Shindaiwa Welder 4 Cycle Diesel Engine User Manual

Table of Contents  
1. Safety Guidelines  
Page  
OWNERS AND  
2
5
OPERATORS MANUAL  
2. Specifications  
3. Use  
6
4. Parts  
5. Equipment  
6
7
7
8
SOUNDPROOFDIESELENGINE  
GENERATOR / WELDER  
5-1. ECO Welding (DGW311DM only)  
5-2. Monitor Lamp  
5-3. Earth Leakage Breaker  
5-4. Slow-Down  
6. Initialization and Pre-check  
6-1. Checking Engine Oil  
6-2. Checking Coolant/Water  
6-3. Checking Fuel  
9
11  
11  
11  
12  
13  
14  
DGW311DM  
DGW311L  
Water-cooled 4 Cycle Diesel Engine  
6-4. Checking Fuel, Engine Oil, and  
water Leakage  
6-5. Checking Battery  
7. Operation  
14  
14  
14  
16  
16  
16  
17  
17  
18  
18  
19  
19  
21  
22  
23  
7-1. Initializing/Preparation  
7-2. Stopping Generator/Welder  
8. Welding Operation  
8-1. Selection – Welding Cable  
8-2. Polarity  
8-3. Connection – Welding Cable  
8-4. Duty Cycle  
8-5. Welding  
9. Generator Operation  
9-1. Output Range  
9-2. Output Limitation  
9-3. Operation  
10. Simultaneous Use of Welding and  
Generating  
11. Checking and Maintenance  
12. Long-term Storage  
13. Troubleshooting  
14. Engine Wiring Diagram  
15. Generator Wiring Diagram  
24  
27  
28  
30  
31  
CAUTION : Do not operate the Generator/Welder, or any other appliance,  
before you have read and understood the instructions for use.  
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1. Safety Guidelines  
Danger : Suffocation from exhaust fume  
z 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  
z Do not touch the output terminals during operation.  
z Do not insert metal objects (such as pin or wire) into plug-in receptacles.  
z Do not touch wiring or electric parts inside the equipment during operation.  
z Before connecting or disconnecting a load cable from output terminals, always turn the circuit  
breaker to OFF position.  
z Before connecting or disconnecting a welding cable from output terminals, stop the engine, and  
remove the engine key.  
z Before performing any equipment check or maintenance, stop the engine, and remove the engine  
key. A person performing the check or maintenance should always keep the key.  
Danger : Burns  
z Do not open the radiator cap while operating this equipment or immediately after stopping the  
equipment, to avoid sustaining burns from hot vapor.  
Danger : Injuries  
z Close all doors and place locks during operating this equipment, to avoid injuries by unintentionally  
touching cooling fan and fan belt.  
Caution : Suffocation from exhaust fume  
z Do not point the exhaust fume toward pedestrians or building.  
Caution : Suffocation from welding fume  
z Be sure to wear a fume proof mask in operation, because welding fume contains poisonous gas  
and dust. Pay attention to the airflow direction and sufficient ventilation also in order to prevent  
from inhaling the fume.  
Caution : Injuries to eyes and skin  
z 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.  
z Battery fluid contains diluted sulfuric acid. Avoid contact with eyes, skin or on clothing. If the acid  
comes in contact, especially with eyes, flush with a lot of water, and contact to your physician  
immediately.  
2
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Caution : Electric shock  
z Do not flush water onto the equipment nor operate it in the rain.  
Caution : Explosion  
z When the liquid level is below the LOWER level, never use the equipment nor recharge the battery.  
z Battery may emit some combustible gas, so keep it away from fire and sparks.  
Caution : Fire  
z The equipment uses Diesel fuel as a fuel. When refueling, always stop the engine and keep away  
from fire. Moreover, always wait until the engine cools down before refueling.  
z Always wipe any drip of Diesel fuel or lubrication oil. Do not use this equipment when a leak is  
found. Repair the equipment before use.  
z Temperature around muffler and exhaust can get extremely high. Keep any inflammable items  
(such as fuel, gas, paint, etc.) away from the equipment.  
z Keep any inflammable items and easily burning items away from the place in welding, because  
welding splashes spatters.  
z Always operate this equipment on flat surface and, at least 1 meter away from any objects (wall,  
box, etc.).  
z Do not connect AC output to any indoor wiring.  
z Always wait until the equipment cools down, before placing any covering materials for storage.  
Caution : Burns  
z Do not touch the engine and muffler during operation and immediately after stopping the equip-  
ment, for the temperature can reach extremely high.  
z When checking engine oil or changing oil, always stop the engine, and wait until the engine cools  
down. If you open either the oil gauge or the oil filter cap during operation, hot oil may cause some  
injury.  
z 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.  
Caution : Injuries  
z When lifting the equipment, always use a lift hook. Do not lift a handle, for it may cause equipment  
to drop due to handle breaking off.  
z Always place the equipment on a flat and stable surface, to keep the equipment from sliding. Be  
sure to lock the wheels for the wheeled models.  
z When starting the engine, turn off the connected equipment and set the circuit breaker to OFF po-  
sition.  
z Do not move the equipment during operation.  
z When performing equipment check and maintenance, always stop the engine.  
z Do not operate the equipment, if the equipment is being modified or if the parts are removed.  
3
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Location of Warning labels  
When the warning labels become unreadable or damaged, place new labels on the appropriate  
locations, as specified in the following figure.  
When ordering the label, use the following part numbers.  
