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Shindaiwa 4 Cycle Diesel Engine manual

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  • Page 1

    OWNER ’ S AND OPERATOR ’ S MANUAL ＤＧＷ３１１ＤＭ ＤＧＷ３１１Ｌ Water-cooled 4 Cycle Diesel Engine CAUTION : Do not operate the Generator/Welder, or any other appl iance, before you have read and unde rstood the instruction s for use. 1. Safety Guidelines 2. S pecifications 3. Use 4. Parts 5. Equipment 5-1. ECO Welding (DGW31 1[...]

  • Page 2

    1 Introduction Thank you for purchasing Shindaiwa Sound Proof Diesel Engine Generator/Welder . z This user manual was created to ensure the safe operation of this equipment. Therefore, the manufacturer of this equipment str ongly recommends that the user follo w the instructions herein, to avoid unnecessary accidents and repairs. z Please operate t[...]

  • Page 3

    2 1. Safety Guidelines Danger : Suffocation from exhaust fume z Exhaust fume from the engine c ontains 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 object s (such as pi[...]

  • Page 4

    3 Caution : Electric shock z Do not flush water onto the equipm ent 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 sp arks. Caution : Fire z The equipment uses Dies el fuel as a[...]

  • Page 5

    4  Location of W arning labels When the warning labels become unreadable or d amaged, place new labels on the appropri ate locations, as specified in the following figure. When ordering the label, use t he following part numbers. ① Suffocation from exhaust fume (No. 19402-00194 ) ② Suffocation from welding fume (No. 19402-00195 ) ③ Electri[...]

  • Page 6

    5 2. Specifications DGW31 1DM D G W 3 1 1 L Model -(W)220B -(W)220B -(W)380A -(W)400A -(W)415A Generating Method Brushless, Rotating Field, Sync hronous AC Generator Rated Current (A) 280 260 R a t e d V o l t a g e ( V ) 3 1 . 2 3 0 . 4 D u t y C y c l e ( % ) 5 0 Rated S peed (min -1 ) 3600 3000 N o L o a d V o l t a g e ( V ) M A X 8 5 Current A[...]

  • Page 7

    6 3. Use z Arc Welding z Power Source for Electric T ools and Home Appliances z Power Source for Lighting Caution : Damage to the equipment or other properties z The equipment is designed for t he above purposes only . Do not us e it for the other purpose. When it will be used for the equipment with the microcomputer control or for the ultra-precis[...]

  • Page 8

    7 5. Equipment 5-1 ECO Welding (DGW31 1DM only) The equipment is incorporated in ECO welding feat ures that are aimed at performing the lower noise, the lower fuel consum ption and the lower gas emissi on than conventional models. When you turn the selector switch to ECO, you will be able to weld with Max. 4.0mm φ welding rod at the Slow-Down spee[...]

  • Page 9

    8 <Caution> z When welding is performed, do not turn the out put 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 T [...]

  • Page 10

    9 level. Check the battery fluid level periodi cally . (Refer to No. 6-5 Checking Battery) 5-2.3 Coolant/Water T emperature 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 op[...]

  • Page 11

    10 The specifications of t he earth leakage breaker : z Rated Sensitive Current: 30mA (or below) (Grounding resistance: 500 Ω or below) z Sensitive time: Within 0.1second 5-3.1 Grounding Work The qualified electrician shoul d perform the grounding work of the following 3 points (500 Ω or below). z The earth grounding terminal in the output termin[...]

  • Page 12

    11 z When the engine is to start, there may be a ca se th at the engine will not start unless the starter switch is restored to ST OP once. 5-3.3 The Earth Leakage Br eaker has activated When the earth leakage breaker has ac tivated, the earth leakage indication lamp turns ON and the breaker (lever) trips to the middle of ON and OFF positions. In t[...]

  • Page 13

    12 <Caution> z If the equipment is not leveled, y ou cannot obt ain 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 temper[...]

  • Page 14

    13 ③ Fill up the radiator up to the top. ④ Install the cap back and tighten. ⑤ Reinstall the top plate. <Caution> z Use soft water , such as tap water . z If the ambient temperatur e is near freezing, use Long Life Coolant (LLC) (30% mixture LLC is filled when shipped from factory). z Mixture ratio of the c oolant should be between 30 t[...]

  • Page 15

    14 6-4 Checking Fuel, Engine Oil and W ater 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 c oolant/water by opening side doors. When checking for any fuel leak, open a f uel l[...]

  • Page 16

    15 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 T emperature around [...]

  • Page 17

    16  Restart after stopping due to fuel shortage This equipment is equipped with aut omatic air vacuuming feature. Therefore, even though the engine stops due to running out of fuel, you can re start the engine easily by the following step s. ① Turn the st arter switch to STOP . ② Fill the fuel. ③ Turn the Slow-Down switch to ON. ④ Turn t[...]

  • Page 18

    17 Size of Cable (Unit: mm 2 ) Welding Cur- rent Return Length 20m 30m 40m 60m 80m 100m 300A 30 38 50 80 100 125 250A 22 30 38 60 80 100 200A 22 30 30 50 60 80 150A 22 22 22 38 50 60 100A 22 22 22 30 30 38 8-2 Polarity There are two kinds of we lding output terminals, 『+』 and 『-』. Select the polarity according to the operation, referring to[...]

