R`S AND EGW150MCI/UK
Contents
1. 10W 20W Single j 20 Grade 30 40 Multi Grade 10W 30 Ambient 10 0 10 20 30 40 lt Temperature 14 32 50 68 86 104 2 Checking Fuel A Caution Fire Always wipe away any drips of fuel or oil Check the fuel level and add fuel if necessary lt Caution gt Replace the fuel when the equipment has not been used for 2 months or more Use unleaded petrol only Keep or turn the fuel lever to CLOSED position beforehand when filling fuel Be sure to use the fuel filter net when filling Never fill fuel above the UPPER level Never smoke whilst refueling LEVEL MARK FUEL LEVER CLOSE N FUEL STRAINER NET 3 Checking Fuel or Oil Leakage A Caution Fire Do not use the equipment if a leak is found Repair the equipment before use Open the front door to check for any fuel leaks or oil leaks at the hose connection When checking for fuel leaks OPEN the fuel lever lt Caution gt Tighten the fuel strainer ring securely in order to prevent any fuel leakage 4 Checking Battery A Caution Injuries to eyes and skin The battery used in the equipment is the sealed type 12V Therefore it is not necessary to check the liquid level and replenish water Do not remove the sealed plug Battery fluid contains diluted sulphuric acid Avoid contact with eyes skin or clothing If the acid comes into2. AC OUTPUT SWITCH Switch the AC output switch to OFF 2 Turn the idle control switch to ECO OIL GAUGE OIL DRAIN PLUG Keep the engine idling for approximately 3 minutes to cool 4 Turn the starter switch to STOP After the engine stops open the front door and turn the fuel lever to CLOSE 215 7 Welding Operation 7 1 Selection Welding Cable Ensure adequate lighting is available ambient light is insufficient use additional lights Select the correct cable based on the allowable amperage and distance as per the table shown below The welding capacity is reduced if too small gauge cable is used lt Caution gt Welding cables should be used uncoiled When the welding cables are used in coiled welding capacity is reduced Correct size of cable Unit mm Return Length Welding Current 140A 22 22 22 38 50 60 100A or below 22 22 22 22 30 38 20m 30m 40m 60m 80m 100m 7 2 Polarity There are two welding output terminal and Select the polarity according to the operation referring to the table below lt Caution gt Follow the instruction the welding rods the polarity will be specified Application Connection Generals Welding to holder Rod such as construction Plus to the Earth Material Thin plate he Earth Reverse Polarity Build up Wel
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4. Keep the equipment away from those devices to avoid any influence from electromagnetic noise Consult with hospital or medical equipment companies before using this equipment on medical apparatus It is recommended you follow this instruction manual strictly to avoid unnecessary accidents repairs and damage 1 AC Output Receptacle 16A 11 Welding Output Terminal 2 AC Output Receptacle 32A 12 Battery 3 Earth Leakage Circuit Breaker 13 Earth Grounding Terminal ELCB 14 Oil Gauge Oil Inlet 4 AC Output Switch 15 Oil Drain Plug 5 Frequency Changeover Switch 16 Fuel Lever 6 Display 17 Top Mounted Lifting lug 7 Current Adjusting Dial 18 Fuel Inlet 8 Idle Control Switch 19 Front Door 9 Starter Switch 20 Wheel 10 Choke 21 Plug Cap Spark Plug Q 508 275 27 EON DA 3 14 E 22 23 24 25 26 27 28 Positioning Handle Air Cleaner Cleaner Cover Recoil Knob Muffler with Exhaust Wire Mesh Exhaust Outlet Wheel Brake Side Door 5 1 Display This equipment has 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 Then the display will alternate between pre set actual welding current Maximum indication up to 9 999hours 2 Welding current pre set actual Default display mode indica
5. 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 SoOVO 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 wheels using the brake to prevent equipment movement When stating the engine turn off all connected equipment and set the AC output switch to the OFF position Do not move the equipment during operation When performing equipment checks and maintenance always stop the engine Do not operate the equipment if the equipment is faulty or if there are missing parts 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 fumes No X505 006400 High Voltage No X505 005080 Positioning handle No X505 006430 Hot surface No X505 006420 Electric