Suffocation from exhaust fume  
Suffocation from welding fume  
Electric shock  
Electric shock  
Injuries  
(No. 19402-00194 )  
(No. 19402-00195 )  
(No. 19402-00192 )  
(No. 19402-00193 )  
(No. 19402-00199 )  
(No. 19402-00201 )  
(No. 19402-00200 )  
(No. 19402-00166 )  
Burns  
Burns  
Fire  
DGW311DM  
DGW311L -(W)220B〕  
DGW311L -(W)380A, -(W)400A, -(W)415A〕  
4
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2. Specifications  
Model  
DGW311DM  
-(W)220B  
DGW311L  
-(W)380A -(W)400A -(W)415A  
-(W)220B  
Generating Method  
Brushless, Rotating Field, Synchronous AC Generator  
Rated Current (A)  
280  
260  
Rated Voltage (V)  
Duty Cycle (%)  
31.2  
30.4  
50  
Rated Speed (min-1 )  
3600  
3000  
No Load Voltage (V)  
MAX 85  
Current Adj. Range (A)  
ECO  
30-160  
2.0-4.0  
Welding Rod (Ф )  
Current Adj. Range (A)  
Single  
Dual  
85-310  
2.6-6.0  
45-160  
2.0-4.0  
45-310  
2.0-6.0  
35-280  
2.0-6.0  
Welding Rod (Ф )  
Current Adj. Range (A)  
Welding Rod (Ф )  
Phase  
3-Phase/1-Phase  
380/220  
Rated Voltage (V)  
Frequency (Hz)  
220/110  
60  
400/230  
50  
415/240  
Rated Output (kVA)  
3-Phase  
1-Phase  
10  
6
8
Rated Speed (min-1 )  
Power Factor  
Rating  
3600  
3000  
3-Phase: 0.8 / 1-Phase: 1.0  
Continuous  
Model  
Type  
Yanmar: 3TNE68-USW2  
Vertical, Water-cooled 4-Cycle Diesel Engine  
0.784  
Displacement (L)  
Rated Output (kW(PS)/min-1 )  
Fuel  
15.1(20.5)/3600  
12.9(17.5)/3000  
Diesel Fuel(ASTM No.2-D) or Equivalent  
Lubricant Oil  
API Class CD or Higher  
Lubrication Oil Volume (L)  
Cooling Water Volume (L)  
Starting Method  
3.5  
3.1  
Starter Motor  
Battery  
46B24L  
37  
Fuel Tank Capacity (L)  
Length (mm)  
1428 (Bonnet Length 1293)  
Width (mm)  
Height (mm)  
700  
760 (870 with wheels)  
370 (380 with wheels)  
Dry Weight (kg)  
5
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3. Use  
z Arc Welding  
z Power Source for Electric Tools and Home Appliances  
z Power Source for Lighting  
Caution : Damage to the equipment or other properties  
z The equipment is designed for the above purposes only. Do not use it for the other purpose. When  
it will be used for the equipment with the microcomputer control or for the ultra-precision devices,  
the load may be malfunctioned.  
4. Parts  
DGW311DM  
CURRENT  
ADJUSTMENT  
DIAL A  
CURRENT  
ADJUSTMENT  
DIAL B  
SLOW-DOWN SWITCH  
STARTER SWITCH  
CIRCUIT BREAKER  
3-PHASE VOLT METER  
MONITOR LAMP  
FUEL GAUGE  
OUTPUT SELECTOR SWITCH  
1-PHASE OUTPUT RECEPTACLE  
HOUR METER  
WELDING OUTPUT TERMINAL A  
EARTH GROUNDING TERMINAL  
BONNET GROUNDING TERMINAL  
WELDING OUTPUT TERMINAL B  
1-PHASE OUTPUT TERMINAL  
3-PHASE/1-PHASE  
OUTPUT TERMINAL  
DGW311L -(W)220B〕  
CURRENT ADJUSTMENT DIAL  
CIRCUIT BREAKER SLOW-DOWN SWITCH  
STARTER SWITCH  
3-PHASE VOLT METER  
MONITOR LAMP  
FUEL GAUGE  
1-PHASE OUTPUT RECEPTACLE  
EARTH GROUNDING TERMINAL  
HOUR METER  
3-PHASE/1-PHASE OUTPUT TERMINAL  
WELDING OUTPUT TERMINAL  
1-PHASE OUTPUT TERMINAL  
BONNE GROUNDING TERMINAL  
6
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DGW311L -(W)380A, -(W)400A, -(W)415A〕  
CURRENT ADJUSTMENT DIAL  
CIRCUIT BREAKER  
SLOW-DOWN SWITCH  
STARTER SWITCH  
3-PHASE VOLT METER  
MONITOR LAMP  
FUEL GAUGE  
EARTH GROUNDING TERMINAL  
HOUR METER  
3-PHASE/1-PHASE OUTPUT  
TERMINAL (U,V, W,O)  
WELDING OUTPUT TERMINAL  
BONNET GROUNDING TERMINAL  
DGW311DM  
DGW311L  
SIDE DOOR  
FUSE  
AIR CLEANER  
RADIATOR  
OIL PLUG,  
ENGINE OIL FILLER  
OIL GAUGE  
BATTERY  
RESERVOIR TANK  
FUEL LEVER/STRAINER  
OIL FILTER  
OIL DRAIN PLUG  
WATER/COOLANT DRAIN PLUG  
FUEL DRAIN PLUG  
FUEL INLET  
MUFFLER  
LIFTING LUG  
HANDLE  
HANDLE  
EXHAUST OUTLET  
TOP PLATE  
5. Equipment  
5-1 ECO Welding (DGW311DM only)  
The equipment is incorporated in ECO welding features that are aimed at performing the lower  
noise, the lower fuel consumption and the lower gas emission than conventional models.  
When you turn the selector switch to ECO, you will be able to weld with Max. 4.0mmφwelding  
rod at the Slow-Down speed.  
7
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<Caution>  
z When welding is performed, do not turn the output selector switch, which causes the burnout  
of the switch.  
z ECO is designed for welding only. The circuit breaker trips when ECO is used for AC power  
supply.  
5-2 Monitor Lamp  
The equipment is equipped with monitoring function of oil  
pressure, battery charge and water/coolant Temperature.  
When it is started by the starter switch from STOP to RUN  
OIL PRESSURE MONITOR LAMP  
under normal condition, Oil Pressure and Battery lamps will  
BATTERY CHARGE MONITOR LAMP  
COOLANT/WATER TEMPERATURE  
MONITOR LAMP  
flash, and then the lamps will go off, immediately after the  
engine starts.  
When abnormality is detected either in water temperature or in oil pressure, the corresponding  
monitor lamp will flash, and the automatic shutoff shall be engaged to the engine.  
When the automatic shutoff is engaged, turn the starter switch to STOP position, and then restart  
the engine. In the event the automatic shutoff is engaged next time, check all parts of the  
corresponding alarm.  
5-2.1 Oil Pressure Monitor Lamp  
Danger : Injuries  
z Close all doors and place locks during operating this equipment, to avoid injuries by uninten-  
tionally touching cooling fan and fan belt.  
Caution : Burns  
z Do not touch the engine and muffler during operation and immediately after stopping the  
equipment, for the temperature can reach extremely high.  
z When checking engine oil, always stop the engine, and wait until the engine cools down. If  
you open either the oil gauge or the oil filter cap during operation, hot oil may cause some  
injury.  
When the engine oil pressure drops during operation, the oil pressure monitor lamp will flash,  
and the automatic shutoff will be engaged.  
When this occurs, check the engine oil level, and replenish to the maximum level if needed.  
