak Output selector switch at ECO Frequency switch at 50Hz Wrong current adjustment dial position Improper connection of cables Improper Cable Diameter Change to NORMAL Change to 60Hz Turn the dial clockwise Connect securely Replace the cables based on the Welding Cable Selection Improper connection to the 6 Connect securely base material Simultaneous use of welding 7 Stop using AC power output and Generating Welding output short circuit 8 Resolving short circuit Excessive Wrong current adjustment dial 1 Turn the dial welding arc Position Counterclockwise The breaker position to 1 Turn to ON OFF NON Output selector switch 2 Change to NORMAL at ECO Wrong frequency 1 Change to load frequency AC output is The rated current of theload 2 Adjust according to exceeds the rated output OUTPUT LIMITATION Simultaneous use of welding 3 Stop welding and Generating Idol control switch is to 1 Turn to AUTO The power consumption of 2 Set the idol control to the Idle control the load is below HIGH 5 Welding output short circuit 3 Resolving short circuit Unable to adjust Connected AC load to 1 Disconnect AC load the welding remote control rece
21. g the display selector switch lt Caution gt eDuring operation AC voltage meter always displays 3 Phase voltage apart from the circuit breaker position to ON or OFF 5 3 Monitor Lamp The equipment is incorporated in monitoring function of I WATER TEMP CHARGE OIL PRESS ITE lt Under normal condition when the starter GI switch changes from STOP to RUN the lamps of CHARGE OIL PRESS will be turned on When the engine starts all the lamps will be turned off When abnormality is detected the corresponding monitor lamp will flash and the engine is 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 investigate where is the abnormality OIL PRESSURE BATTERY CHARGE WATER TEMP 1 Coolant Water Temperature Monitor Lamp Q Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentional contact with cooling fan and fan belt A 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 muffle
22. h the bonnet to short circuit 18 8 4 Welding 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 Caution Suffocation from welding fume Be sure to wear 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 A Caution Injuries to eyes and skin Be sure to wear spark 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 Standard for Spark Protection Glass Japan Industrial Standard No 7 8 9 10 11 12 13 Welding Current A 30 75 76 200 201 400 A Caution Fire Keep any inflammable items and easily burning items away from the place in welding because welding splashes spatters A Caution Burns Be sure to wear leather gloves apron shoe covers eye protection glass es mask safety shoes safety cap and long sleeve shirts because welding splashes spatters The output adjustable range by the current adjustment dial depends on the position each of the output selector switch and frequency change switch Refer to 2 Specifications DTurn the idle control switch and frequency change
23. he breaker to ON Caution gt care for overload referring to 9 2 Output Limitation 10 Simultaneous Use of Welding and Generating The circuit breakers react 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 table and limit the AC power use Limitation of AC power supply the simultaneous use of welding and generating Instance of 60Hz Welding Output AC Power Output 3 Phase Output Welding Rod Amperage 1 Phase Output 0 8 2 0 60A 9 3kVA 7 4kVA 62 6mm7 120A 7 2kVA 5 7kVA 63 2mm7 140A 6 4kVA 5 1kVA 4 0mm 160A 5 7kVA 4 5kVA 5 0mm 7 240A 2 0kVA 1 6kVA 6 0mm 300A OkVA OkVA The 1 figure shown is the total output of 1 230 250 1 400 440V lt Caution gt e simultaneous use of Eco welding and AC power is NOT available Avoid the simultaneous use in the case high quality result in welding is required 22 11 Inspection and Maintenance Danger Electric Shock Injuries Before performing any equipment check or maintenance stop the engine and remove engine key A person performing the maintenance should always keep the key Close all doors and place locks during operating this equipment to avoid injuries by unintentional contact with cooling fan and fan belt A Caution Fire Burns Keep the e
24. ield Rated Current A 2607280 5 Rated Voltage V 30 4 31 2 Duty Cycle 100 8 Rated Speed 3000 3600 Load Voltage V MAX 85 D Current Adj Range 30 160 g Welding Rod mm 2 0 4 0 Current Adj Range 35 280 45 310 NORMAL Welding Rod mm 2 0 6 0 Rated Frequency Hz 50 60 Rated Speed min 3000 3600 8 1 3 Phase 5 Rated Voltage V 230 250 400 440 8 Rated Current A 15Ax2 14 3 13 0 Power Factor 1 0 0 8 Rated Output kVA 6 9 7 5 9 9 Rating Continuous Model Kubota D722 Type Water Cooled 4 Cycle Diesel Engine Displacement L 0 719 Rated Output KW min 11 7 73000 14 0 3600 5 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 Starting Method Starter Motor Battery 46B24L Japan Industrial Standard Fuel Tank Capacity L 37 Length mm 1410 E 5 Width mm 566 2 Height mm 760 Dry Weight kg 333 Full Weight kg 377 eArc Welding Source Electric Tools and Home Appliances Power Source for Lights A Caution Damage to the equipment or other properties Do not use other than the above purposes Whenever connecting to use medical equipment or appliances be sure to consult with the medical equipment company doctor or hospital personnel 4 Name of Parts CURRENT ADJUSTMENT