6. fumes from the engine contains many elements harmful to humans Do not operate equipment in poorly ventilated areas such as inside a room or ina tunnel Danger Electric Shock Do not touch the equipment if 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 Before connecting or disconnecting a welding cable from output terminal stop the engine and remove the key Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the check or maintenance should always keep the key Caution Suffocation from exhaust fumes Do not point the exhaust fume outlet pipe in the direction of pedestrians building Caution Suffocation from welding fumes 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 also in order to prevent inhalation of the fume A Caution Injuries to eyes and skin sure to wear spark protection glasses mask long sleeve shirts gloves etc in order to protect and skin from harmful sparks during welding Battery fluid contains diluted sulphuric acid Avoid contact with eyes skin clothing If the acid comes in contact with eyes flush with lots of water and contact to your physici
7. or below 1 Grounding Work A qualified electrician should perform the grounding work at the 2 points as shown below 50062 or below The grounding terminal of this equipment TA The Outer Casing of the load GROUNDING TERMINAL lt Caution gt Inthe event you cannot ground the generator to the earth consult with the authorized distributor or our dealer ae it wa n E GROUNDING ROD 2 Operation Check Before operating the equipment follow the instructions below Start the engine as per starting procedure Please refer to Starting P14 Turn the AC output switch to ON Switch the ELCB lever to the ON position Press the test button Gray color in the ELCB Once the test button is pressed the ELCB indicator White must be out and the switch will be moved in between ON OFF Push down the ELCB switch OFF Return the ELCB switch to ON position The ELCB indicator white will be 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 Be sure to set the AC output switch position to OFF before starting the engine 3 The Earth Leakage Relay has activated A Caution Electric Shock Injuries Be sure to disconnect all the loads to the equipment before turning the ELCB ON again after the earth leakage relay has activated When
8. periods exceed 5 minutes or if break period is reduced This machine produces drooping characteristics to EN60974 1 7 5 Welding A Caution 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 fume Caution Injuries to eyes and skin sure to wear spark protection glasses long sleeve shirts gloves etc in order to protect eyes and skin from harmful sparks during welding Refer to the table below Light Shielding Standard Glass Light Shielding Degree No 7 8 9 10 12 13 Welding Current 30 75 76 200 201 400 A Caution Fire Keep any inflammable items and combustible materials away from the welding area Caution Burns Be sure to wear leather gloves apron shoe covers eye protection glasses mask safety shoes safety cap and long sleeve shirts as welding creates hot sparks Start the engine Adjust the current by the current adjusting dial Be sure to check the preset welding mode lamp turns on Rotate the current dial to desired preset welding current as indicated on the display After striking welding arcs display indicates actual welding current and the actual welding lamp illuminates 17 8 Generator Operation Danger Electric Shock Do not operate the
9. seconds or more When the engine starts release the starter switch key immediately lt Caution gt Never turn the starter switch to START once the engine is running 5 Push back the choke 14 lt Caution gt Just after starting the engine may stop if the choke is prematurely pushed back in In this case push back the choke slowly once the engine is warm Keep engine idling for approximately 5 minutes 2 Starting by Recoil Starter STARTER SWITCH HOUR WELDING CURRENT AC OUTPUT SWITCH Switch the AC output switch to OFF CLEANER RECOIL KNOB SIDE DOOR Open the front door and turn the fuel lever to OPEN 3 Pull out the choke 4 Turn the starter switch to RUN 5 Pull the recoil knob slowly to the compression point and then allow the recoil knob to return and pull it again to start lt Caution gt Do not fully extend the recoil knob After the engine starts push back the choke lt Caution gt Just after engine starting the engine may stop if the choke is prematurely pushed back in Therefore push back the choke slowly along the engine condition and keep the choke back always when the engine is warm Keep engine idling for approximately 5 minutes 6 3 Stopping STARTER SWITCH HOUR WELDING CURRENT rreser AC OUTPUT FREQUENCY