<Caution>  
z The engine oil pressure monitor cannot detect the degradation of engine oil itself. Please  
check the engine oil periodically, and change if needed. (Refer to No. 11. Maintenance.)  
5-2.2 Battery Charge Monitor Lamp  
When the battery is unable to be charged during operation, the battery charge monitor lamp will  
flash and the automatic shutoff will be engaged. In the event it will happen, consult with the au-  
thorized distributor or our engineering section.  
<Caution>  
z The battery charge monitor cannot detect the degradation of battery life nor the battery fluid  
8
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level. Check the battery fluid level periodically. (Refer to No. 6-5 Checking Battery)  
5-2.3 Coolant/Water Temperature Monitor Lamp  
Danger : Injuries  
z Close all doors and place locks during operating this equipment, to avoid injuries by uninten-  
tionally touching cooling fan and fan belt.  
Danger : Burns  
z Do not open the radiator cap while operating this equipment or immediately after stopping the  
equipment, to avoid sustaining burns from hot vapor.  
Caution : Burns  
z Do not touch the engine and muffler 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  
flash, and the automatic shutoff will be engaged.  
When this occurs, check the coolant/water reservoir tank, and replenish if needed. (Refer to No.  
6-2 Checking coolant/water temperature.) If the water level is normal there may be a possibility  
of overloading and always use equipment within the rated amperage.  
<Caution>  
z Check the fuse next, after oil pressure, battery charge and water temperature will be found  
normal when you have checked them in the first place. If the fuse is burned out, consult with  
our authorized distributor or our engineering section, because there may be an abnormality  
of electric/electronic parts or wiring and repairing may be required.  
5-3. Earth Leakage Breaker  
Danger : Electric Shock  
z All the grounding terminals must be grounded. If one of them is not grounded, human body  
may get a serious electric shock by leaked current.  
z Even though all the terminals of the loads have been grounded to the earth, the earth  
grounding terminal and the outer bonnet (canopy) grounding terminal should be grounded to  
the earth.  
z Grounding should be made after the engine is stopped.  
z Whenever the earth leakage breaker has activated, you should always repair the leaking  
place first of all.  
<Caution>  
z The earth leakage breaker activates only for AC power supply.  
z The circuit breaker trips to protect the loads, whenever AC power is used if the selector  
switch is in the ECO position. (DGW311DM only)  
The equipment is provided with the earth leakage breaker to detect any leakage arisen due to  
such the troubles as insulation failure of the load while the generator is running and to cut off the  
circuit for protection against any accident such as electrical shock resulting from the trouble.  
9
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The specifications of the earth leakage breaker :  
z
z
Rated Sensitive Current: 30mA (or below) (Grounding resistance: 500Ω or below)  
Sensitive time: Within 0.1second  
5-3.1 Grounding Work  
The qualified electrician should perform the grounding work of the following 3 points (500Ω or  
below).  
z
z
z
The earth grounding terminal in the output terminals  
The Outer Bonnet (Canopy) of the generator  
The Outer Bonnet of the load  
<Caution>  
z In the event you cannot ground the generator to the earth, consult with the authorized dis-  
tributor or our engineering section.  
DGW311DM  
DGW311L  
EARTH GROUNDING TERMINAL  
EARTH GROUNDING TERMINAL  
BONNET GROUNDING  
TERMINAL  
BONNET GROUNDING  
TERMINAL  
GROUNDING ROD  
GROUNDING ROD  
5-3.2 Operation Check  
Before operating the generator, check always if the device can work.  
Turn the starter switch from STOP to Run.  
Turn (Push-up) the circuit breaker (lever) to ON position.  
Push the test button. (When the button is pushed, the earth  
leakage indication lamp turns ON and the circuit breaker is po-  
sitioned in the middle of ON and OFF positions, the device can  
work normal.)  
RESET BUTTON  
EARTH LEAKAGE  
INDICATION LAMP  
TEST BUTTON  
Push the reset button. (The earth leakage indication lamp (red)  
turns OFF subsequently.)  
Turn (push down) the circuit breaker (lever) to OFF position.  
Restore the switch to STOP.  
<Caution>  
z In the event you cannot complete every step of the above procedure to the end, the device is  
out of order. Consult with our authorized distributor or our engineering section to repair.  
10  
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z When the engine is to start, there may be a case that the engine will not start unless the  
starter switch is restored to STOP once.  
5-3.3 The Earth Leakage Breaker has activated  
When the earth leakage breaker has activated, the earth leakage indication lamp turns ON and  
the breaker (lever) trips to the middle of ON and OFF positions. 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.  
Push the reset button or stop the engine.  
Restore (push down) the breaker (lever) to OFF position.  
By the above procedures, you can reset the breaker to ON position.  
<Caution>  
z When the breaker trips to the middle but the lamp does not turn RED simultaneously, the  
cause is Over-loaded or the output selector switch is positioned to ECO. Restore as per the  
procedures No. 9-3 Operation.  
5-4 The Slow-Down Feature  
The Slow-Down feature is to set the engine speed low automatically (in about 8 seconds)for the  
purpose of reducing noise and fuel consumption, whenever welding operation or electric supply  
is not performed.  
In the case of using the Slow-Down feature, turn the Slow-Down switch to ON. The engine  
automatically moves to high speed, when welding operation or electric supply starts.  
Caution : Damage to the equipment or other properties  
z Turn always the Slow-Down switch to OFF, when the load is incorporated with a electro-  
magnetic switch.  
<Caution>  
z When the load of less than 0.5A is connected to use, the Slow-Down feature does not func-  
tion sometimes. Therefore, turn the switch to OFF.  
z When welding operation or electric supply is used intermittently, turn the switch to OFF.  
z When the output selector switch is positioned to ECO, the engine does not turn to high speed.  
(DGW311DM only)  
6. Initialization and Pre-check  
Caution : FireBurnsInjuries  
z When checking engine, always stop the engine, and keep away from fire. Wait until the en-  
gine cools down, before performing any checks.  
OIL GAUGE (YELLOW)  
OIL FILLER  
6-1 Checking Engine Oil  
When checking for engine oil, be sure to keep the equipment  
leveled, and insert the oil gauge all the way in.  
Prior to starting the equipment, make sure to fill the engine oil  
to the HIGH level through the oil inlet.  
OIL PLUG (YELLOW)  
SIDE DOOR  
11  
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<Caution>  
z If the equipment is not leveled, you cannot obtain accurate oil level.  
z Do not overfill (over H line) the engine oil. The excessive volume of engine oil may damage  
the engine (inside the cylinders)  
Selecting proper engine oil  
Use the engine oil for Diesel engine in proper viscosity, in  
compliance with the ambient temperature.  
