Multiquip BLW-400SSW User Manual
PARTS AND OPERATION MANUAL
Table of Contents
PARTS AND OPERATION MANUAL
MQ POWER
TM
DUELWELD
WELDER/AC GENERATOR
MODEL BLW-400SSW
© COPYRIGHT 2001, MULTIQUIP INC.
S/N 5308765~
Revision #1(06/15/01)
MUL TIQUIP INC. PARTS DEPARTMENT:
18910 WILMINGTON AVE. 800-427-1244
CARSON, CALIFORNIA 90746 FAX: 800-672-7877
310-537-3700
800-421-1244 800-835-2551
F AX: 310-537-3927 F AX: 310-638-8046
E-mail:mq@multiquip.com • www:multiquip.com
SERVICE DEPARTMENT:
PAGE 2 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
Table of Contents
HERE'S HOW TO GET HELP
Table of Contents
PLEASE HAVE THE MODEL AND SERIAL NUMBER
ON-HAND WHEN CALLING
PARTS DEPARTMENT
800/427-1244 or 310/537-3700
FAX: 800/672-7877 or 310/637-3284
SER VICE DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
WARRANTY DEPARTMENT
800/835-2551 or 310/537-3700
FAX: 310/638-8046
MAIN
800/421-1244 or 310/537-3700
FAX: 310/537-3927
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 3
TABLE OF CONTENTS
Here’s How to Get Help........................................... 3
Parts Ordering Procedures ..................................... 5
Rules for Safe Operation ..................................... 6-7
Operation and Safety Decals ............................... 8-9
Specifications ........................................................ 10
General Information.............................................. 11
Dimensions ........................................................... 12
Trailer Safety Guidelines..................................13-18
Trailer Wiring Diagram........................................... 19
Electrical Brake Troubleshooting........................... 20
Towing Safety Guidelines...................................... 2 1
Controls and Indicators.................................... 22-23
Output Terminal Overview................................24-25
Installation............................................................. 26
Pre-Set Up ....................................................... 27-29
Load Application ................................................... 3 0
Welder Operating Instructions ......................... 31-32
Welder/AC Generator Star t-up Instructions ..... 33-34
Shutdown Instructions........................................... 35
Maintenance ......................................................... 36
Preparation for Long Term Storage ...................... 37
Generator Wiring Diagram ............................... 38-39
Engine Wiring Diagrams................................... 40-41
Engine Troubleshooting .................................... 42-44
Welding Troubleshooting ....................................... 4 5
Explanation of Codes in Remarks Section............ 4 6
Suggested Spare Parts List .................................. 4 7
BLW-400SSW WELDER/
AC GENERA TOR
Generator Assembly ........................................ 48-51
Control Box Assembly...................................... 52-55
Control Parts Assembly, par t 1 ........................ 56-57
Control Parts Assembly, par t 2 ........................ 58-59
Engine and Radiator Assembly........................ 60-61
Battery Assembly .............................................62-63
Muffler Assembly ............................................. 64-65
Fuel Tank Assembly ......................................... 66-67
Enclosure Assembly......................................... 68-69
Rubber Seals Assembly................................... 70-71
Decal Assembly ............................................... 72-73
KUBOT A V1205B ENGINE
Crankcase Assembly ....................................... 74-75
Oil Pan Assemb ly ............................................. 76-77
Cylinder Head Assembly..................................78-79
Gear Case Assembly ....................................... 80-81
Main Bearing Case Assembly.......................... 82-83
Head Cover Assembly ..................................... 84-85
Inlet Manifold Assembly ................................... 86-87
Exhaust Manifold Assembly ............................. 88-89
Rocker Arm Valve Assembly ............................ 90-91
Camshaft Assembly ......................................... 92-93
Piston Crankshaft Assembly ............................ 94-95
Flywheel Assembly .......................................... 96-97
Injection Pump Assembly................................. 98-99
Fuel Camshaft Assembly .............................100-101
Nozzle Holder Assembly .............................. 102-103
Idling Apparatus Assembly .......................... 104-105
Governor Assembly ..................................... 106-107
Speed Control Plate Assembly .................... 108-109
Dynamo Assembly ....................................... 110-111
Water Flange Assembly ............................... 112-113
W ater Pump Assembly................................. 114-115
Fan Assembly............................................... 116-117
Radiator Assembly....................................... 118-119
Air Cleaner Assembly................................... 120-121
Fuel Filter Component Assembly................. 122-123
Dynamo Component Assembly ................... 124-125
Star ter Component Assembly ...................... 126-127
Nozzle Holder Component Assembly .......... 128-129
Injection Pump Component Assembly ......... 130-133
Accessories.................................................. 134-135
Terms and Conditions - Sales ............................. 136
NOTE
Specification and part number
are subject to change without
notice.
PAGE 4 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
PARTS ORDERING PR OCEDURES
Table of Contents
■■
■ Dealer account number
■■
■■
■ Dealer name and address
■■
■■
■ Shipping address (if different than billing address)
■■
■■
■ Return fax number
■■
■■
■ Applicable model number
■■
■■
■ Quantity, part number and description of each part
■■
■■
■ Specify preferred method of shipment:
■■
UPS Ground
•
UPS Second Day or Third Day*
•
UPS Next Day*
•
Federal Express Priority One (please provide us with your Federal
•
Express account number)*
Airborne Express*
•
Truck or parcel post
•
*Normally shipped the same day the order is received, if prior to 2PM west coast time.
Earn Extra Discounts when
you order by FAX!
