Table of Contents Page

OWNER’S AND 1.Safety Guidelines 2

OPERATOR’S MANUAL 2.Specifications
3.Use
5
5
4.Parts 6
5.Equipment 7
5-1.Monitor Lamp 7
SOUND PROOF DIESEL 5-2.Throttle 9
5-3.Circuit Breaker 10
ENGINE 5-4.Slow-Down 10
6.Initialization and Pre-check 10
GENERATOR/WELDER 6-1.Checking Engine Oil 10
6-2.Checking Coolant/Water 11
6-3.Checking Fuel 12

DGW201M
6-4.Checking Fuel, Engine Oil 12
and Water Leakage
6-5.Checking Battery 13
7.Operation 13
Vertical, Water-Cooled 7-1.Start up 14
4-Cycle Diesel Engine 7-2.Stopping 15
8.Welding Operation 15
8-1.Selection-Welding Cable 15
8-2.Polarity 16
8-3.Connection-Welding Cable 16
8-4.Duty Cycle 16
8-5.Welding 17
9.Generator Operation 18
9-1.Operation 18
9-2.Output Limitation 19
10.Simultaneous Use of Welding and 20
Generating
11.Checking and Maintenance 21
12.Long-term Storage 26
13.Troubleshooting 26
14.Engine Wiring Diagram 28
15.Generator Wiring Diagram 29

CAUTION: Do not operate the Generator/Welder, or any other appliance, before you
have read and understood the instructions for use.

DGW201M-220A
X750803-2100
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 strongly recommends that the
user follow the instructions herein, to avoid unnecessary accidents and repairs.
z Please operate this equipment after thoroughly reviewing and understanding the
contents of this manual.
z Please attach this manual, if the equipment will be sub-leased.
z Please store this manual near 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

Caution
other properties.

<Caution> Other types of caution

z Even some of the items noted in『 Caution 』may lead to serious injuries.
Please read all item and follow all the safety guidelines.

-1-
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 operate the equipment, if the equipment or you are wet.
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 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.

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.

-2-
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 equipment, 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 plug 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.
z Do not open the side panel during operation and immediately after stopping the
equipment, because some parts/components (flexible tube, resistors, etc.) can
reach very high temperature inside the equipment.

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 position.
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-
„ 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.

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

② Suffocation from welding fume (No. 19402-00195)
③ Burns (No. 19402-00200)
④ Electric shock (No. 19402-00193)
⑤ Injuries (No. 19402-00199)
⑥ Burns (No. 19402-00201)

-4-
2. Specifications

Model DGW201M
Generating Method Rotating Field, Synchronous AC Generator
Rated Current (A) 170 / 190
Welding Generator

Rated Voltage (V) 26.8 / 27.6

Duty Cycle (%) 50
-1
Rated Speed (min ) 3000 / 3600
No Load Voltage (V) MAX 80
Current Adj. Range (A) 60 – 180 / 50 - 200
Welding Rod (Ф ) 2.0 - 4.0
Rated Frequency (Hz) 50 / 60
Rated Speed (min-1 ) 3000 / 3600
AC Generator

Phase 1-Phase
Rated Voltage (V) 220
Power Factor 1.0
Rated Current (A) 13.6 / 15.9
Rated Output (kVA) 3.0 / 3.5
Rating Continuous
Model Kubota Z482-B
Type Vertical, Water-Cooled 4-Cycle Diesel Engine
Displacement (L) 0.479
-1
Rated Output (kW/min ) 7.8 / 3000 or 9.2 / 3600
Engine

Fuel ASTM No.2 Diesel Fuel or Equivalent

Lubricant Oil API Class CD or Higher
Lubrication Oil Volume (L) 2.05 (Effective 0.7)
Cooling Water Volume (L) 2.8 (Sub Tank Capacity 0.6 L included)
Starting Method Starter Motor
Battery 44B19L
Fuel Tank Capacity (L) About 15
Length (mm) 998
Dimens
-ion

Width (mm) 603

Height (mm) 773
Dry Weight (kg) 212

3. Use
z Arc Welding
z Power Source for electric tools and home appliances
z Power Source for lights

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 microcomputers
control or for the ultra-precision devices, the load may be malfunctioned.