UPPER LIMIT (H)  
REQUIRE LEVEL  
LOWER LIMIT (L)  
<Caution>  
z Use the API class CD grade or higher.  
Viscosity and Temperature  
Temperature  
Viscosity  
Over +20℃  
+10 - +20℃  
-10 - +40℃  
SAE30  
SAE20  
SAE10W/30  
6-2 Checking Coolant/Water  
Danger : Injuries  
z Close all doors and place locks during operating this equipment, to avoid injuries by uninten-  
tionally touching cooling fan and fan belt.  
Danger : Burns  
z Do not open the radiator cap while operating this equipment or immediately after stopping the  
equipment, to avoid sustaining burns from hot vapor.  
Caution : Burns  
z Do not touch the engine and muffler during operation and immediately after stopping the  
equipment, for the temperature can reach extremely high.  
Check to see if the coolant/water level is between FULL and LOW levels in the reservoir tank. If  
the coolant/water is below the LOW level, fill the tank and the radiator accordingly.  
6-2.1 Filling to the Reservoir Tank  
SIDE DOOR  
Take out the reservoir tank to remove the cap.  
Fill up the reservoir tank to the FULL level.  
CAP  
Install the cap back and tighten, and reinstall the tank to  
the equipment.  
RESERVOIR TANK  
6-2.2 Filling to the Radiator  
Remove the top plate.  
Remove the radiator cap.  
12  
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Fill up the radiator up to the top.  
Install the cap back and tighten.  
Reinstall the top plate.  
TOP PLATE  
<Caution>  
z Use soft water, such as tap water.  
z If the ambient temperature is near freezing, use Long  
Life Coolant (LLC) (30% mixture LLC is filled when  
shipped from factory).  
RADIATOR CAP  
WATER FILLER  
z Mixture ratio of the coolant should be between 30 to  
45%, depending on the outside temperature.  
z Use the same LLC in identical mixture ratio to the res-  
ervoir tank.  
RESERVOIR  
TANK  
z Replace LLC at every year or 1000 hours.  
Mixture Ratio (for reference only): ℃  
Lowest Ambient  
Temperature  
-15℃  
-20℃  
-30℃  
Mixture Ratio  
30%  
35%  
45%  
6-3 Checking Fuel  
Caution : Fire  
z Always wipe any drip of fuel. Do not use this equipment when a leak is found. Repair the  
equipment before use.  
Check for the fuel level in the tank. Add if necessary.  
<Caution>  
z Use Diesel fuel, ASTM D975 No.2-D in the event ambient  
temperature reaches down to -5.  
TANK CAP  
z The engine is designed to use either No.1-D or No.2-D  
Diesel fuel. However, for better economy, use No. 2-D Die-  
sel Fuel whenever possible. At the temperature less than  
FUEL INTAKE  
FUEL STRAIN NET  
-7(20F), No.2-D fuel may pose operating problems (see  
“Cold Weather Operation” which follows). At colder tem-  
peratures, use No.1-D fuel (if available) or use a “winter-  
ized” 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.  
z Always use the Diesel fuel strainer.  
z Fill the fuel tank slightly less than the FULL tank.  
13  
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6-4 Checking Fuel, Engine Oil and Water Leakage  
Caution : Fire  
z Always wipe any drip of Diesel fuel or oil. Do not use this equipment when a leak is found.  
Repair the equipment before use.  
Be sure to check for any fuel leak at the hose connection, and oil and coolant/water by opening  
side doors. When checking for any fuel leak, open a fuel lever and be sure to close the fuel lever  
after checking.  
6-5 Checking Battery  
Caution : Injuries to eyes and skin  
z Battery fluid contains diluted sulfuric acid. Avoid contact with eyes, skin or clothing. If the acid  
comes in contact, especially with eyes, flush with a lot of water, and contact your physician  
immediately.  
Caution : Explosion  
z When the liquid level is below the LOWER level, never use the equipment nor recharge the  
battery.  
z Battery may emit some combustible gas, so keep it away from fire and sparks.  
Check the fluid level. If the level is near or lower than the  
TERMINAL  
LOWER level, add distilled water until the fluid level reaches  
the UPPER level.  
UPPER  
Make sure that the battery cables are firmly secured to the  
LEVEL  
LOWER  
posts. Tighten the clamps if necessary.  
LEVEL  
<Caution>  
z Check the hydrometer of the battery fluid. If it falls below 1.23, the battery requires recharg-  
ing. Please consult with our authorized distributor or our engineering section.  
INS-CAP  
- TERMINAL  
+ TERMINAL  
Replacing battery  
Remove the clamp and cable from negative (-) post in  
the battery. (Remove always negative side first)  
Remove the hold-down clamp from the battery.  
Remove the clamp and cable from positive (+) post in  
the battery.  
HOLD-DOWN  
CLAMP  
BATTERY  
Remove the battery from the seat.  
Reinstall a new battery in the reverse order. (Install always the cable to the positive (+) post  
in the new battery first.)  
<Caution>  
z Use the following battery.  
46B24L  
7. Operation  
7-1 Initializing/Preparation  
14  
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Danger : Suffocation from exhaust fume  
z 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  
z Do not point the exhaust fume toward pedestrians or building.  
Caution : Fire  
z Temperature around muffler and exhaust can get extremely high. Keep any inflammable  
items (such as fuel, gas, paint, etc.) away from the equipment.  
z Always operate this equipment on flat surface and, at least 1 meter away from any objects  
(wall, box, etc.)  
Caution : Injuries  
z Always place the equipment on flat and stable surface, to keep the equipment from sliding.  
Be sure to lock the wheels for the wheeled models.  
z When starting the engine, turn off the connected equipment and set the circuit breaker to  
OFF position.  
Turn the circuit breaker to OFF position.  
Turn the fuel lever to OPEN.  
Turn the Slow-Down switch to ON.  
FUEL LEVER  
When the temperature is below 5℃,turn the starter  
switch to PREHEAT. The preheating lamp flashes 15  
CLOSE  
seconds. The lamp comes off when the PREHEAT fin-  
OPEN  
ishes.  
Turn the starter switch to START to start the engine by the  
starter motor.  
<Caution>  
z Do not drive the starter motor for more than 15 seconds successively.  
z If you need to restart, wait for 30 seconds or more before retry.  
Release the starter switch, as soon as the engine is started.  
<Caution>  
z Once the engine is started, do not turn the starter switch to START.  
Make sure the frequency to the monitor on the control panel.  
