CERTIFIED

SALES MANUAL

DGW500DM/ANZ
LOW NOISE DIESEL POWERED
WELDER

Shindaiwa Corporation
INTRODUCTION

This manual contains brief information for the features and

Benefits of the Shindaiwa diesel welder DGW500DM/ANZ.

Please read this manual carefully, and utilize to enhance your

marketing and new model launch.

ENGINE MODEL ： KUBOTA V1505

CONTENTS

1.PRODUCT CONCEPT ……………………………………………….1

1-1. BACK GROUND OF THE DEVELOPMENT……….1
1-2. COMPARISON OF MODEL LINE UP………………4
1-3. COMPETITOR’S SPEC COMPARISON..………….5
1-4. FEATURES AND BENEFIT………………………….6

2.SPECIFICATION ……………………………………………………..9
2-1.TECHNICAL SPECIFICATION ………………………9
2-2. OUTLINE VIEW………………………………………..10

3.FUNCTION ……………………………………………………………12
3-1. CONTROL PANEL ………………..……………….….12
3-2. AUXILIARY AC OUTPUT PANEL .……………….….14
3-3. OPERATION MODE (Single output) .………………..15
3-4. OPERATION MODE (Dual output ) .…………………16

4. MEMO………….………………………………………………………17
1. PRODUCT CONCEPT

1-1.BACK GROUND OF
THE DEVELOPMENT

Pipeline welding business

are steadily growing in the
country where has rich
natural resource of
oil & gas area.

Reserved oil(2007): over 1,400 Bb

World annual oil production(2007) = 29.2 Bb
1600.0
1400.0
1200.0 Canadian Oil Sands
1000.0 Former Soviet Union
Non-OPEC £
800.0
OPEC
600.0 OECD
400.0 European Union
200.0
0.0
1999 2000 2001 2002 2003 2004 2005 2006 2007

World Natural Gas field Map

1
1. PRODUCT CONCEPT

Both Pipeline and Mine site construction with periodical maintenance business
are steady and the contractors are waiting to procure best performance machine
with reasonable cost against their profit.

Oil plant Mine site

Oil/Gas Pipeline maintenance project

2
1. PRODUCT CONCEPT

Competitors (Lincoln & Miller) are concentrating with inverter welder and old dated
single diesel welders as they are not focusing the necessity of
true Dual Diesel Welder into the industry.

Rental single welding machine for pipeline subcontractors

Pipeline dual welding process

3
1. PRODUCT CONCEPT

1-2.COMPARISON OF MODEL LINE UP

Shindaiwa Miller Lincoln Denyo

700A

600A

New
New
500A

400A

300A

200A

4
1. PRODUCT CONCEPT

1-3. COMPETITOR’S SPEC COMPARISON

Specification Shindaiwa Miller Lincoln

DGW500DM/ANZ Big Blue 500 SAE 500
Dimension (mm) 1680 x 700 x 950, 1637x724x1092, 2109x711x1273,
Dry Weight（
（KG) 613 769 928

Engine type Kubota V1505 Deutz Kubota V3800T

1.5L D2011L04i 3.6L
24.5 kW 36.5 kW 43.5 KW

Output / Single Single Single

Duty cycle 480A(39V) 60% 500A(40V) 100% 500A(40V) 60%
Dual 400A(40V) 100%
230A(29V)x2 80%
AC rated 240 x 3 120V x 1 115V x1
voltage (V) 415 x 1 240V x 1 230V x 1

AC rated 15 5.5 3
output (kVA)
Noise level 59 76 N/A
dB(A) / 7m
Fuel tank (L) 63 95 109.8

5
1. PRODUCT CONCEPT

1-4. FEATURES AND BENEFIT

Comparison spider chart
Shindaiwa
Size
Miller
5
Lincoln
AC output
4 Weight
3
2
1
Ease of Control 0 Performance

Reliability Fuel consumption

Noise

Compact Size and Mobility (500A class)

3.818M3

2.588M3 Dual output for

Pipeline welders

1.117M3
Shindaiwa Miller Lincoln
Dual ＜
Single
＜
Single
(613kg) (769kg x 2) (928kg x 2)
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1. PRODUCT CONCEPT

 PERFORMANCE

OPTIMUM WELDING OUTPUT amongst the competitors for the pipeline

Rated output(50Hz): Single: 480A@60% duty cycle
Dual : 230A@80% duty cycle

CC MODE for stick welding : Low Hydrogen, Cellulose, and Various
Single : 2.6-8.0mm rods
Dual : 2.0-6.0mm rods

GOUGING capability (CC mode) is enhanced for up- to 9.5mm rods
Single : 3.2-9.5mm rods
Dual : 3.2-5.0mm rods