10. temperature and or humidity is higher than the reference conditions a reduction in power may be necessary 18 lt Caution gt Single phase AC output from the 32Amps and 16Amps sockets are as follows 110V 16 2 110V 23A Total current should be limited within the rated current specification The rated current for this equipment 23A 50Hz 23A 60HZ 8 1 Operation Set the frequency 50Hz Turn the frequency changeover switch to 50Hz 60Hz Turn the frequency changeover switch to 60Hz 2 Turn the AC Output Switch to ON Turn the ELCB to ON 8 2 Output Limitation Please refer to the following table 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 only Capacity Watt Load High Speed Low Speed 50Hz 60Hz Electric Bulb Heater etc 2500 2500 Electric Tools Series Motor etc 1200 1200 Mercury Bulb High Power Factor Type 1000 1000 Submersible Pump Compressor etc Induction Motor 1000 1000 lt Caution gt Be sure to use correct frequency for mercury bulbs and induction motors The start load may require more power than the rated power Consult with our authorized distributor or our dealer to clarify When using both sockets start the load one by one and not simultaneously Be sure not to
11. the Earth Leakage Relay has activated the ELCB indicator button White will be out and the ELCB switch will have moved to the position in between ON and OFF In this case stop the engine and find the earth leakage fault and repair After repairing leakage fault reset the ELCB using the following procedure Push the ELCB switch down to OFF Lift the ELCB switch to return to the ON position 9 lt Caution gt lf the ELCB indicator button is not out the AC Output current may have over supplied Please refer to Output Limitation P18 for the table showing maximum currents from the circuit After disconnecting all the loads to the equipment reset the ELCB once more 5 6 Wheel Brake A Caution Injuries Be sure to place this equipment on a flat surface and lock the wheel by lifting the brake arm as shown below The wheel Brake is designed to lock the wheel to avoid unnecessary movement of the equipment when operating on the flat surface It is recommended you secure additional brake and or ropes to fix the position during transportation or when operating the machine on uneven ground 1 Lock the wheel Lift the brake arm upward to position 1 Gently lock the equipment to slide the brake arm to position 2 with a clicking noise Confirm the equipment is now locked 2 Unlock the wheel Slide the brake arm to position 1 and then default position 1 lt Caution gt Be sure to unlock the brake before attempti
12. 6 Clean Change Air Cleaner O O Clean Change 7 Clean Adjust Spark Plug O O Clean Adjust 8 Clean Exhaust Wire Mesh O 9 Overhaul J 10 Check Carbon Brush 11 Check Adjust Engine Valve Clearance 12 Clean Fuel Tank Fuel Strainer 13 Change Fuel Pipe 14 Change Vibration Absorbing Rubber lt Caution gt Use always the genuine part 20 1 Change Engine Oil First Time 20 hour mark 2 or after Every 50 hours Remove the oil gauge Loosen the oil drain plug and allow the oil drain fully Reinstall the oil drain plug Checking the oil level by the oil gauge add oil into the oil fill up to the max level approximately 1 0 Liter 5 Reinstall the oil gauge hand tight Qe L Cay FUEL LEVER OIL GAUGE OIL DRAIN PLUG 2 Clean Adjust Spark Plug Clean Every 50 hours Adjust Every 200 hours Remove the plug cap and remove the spark plug off by spark plug wrench If the spark plug is dirty wipe out the dirt by using a spark plug cleaner or wire brush Adjust the opening to 0 6 0 7mm between the electrodes lt Caution gt Use the plug of lt NGK BR6HS gt In GAP 0 6mm to 0 7mm 0 024in to 0 028in 3 Clean Air Cleaner lt Caution gt Clean more frequently if used dusty environment Clean Every 50 hours Adjust Every 500 hours Remove the cleaner cover Clean the urethane part in ker