Keep the engine idle for about 5 minutes.  
DGW311DM  
DGW311L  
CIRCUIT BREAKER  
STARTER SWITCH  
SLOW-DOWN SWITCH  
STARTER SWITCH  
SLOW-DOWN SWITCH  
CIRCUIT BREAKER  
PREHEAT LAMP  
PREHEAT LAMP  
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Restart after stopping due to fuel shortage  
This equipment is equipped with automatic air vacuuming feature. Therefore, even though the  
engine stops due to running out of fuel, you can restart the engine easily by the following steps.  
Turn the starter switch to STOP.  
Fill the fuel.  
Turn the Slow-Down switch to ON.  
Turn the starter switch to RUN.  
Turn the starter switch to START and drive the starter motor.  
<Caution>  
z Do not drive the starter motor for more than 15 seconds successively.  
z If you need restart, wait for 30 seconds or more before retry.  
Release the starter switch, as soon as the engine started.  
<Caution>  
z Once the engine is started, do not turn the starter switch to START.  
Wait for about 1 minute to vacuum the air out.  
(The engine speed becomes stable when the air is extracted.)  
<Caution>  
z
Keep the Slow-Down switch ON unit the air is completely extracted out (unit the engine  
speed becomes stable), otherwise the engine may disorder.  
7-2 Stopping Generator/Welder  
Turn (Push down) the breaker to OFF.  
Turn the Slow-Down switch to ON.  
Keep the engine idle (cooling down) for about 5 minutes.  
Turn the starter switch to STOP.  
After the engine stops, turn the fuel lever to CLOSE.  
<Caution>  
z When 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, consult with our authorized distributor or our engineering section and ask to re-  
pair.  
8. Welding Operation  
8-1 Selection – Welding Cable  
Select the cable with proper gauge, based on the allowable amperage and distance per the table  
shown below.  
The welding capacity is reduced if the small gauge cable is used.  
<Caution>  
z Welding cables should be used unstrained.  
z When the welding cables are used in swirl, the welding capacity is reduced.  
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Size of Cable (Unit: mm2)  
Welding Cur- Return Length 20m 30m 40m 60m 80m 100m  
rent  
300A  
250A  
200A  
150A  
100A  
30  
22  
22  
22  
22  
38  
30  
30  
22  
22  
50  
38  
30  
22  
22  
80  
60  
50  
38  
30  
100  
80  
60  
50  
30  
125  
100  
80  
60  
38  
8-2 Polarity  
There are two kinds of welding output terminals, 『+』and 『-』.  
Select the polarity according to the operation, referring to the table below.  
<Caution>  
z Follow the instruction of the welding rods, the polarity of which is specified.  
Application  
Connection  
Normal Polarity  
Reverse Polarity  
General Welding,  
such as construction  
Plus to the Earth (Material)  
Minus to holder (Rod)  
Thin Plate, Build up  
Welding, Stainless  
Steel  
Plus to holder (Rod)  
Minus to the Earth (Material)  
8-3 Connection – Welding Cable  
Danger : Electric Shock  
z Before connecting or disconnecting a welding cable from welding output terminals, stop the  
engine, and remove the engine key. A person performing should always keep the key.  
Stop the engine.  
WELDING CABLE  
Connect a welding cable to a crimping terminal and a welding  
WELDING ROD  
HOLDER  
CRIMPING  
TERMINAL  
rod holder, and connect the other cable to a crimping terminal  
and a material holder.  
Connect the welding cables to the output terminals.  
In terms of DGW311DM, connect cables to the welding output  
terminals, referring to the table below.  
MATERIAL HOLDER  
ECO (Single)  
Single  
Dual  
Welding Rod  
Welding Rod  
Welding Rod  
φ2.0 – φ4.0  
φ2.6 – φ6.0  
φ2.0 – φ4.0  
Welding Output Terminal A  
Welding Output Terminal A  
Welding Output Terminal A and  
Welding Output Terminal B  
Close the output terminal cover, after finishing connections, and fix the cover with bolts.  
<Caution>  
z Be sure to crimp a crimping terminal to a cable and connect the cable to welding output ter-  
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minal. Otherwise, welding output terminals may burn out by the heat caused by insufficient  
connections.  
z Do not use a cable without a crimping terminal. If you use the cable, the insulation is peeled  
off partly, to bind to an output terminal, the output terminal may burn out by the heat caused  
by insufficient connections and also a bare part of the cable may touch the bonnet to short-  
circuit.  
8-4 Duty Cycle  
Duty cycle means the welding time ratio for 10 minutes. This equipment is the rated duty cycle is  
50%, namely, the welding time is 5 minutes or less. Be sure to take 5 minutes recess after 5  
minutes welding.  
<Caution>  
z The equipment may be damaged due to overheat, if welding more than 5 minutes succes-  
sively or short time recess after the welding.  
8-5 Welding  
Caution : Suffocation from welding fume  
z Be sure to wear a fume proof mask in operation, because welding fume contains poisonous  
gas and dust. Pay attention to the airflow direction and sufficient ventilation also in order to  
prevent from inhaling the fume.  
Caution : Injuries to eyes and skin  
z 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)  
Light Shielding Degree No.  
7
8
9
10  
11  
12  
13  
Welding Current (A)  
30-75  
76-200  
201-400  
Caution : Fire  
z Keep any inflammable items and easily burning items away from the place in welding, be-  
cause welding splashes spatters.  
Caution : Burns  
z 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.  
<Caution>  
z Never turn the output selector switch during welding, because it causes burnout of the switch.  
(DGW311DM only)  
8-5.1 DGW311DM  
The equipment can be welding by 2 persons simultaneously.  
Each person can adjust the welding current individually.  
The current adjustable range by the current adjustable dial depends on the position each of the  
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welding output selector switch (ECO,SingleandDual』).  
Welding Current Adjustable Range  
Selector Position Current Adjustable Range  
Welding Rod  
φ2.0-4.0  
φ2.6-6.0  
φ2.0-4.0  
Single  
Dual  
ECO  
30-160A  
85-310A  
45-160A  
Single Use  
Dual Use  
After the engine is started (Refer to No. 7.1 Initializing/Preparation), operate as per the proce-  
dures in the following table.  
CURRENT ADJUSTMENT  
DIAL A  
CURRENT ADJUSTMENT  
DIAL B  
OUTPUT SELECTOR  
SWITCH  
WELDING OUTPUT  
TERMINAL B  
WELDING OUTPUT  
TERMINAL A  
Welding Operation Procedure  
Procedure  
Operation  
ECO (Single)  
Welding Rod  
φ2.0-φ4.0  
Single Welding  
Welding Rod  
φ2.6-φ6.0  
Dual Welding  
Welding Rod  
φ2.0-φ4.0  
Selector  
ECO』  
SINGLE』  
DUAL』  
Current  
Adjustment  
Current Adjust.  