-5-
4. Parts

CURRENT ADJ. DIAL

BREAKER
STARTER SWITCH
OUTPUT RECEPTACLE MONITOR LAMP

SLOW-DOWN SWITCH

THROTTLE

HANDLE

BONNET GROUNDING WELDING TERMINAL

TERMINAL

OIL GAUGE AIR CLEANER OIL PLUG

(OIL INLET)
HOUR METER(OPTION)
SIDE DOOR

FUSE
UPPER 40A
LOWER 10A
SUB TANK

BATTERY

WHEELS
OIL DRAIN PLUG

FUEL LEVER WATER DRAIN PLUG

STRAINER
FUEL DRAIN PLUG

-6-
 HANDLE
SIDE COVER

OIL FILTER

FUEL INLET LIFTING LUG MUFFLER

EXHAUST PORT

FUEL METER TOP PLATE(RADIATOR CAP)

5. Equipment

5-1. Monitor Lamp

The equipment is equipped with monitoring function of Oil Pressure, Battery Charge
and Water/Coolant Temperature.

COOLANT/WATER TEMPERATURE MONITOR LAMP

BATTERY CHARGE MONITOR LAMP
OIL PRESSURE MONITOR LAMP

-7-
 When it is started by the starter switch from STOP to RUN under normal condition,
Oil Pressure and Battery Lamps will 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
correspondent 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 correspondent alarm.

(1) Oil Pressure Monitor Lamp

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 : 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 『11. Maintenance』)

(2) Battery Charge Monitor Lamp

When the battery is unable to be charged during operation, the battery charge
monitor lamp flash and the automatic shutoff will be engaged. In the event it will
happen, consult with the authorized distributor or our engineering section.

<Caution>
z The battery charge monitor cannot detect the degradation of the battery nor the
battery fluid level. Check the battery fluid level periodically.
(Refer to 『6-5. Checking Battery』)

-8-
(3) Coolant/Water Temperature Monitor Lamp

Danger: Injuries
z Close all doors and place during operating this equipment, to avoid injuries by
unintentionally 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 『 6-2. Checking Coolant / Water 』)
If the water level is normal, there may be a possibility of overloading and always use
equipment within the rated amperage.

<Caution>
z In the event coolant/water level is too low to detect, the sensor does not monitor
temperature. Be sure to check the level in the sub tank before operation.
z Check the fuse next, after oil pressure, battery charge and water temperature will be
found normal. 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.

5-2. Throttle
The device is to select the output in conformity with the application. You can save
fuel consumption and lower noise by selecting [low speed welding/50Hz].

Low Speed Welding Welding 170A Duty Cycle 50%

Throttle

50Hz AC 220V 50Hz 3.0kVA

High Speed Welding Welding 190A Duty Cycle 50%
60Hz AC 220V 60Hz 3.5kVA

<Caution>
z Before turning the throttle, be sure to confirm that engine has stopped or at the
slow-down speed where the slow-down switch positions [ON].

-9-
 5-3. Circuit Breaker

Danger : Injuries
z Be sure to turn off the power switch in the load when re-turning the circuit
breaker to ON, in case the circuit breaker has activated.

In case the electric supply exceeds the rated output (overload), the circuit breaker
activated to trip off in order to shut off the circuit. When the load stops during
operation, check the breaker first of all. If you will find the breaker positions at OFF,
recover it by the following procedures.
① Turn off all the power switches in the loads.
② Return the breaker to ON.

<Caution>
z Refer to 『 9-2. Output Limitation 』 and be careful not to use overloaded (over
current)

5-4. Slow-Down
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 generating operation is not performed. In case of using the slow-down
feature, turn the slow-down switch to ON
The engine automatically moves to high speed when welding or electric supply starts.

Caution : Damage to the equipment or other properties

z Always turn the slow-down switch to OFF in case the load is incorporated with
electro magnetic switch.