13. ISO 9001 CERTIFIED OWNER S MANUAL Table of Contents Page 1 Safety Guidelines 2 2 Specifications 4 SOUND PROOF 3 Use 5 4 Parts 5 PETROL ENGINE 5 Equipment 7 5 1 Display 7 GENERATOR WELDER 5 2 Oil Sensor 7 5 3 Overload Overheat 8 Protection Devices EG WI5SO0MCVUK 5 4 Eco Mode Engine speed control 5 5 Earth Leakage Circuit Breaker Air Cooled 4 Cycle OHC Engine and Grounding 10 5 6 Wheel Brake 10 6 Operation 10 6 1 Initialization Pre check 14 6 2 Starting 15 6 3 Stopping 16 7 Welding Operation 16 7 1 Selection Welding Cable 16 7 2 Polarity 16 7 3 Connection Welding Cable 17 7 4 Duty Cycle 17 7 5 Welding 18 8 Generator Operation 18 8 1 Operation 18 8 2 Output Limitation 19 9 Simultaneous Use of Welding and Generating 19 10 Checking and Maintenance 23 11 Long term Storage 24 12 Troubleshooting 25 13 Wiring Diagram CAUTION Do not operate the Generator Welder or any other appliance before you have read and understood the instructions for use EGW150MCI UK X750804 2003 Introduction Thank you for purchasing Shindaiwa Sound Proof Petrol 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 repairs Please operate this equipment after thoroughly revie
14. Shock No X505 004930 2 Specifications Model EGW150MCI UK Generating Method Rotating Field Synchronous AC Generator 5 Rated Current A 140 Duty Cycle 50 5 Rated Speed 3600 No Load Voltage V MAX 75 5 Current Adjustable Range A 40 155 Welding Rod 2 0 3 2 Phase 1 Phase Rated Voltage V 110 z Frequency Hz 50 60 Rated Speed min 3400 8 Rated Output kVA 2 5 9 Rated Current A 23 Power Factor 1 0 Rating Continuous Model Robin EX27DS Type Air cooled 4 Cycle OHC Gasoline Displacement L 0 265 Rated Output kW min 5 1 3600 5 Fuel Unleaded Petrol Lubricant Oil API Class SE or higher Lubricant Oil Volume L 1 0 about Starting Method Recoil Start and Starter Motor Spark Plug NGK BR6HS Battery Yuasa YTX9 BS or 34A19L Fuel Tank Capacity L 12 Dimension LxWxH mm 706 x 494 x 625 Dry Weight kg 79 GENERATING SET ISO 8528 8 G2 EMC Group 2 Class A Arc welding Power source for electric tools Power source for lights Voltage classification G2 Classification Group 2 Class A Caution Damage to the equipment or other properties Consult with our dealer or authorized distributor when utilizing this equipment around the devices with the microcomputer control or the ultra precision items which are very sensitive for the voltage fluctuation
15. Wait until the engine cools down before performing any checks If the equipment is not to be used for more than 2 months perform the following maintenance and storage procedures Turn the fuel lever to CLOSE Unscrew the bolts off Pull out the fuel lever Loosen the ring and remove the strainer cup 3 Turn the fuel lever to OPEN drain all the fuel in the fuel tank Turn the fuel lever to CLOSE and re fit the strainer cup tight with the ring lt Caution gt Be sure to check for any contaminants the seal whenever reinstalling the strainer cup Set the fuel lever with the bolts Start the engine and leave running until it stops The fuel in the carburetor is consumed Turn the starter switch to STOP Change the engine oil Remove the spark plug and inject the engine oil to approximately 5ml Use the starter switch to crank the engine for approximately 5 seconds 17 Re fit the spark plug and ensure it is tight 12 Clean the air cleaner 13 Remove the battery Remove always negative side first and reinstall always positive side first Clean the parts all cover and store it in clean and dry place lt Caution gt Store the removed battery the place where ventilation is good and doesn t have fire keeping it away from children Recharge the battery once in a month periodically 53 12 Troubleshooting Danger Electric Shock Do not touch the equipment if you or the equipmen
16. an immediately A Caution Electric shock Do not flush water onto the equipment or operate it in the rain This machine is rated to IP23 Do not touch a spark plug plug cap or high voltage wiring during operation Caution Explosion Do not use the equipment or charge the battery when the battery fluid level is below the LOWER level marker The battery may emit some combustible gas Keep it away from fire and sparks A Caution Fire The equipment uses Unleaded Petrol as a fuel When inspecting the equipment refueling always stop the engine and keep away from sparks or naked flames Always wait until the engine cools down before refueling Always wipe away any drips of fuel or lubrication 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 inflammable items such as fuel gas paint etc away from the equipment Keep any inflammable items and combustible items away from the welding area 07 as welding creates hot sparks Always operate this equipment on flat surface and with at least 1 metre clearance from all objects Do not connect AC output to any indoor wiring Always wait until the equipment cools down before covering for storage Keep children at a safe distance from the machine at all times A Caution Burns Do not touch the engine and muffler during operation and immediately after