Dial A  
Current Adjust.  
Dial A  
Current Adjust.  
Dial A + B  
8-5.2 DGW311L  
Start the engine. (Refer to No. 7.1 Initializing/Preparation)  
Adjust the current by the current adjustment dial.  
Welding Current Adjustable Range  
CURRENT ADJUSTMENT DIAL  
BREAKER  
CURRENT ADJUSTMENT  
Current Adjustable Range  
Welding Rod  
50Hz  
60Hz  
-(W)380A,-(W)400A,-(W)415A  
-(W)220B  
35-280A  
45-310A  
φ2.0-φ6.0  
9. Generator Operation  
9-1 Output Range  
9-1.1 DGW311DM-(W)220B, DGW311L-(W)220B  
9-1.1.1 3-Phase 220V Output – Terminals  
Maximum output from the terminals (U, V, W) is 10kVA.  
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9-1.1.2 1-Phase 220V Output – Terminals (using the terminals only)  
1-Phase 220V Output is available, using the 3-phase output terminals. Maximum output available  
for the one set of the terminals is 6kVA but the total output for the 3 sets is 8kVA, which please  
note.  
9-1.1.3 1-Phase 110V Output – Receptacles & Terminals  
1-Phase 110V Output is available through 2 receptacle sets and one terminal set.  
Maximum output per one receptacle is 1.5kVA and one terminal set is 3kVA. The total output for  
the receptacles and the terminal set is 6kVA.  
9-1.2 DGW311L-(W)380A, DGW311L-(W)400A, DGW311L-(W)415A  
9-1.2.1 3-Phase Output – Terminals  
Maximum output from the terminals (U, V, W) is 10kVA.  
DGW311L  
-(W)380A  
-(W)400A  
-(W)415A  
Output  
voltage  
380V  
400V  
415V  
9-1.2.2 1-Phase Output – Terminals  
1-Phase Output is available, using the 3-Phase output terminals. Maximum output available for  
the one set of the terminals is 6kVA but the total output for the 3 sets is 8kVA, which please note.  
DGW311L  
-(W)380A  
-(W)400A  
-(W)415A  
Output  
voltage  
380V  
400V  
415V  
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9-1.2.3 1-Phase Output – Terminals  
1-Phase Output is available, using the 3-Phase output terminals and the other terminal (O).  
Maximum output available for the one set of terminals is 3kVA but the total output for 3 sets is  
8kVA, which please note.  
DGW311L  
-(W)380A  
-(W)400A  
-(W)415A  
Output  
voltage  
220V  
230V  
240V  
<Caution>  
z When using 1-Phase output, connect the loads evenly to each terminal set as much as pos-  
sible.  
9-2 Output Limitation  
Please refer to the following table, because electric tools and home appliances cannot be judged  
only by the rated output or the power consumption due to the efficiency and characteristic of the  
components.  
DGW311DM-(W)220B, DGW311L-(W)220B :  
Applicable Load (For reference purpose only)  
Capacity (kW)  
1-Phase 220V  
(60Hz)  
1-Phase 110V  
3-Phase  
220V  
Loads  
Receptacle  
& Terminal  
Total  
Receptacle Terminal  
Terminal  
1 set  
Terminal Terminal  
3 sets  
Total  
1 unit  
1 set  
Electric Bulb, Heater, etc.  
1.5  
3.0  
6.0  
3.0  
2.4  
2.4  
6.0  
3.0  
2.4  
2.4  
8.0  
4.0  
3.2  
3.2  
-
-
Electric Tools (Series Motor),  
etc.  
0.7  
0.6  
0.6  
1.5  
1.2  
1.2  
Mercury Bulb (High Power  
Factor Type)  
-
Submersible Pump, Com-  
pressor, etc. (Induction Mo-  
tor)  
4.0  
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DGW311L-(W)380A, DGW311L-(W)400A, DGW311L-(W)415A :  
Applicable Load (For reference purpose only)  
(50Hz)  
Capacity (kW)  
1-Phase  
(O & U, V, W)  
1-Phase  
(U, V, W)  
3-Phase  
(U, V, W)  
Terminal  
Loads  
Terminal  
1 set  
Terminal  
3 sets  
Total  
Terminal  
1 set  
Terminal  
3 sets  
Total  
Electric Bulb, Heater, etc.  
3.0  
6.0  
6.0  
3.0  
2.4  
2.4  
8.0  
-
-
Electric Tools (Series Motor),  
etc.  
1.5  
1.2  
1.2  
3.0  
2.4  
2.4  
4.0  
3.2  
3.2  
Mercury Bulb (High Power  
Factor Type)  
-
Submersible Pump, Com-  
pressor, etc. (Induction Mo-  
tor)  
4.0  
Series Motor: Motor with brush  
Induction Motor: Brushless Motor  
The value described is OUTPUTfor Induction Motor loads and POWER CON-  
SUMPTIONfor the other equipment.  
<Caution>  
z Be sure to use the frequency designated in the equipment incorporated in mercury lamp or  
induction motor.  
z The load incorporated in motor may require bigger power than the rated power consumption.  
Therefore, consult with our authorized distributor or our engineering section to clarify.  
z When connecting 2 or more sets to use, start the load one by one, not to start them simulta-  
neously.  
z When switching a Mercury bulb ON again, wait for 15 minutes (about) until it cools down.  
z A Mercury bulb may flicker sometimes.  
9-3 Operation  
Danger : Electric Shock  
z Before connecting or disconnecting a load cable from output terminals, always turn a circuit  
breaker to OFFposition.  
z All the grounding terminals must be grounded. If one of them is not grounded, human body  
may get a serious electric shock by leaked current. (Refer to5-3 Earth Leakage Breaker』)  
z Grounding should be made after the engine is stopped.  
z Whenever the earth leakage breaker activates, you should repair the leaking place first of all.  
Caution : Injuries  
z 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.  
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Caution : Damage to the equipment or other properties  
z In the event using the equipment to computers, microcomputers incorporated loads and pre-  
cision equipment, there is a possibility for them to be mal-functioned or broken down.  
<Caution>  
z Be sure to use the power cord with crimping terminal to connect to output terminals.  
z Volt meter reads the 3-Phase figures, even if the circuit breaker is positioned toOFF, when  
the engine is driving.  