<Caution>
z In case the load of less than 0.5A is connected to use, the slow-down feature does
not function sometimes. Therefore, turn the switch to OFF.
z When welding operation or electric supply is used intermittently, turn the switch to
OFF.

6. Initialization and Pre-check

Caution : Fire・Burns・Injuries
z When checking engine, always stop the engine, and keep away from fire. Wait
until the engine cools down, before performing any checks.

6-1. Checking Engine Oil

When checking for engine oil, be sure to OIL PLUG
keep the equipment leveled, and insert OIL GAUGE
(OIL INLET)
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 Volume: about 2.0L (Total)
Effective Oil Volume: about 0.7L
(from the lower limit to higher limit)

- 10 -
<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.

„ Selecting proper engine oil

Use the engine oil for Diesel
engine in proper viscosity, in
compliance with the ambient UPPER LIMIT(H)
temperature (Refer to the chart). EFFECTIVE

<Caution> LOWER LIMIT(L)

z Use the API class CD or higher.

Viscosity and Temperature

Temperature Over +20℃ +10～+20℃ -10～+40℃

Viscosity 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 unintentionally 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 sub
tank. If the coolant/water is below the LOW level, fill the tank and the radiator
accordingly.
SIDE DOOR
(1) Filling to the Sub Tank
CAP
① Remove the sub tank cap.
② Fill up the sub tank to the FULL level.
③ Install the cap back. SUB TANK

(2) Filling to the Radiator

① Remove the top plate.
② Remove the radiator cap.
③ Fill up the radiator up to the top.
④ Install the cap back and tighten. TOP PLATE
⑤ Reinstall the top plate.
RADIATOR CAP

- 11 -
<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)
z Mixture ratio of the coolant should be 30%-45%,
depending on the ambient temperature.
z Use the same LLC to the sub tank.
z Replace LLC at every 2 year or 2000 hours.

LLC Maximum Mixture Ratio

Lowest Ambient
-15℃ -20℃ -30℃
Temperature
Max Mix. 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℃. RING
z At the temperature less than -7℃, No.2 D fuel
may pose operating problem. At colder
temperature, use No.1-D fuel (if available) or
use “winterized” No.2-D (a blend of No.1-D
and No.2-D).
z Always use the fuel strainer.
z Fill the fuel tank slightly less than the ring level. FUEL STRAINER

6-4. Checking Fuel, Engine Oil and Water Leakage

Caution : Fire
z Always wipe any drip of Diesel fuel or oil. Never use this equipment when a
leak is found. Repair the equipment before use.

Be sure to check for any fuel leak at hose connection, and oil and coolant/water by
opening side doors. When checking for fuel leak, open a fuel lever and be sure to
close the fuel lever after checking.

- 12 -
 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 to your physician immediately.

Caution : Explosion
z When the liquid level is below the LOWER level, never use the equipment
nor recharge battery.
z Battery may emit some combustible gas, so keep it away from fire and sparks.

Caution : Fire
z Battery may emit some combustible gas, so keep it away from fire and sparks.

① Check the fluid level. If the level is near or

lower than LOWER level, add distilled water
until the fluid level reaches UPPER level.
② Make sure that the battery cables are firmly
secured to the posts. Tighten the clamps
if necessary.

<Caution>
z Check the hydrometer of the battery fluid. If it falls below 1.23, the battery requires
recharging. Please consult with our authorized distributor or our engineering
section.
INS. CAP
„ Replacing battery
① Remove the clamp and cable +TERMINAL
○
from negative (-) post in the battery.
(Remove always negative side first)
② Remove the hold-down clamp from ○
-TERMINAL
the battery.
③ Remove the clamp and cable
from positive (+) post in the battery.
④ Remove the battery from the seat. HOLD-DOWN CLAMP BATTERY

※ 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.
44B19L

7. Operation

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 a room
or in a tunnel.

- 13 -
 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.

7-1. Start up
① Turn the circuit breakers to OFF position.
② Turn the fuel lever to OPEN.
③ Turn the Slow-Down switch to ON.
④ When the ambient temperature is below 5℃, turn the starter switch to
PREHEAT. The lamp comes off when the preheating finished in about 5
seconds.
⑤ 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.
⑥ 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.
⑦ Keep the engine idle for about 5 minutes.