17. contact with eyes flush with lots of water and seek medical attention immediately A Caution Explosion While utilizing sulphuric acid type battery 34 191 be sure not to use recharge the battery if the fluid level is lower than the lowest limit Battery may emit some combustible gas therefore keep it away from flames or sparks Open the front door Make sure that the battery cables are firmly secured to the posts Tighten the clamps if necessary lt Caution gt Check and measure the voltage between terminals If it is lower than 12 8V recharge is necessary 12 Replacing battery Remove the clamp and the cable from the negative post in the battery Always remove negative side first Remove the clamp and cable from the positive post on the battery Never touch the battery fixing plate to the terminals Remove the battery fixing plate from the battery Never touch the battery fixing plate to the terminal Pull out the battery Never touch the terminals to the equipment body X Reinstall a new battery in reverse order Always attach the cable to the positive post on a battery first lt Caution gt Use the following battery Yuasa YTX9 BS or 34A19L Replacing battery for sulphuric acid type battery 34A19L Remove the sealed battery as per above procedure Remove the rubber band which is securing fuel hose and battery positive cable Remove the fixing bolt
18. ding ee ee Stainless Steel 7 3 Connection Welding Cable Danger Electric Shock Always examine welding cables power cables and plugs etc to ensure there are no defects present prior to operation Before connecting or disconnecting a welding cable from welding output terminals stop the engine and remove the engine key The person performing this task must always keep the key Stop the engine Connect a welding cable to the DINSE connectors a welding rod WELDING CABLE holder and a material holder WELDING ROD HOLDER DINSE CONNECTORS MATERIAL HOLDER lt Caution gt Always fit the correct size DINSE connectors Recommended parts DIX SK 35 or DIX SK 50 or DIX SK 70 Ensure the welding cables connections are made correctly Be sure to connect the welding cables securely to welding output terminals Welding output terminals may burn due to the heat caused by poor connections Do not use a cable without the DINSE connectors Personal injury or damage to the machine may result as a consequence 7 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 of welding time Be sure to take 5 minutes break after each 5 minutes of continuous welding time lt Caution gt The equipment may become damaged due to overheating if continuous welding
19. e level and fuel consumption Turn the Idle control switch to Eco position to use this function 1 Welder When welding current output is detected the engine turns to appropriate speed and returns to idling rpm approximately 8 seconds from 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 lt Caution gt Always select High mode while utilizing high load equipment to ensure constant output 5 5 Earth Leakage Circuit Breaker and Grounding Danger Electric Shock Ground the grounding terminal to the earth as set out in the manual Failure to do so could result in injury Even though all the load terminals have been grounded to the earth the canopy grounding terminal should also be grounded to the earth Grounding should be made whilst the engine is stopped Whenever the earth leakage relay has activated you should always repair the fault before re using the machine The equipment is provided with an Earth Leakage Relay ELR within the Main Circuit Breaker MCB to detect any earth leakage due to problems such as insulation failure of the load whilst the generator is running When activated the ELR will automatically switch the MCB to the OFF position The specifications of the earth leakage relay Rated Sensitive Current 30mA or below Grounding resistance 500