After the engine starts (Refer to7-1 Initializing/Preparation), operate the equipment as per the  
following procedures.  
Turn off the power switch in the load, and then turn the circuit breaker to OFF.  
Connect the load to the output terminals or receptacles.  
Close the output terminal cover, after finishing connections and fix the cover with bolts.  
Turn the circuit breaker to ON.  
When finishing the load operation, always turn the circuit breaker toOFF』.  
The Circuit Breaker  
Caution : Injuries  
z Be sure to turn off the power switch in the load when turning the circuit breaker to ON,  
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 off the circuit. When the load in operation stops, check the breaker. When the  
circuit breaker is positioned intermediaryONandOFF, check if the earth leakage indication  
lamp turns ON or not. In the case the lamp turning ON, refer to 5-3 Earth Leakage Breaker. In  
the case the lamp NOT turning ON, follow the next procedures to restore the circuit breaker.  
Turn off all the power switches in the loads.  
Turn (Push) down the circuit breaker toOFFonce and then turn (push) up the circuit  
breaker toON』.  
<Caution>  
z Take care for overload, referring to 9-2 Output Limitation』.  
z When the output selector switch is positioned to ECO and AC power is used, the circuit  
breaker trips off to shut down the circuit. Stop using AC power and follow the above proce-  
dures to restore the circuit breaker. (DGW311DM only)  
10. Simultaneous Use of Welding and Generating  
The circuit breaker reacts on the AC power supply circuit only. In the simultaneous use of welding  
and generating, there sometimes happens overload to the engine.  
Refer to the following table and limit the AC power use.  
DGW311DM-(W)220B, DGW311L-(W)220B :  
Limitation of AC Power Supply in the simultaneous use of welding and generating (60Hz)  
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Welding Output  
AC Power Output  
3-Pase Power use only  
9.5kVA or below  
Welding Rod/Current  
φ2.0mm/50A or below  
1-Phase Power Use only  
7.6kVA or below  
8.6kVA or below  
7.2kVA or below  
5.2kVA or below  
3.0kVA or below  
0kVA or below  
6.8kVA or below  
5.7kVA or below  
4.1kVA or below  
2.4kVA or below  
0kVA or below  
φ2.6mm/80A  
φ3.2mm/120A  
φ4.0mm (φ2.0mmx2)/170A  
φ5.0mm (φ2.6mmx2)/220A  
φ6.0mm (φ3.2mmx2)/280A  
(  
) indicates 2-Persons Dual Use. (DGW311DM only)  
<Caution>  
z The simultaneous use of ECO welding and AC power is not available. (DGW311DM only)  
DGW311L-(W)380A, DGW311L-(W)400A, DGW311L-(W)415A :  
Limitation of AC Power Supply in the simultaneous use of welding and generating (50Hz)  
Welding Output  
AC Power Output  
3-Pase Power use only  
8.5kVA or below  
Welding Rod/Current  
φ2.0mm/50A or below  
1-Phase Power Use only  
6.8kVA or below  
7.6kVA or below  
6.2kVA or below  
4.2kVA or below  
2.0kVA or below  
0kVA or below  
6.0kVA or below  
4.9kVA or below  
3.3kVA or below  
1.6kVA or below  
0kVA or below  
φ2.6mm/80A  
φ3.2mm/120A  
φ4.0mm/170A  
φ5.0mm/220A  
φ6.0mm/260A  
11. Checking and Maintenance  
Danger : Electric ShockInjuries  
z Before performing any equipment check or maintenance, stop the engine, and remove en-  
gine key. A person performing the maintenance should always keep the key.  
Caution : FireBurns  
z When checking the engine, always stop the engine, and keep away from fire. Wait until the  
engine cools down, before performing any checks.  
To optimize the use of this equipment, we recommend the periodical equipment checks and  
maintenance based on the following matrix.  
<Caution>  
z The authorized technicians should perform all checking and maintenance work, except for  
the pre-startup checks.  
z Request for the maintenance item with mark to the authorized distributor or our engi-  
neering section.  
z This table only covers the simple checks and maintenance for the engine. For more detailed  
guide, please refer to the User’s Manual for the engine.  
z Always use our genuine replacement parts.  
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Use the hour meter as a guide for the operating time.  
Checking Items  
Startup  
Check  
Checking Time  
Every  
1000 hrs  
Every  
2000 hrs  
Every  
Every  
At  
50hrs  
200hrs 400hrs  
1
2
3
Check and Supply Fuel  
Check and Supply Engine Oil  
Engine Oil Change  
2nd or  
1st ○  
after ○  
2nd or  
1st ○  
4
Oil Filter Change  
after ○  
5
6
Check/Add Water/Coolant  
Water/Coolant Change  
or  
one year  
7
8
Clean/Change Fuel Filter  
Drain Water from Fuel Tank  
(Clean)  
(change)  
9
10  
Check Leakage FuelOilWater  
Check/Add Water Battery  
11  
12  
Clean/Change Air Cleaner Element  
Adjust Tension V-Belt  
(Clean)  
(change)  
2nd or  
1st ●  
after●  
13  
14  
Clean Radiator Fin  
Change Hose FuelRadiator  
Change Vibration-Absorbing Rubber  
Adjust Engine Valve Clearance  
or 2  
years  
15  
(Adjust)  
(Adjust)  
16  
17  
Check/Adjust Injection Nozzle  
Check/Adjust Injection Pump  
11.1 Oil Change  
First Time  
2nd or after  
50 hour mark  
Every 200 hours  
SIDE  
DOOR  
Remove the oil plug.  
Loosen the oil drain plug and allow the oil to drain fully.  
Reinstall the oil drain plug.  
OIL  
FILLER  
Checking the oil level by the oil level gauge, add oil  
into the oil filler to fill up to the max level. (3.5 liter Max)  
Reinstall the oil plug hand tight.  
OIL PLUG (YELLOW)  
OIL DRAIN PLUG  
<Caution>  
z Refer to 6-1 Checking Engine Oilto select engine oil.  
11.2 Oil Filter Change  
First Time  
50 hour mark  
2nd or after  
Every 200 hours  
Drain the engine oil fully, as describe in 11-1 Oil Change』.  
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Loosen and remove the oil filter, using an oil filter  
wrench.  
OIL GAUGE (YELLOW)  
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, give it additional  
1.1/4 Turnto seat the filter, using an filter wrench.  
Supply oil and install the filler cap.  