CV MODE for optional MIG / MAG / Wire Feeder

SUPER SOUND PROOF TECHNOLOGY : 57db(A)/7m at no load

Powerful Kubota V1505 engine complies EPA Interim Tier 4 engine specification

 FEATURES & BENEFIT

Ease of 1 x Three phase & 3x Single phase OUTPUT RECEPTACLES

for electrical equipment

SELECTIVE KEY SWITCH for Welding / Generating / Simultaneous mode

EMERGENCY STOP SWITCH for safety operation

Internal BATTERY ISOLATOR for ease of operation management

ARC FORCE control dial can be maximized efficiency with Cellulose rod mode

14 pins Dual wire feeder connectors for optional wire feeder with CV mode

Wire feeder voltmeter switch (+/-) for accurate display at wire feeder meter

Wire feeder volt selector (42V/115V) for required optional feeder specification

9 pins Dual Remote control connectors for individual current control
with optional remotes which can be extended up to 100m

7
1. PRODUCT CONCEPT

 CUSTOMER FRIENDLY & ECONOMY

Environmental friendly FUEL TANK for 12 hours non-stop running

with lowered position for ease of refueling from the side

VRD PROTECTION (less than 35V) while actual welding work

ONE SIDE maintenance is adopted for easy access with tight space

Hinge type front panel for easy access of electrical components maintenance

Full digital display for both welding & generating operation

Fuel meter with illuminating lamp

Six (6) digits hour meter for up to 100,000hrs without key switch operation

20 units will be fit into one 20ft container for maximum load capacity

Ease of unit handling with reliable lifting eye

 RELIABILITY

“HEAVY DUTY” quality for reliability and enclosure protection of

internal components from the dust, heat and impact.

Safety breaker is standard to protect the optional wire feeders

Enlarged welding terminal nuts for enhanced durability

Welding duty-cycle over load protection

AC output duty-cycle over load protection

Starter motor safety protection

Fuel inlet rain protection

Automatic fuel line air extractor

Complied with IP23 regulation for optimum protection for the customers

Newly-designed reliable alternator for continuous heavy duty operation

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2.SPECIFICATION
2-1. TECHNICAL SPECIFICATION
Model DGW500DM/ANZ
Generating Method Rotating Field
Rated Current Single / Dual (A) 480 / 230
Welding Generator

Rated Voltage Single / Dual (V) 39.2(CC)- 39.0(CV) / 29.2(CC)-22.5(CV)

Duty Cycle Single / Dual (%) 60 / 80
Rated Speed (min-1 ) 3000
No Load Voltage (V) MAX 85
Current Adj. Range (A) 60 - 500
Ф mm)
Output Single
Welding Rod ( (Welding rod: 2.6 – 8.0, Gouging rod: 3.2-9.5)
Current Adj. Range (A) 30 - 280
Ф mm)
Dual
Welding Rod ( (Welding rod: 2.0 – 6.0, Gouging rod: 3.2-5.0)
Rated Frequency (Hz) 50
AC Generator

Rated Speed (min-1 ) 3000

Phase 1-Phase(50Hz) 3-Phase(50Hz)
Rated Voltage (V) 240 415
Power Factor 1.0 0.8
Rated Output ( kVA ) 10.8 15
Rating Continuous
Model Kubota V1505
Type Vertical, Water-Cooled 4-Cycle Diesel Engine
Displacement (L) 1,498
Rated Output (kW/min-1) 24.5 / 3000
Engine

Fuel ASTM No.2 Diesel Fuel or Equivalent

Lubricant Oil grade API Class CD or Higher
Lubrication Oil Capacity (L) 6.0 (Effective 2.0)
Cooling Water Capacity (L) 5.8 (Sub Tank Capacity 0.85 L included)
Starting Method Starter Motor
Battery 75D31
Fuel Tank Capacity (L) 63
Dimension

Length (mm) 1680

Width (mm) 700
Height (mm) 950
Dry Weight (kg) 613

9
2.SPECIFICATION
2-2. OUTLINE VIEW

10
2.SPECIFICATION

11
3. FUNCTION

3-1 CONTROL PANEL

1 5 12 13

6
14 15 16 17
2 7

8 18 19 20 21 18 19 21
3
9

22 23 24 25
4 10 11 10 11

NO. Name Description of function

1 AC Voltage/Frequency meter
2 Operation mode selector key
3 Emergency stop switch
4 Unit Serial Number (PID)
5 Welding output
amperage/voltage meter
6 Voltage Reduction Device
indicator
Indicates generated AC voltage and frequency
Three operational mode (Welder / Generator / Simultaneous) can be
selected by switching this key
Shut off the engine operation when the switch is pressed
Production serial number (7digit) for identification
Indicates A/B side welding amperage/voltage at actual operation, and
monitor for preset data while interval
Detects Automatic VRD is on (less than 35V) while welding with green
lamp, and off (more than 35V) while interval with red lamp for both A
and B output