20. equipment if the equipment or you are wet Caution Injuries Be sure to connect to the receptacles after confirming that all the switches on the loads are set to the OFF position Always examine welding cables power cables and plugs etc to ensure there are no defects present prior to operation Do not connect the equipment to any power supply network Extra precautions must be taken whenever performing more hazardous welding operations such as Environments with increased risk of electric shock for example due humidity or conductivity Inflammable surroundings and or atmospheres Inflammable products Closed containers Elevated working positions or platforms Caution Damage to the equipment or other properties Consult with our dealer or authorized distributor when utilizing this equipment on devices with microcomputer control or the ultra precision items which are very sensitive to voltage fluctuation Keep the equipment away from those devices to avoid any influence from electromagnetic noise Consult with hospital or medical equipment company before using this equipment on medical apparatus It is recommended to follow this instruction manual strictly to avoid any unnecessary accidents repairs and damage Voltage classification G2 EMC Classification Group 2 Class A Do not use this equipment for the purpose of thawing pipes If utilizing this equipment in conditions where altitude ambient
21. exceed the rated current 9 Simultaneous Use of Welding and Generating Refer to the following table and limit the AC power use Limitation of AC Power Supply in the simultaneous use of welding and generating Welding Output AC Output Welding Rod Amperage 50 60Hz 2 6mm 100A 2 l 3 2mm 120A i PREN lt Caution gt While utilizing AC single phase output when welding be sure to keep the welding current less than 100A to avoid fluctuation or insufficient AC output 19 10 Checking and Maintenance Danger Electric Shock Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the check or maintenance should always keep the key Caution Fire Burns Never close the equipment to fire When checking the equipment always stop the engine and wait until the engine cools down To optimize the use of this equipment we recommend periodical checks and maintenance as per the following maintenance matrix lt Caution gt Request for the maintenance items with mark to the authorized distributor or our dealer oe Every Every Every Every 12 Checking item Startup 50hrs 200hrs 500hrs months 1 Check and Supply Engine Oil 2 Check Water in Battery O 3 Check Leakage Fuel Engine Oil 4 Engine Oil Change 1 0 20 20 hrs 5 Clean Fuel Strainer O
22. ng to move the equipment to avoid a locking system malfunction 6 1 Initialization Pre check A 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 inflammable products Maintain a minimum clearance of 1 metre around the equipment 1 Checking Engine Oil Insert the oil gauge into oil inlet to check the engine oil level Do not screw the oil gauge into the oil tank whilst positioning the equipment on a flat and stable surface Before operation ensure oil level is to the UPPER level Oil Capacity approximately 1 litre maximum Effective Oil Volume about 0 5 litre between the LOWER and UPPER lt Caution gt You cannot measure the oil level accurately when the equipment is on an uneven surface f the machine is placed on an uneven surface it is still possible for the engine to 10 run however the oil sensor may not detect accurately the true level of oil and this may cause engine failure C FUEL LEVER OIL GAUGE OIL DRAIN PLUG Engine Oil Selection Use engine oil with the correct viscosity based on the ambient temperature refer to the chart lt Caution gt Use the oil of Class SE or superior Check the remaining oil level more frequently when using multi grade type as the oil consumption rate increases under high ambient temperature Oil Selection Criteria
