Shindaiwa DGW400DM-C Bedienungsanleitung

OWNER’S MANUAL

DGW400DM-C

1. Introduction

Thank you for purchasing this Shindaiwa Sound Attenuated Diesel Engine Powered Welder/Generator.

•This manual was created to help ensure the safe operation of this equipment. To avoid

unnecessary accidents and/or repairs, it is strongly recommended that the user closely follow

all the instructions contained in this manual.

•Do not operate this equipment until you have thoroughly read and understand the contents of

this manual.

•For easy reference, this manual should always be stored on or near the equipment.

The following convention will be used throughout this manual to indicate various

degrees of warnings.

Danger

Can cause serious injuries or death.

Caution Can cause minor injuries or damage to the equipment or

other properties.

<Caution> Other types of caution

•Even some of the items noted in Caution may lead to serious injuries. Be sure to fully

read and understand all instructions prior to operating this equipment and follow all safety

guidelines during equipment operation.

2. Safety Guidelines

Danger: Suffocation from exhaust fumes

•Exhaust fumes from the engine used on this equipment contain many elements that have been

proven to be harmful to humans. Do not operate this equipment without adequate ventilation.

Danger: Electric Shock

•Do not come in contact with the output terminals during operation.

•Do not insert metal objects (such as pins or wires) into plug-in receptacles.

•Do not touch any wiring or electrical parts inside the equipment during operation.

•Before connecting or disconnecting a load cable from the output terminals, ensure that the

output circuit breaker is in the OFF position.

•Before connecting or disconnecting welding cables from the output terminals, stop the engine

and remove the engine key. The person connecting or disconnecting the cables should always

retain possession of the key.

•Before performing any equipment check or maintenance, stop the engine and remove the

engine key. The person performing the maintenance should always retain possession of the

key.

Danger: Burns

•To avoid sustaining burns from hot vapor, do not open the radiator cap either while operating

or immediately after stopping this equipment.

Danger: Injuries

•To avoid injuries due to accidental contact with the cooling fan, fan belt, or other moving parts,

close and lock all doors during the operation of this equipment.

Caution: Suffocation from exhaust fumes

•Direct exhaust fumes away from other personnel and/or buildings.

Caution: Suffocation from welding fumes

•Welding fumes may contain poisonous gas and/or dust. Ensure that there is adequate

ventilation of the welding area and if necessary, that the proper respiratory equipment is worn.

Caution: Injuries to eyes and skin

•Welding helmets or hand shields containing appropriate filter lenses and cover plates must be

worn during welding operations.

•Always wear the proper protective clothing such as long sleeve shirts, pants without cuffs,

covered pockets, sturdy shoes or boots, and durable gloves while welding.

•Battery fluid contains dilute sulfuric acid. Avoid contact with the eyes, skin or clothing. If

contact with the acid does occur, especially with the eyes, flush with large volumes of clean

water, and contact your physician immediately.

Caution: Electric shock

•Keep water and moisture from entering the interior of the enclosure.

Caution: Explosion

•Do not use this equipment or charge the battery if the battery fluid level is lower than the

LOWER level mark on the battery case.

•The battery may emit highly explosive gases. Never expose it to flames or spark producing

devices.

Caution: Fire

•This equipment uses diesel (a flammable liquid) as a fuel. When refueling, always stop the

engine and maintain an adequate distance from flames and spark producing devices. Allow the

engine to cool down before refueling.

•Immediately wipe up any diesel fuel or engine oil that may be spilled. Do not use this

equipment if there are any fuel or lube oil leaks. Repair the equipment before further use.

•Temperatures around the muffler and exhaust piping can get extremely high. Keep any

flammable items (such as fuel, gas, paint, cloth, paper etc.) away from these areas.

•Keep flammable items away from the welding area to prevent ignition of these items by

welding spatter.

•This equipment must be operated only on flat stable surfaces and at least 3 feet away from

any obstructions (such as walls) that would hinder airflow.

•Do not connect the AC output to any indoor wiring without an approved disconnecting device

between the generator output and the building’s electrical service and then only if done by a

qualified electrician.

•Allow the equipment to cool down before covering it for storage.

Caution: Burns

•Due to the extremely high temperatures in these areas, do not come in contact with the engine

or muffler during operation or immediately after stopping the equipment.

•Do not check or change the engine oil while the engine is running. Stop the engine and allow

it to cool down prior to checking or changing the engine oil. Opening either the line to the oil

gauge or the oil filler cap during operation may cause injury due to hot oil.

•Always wear the proper protective clothing such as long sleeve shirts, pants without cuffs,

covered pockets, sturdy shoes or boots, and durable gloves while welding.