25. ignated in the loads Otherwise the loads may be damaged lt Caution gt e During operation AC voltage meter always displays the voltage in 400 440V AC output both at the breaker position ON and OFF DSelect the correct frequency designated in the loads Refer to 5 8 Frequency Change Turn the power switch to OFF in the load Start the engine Refer to 7 1 Starting Turn the breaker to OFF 5 the load to the output receptacles or terminal 21 BREAKER RECEPTACLE connecting cables be sure to close output terminal covers fit it with the bolt Turn the breaker to ON The Circuit breaker has activated due to overload Caution Injuries Be sure to turn the power switch off in the load when turning the circuit breaker to ON again when the circuit breaker has activated When the electric supply exceeds the rated output overload the circuit breaker activates to trip off in order to shut down the circuit When the load operation stops during operation check the circuit breaker When breaker has tripped restore the circuit breaker as per the following procedure off all the power switches in the loads Turn up t
26. ithin the output capacity you raise the voltage exceeding the allowable voltage range which causes lt the damage to the loads DECREASE INCREASE 5 8 Frequency Change Q Danger Injuries Frequency change should be done only after stopping the engine Moreover close doors and place locks during operating this equipment to avoid injuries and electric shock A Caution Burns Do not touch the engine during operation and immediately after stopping the equipment for the temperature can reach extremely high 12 The equipment be used to 50Hz 60Hz FREQUENCY CHANGE SWITCH Select the frequency according to the load by the frequency change switch located inside of the front door 6 Initialization and Pre operation check 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 firmly Prior to starting the equipment make sure to fill the engine oil to the UPPER line through the oil inlet Caution gt elf the equipment is not leveled you INLET GAUGE cannot obtain accurate oil level Do not overfill over UPPER line the engine oil The excessive amount of engine oil may damage the
27. lt Caution gt eWhen the remote control box is connected the current adjustment dial of the equipment s front panel will not work eWhen 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 e Never connect the plug of the remote control box to the receptacle of the extension cable reel when the reel is connected to AC output receptacle e Never connect the other loads additionally than the remote control box the case the extension cable reel is installing the breaker use the equipment to have turned the breaker ON 5 5 Earth Leakage Relay and Grounding Q Danger Electric Shock Ground every grounding terminal to the earth as set out in the manual If even one of all is disconnected by mistake or accident it will be much more dangerous for human injury or burns 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 you should always repair the leaking place first of all lt Caution gt e The earth leakage relay activates only for AC output eThe earth leakage relay activates when AC output is used with the o
28. mp Fill the radiator coolant water up to the MAX level to the upper edge of the inlet Reinstall the radiator cap WATER DRAIN PLUG Close the top plate Caution After reinstalling the water drain plug tightly keep the engine drive for a while to check no water leakage and then stop the engine 12 Long Term Storage 4 Danger Electric Shock 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 A 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 27 A Caution Fire Burns When checking engine always stop the engine and keep far away from fire Temperature around muffler and exhaust can get extremely high Wait until the engine cools down before performing any inspection If the equipment will not be used for more than two months perform the following maintenance and storage procedures Remove the battery Change the engine oil Drain fuel from the fuel tank the fuel strainer Remove the engine key and save it Clean all parts cover the generator welder and keep it in the storage away from dust and humidity Caution Recharge the removed battery once a month 13 Troubleshooting Danger Electric Shock D