OUTPUT RECEPTACLE CURRENT ADJ. DIAL FUEL LEVER

BREAKER PREHEAT LAMP
CLOSE
SLOW-DOWN
SWITCH
OPEN
STARTER SWITCH
THROTTLE

„ Restart after stopping due to fuel shortage

This equipment is equipped with automatic air vacuuming feature. Therefore, even
though the engine stops due to out of fuel, you can restart the engine easily by the
following steps.

① Turn the starter switch to STOP.

② Fill the fuel.
③ Turn the Slow-Down switch to ON.
- 14 -
 ④ Turn the starter switch to RUN (Operation).
⑤ Turn the starter switch to START and drive the starter motor in about 10
seconds.

<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.

⑥ 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.

⑦ 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 until the air is completely extracted out (until
the engine speed becomes stable), otherwise the engine may disorder.

7-2. Stopping
① Turn (Push-down) the breaker to OFF.
② Turn the Slow-Down switch to ON.
③ Keep the engine idle (cooling down) for about 5 minutes.
④ Turn the starter switch to STOP.
⑤ 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, the engine will stop in a few minutes.
In this case, consult with our authorized distributor or our engineering section
and ask repair.

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 to 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.

Proper size of cable (Unit: mm2)

Return Length
20m 30m 40m 60m 80m 100m
Welding Current
200A 22 30 30 50 60 80
150A 22 22 22 38 50 60
100A or below 22 22 22 22 30 38

- 15 -
8-2. Polarity
There are two kinds 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
Generals Welding for Plus to the Earth (Material)
Normal Polarity construction material Minus to holder (Rod)

Thin Plate, Build-Up , Plus to holder (Rod)

Reverse Polarity Stainless Steel 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.

① Stop the engine.

② Connecting a welding cable to a
crimping terminal and a welding rod
holder, and connect the other cable
to a crimping terminal and a material
holder.
③ Connect the welding cables to the
welding output terminals.

<Caution>
z Be sure to crimp a crimping terminal to a cable and connect the cable to welding
output terminal. 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. The duty cycle of the
equipment is 50%, namely, the welding time is 5 minutes or less in continuous 10
minutes. Be sure to take 5 minutes recess after 5 minutes welding.
<Caution>
z The equipment may be damaged due to overheat, if welding in more than
successive 5 minutes or short time recess.

- 16 -
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.
Light Shielding Standard 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, because 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.

After engine is started (Refer to 『 7-1. Start up 』), operate as per the following
procedures.

① Turn the Slow-Down switch ON.

② Turn the throttle either to [Low Speed Welding 50Hz] or [High Speed Welding
60Hz].

[LOW SPEED WELDING 50Hz] [HIGH SPEED WELDING 60Hz]

PULL THE THROTTLE AND TURN PUSH THE THROTTLE AND TURN

THROTTLE

THROTTLE

③ Adjust the current by the current adjustment dial.

The adjustable current range is different from the throttle position., [Low Speed
Welding 50Hz] and [High Speed Welding 60Hz].

Welding Current Adjustable Range

Throttle Position Current Adjustable Range Welding Rod
Low Speed Welding 50Hz 60-180A φ2.0 – φ4.0mm
High Speed Welding 60Hz 50-200A φ2.0 – φ4.0mm

- 17 -
 OUTPUT RECEPTACLE BREAKER CURRENT ADJ.DIAL

PREHEAT LAMP

SLOW-DOWN SWITCH

STARTER SWITCH

THROTTLE

9. Generator Operation

Danger : Electric Shock

z Do not operate the equipment, if the equipment or you are wet.

Caution : Injuries
z Before connecting or disconnecting a load cable from output terminals,
always turn a circuit breaker to [OFF] position.
z Be sure to use the frequency designated in the load.
(Refer to 『 5-2. Throttle 』)
Caution : Damage to the equipment or other properties
z In the event using the equipment to computers, microcomputers
incorporated loads and precision equipment, there is a possibility
for them to be mal-functioned or break down.
z Be sure to use the frequency designated in the load.
(Refer to 『 5-2. Throttle 』), otherwise the load may be damaged.