Caution: Injuries

•Lift this equipment only with the installed lifting hook.

•Operate this equipment only on a flat and stable surface. For wheeled models, lock the

wheels during operation.

•Never start the engine with loads connected to the generator output. Prior to starting,

disconnect the loads and turn the main output circuit breaker to OFF.

•Do not move this equipment during operation.

•Stop the engine before performing any equipment checks and/or maintenance.

•Do not operate this equipment if it is being modified or if any parts have been removed.

3. Labels

Caution, Danger, Warning and Operation Information Labels: Make sure all information labels are

undamaged and readable. Immediately replace damaged or missing information labels. New

labels are available from your local authorized Shindaiwa distributor or dealer.

When ordering labels, use the following part numbers:

1 Suffocation from exhaust fumes (No. 19402-00194)

2 Suffocation from welding fumes (No. 19402-00195)

3 Electric Shock (No. 19402-00193)

4 Burns (No. 19402-00201)

5 Injuries (No. 19402-00199)

6 Burns (No. 19402-00200)

7 Fire (No. 19402-00166)

8 Burns (No. 19402-00256)

9 Caution Earth Leakage (No. 19402-00187)

2 7

4. Specifications

Model DGW400DM - C

Generating Method Rotating Field

Rated Current (A) 390 @ 60% Duty Cycle, 302 @ 100% Duty Cycle

Rated Voltage (V) 35.6

Rated Speed (rpm) 3600

No Load Voltage (A) MAX 85

Current Adj. Range (A) 110 - 400

Single Welding Rod Diameter 5/64 – 5/16

Current Adj. Range (A) 55 - 210

Dual Welding Rod Diameter 5/64 – 5/32

Current Adj. Range (A) 40 – 220

Welding Generator

Output Change

(CC power)

Eco Welding Rod Diameter 5/64 – 3/16

Rated Frequency (Hz) 60

Rated Speed (rpm) 3600

Phase 1-Phase 1-Phase 3-Phase

Rated Voltage (V) 120 240 480

Power Factor 1.0 1.0 0.8

Rated Output (kVA) 2.2 4.3 15

AC Generator

Rating Continuous

Model Kubota D1005

Type Vertical, Water-Cooled 4-Cycle Diesel Engine

Displacement (L) 1.001

Rated Output (kW/rpm) 20.4/3600

Fuel ASTM No.2 Diesel Fuel or Equivalent

Lube Oil API Class CC or Higher

Lube Oil Volume (Quarts/L) 5.4/5.1

Cooling Water Volume (Quarts/L) 4.5/4.3

Engine

Starting Method 12V DC Starter Motor

Battery 55B24L

Fuel Tank Capacity – (Gallons/L) 9.8 /37

Length – (Inches/mm) 59.8/1519

Width - (Inches/mm) 27.6/700

Dimen

sion

Height – (Inches/mm) 29.9/760

Dry Weight – (Pounds/kg) 972/441

5. Use

•Arc Welding (CC or CV), MIG, TIG, Gouging

•CV Power Output (Side A only)

•Auxiliary AC power source up to the rating of the AC generator.

Caution: Potential damage to this equipment or other equipment

•This equipment is designed for the above purposes only. Do not use it for any other purposes.

6. Parts

DC METERS CURRENT ADJ. DIAL A

ECO/SINGLE/DUAL

WELDING TERMINALS A

MONITOR LAMPS

STARTER SWITCH

FUEL METER

REMOTE CONTROL

RECEPTACLE

SLOW DOWN SWITCH

CURRENT ADJ. DIAL B

CV/CC

SELECTOR SWITCH

AC METERS SELECTOR SWITCH

VOLTAGE ADJ. DIAL

HOUR METER

3-P BREAKER

ENCLOSURE GROUNDING WELDING TERMINALS B

TERMINAL

1-P 120V RECEPTACLE

1-P BREAKER

EARTH GROUNDING

TERMINAL

3-P RECEPTACLE

1-P 120/240V RECEPTACLE

FORKLIFT POCKETS

LIFTING LUG

FUEL INLET MUFFLER

HANDLE

RADIATOR ACCESS

HANDLE

EXHAUST PORT

LOWER 20A

FUSE

UPPER 50A

BATTERY

FUEL STRAINER

FUEL DRAIN PLUG OIL DRAIN PLUG WATER DRAIN PLUG

OIL FILTER

OIL GAUGE

OIL PLUG

RADIATOR

AIR CLEANER

SIDE DOOR

7. Equipment

7-1 Eco Welding

This equipment incorporates the Eco welding feature that allows welding operations at a reduced

speed (2100 rpm) which results in lower noise levels, reduced fuel consumption and lower emission

levels than with conventional welders.