OIL FILTER  
GASKET  
<Caution>  
z If an oil filter wrench is not available, contact our au-  
thorized distributor or our engineering section.  
z Oil Filter Part No.: 119305-35151 (Yanmar)  
11.3 Cleaning/Changing Air Filter Element  
Clean  
Every 200 hours  
Every 400 hours  
Replace  
Unfasten clips in the cleaner cap and remove the air  
cleaner cap.  
AIR CLEANER  
Unscrew the wing bolt and remove the air filter ele-  
ment.  
SIDE DOOR  
Clean or replace the air filter element, and reinstall it  
in reverse order.  
<Caution>  
CLIP  
ELEMENT  
z Clean more frequently, if used in dusty environment.  
z Air Filter Element Part No. 121465-12510 (Yanmar)  
WING BOLT  
How to clean air filter element  
CLEANER  
<If the element has dried contaminants>  
It may be cleaned by blowing compressed air from the inside.  
<If the element has carbon or oil>  
It should be replaced to a new one.  
11.4 Cleaning/Changing Fuel Filter  
FUEL LEVER  
Clean  
Every 200 hours  
Every 400 hours  
Replace  
CLOSE  
RETAINING  
RING  
OPEN  
Turn the fuel line valve lever to CLOSE.  
Unscrew the retaining ring by turning counterclockwise, and  
CUP  
remove the cup and fuel filter element.  
Discard any dust or water inside the cup, and clean the filter element by blowing compressed  
air. (or replace, if necessary) (When you replace the filter element, be sure to replace a o-ring  
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as well)  
Reassemble it back.  
<Caution>  
z Be sure to check for any contaminants on the packing, whenever reinstalling the cup.  
z Turn the fuel line valve lever OPENafter assembling, and check for any leak. Confirming  
no leak, turn the fuel line valve CLOSE.  
z Fuel Element Part No.: 124550-55700 (Yanmar)  
11.5 Draining Water from Fuel Tank  
Drain Water  
Every 200 hours  
SIDE DOOR  
FUEL DRAIN  
Unscrew the fuel drain plug.  
Reinstall the drain plug, after draining the water entirdy.  
WATER DRAIN  
PLUG  
11.6 Changing Coolant/Water  
Replace  
Every 1 year or 1000 hours  
TOP PLATE  
Remove the top plate.  
Remove the radiator cap.  
Loosen the water drain plug.  
After draining all the water, reinstall the water drain plug.  
Remove the reservoir tank and replace all the water.  
Install the reservoir tank back, and fill the radiator with  
coolant/water up to radiator filler neck. (Total cool-  
ant/water Capacity is 3.1 liter.)  
RADIATOR CAP  
WATER FILLER  
SIDE DOOR  
CAP  
Reinstall the radiator cap.  
Install the top plate back.  
RESERVOIR TANK  
12. Long - Term Storage  
Danger : Electric Shock  
z Before performing any equipment check or maintenance, stop the engine, and remove the  
engine key. A person performing the maintenance should always keep the key.  
Caution: Injuries  
z Before performing any equipment check or maintenance, stop the engine, and remove the  
engine key. A person performing the maintenance should always keep the key.  
Caution : FireBurns  
z When checking engine, always stop the engine, and keep away from fire.  
z Temperature around muffler and exhaust can get extremely high. Wait until the engine cools  
down, before performing any checks.  
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If the generator/welder will not be used for more than two months, perform the following  
maintenance and storage procedures.  
Remove battery.  
Change engine oil.  
Drain fuel from fuel tank and fuel filter.  
Clean all parts, cover the generator/welder, and keep it in the storage, away from dust and  
humidity.  
<Caution>  
z Recharge the removed battery once a month.  
13. Troubleshooting  
Danger : Electric Shock  
z Do not operate the equipment, if the equipment or you are wet.  
z Before performing any equipment check or maintenance, stop the engine.  
Caution : Injuries  
z When performing equipment check and maintenance, always stop the engine.  
Caution : FireBurns  
z When checking engine, always stop the engine, and keep away from fire.  
z Temperature around engine, muffler and exhaust can get extremely high. Wait until the en-  
gine 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 the authorized distributor or our engineering sec-  
tion to request the repair.  
Symptoms  
Possible Cause  
Corrective Actions  
Starter motor does not start  
1. Weak Battery  
2. Dead Battery  
1. Recharge Battery  
2. Replace Battery  
1. Fuel lever to OPEN  
2. Replenish fuel  
3. Drain water or clean fuel tank,  
fuel filter, and water sediments  
Engine does not start  
1. Fuel lever to CLOSE  
2. Insufficient Fuel  
3. Water or contaminants in fuel  
Engine starts, but stalls imme- 1. Insufficient oil  
1. Replenish oil  
diately  
2. Insufficient coolant/water  
2. Replenish coolant/water  
1. Output selector switch is toECO1. Turn to SINGLEor RATED  
Welding Arc is weak  
or DUAL』  
SPEED』  
2. Wrong current adjustment dial set- 2. Turn the dial clockwise  
ting  
3. Poor contacts of cables  
4. Improper Cable Diameter  
3. Connect securely  
4. Change cables according to  
Selection – Welding Cable』  
5. Connect securely  
6. Stop using AC Power  
7. Keep 50% duty cycle  
5. Insufficient connection to material  
6. Dual Use  
7. Engine output is down  
1. Output selector switch is to  
SINGLEor RATED OUTPUT』  
2. Wrong current adjustment dial po-  
sition  
1. Turn to ECOor DUAL』  
Excessive Welding Arc  
2. Turn the dial counterclockwise  
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1. Circuit breaker is to OFF』  
2. Output selector switch is toECO2. Turn to SINGLEor DUAL』  
1. Turn to ON』  
No AC output  
1. The power consumption of the load  
exceeds the rated output  
2. Dual Use  
1. Adjust according to OUTPUT  
LIMITATION』  
2. Stop welding  
AC Output is Weak  
1. Short circuit of welding cable  
2. The power consumption of the load 2. Turn the Slow-Down switch to  
is 0.5A or below  
1. Repair the short circuit  
Slow-Down does not activate  
Engine does not stop  
OFF』  
1.Turn the fuel lever to CLOSE』  
to stop and repair  
1. Stop Solenoid disorder  
Black and white smoke exhaust  
from muffler successively  
1. Keep the duty cycle  
2. Adjust according to OUTPUT  
LIMITATION』  
1. Overloaded use  
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14. Engine Wiring Diagram  
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15. Generator Wiring Diagram  
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Head Office : 1,uka,  
sh,  
731167,apan  
Telephone : 81-82-849-2220 FAX : 81-82-849-2481  
71902-94012  
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