<Caution>
z Maximum output current from 15A receptacle is 15A.
z Total output current from 2 receptacles is as follows.
Rated Output 50Hz: 13.6A
60Hz: 15.9A

9-1. Operation
After engine is started (Refer to 『 7-1. Start up 』), operate as per the following
procedures.

① Turn the Slow-Down Switch [ON].

② Select the frequency.
50Hz: Pull the throttle and turn
60Hz: Push the throttle and turn
③ Turn the breaker [ON].
By the above procedures, you can use 220V AC power from receptacles.

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 BREAKER
LOW SPEED WELDING 50Hz
OUTPUT RECEPTACLE CURRENT ADJ.DIAL
HIGH SPEED WELDING 60Hz

PREHEAT LAMP
SLOW-DOWN SWITCH
STARTER SWITCH

THROTTLE

[LOW SPEED WELDING 50Hz] [HIGH SPEED WELDING 60Hz]

PULL THE THROTTLE AND TURN PUSH THE THROTTLE AND TURN

THROTTLE

THROTTLE

9-2. Output Limitation

Please refer to the following table, because electric tools and home appliances
cannot be judged only by the rated output or the power consumption due to the
efficiency and character of the components.

Applicable Load (For reference only)

Capacity (kW)
Loads
50Hz 60Hz
Electric Bulb, Heater, etc. 3.0 3.5
Electric Tools, etc
1.5 1.7
(Series Motor),
Mercury Bulb
1.2 1.4
(High Power Factor Type)
Submersible Pump, Compressor, etc
1.2 1.4
(Induction Motor)
※ Series Motor : Motor with brush
※ Induction Motor : Brushless Motor
※ The value shown above is 『Output Power』 in Induction motor and
『Consumption Power』 in other equipment.

<Caution>
z Be sure to use the frequency designated in the load incorporated in mercury bulb or
induction motor.
- 19 -
 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 .
z When connecting to use 2 sets or more to use, start the load one by one, not to
start them simultaneously.
z When switching a Mercury bulb again, wait for 15 minutes (about) until it cools
down.
z A mercury bulb may flicker.

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 Supply in the simultaneous use of welding and generating
(For reference only as a kind of rod may require more current)
Welding Output AC Power Output
Welding Rod / Current 50Hz 60Hz
φ2.0mm/60A 3.0kVA or below 3.5kVA or below
φ2.6mm/100A 2.5kVA or below 3.0kVA or below
φ3.2mm/140A 1.0kVA or below 1.5kVA or below
φ4.0mm/170A 0.5kVA or below 0.5kVA or below

- 20 -
11. Checking and Maintenance

Danger : Electric Shock・Injuries

z Before performing any equipment check or maintenance, stop the engine, and
remove engine key. A person performing the 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.
Caution: Fire・Burns
z Keep the equipment far away from fire.
z When checking engine, always stop the engine, and keep away from fire. Wait
until the engine cools down, before performing any checks.
Do not touch the engine and muffler immediately after stopping the equipment,
for the temperature can reach extremely high. Wait until the engine cools down
before performing any checks

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 to your physician immediately.

Caution : Explosion
z When the liquid level is below the LOWER level, never use the equipment
nor recharge battery.
z Battery may emit some combustible gas, so keep it away from fire and sparks.

Caution : Fire
z Battery may emit some combustible gas, so keep it away from fire and sparks.

<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
engineering section.
z Always use our genuine parts of replacement.

To optimize the use of this generator/welder, we recommend the periodical

equipment checks and maintenance based on the following matrix.
Use the hour meter as a guide for the operating time.