23. ngine Oil P10 lt Caution gt The engine oil sensor cannot detect the degradation of engine oil Please check the engine oil periodically and change if required Refer to Change Engine Oil P20 5 3 Overload Overheat Protection Devices A Caution Injuries Be sure to turn off the connected equipment before restarting the engine after the overload and or overheat protection devices are activated This device is designed to protect the welding machine by tripping the circuit output when overload or extreme temperatures are detected in the inverter circuit Display will indicate the following abbreviations when the device is activated OC Over load over current OH Over heat extreme high temperature at inverter circuit Follow the below instruction below to reset the device after the protection has been activated Shut off any connected equipments and turn off the AC output switch Allow the unit for cool down during idling mode for a minimum of five minutes Shut off the engine Turn the engine on again and then turn on the AC output switch lt Caution gt Refer to Output Limitation P18 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 4 Eco mode Engine revolution control The Eco mode is designed to control the engine speed based on the required current to minimize the nois
24. ntilated areas such as inside a room or in a tunnel Caution Suffocation from exhaust fumes Do not point the exhaust fumes toward pedestrians or building Caution Fire Temperatures around the muffler and exhaust can reach extremely high levels Keep inflammable items such as fuel gas paint etc away from the equipment Always operate this equipment on a flat surface and at least 1 metre clearance from any objects Caution Injuries Always place the equipment on a flat and stable surface and fix wheels with brake to avoid the equipment from sliding When starting the engine turn off the connected equipment and set the AC output switch to OFF position Total operation hours will be indicated for 5 seconds only after the engine has started Then the display will be automatically changed to pre set welding current The pre set welding current lamp turns on 1 Starting by Starter Motor STARTER SWITCH DISPLAY HOUR WELDING CURRENT IES REQUENCY y xX J E A 9 i 1 N 328 FRONT DOOR A AC OUTPUT SWITCH OIL GAUGE OIL DRAIN PLUG Select the AC output to OFF Open the front door and turn the fuel lever to OPEN 3 Pull out the choke Turn the starter switch to START The starter motor starts and then the engine starts lt Caution gt Do not keep the starter motor ON for than 5 seconds When restarting wait for 30
25. on the left side of the battery by loosening the nut and then place the bolt on the bolt hole on the back side Fig A Remove the fixing bolt on the right side of the battery and place the bolt on the hole of the right bottom Fig A Install the sulphuric acid battery 34A19L into the battery space Insert the battery fixing plate on the bolt as shown Fig B and tighten the wing nuts Be sure to connect the positive cable first to the positive terminal to avoid unnecessary sparks Next connect the negative cable to the negative terminal Attach the fuel hose and battery positive cable to the battery fixing bolt by rubber band Fig C BATTERY FIXING PLATE RUBBER Fig A Position of the Fixing Bolt Fig B Direction of the Fixing plate Fig C Completion Inspection of the sulphuric acid type battery 34A19L Open the front door Check the fluid level If the level is near or lower than lowest level add distilled water within the upper level 3 Make sure that the battery cables are securely tightened to the terminal Retighten the clamps if necessary 13 lt Caution gt Check the gravity of the battery fluid If it is under 1 23 the battery requires recharging Please consult with our dealer or authorized distributor 6 2 Starting Danger Suffocation from exhaust fumes Exhaust fumes from the engine contains many elements harmful to humans Do not operate this equipment in poorly ve
26. osene And then dip it into liquid of 3 parts kerosene 1 part engine oil and squeeze it tight 21 CLEANER RECOIL KNOB SIDE DOOR CLEANER COVER URETHANE PART 4 Clean Fuel Strainer Clean Every 200 hours Open the front door 2 Turn the fuel lever to Close Unscrew the bolts Pull out the fuel lever 5 Remove the strainer cup by turning the ring counter clockwise Discard any dust or water inside the strainer cup and clean away dust from the net Reassemble and be sure to screw tightly to prevent leaks lt Caution gt Be sure to remove any contaminants on the seal whenever reassembling the strainer cup Turn the fuel lever to OPEN after assembling and check for any leaks FUEL LEVER lt gt _ PACKING STRAINER CUP CLOSE STRAINER CUP ey ine 5 Clean Exhaust Wire Mesh Clean Every 500 hours Loosen the bolt and remove the exhaust wire mesh and holder 2 Clean up the carbon deposit from the exhaust s wire mesh using wire brush EXHAUST WIRE MESH 22 11 Long term Storage Danger Electric Shock Before performing any equipment check or maintenance stop the engine and remove the engine key The person performing the maintenance should always keep the key A Caution Fire Burns When checking engine always stop the engine and keep away from fire Temperatures around the muffler and exhaust can get extremely high