  • Page 19

    18 minal. Otherwise, welding output terminals may burn out by the heat caus ed by insufficient connections. z Do not use a cable without a crimping terminal. If you use the cable, the insulation is peeled off p artly , to bind to an output terminal, the output terminal may burn out by the heat caused by insufficient connections and also a bare p ar[...]

  • Page 20

    19 welding output selector switch ( 『 ECO 』 , 『 Single 』 and 『 Dual 』). W elding Current Adjustable Range Selector Position Current Adjustable Range W elding Rod ECO 30-160A φ 2.0-4.0 Single Single Use 85-310A φ 2.6-6.0 Dual Dual Use 45-160A φ 2.0-4.0 After the engine is started (Refer to No. 7.1 Initializing/Prep aration), ope rate [...]

  • Page 21

    20 9-1.1.2 1-Phase 220V Output – T erm inals (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 6kV A but the total output for the 3 sets is 8kV A, which please note. 9-1.1.3 1-Phase 1 10V Output – Receptacles & T erminals 1-Phase 1 10[...]

  • Page 22

    21 9-1.2.3 1-Phase Output – T erminals 1-Phase Output is available, using the 3-Phase output terminals and the other terminal (O). Maximum output available for the one set of termin als is 3kV A but the total output for 3 se ts is 8kV A, which please note. <Caution> z When using 1-Phase output, connec t the loads evenly to each term inal se[...]

  • Page 23

    22 DGW31 1L-(W)380A, DG W31 1L-(W)400A, DGW31 1L-(W )415 A : Applicable Load (For referenc e purpose only) (50Hz) Capacity (kW) 1-Phase ( O & U , V , W ) 1-Phase ( U , V , W ) 3-Phase (U, V , W) Loads T erminal 1 set T erminal 3 sets To t a l T erminal 1 set T erminal 3 sets To t a l T erminal Electric Bulb, Heater , etc. 3.0 6.0 6.0 8.0 - Elec[...]

  • Page 24

    23 Caution : Damage to the equipment or other properties z In the event using the eq uipment to comput ers, 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 V olt m[...]

  • Page 25

    24 Welding Output AC Power Output Welding Rod/Current 3-Pase Power use only 1-Phase Power Use only φ 2.0mm/50A or below 9.5kV A or below 7.6kV A or below φ 2.6mm/80A 8.6kV A or below 6.8kV A or below φ 3.2mm/120A 7.2kV A or below 5.7kV A or below φ 4.0mm ( φ 2.0mmx2)/170A 5.2kV A or below 4.1kV A or below φ 5.0mm ( φ 2.6mmx2)/220A 3.0kV A or[...]

  • Page 26

    25 Use the hour meter as a guide for the operating time. Checking T ime Checking Items S tartup Check At 50hrs Every 200hrs Every 400hrs Every 1000 hrs Every 2000 hrs 1 Check and Supply Fuel ○ 2 Check and Supply Engine Oil ○ 3 Engine Oil Change 1 st ○ 2 nd or after ○ 4 Oil Filter Change 1 st ○ 2 nd or after ○ 5 Check/Add Water/Coolant ?[...]

  • Page 27

    26 ② Loosen and remove the oil fi lter , using an oil filter wrench. ③ Smear a little engine oil on the rub ber gasket of a new filter . ④ Screw the new filter into place and tighten it by hand until the gasket contact the s eat. Then, give it additional 『 1.1/4 T urn 』 to seat the filter , using an filter wrench. ⑤ Supply oil and insta[...]

  • Page 28

    27 as well) ④ 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 『 OPEN 』 after assembling, and check for any leak. Confirming no leak, turn the fuel line valve 『 CLOSE 』 . z Fuel Element Part No.: 124550-55700 (Y anmar) 1 1.5 Draining[...]

  • Page 29

    28 If the generator/welder will not be used for more than two months, perform the following maintenance and storage procedures. ① Remove battery . ② Change engi ne oil. ③ Drain fuel from fuel tank and fuel filter . ④ Clean all parts, cover the generator/welder , and k eep it in the storage, away from dust and humidity . <Caution> z Re[...]

  • Page 30

    29 No AC output 1. Circuit breaker is to 『 OFF 』 2. Output selector switch is to 『 ECO 』 1. T urn to 『 ON 』 2. T urn to 『 SINGLE 』 or 『 DUAL 』 AC Output is Weak 1. The power consumption of the load exceeds the rated output 2. Dual Use 1. Adjust according to 『 OUT PUT LIMIT A TION 』 2. S top welding Slow-Down does not activat[...]

  • Page 31

    30 14. Engine Wiring Diagram DGW31 1DM DGW31 1L[...]

  • Page 32

    31 (220V 60Hz) 15. Generator Wiring Diagram[...]

  • Page 33

    32 DGW31 1L - ( W ) 220B (220V 60Hz)[...]

  • Page 34

    33 DGW31 1L - ( W ) 380 A (380V 50Hz)[...]

  • Page 35

    34 DGW31 1L - ( W ) 400 A (400V 50Hz)[...]

  • Page 36

    35 DGW31 1L - ( W ) 415 A (415V 50Hz)[...]

  • Page 37

    Head Office : ６−２−１１，Ｏｚｕｋａ−Ｎｉｓｈｉ， Ａｓａｍｉｎａｍｉ−Ｋｕ，Ｈｉｒｏｓｈｉｍａ， ７３１−３１６７，Ｊａｐａｎ T elephone : 81-82-849-2220 F AX : 81-82-849-2481 71902-94012[...]