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 Checking Time
Start
At Every Every Every Every Every
Checking Items up
50hrs 100 200 400 1000 2000
Check hrs hrs hrs hrs hrs
1 Check and Supply Fuel ○
Check and Supply
2 ○
Engine Oil
2nd or
1st
3 Engine Oil Change after
○
○
2nd or
1st
4 Oil Filter Change after
○
○
Check/Add
5 ○
Water/Coolant
○ or
6 Water/Coolant Change 2
years
2nd or
1st
7 Clean Fuel Strainer after
○
○
8 Change Fuel Filter ○
Drain Water/Clean Fuel
9 ○
Tank
Check Leakage Fuel,
10 ○
Oil, Water
Check/Add Battery
11 ○
Water
2nd or
1st
12 Clean Air Element after
○
○
13 Change Air Element ○
nd
2 or
1st
14 Adjust Tension V-Belt after
●
●
● or
15 Change V-Belt 2
years
16 Clean Radiator Fin ●

17 Check Carbon Brush ●

18 Clean Radiator (inside) ●

Change Fuel Hose, ● or

19 Oil Hose, Water Hose 2
Vibration-Absorbing Rubber years
Adjust/Polish Engine ● ●
20
Valve Clearance Adjust Polish
Check/Adjust Injection
21 ●
Nozzle
Check/Adjust Injection
22 ●
Pump

- 22 -
(1) Oil Change

First Time 50 hour mark

2nd or after Every 100 hours

① Remove the oil plug.

② Loosen the oil drain plug and allow the
oil to drain fully. OIL DRAIN PLUG
③ Reinstall the oil drain plug.
④ Checking the oil level by the oil level gauge, add oil into the oil filler (inlet) to fill
up to the max level (about 2.0 liter max).
④ Reinstall the oil plug hand tight.

<Caution>
z Refer to 『6-1. Checking Engine Oil』to select engine oil.
z Whenever changing oil, change the packing as well,
z Packing No. : 6C090-58961 (Kubota)

(2) Oil Filter Change

First Time 50 hour mark

nd
2 or after Every 200 hours

① Drain the engine oil completely, as

described in 『11-1. Oil Change』.
② Remove the side cover.
SIDE COVER
③ Loosen and remove the oil filter,
using oil filter wrench.
④ Smear engine oil a little on the rubber
gasket in a new oil filter.
⑤ Screw the new filter into place and
tighten it by hand until the gasket contact
onto the seat. Then, give it additional
『1.1/4 Turn』to seat the filter, using OIL FILTER
an filter wrench.
⑥ Supply oil and install the filler cap.

<Caution>
z If an oil filter wrench is not available to get,
contact our authorized distributor or our
engineering section.
z Oil Filter Part No.: 15853-32433 (Kubota)

- 23 -
(3) Clean/Change Air Element

Clean 1st 50 hours and 2nd or after every 100 hours

Change Every 400 hours

① Loosen the wing bolt to remove the AIR CLEANER

cleaner cap.
② Remove the air element.
③ Clean or replace the air element and
reinstall in reverse order.

<Caution>
z Clean more frequently, if used in dusty
environment.
z Air Element Part No. 67980-82632 (Kubota)
CLEANER CAP
„ How to clean air element
<If the element has dried contaminants>
It may be cleaned by blowing compressed
air from the inside.
<If the element has carbon or oil> AIR ELEMENT
It should be replaced to a new one. WING BOLT

(4) Clean/Change Fuel Strainer

Clean 1st 50 hours and 2nd or after every 100 hours

Change Every 400 hours

① Turn the fuel valve lever to [CLOSE]. FUEL LEVER RETAINER RING
② Unscrew the retainer ring
CLOSE
counterclockwise, and remove
the cup and the fuel element.
③ Discard any dust or water inside
the cup, and clean the fuel element OPEN
by blowing compressed air, or
replace if necessary.
④ Reassemble it in reverse order.

<Caution> CUP
z Be sure to check for any contaminants
the packing, whenever reinstalling the cup.

z Turn the fuel valve lever to 『OPEN』after assembling, and check for any leak. After
confirming no leak, turn the fuel valve to [CLOSE].
z Fuel Element Part No.: 16271-43561 (Kubota)

- 24 -
(5) Drain Water from Fuel Tank
Drain Water Every 200 hours

① Unscrew the fuel drain plug.