27. t is wet Before performing troubleshooting stop the engine and remove the engine key A person performing shooting trouble should always keep the key A Caution Injuries Before performing troubleshooting stop the engine and remove the engine key A person performing the maintenance should always keep the key A Caution Fire Burns When checking engine always stop the engine and keep away from fire Temperature around 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 this troubleshooting guide contact our authorized distributor or our dealer to request the repair Symptoms Presumed Cause Corrective Actions Starter motor 1 Weak Battery 1 Recharge Battery does not start 2 Dead Battery 2 Replace Battery Engine does not 1 Fuel Lever to CLOSE 1 Fuel Lever to OPEN start 2 Insufficient fuel 2 Replenish fuel 3 Fuel is contaminated by the 3 Drain water or clean fuel water or dust tank fuel strainer Engine starts but 1 Oil sensor activates 1 Replenish oil stalls immediately Welding arc is 1 Wrong setting of current 1 Turn the dial CLOCKWISE weak adjustment dial 2 Poor contacts of cables 2 Contact cables securely 3 Improper cable diameter 3 Change cables according to Selection Welding Cable 4 Improper connec
28. tes 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 has activated during operation the display will indicate OIL Please refer to Oil Sensor P7 4 Over load warning When the AC output current exceeds the machine rating the display will indicate OC Please refer to Overload Overheat Protection Devices P8 5 Over heat warning When extreme high temperature is detected at the inverter circuit the display will indicate OH Please refer to Overload Overheat Protection Devices 8 5 2 Oil Sensor A Caution Burns 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 A 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 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 which is the function of oil sensor unit After the engine stops the display on the control panel shows OFF You should check the engine oil level and replenish to the maximum level if needed Please refer to Checking E
29. tion to the 4 Contact securely base material 5 Engine output is down 5 Keep 50 duty cycle and or repair the engine Excessive welding 1 The wrong setting of 1 Turn the dial arc current adjustment dial COUNTER CLOCKWISE No AC 100V 1 The AC output switch 1 Select the AC output switch output Position is OFF to ON position 2 The ELCB Position is OFF 2 Select the ELCB to ON position 3 Display indicates OC or 3 Restart the engine OH AC 100V output is 1 Wrong frequency 1 Change the frequency to the weak correct one 2 The current in the load 2 Refer to the item of Output exceeds the rated current Limitation Unable to activate 1 The Idle Control switch 1 Select the Idle Control Eco Mode Position is HI switch to ON position 24 lt 93103903 039142 LINN YALYSANT 121 519 0 11 94 E 1 MI 3015 an A 95 5 a 9 2 8 510 da LINOUID GALNIYd 40151539 ONIGNNOYS thy duayvaua 11095154 431511238 q 9 7 Hlava ASYHd 1 i 9 2 4 1 tn mf at 69 Lae a HITIOULNOD LAI 1109419 O3LNIYd NEED YZE A S 9 9 9 9 5
30. wing and understanding the contents of this operators manual Please attach this manual if the equipment is to be on sold or rented out Please store this manual with the equipment for easy reference Following convention will be used throughout the manual to indicate the degree of cautions Danger Can cause serious injuries or death Can cause minor injuries or damage to the equipment or other Caution properties lt Caution gt Other types of caution Some of the items noted in Caution may lead to serious injuries Please read all items and follow all the safety guidelines The following statement refers to the noise level data contained in the EC Declaration of Conformity attached to 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 weather 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 1 Safety Guidelines Danger Suffocation from exhaust fumes Exhaust
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