29. n gt sure to check for any contaminants on the packing whenever reinstalling the cup e Turn the fuel lever to OPEN after assembling and check for any leak Having confirmed no leak without fail turn the fuel lever to CLOSE e Element Part No 16271 43561 Kubota 26 5 Drain Water from Fuel Tank Drain Water Every 200 hours ol ha DUnscrew the fuel drain plug Reinstall the drain plug after Ta draining water completely FUEL DRAIN PLUG Caution eChange the packing whenever drain water e Packing Part No 67090 58961 Kubota e After reinstalling the fuel drain plug tightly check no fuel leakage 6 Changing Coolant Water Change Every 2000 hours or 2 years Total coolant water capacity about 3 L including sub tank capacity 0 6 L Open the top plate Remove the radiator Loosen the water drain plug Atter draining all the water reinstall the water drain plug lt Caution gt e Change the packing whenever changing coolant water e Packing Part No 6 090 58961 Kubota 5 all the water in the sub tank a
30. o 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 maintenance always stop the engine A Caution Fire Burns When checking engine always stop the engine and keep far away from fire Temperature around muffler and exhaust can get extremely high Wait until the engine cools down before performing any inspection Follow the guideline below when performing any troubleshooting If you cannot resolve the problems by this troubleshooting guide contact with authorized distributor to request the repair Symptoms Possible cause Corrective actions Starter motor does not start Weak battery Dead battery Recharge battery Replace battery Engine does not start Fuel lever on fuel strainer to CLOSE Insufficient fuel Fuel is contaminated by the water or dust Fuse burnt Open the fuel lever for fuel strainer Replenish fuel Drain water or clean fuel tank fuel strainer Repair the fuse Engine starts but stalls immediately Insufficient oil High water temperature Unable to charge Replenish oil Operate the machine within the rated output Repair 28 Symptoms Possible cause Corrective actions Excessive black smoke exhaust from muffler Overloaded use Operate the machine within the rate
31. pped position between ON and OFF Push the reset button the earth leakage indicator light turn off 5 the circuit breaker by pushing it down to the OFF position Restore the starter switch to STOP In the event you cannot complete all steps in the above procedure to the end the device is out of order Consult with the authorized distributor to repair 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 When the earth leakage relay has activated the circuit breaker lever move to the tripped position between ON and OFF In the case stop the engine promptly and find the leakage point to repair After repairing leakage point s proceed with the following restoration steps DPush the reset button or stop the engine 2 Restore Push down the circuit breaker lever to OFF position By the above procedures You can reset the breaker to ON position Caution gt eWhen the breaker has tripped to the middle but the lamp does not turn ON simultaneously the cause to have tripped is OVER LOAD or AC output is used with the output selector switch at ECO position 24 5 6 Auto Idle Feature The Auto Idle feature is to set the engine speed low automatically in about
32. ptacle current by The switch breaker on the 2 Turn to ON remote controller cord reel at OFF 29 m 20 gt m 2 lt 2 r gt lt 14914610 12 43711081802 H3MOd Q10N3105 aus LI gt gt c O T HOLIMS 755384 110 211 5 dW3l udlvM ONLI A ONTHIA MOLVHINJO MO1VH3N35 E E CHAHO isis 81 ussugiubi1 1 1 ang a uno an Ot 0 9 J en O UOLOH Em SNL LUVIS B 9018 08 ov 6E 3002 80102 ES ERN CREDIS 540105 01122 02 H LIMS H31HVIG HOLIMS 2I L3NOVW M u 8 01140 eo 28 YILIW 1 15 w 05 A079 ain 9 u A I 1 bd LI 4 E Wz 8 9 7 na WoL 3504 a 4 D d E 9 6 20 e a 6 9 gt og oe RD m 11 2 a ana E d J39 F 8
33. quipment far away from fire Wait until the engine cools down before performing any inspection Because some parts components flexible tube etc could reach very high temperature inside the equipment A 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 A Caution Injuries to eyes and skin Battery fluid contains diluted sulfuric acid Avoid contact with eyes skin or clothing f the acid comes to contact especially with eyes flush with a lot of water and contact your physician immediately A 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 To optimize the use of this generator welder we recommend the periodical equipment checks and maintenance based on the following matrix Use the hour meter as a guide for the operating time lt Caution gt authorized technicians should perform all checking and maintenance work except for the pre startup checks e Request for the maintenance item with amp mark to authorized distributor e Always use our genuine parts of replacement eWhen draining waste fluid from the equipment catch it by tray eWhen disposing of oil fuel coolant LLC fuel filter battery and or other harmful disposal
34. r e Fill the fuel tank slightly less than the full tank e Diesel fuel specification type and sulfur content ppm used must be compliant with all applicable emission regulations for the area in which the engine is operated 6 4 Checking Fuel Engine Oil and Water Leakage Caution Fire Do not use this equipment when leakage 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 f the acid comes to contact especially with eyes flush with a lot of water and contact your physician immediately A 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 DCheck the fluid level If the level is TERMINAL near or lower than LOWER level add distilled water until the fluid level reaches UPPER level 2 sure that the battery cables are firmly secured to the posts Tighten the clamps if necessary Caution gt eCheck the hydrometer of the battery fluid If it falls below 1 23 the battery