② Reinstall the drain plug, after draining
water completely

<Caution>
z Change the packing, whenever changing oil.
FUEL DRAIN PLUG
z Packing Part No.: 6C090-58961 (Kubota)

(6) Changing Coolant/Water

Change Every 2000 hours or 2 years
(Total Coolant/Water Capacity: about 2.8 liter, including sub tank cap. 0.6 liter.)

① Remove the top plate. TOP PLATE

② Remove the radiator cap.
③ Loosen the water drain plug.
④ After draining all the water, reinstall the water
drain plug.

<Caution>
z Change the packing, whenever changing oil.
z Packing Part No.: 6C090-58961 (Kubota) RADIATOR CAP

⑤ Replace all the water in the sub tank.

⑥ Fill the coolant/water to the neck of the water
inlet.
⑦ Reinstall the radiator cap.
⑧ Install the top plate back.

WATER DRAIN PLUG

SIDE DOOR

CAP

SUB TANK

- 25 -
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 : Fire・Burns
z When checking engine, always stop the engine, and keep far away from fire.
Temperature around muffler and exhaust can get extremely high. Wait until the
engine cools down, before performing any checks.

If the generator/welder will not be used for more than two months, perform the
following maintenance and storage procedures.
① Remove the battery.
② Change the engine oil.
③ Drain fuel from the fuel tank and the fuel strainer.
④ 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.
Before performing any equipment check or maintenance, stop the engine.

Caution : Injuries
z When performing equipment check and maintenance, always stop the engine.

Caution : Fire・Burns
z When checking engine, always stop the engine, and keep away from fire.
Temperature around engine, 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 the authorized distributor
or our engineering section to request the repair.

- 26 -
Symptoms Presumed Cause Corrective Actions
Starter motor does not 1. Battery Weak 1. Recharge Battery
start 2. Battery Dead 2. Change Battery
Engine does not start 1. Fuel lever to CLOSE 1. Fuel lever to OPEN
2. Insufficient fuel 2. Replenish fuel
3. Water or contaminants in 3. Drain water or clean fuel
fuel tank , fuel strainer
4. Fuse burnt 4. Repair

Engine starts, but stalls 1. Insufficient oil 1. Replenish oil

immediately 2. High water temperature 2. Keep the duty cycle of
3. Charging current is not 50% [Refer to the article of
censored Output Limitation]
3. Repair

Welding arc is weak 1. The throttle at [Low Speed 1. Turn the throttle to [High
Welding/50Hz] Speed Welding/60Hz]
2. Wrong setting of current 2. Turn the dial clockwise
adjustment dial 3. Contact cables securely
3. Poor contacts of cables 4. Change cables according
4. Improper cable diameter to [Selection-Welding
5. Insufficient contact to Cable]
material 5. Contact securely
6. The total loads exceed the 6. Refer to [Simultaneous
rated simultaneous use use of Welding and AC
output limit output]
7. Engine output is down 7. Clean air element

Excessive welding arc 1. The setting of current 1. Turn the dial

adjustment dial counterclockwise

No AC output 1. The breaker to [OFF] 1. Set the breaker to [ON]

AC output is weak 1. Wrong frequency 1. Change the frequency to

2. The current in the load the correct one
exceeds the rated current 2. Refer to the article of
3. The loads used Output Limitation
simultaneously exceed 3. Refer to [Simultaneous
the rated output use of Welding and AC
output]

Slow-Down does not 1. Short circuit of welding 1. Repair the short circuit
activate cable 2. Turn the Slow-Down
2. The power consumption switch to [OFF]
of the load is 0.5A or
below
Engine does not stop 1. Stop solenoid disorder 1. Turn the fuel valve lever to
2. Fuse burnt [CLOSE] to stop and
repair
2. Repair

Black and white smoke 1. Overloaded use 1. Keep the duty cycle of
exhaust from the muffler 50% and the rated output
(Refer to [Output
Limitation])

- 27 -
14. Engine Wiring Diagram

- 28 -
15. Generator Wiring Diagram

- 29 -
- 30 -