12
3. FUNCTION

NO. Name Description of function

7 Amperage/Voltage dial Adjust amperage (CC) and voltage (CV) for desired output

8 Single/Dual Mode selector Select the Single (output A) or Dual (output A/B) by flipping this
switch toggle switch
9 CV/CC selector switch Select CV (Wire feeder) or CC (Stick/Gouging) for both A and B
output individually
10 Arc force dial Adjust Arc force effect while welding cellulose rods

11 Welding rod selector switch Select Cellulose (for pipe welding) or Others (for general welding)

12 Hour meter Indicates total operating hours of the welder unit

13 Warning indicator Lights when an equipment malfunction occurs

14 Voltage Reduction Device Always stay ON while in operation, unless toggle switch is flipped
switch down for test purpose
15 Idling rpm control Select the idling speed by switching HIGH or AUTO position

16 Starter switch STOP: Stops an engine operation

RUN : Continue an engine operation
PREHEAT: Warm-up for control operation and starts pre-heating
START: Starts an engine operation
17 Fuel gauge Indicates remaining diesel fuel in the fuel tank

18 Welding terminal
output selector
19 Pole selector for optional
Wire Feeder
20 Voltage selector for
optional Wire Feeder
Select the output control by switching this toggle switch for CC
(Welding terminal ON) and CV (Wire Feeder remote control)
Select the pole by switching this toggle for accurate indication of
optional Wire Feeder voltage meter
Select the pole by switching this toggle for optional Wire Feeder
power source (42V or 115V)

21 Safety breaker Protect the internal circuit of optional Wire Feeder by tripping this
breaker
22 Remote control connector Connect 9 pins optional remote control for extended welding cables
(output A)
23 Wire Feeder connector Connect optional 14 pins Wire Feeder for CV operations
(output A)
24 Remote control connector Connect 9 pins optional remote control for extended welding cables
(output B)
25 Wire Feeder connector Connect optional 14 pins Wire Feeder for CV operations
(output B)

13
3. FUNCTION

3-2 AUXILIARY AC OUTPUT PANEL

27 26

29
28

32
30 31
27 27

NO. Name Description of function

26 Three phase receptacle 1 x 415V output receptacle
27 Single phase receptacles 3 x 240V output receptacles
28 Main Circuit Breaker Indicates rotating speed of the engine, and indicates
Total operating hours of the generator unit
29 Earth leakage relay Detects electric leakage in the 3 phase,4wire output, and turns
the circuit breaker OFF when activated
30 Single Phase circuit breaker Turns the power supply to load equipment ON (closed) and
OFF (open)
31 Three phases circuit breaker Turns the power supply to load equipment ON (closed) and
OFF (open)
32 Bonnet grounding terminal Ground the bonnet to prevent the electrical shock

14
3. FUNCTION

3-3. OPERATION MODE (Single output)

13
5 12
1
6 14 15
2
7 7
18 19 20 21 18 19 21
3 9 9
8
<CC Cellulose>
22 23 24 25
4
10 11 10 11
Cellulose rod : 2.6 -8.0mm

Remote Control
A Terminal (Option)

13
5 12
1
6 14 15
2
7 7
<CC Gouging and others> 18 19 20 21 18 19 21
3 9 9
8
Gouging : 3.2-9.5mm
22 23 24 25
4
10 11 10 11
Other rod : 2.6 -8.0mm

Remote Control
A Terminal (Option)

13
5 12
1
6 14 15
2
7 7
18 19 20 21 18 19 21
3 9 9
8
<CV with optional wire feeder> 22 23 24 25
4
10 11 10 11
Voltage : 14 - 40V

Wire Feeder A
(Option)

15
3. FUNCTION

3-4. OPERATION MODE (Dual output )

13
5 12
1
6 14 15
2
7 7
8 18 19 20 21 18 19 21
<CC Cellulose> 3 9 9

Cellulose rod : 2.0 - 6.0mm x 2 4

22 23 24 25
10 11 10 11

22 23 24 25

A Terminal B Terminal

Remote Control Remote Control

(Option) (Option)

13
5 12
1
6 14 15
2
7 7
8 18 19 20 21 18 19 21
<CC Gouging and Other rod>
3 9 9

Gouging : 3.2 - 5.0mmx 2 22 23 24 25

4
10 11 10 11

Other rod : 2.0 - 6.0mm x 2

A Terminal B Terminal

Remote Control Remote Control

(Option) (Option)

13
5 12
1
6 14 15
2
7 7
18 19 20 21 18 19 21
<CV with optional wire feeder> 8
3 9 9

Voltage : 14 - 29V x 2 22 23 24 25
4
10 11 10 11

Wire Feeder A
(Option)

Wire Feeder B
(Option)

16
4. MEMO

April, 2009
71923-00000

Shindaiwa Corporation

17