35. r 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 be flashing 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 output 2 Battery Charge Monitor Lamp When the battery turns unable to be charged during operation the battery charge monitor lamp will be flashed and the automatic shut off will be engaged In the event this occurs consult with authorized distributor lt Caution gt eThe 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 Pressure Monitor Lamp Danger Injuries Close all doors and place locks during operating this equipment to avoid injuries by unintentional contact with cooling fan and fan belt A Caution Burns Do not touch the engine and muffler during operation and immediately after stopping the equipment for the temperature could reach extremely high temperature When checking engine oil always stop the engine and wait until the engine cools down If you open either the oil gauge or the
36. r lubrication oil Do not use this equipment when leakage 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 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 A 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 temperature 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 glass es mask safety shoes safety cap and long sleeve shirts because welding splashes spatters Do not open the side door during operation and immediately after stopping the equipment because some parts components fle
37. requires recharging Please consult with authorized distributor Replacing battery Nscap HOLD 1pogr Remove the under plate POST CIIM M6 Bolt 2 pieces Xx 2 the clamp and cable from ACE negative post on the battery Remove always negative side first Remove the hold down clamp from the battery UNDER PLATE Remove the clamp and cable from positive post on the battery amp Remove the battery from the seat 15 gt lt Reinstall a new battery in the reverse order Install always the cable to the positive post in the new battery first lt Caution gt Use the following battery Japan Industrial Standard 46B24L gt eWhen replacing a battery remove the under plate firstly Otherwise the battery slanted and the fluid may leak and contact to eye or skin 7 Operating the Engine Danger Suffocation from exhaust fume e 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 redirect the exhaust fume toward pedestrians or building Caution Fire Temperature around muffler and exhaust can get extremely high Keep any inflammable items such as fuel gas paint etc away from the equipment e Always operate this equipment on flat surface and at least 1 meter away from any objects
38. s during operating this equipment to avoid injuries by unintentional contact with cooling fan and fan belt A Caution Suffocation from exhaust fume Do not redirect 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 A Caution Injuries to eyes and skin Be sure to wear spark protection glass es long sleeve shirts gloves etc in order to protect eyes and skin from harmful spark in welding 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 your physician immediately 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 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 Caution Fire The equipment uses Diesel Oil as a fuel When inspecting the equipment refueling always stop the engine and keep away from fire Moreover always wait until the engine cools down before refueling Always wipe any drip of Diesel fuel o
39. sed by two types of machine the voltage between folders may receive an electric shock That one operator has two folders absolutely should avoid Application Connection Generals Welding such as Minus to holder Rod Normal Polarity Construction Plus to the Earth Material Thin Plate Build Up Welding Minus to the Earth Material Reverse Polarity Stainless Steel Plus to holder Rod 8 3 Connection Welding Cable Danger Electric Shock Before connecting or disconnecting welding cable from welding output terminals stop the engine and remove the engine key A person performing should always keep the key DStop the engine Connect a welding cable to a crimping terminal a welding rod holder and a material holder S Connect a welding cable to a welding output terminal After connecting cables be sure to close output terminal covers Caution gt AE WELDING ROD sure to crimp a crimping terminal to a cable and HOLDER connect the cable to welding output terminal WELDING CABLE Otherwise welding output terminals may burn out by the heat caused by insufficient connections e Do not use a cable without a crimping terminal If eT 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 connections also a bare part of the cable may TERMINAL touc