With the selector switch in the Eco position, welding can be done with up to 3/16” (5.0 mm) welding

rod even though the engine is turning at a reduced speed.

•Do not turn the output selector switch while welding.

•The Eco feature is available for welding only. In the Eco mode the generator output is not

available.

7-2. CV/CC

Side A of this welder can be a Constant Voltage Power Source. By connecting a wire feeder to side A,

and then turning the CC/CV Selector Switch to CV, you have the ability to perform semi-automatic

welding such as MIG, MAG, SS, etc.

When the CC/CV selector switch is positioned to CV, Side A terminals become a Constant Voltage

Power Source. In this position voltage is adjusted with the voltage adjust dial A.

When the CC/CV selector switch is positioned to CC, Side A terminals become a Constant Current

Power Source. In this position current is adjusted with the current adjust dial A.

•Do not turn the output selector switch while welding.

•Side B Output Terminals can be used only as a Constant Current Power Source.

7-3. Remote Control (Optional)

Remote control operation using the Side ATerminals is available by plugging a remote control into

the receptacle on the lower right side of the control panel. This will allow you to adjust either welding

voltage or welding current from the Side A Terminals up to 295 feet away from the welder when using

an optional extension cord.

Remote Control Connection

REMOTE CONTROL

•Do not plug the remote control box into any energized AC receptacle.

•Do not connect other loads to the circuit that is powering the remote control.

7-4. Meters

This equipment features reliable digital meters for welding voltage and current and alternator three

phase output voltage and frequency

DC Volt Meter and Ampere Meter for welding Side A and Side B.

•When the output selector switch is positioned at [Eco] or [Single], the Side B meters are

inoperative.

3-Phase Volt Meter

•This meter displays the 3-Phase output voltage of the AC generator.

Frequency Meter

•This meter displays the AC generator output frequency in Hertz.

7-5. Monitor Lamps

This equipment has monitoring lamp indication for WATER TEMPERATURE, BATTERY CHARGING,

OIL PRESSURE, PREHEAT, AND OVERHEAT.

Overheat

eat

Oil Pressure

Battery Charge

Water Temperature

When the starter switch is placed in the RUN position, the monitoring lamps indicating BATTERY

CHARGING, OIL PRESSURE and OVERHEAT will turn ON. Once the engine starts, if there are no

abnormalities in the parameters these circuits monitor, the lamps will turn OFF. If an abnormality is

detected on any of the circuits monitored, other than OVERHEAT, the corresponding monitor lamp will

flash, and the engine will automatically shut down. An OVERHEAT abnormality will cause the lamp to

flash and the output of the welder to be decreased.

If there is an automatic shutdown, turn the starter switch to the STOP position. Investigate the cause

of and correct the reason for the shutdown prior to trying to restart the engine.

Coolant/Water Temperature Monitor Lamp

Danger: Injuries

To avoid accidental contact with the cooling fan or fan belts, do not operate this equipment unless

all doors are closed.

Danger: Burns

To avoid sustaining burns from hot vapor, do not open the radiator cap while operating or

immediately after stopping this equipment

Caution: Burns

Due to extremely high temperatures, do not come in contact with the engine or muffler while

operating or immediately after stopping this equipment.

If the water temperature rises to an unsafe level, the coolant/water temperature monitor lamp will flash,

and the engine will automatically shut down. If this occurs, check the coolant/water reservoir tank, and

refill it if needed. (Refer to Section 6-2 Checking Coolant/Water)

If the water level is normal after shutting down because of a coolant/water temperature monitoring

lamp situation, there is a possibility that the machine is over loaded causing the coolant temperature to

rise to an unacceptable level. Never operate this equipment at greater than the rated duty cycle and/or

output power.

Battery Charge Monitor Lamp

If the battery becomes unable to be charged during operation, the battery charge monitor lamp will flash

and the engine will automatically shut down. If this occurs, check the battery. (Refer to Section 6-5

Checking Battery)

•The battery charge monitor cannot detect the degradation of the battery or the battery fluid level.

Check the battery fluid level periodically. (Refer to Section 6-5 Checking Battery)

Oil Pressure Monitor Lamp

Danger: Injuries

•To avoid accidental contact with the cooling fan or fan belts, do not operate this equipment

unless all doors are closed.

Caution: Burns

•Due to extremely high temperatures, do not come in contact with the engine or muffler while

operating or immediately after stopping this equipment.

•Prior to checking engine oil, stop the engine, and wait until the engine cools down. If you open

either the oil gauge supply line or the oil filler cap during operation, hot oil may cause injury.

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