40. te SUB TANK Caution gt Use Long Life Coolant LLC for prevent freeze and rust 50 mixture LLC is filled when shipped from factory e Mixture ratio of the coolant should be 30 50 depending on the ambient temperature Replace LLC at every 2year or 2000 WATER INLET hours Mixture Ratio for reference only 15 C 23 35 Lowest Ambient Temperature Mixture Ratio 30 40 50 6 3 Checking Fuel Caution Fire Always wipe any drip of fuel Do not use this equipment when leakage is found Repair the equipment before use Check for the fuel level in the tank Add if necessary After adding fuel retighten the tank cap securely lt Caution gt Use Diesel fuel ASTM D975 No 2 D in T FUEL the event ambient temperature reaches STRAINER down to 5 C e Always use No 2 D diesel fuel You are required not to use alternative fuel because its quality is unknown or it may be inferior in quality e At temperatures less than 7 C 20F No 2 D fuel may pose operating problems At colder temperatures use No 1 D fuel if available or use a 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 14 Always use the fuel straine
41. utes Turn the starter switch to STOP After the engine has stopped turn the every fuel lever to CLOSE lt Caution gt eWhen the engine does not stop in spite of turning the starter switch to STOP Turn the fuel lever to CLOSE then the engine will stop in a few minutes In this case be sure to consult with authorized distributor and ask to repair e Do not attempt to turn to STOP position while actual welding or utilizing AC power source it may cause the serious damage on the unit 8 Welding Operation 8 1 Selection Welding Cable Select the cable with proper gauge based on the allowable amperage and the length per the table shown below The welding capacity is to reduce if the small gauge cable is used Caution gt e Welding cables should be used unstrained When the welding cables are used in swirl the welding capacity is to reduce 17 Size of Cable Unit mm Return Length 20m 30m 40m 60m 80m 100m Welding Current 300A 30 38 50 80 100 125 250A 22 30 38 60 80 100 200A 22 30 30 50 60 80 150A 22 22 22 38 50 60 100A 22 22 22 30 30 38 8 2 Polarity There are two welding output terminals and Select the polarity according to the operation referring to the table below Caution gt e Follow the instruction of the welding rods the polarity of which is specified elf connected by different polarity and the same work is simultaneously u
42. utput selector switch at ECO position for protection load damage 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 e Rated Sensitive Current 30mA or below Grounding resistance 5002 or below eSensitive time Within 0 1 second 10 1 Grounding Work The qualified electrician should perform EARTH the grounding work of the following 2 GROUNDING TERMINAL points 5009 or below e The Outer Bonnet of the equipment Earth grounding terminal and Bonnet grounding terminal e The Outer Bonnet of the load GROUNDING GROUNDING ROD TERMINAL lt Caution gt the event you cannot ground the generator to the earth consult with the authorized distributor 2 Operation Check Before operating the equipment check always TEST BUTTON if the device can work duly as shown in the following procedure Turn the starter switch to RUN Turn Push up the circuit breaker lever to ON position Push the test button The device is EARTH RESET operating normally if the earth leakage LEAKAGE BUTTON INDICATOR indicator light turns on and the circuit breaker lever move to the tri
43. when disposing of equipment Following convention will be used throughout the manual to indicate the degree of cautions Danger Can cause serious injuries or death A 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 item and follow all the safety guidelines Table of Contents 1 Safety Guidelines ee ee 2 2 Specifications um 5 3 Usage 5 4 Names of Parts ee ee 6 5 Equipment ee ee ee 8 5 1 Eco Welding WO 9 3 3 9 3 8 3 33 3 3 2 3 3 3 9 3 3 3 3 9 8 5 2 Display mE 8 5 3 Monitor Lamp Wo 9 39 3 3 373 8 3 3 3 3 3 3 3 3 33 33 33 3333333333333 8 5 4 Remote Control Option 9 5 5 Earth Leakage Relay and Grounding 10 5 6 Auto Idle Feature rr 12 5 7 AC Voltage Adjustment Dial n 66 6686 12 5 8 Frequency Change 9 5333335533533333333335335333333 12 6 Initialization and Pre operation
44. xible tube resistors etc can reach very high temperature inside the equipment A Caution Injuries When lifting the equipment always use a lifting lug Do not lift a handle for it may cause equipment to drop due to handle breaking off 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 of Warning labels When any warning label becomes unreadable or damaged place a new label on the appropriate location When ordering a new label use the following part number CDSuffocation from exhaust fume No X505 004 90 0 Suffocation from welding fume No X505 004 91 0 Electric Shock No X505 004 92 0 Electric Shock No X505 004 93 0 5 Injuries No X505 004 94 0 Fire No X505 004 88 0 Burns CNo X505 004 95 0 Burns CNo X505 004 96 0 2 Specifications Model DGW310MC RS Generating Method Rotating F
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