All parts orders which include complete par t numbers
and are received by fax qualify for the following extra
discounts:
Number of
line items ordered Additional Discount
1-9 items 3%
10+ items** 5%
Get special freight allowances
when you order 10 or more
line items via FAX!**
■■
■
UPS Ground Service at no charge for freight
■■
■■
■
PS Third Day Service at one-half of actual freight cost
■■
No other allowances on freight shipped by an y other carrier.
**Common nuts, bolts and washers (all items under $1.00 list price)
do not count towards the 10+ line items.
Extra Fax Discount
for Domestic USA
Dealers Only
UPS
Special
For faxed orders only
Now! Direct TOLL-FREE access
to our Par ts Depar tment!
Toll-free nationwide:
800-421-1244
Toll-free FAX:
*DISCOUNTS ARE SUBJECT TO CHANGE*
Fax order discount and UPS special programs revised June 1, 1995
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 5
800/6-PARTS-7 • 800-672-7877
RULES FOR SAFE OPERATION
Table of Contents
CAUTION:
■
Failure to f ollow instructions in this manual may
lead to serious injury or even death! This
equipment is to be operated by trained and
qualified personnel only! This equipment is for
industrial use only .
The following safety guidelines should always be used when
operating the BL W-400SSW W elder/AC Generator:
GENERAL SAFETY
■
DO NOT operate or service this equipment before
reading this entire manual.
■
This equipment should not be operated by
persons under 18 years of age.
■
NEVER operate this equipment without proper
protective clothing, welding shield, ventilator,
steel-toed boots and other protective devices
required by the job.
NEVER touch the hot exhaust
manifold, muffler or cylinder. Allow
these parts to cool before servicing
engine or welder/AC generator .
■
High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact
hot
with
■
The engine of this welder/AC generator requires an adequate
free flow of cooling air . Ne ver operate the welder/A C generator
in any enclosed or narrow area where free flow of the air is
restricted. If the air flow is restricted it will cause serious damage
to the welder/AC generator engine and may cause injury to
people. The engine gives off DEADLY carbon monoxide gas .
CAUTION
■
NEVER operate this equipment when not feeling
well due to fatigue, illness or taking medicine.
■
NEVER operate this equipment under the
influence or drugs or alcohol.
components can cause serious burns.
:
Always refuel in a well-ventilated area, away
from sparks and open flames.
Always use extreme caution when working with
flammable liquids. When refueling, stop the
engine and allow it to cool. DO NOT
around or near the machine. Fire or
explosion could result from fuel vapors, or if
fuel is spilled on a hot engine.
smoke
■
NEVER use accessories or attachments, which are not
recommended by MQ P ower f or this equipment. Damage to
the equipment and/or injury to user may result.
■
Manufacture does not assume responsibility for any accident
due to equipment modifications.
■
Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
■
Always check the machine for loosened threads or bolts before
starting.
PAGE 6 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
■
NEVER operate the welder/AC
generator in an explosive atmosphere or
near combustible materials. An explosion or
fire could result causing severe
or even death.
■
Topping-off to filler port is dangerous, as it tends to spill fuel.
bodily harm
RULES FOR SAFE OPERATION
Table of Contents
CAUTION:
This welder/AC generator is a source of
providing LETHAL high voltages. Never
permit unqualified personnel-especially
children to operate the welder/AC gener ator.
■
This welder/AC generator is equipped with a
for your protection. Always complete the grounding path from
the welder/AC generator to an external grounding source.
■
NEVER operate this welder/AC generator, or handle any
electrical equipment while standing in
while hands are wet, or in the rain. Dangerous electrical
shock could occur causing severe bodily harm or even death.
■
This welder/AC generator requires an adequate free flow of
cooling air. Never operate the welder/AC generator in any
enclosed or narrow area where free flow of the air is restricted.
If the air flow is restricted it will cause serious damage to the
welder/AC generator and may cause injury to people.
■
Arc rays can cause blindness. Always wear protective
shield when welding.
CAUTION
:
ground terminal
water , while bare foot,
CAUTION
■
Never use damaged or worn cables when connecting
power tools or equipment to the w elder/AC generator. Make
sure power connecting cables are securely connected to
the generator’s output terminals. Insufficient tightening of
the terminal connections may cause damage to the welder/
AC generator and electrical shock.
CAUTION
:
:
DO NOT touch or open coolant dr ain plug,
radiator cap, or engine oil drain plug while
the welder/AC generator is running. Always
allow sufficient time for the engine and
generator to cool before performing
maintenance.
Emergencies
■
Always know the location of the nearest
and
Also know the phone numbers of the nearest
■
NEVER touch output terminals or electrode during
operation. This is extremely dangerous. Always stop the
machine when contact with the output terminals and
welding electrode.
CAUTION
■
Never connect the welder/AC generator to house wiring.
This is illegal and very dangerous. Electrical shock could
occur causing damage to the welder/AC generator and
bodily harm even death.
:
doctor
in the case of an emergency .
Maintenance Safety
■
■
■
■
■
■
■
fire extinguisher
first aid kit
and
NEVER lubricate components or attempt service on a running
machine.
Always allow the machine a proper amount of time to cool
before servicing.
Keep the machinery in proper running condition.
Fix damage to the machine immediately and always replace
broken parts.
Dispose of hazardous waste properly . Examples of potentially
hazardous waste are used motor oil, fuel, coolant and fuel
filters.
DO NOT use plastic containers to dispose of hazardous
waste.
DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.
. Know the location of the nearest telephone.
ambulance
fire department
. This inf ormation will be invaluable
,
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 7
OPERA TION AND SAFETY DECALS
Table of Contents
PAGE 8 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
OPERA TION AND SAFETY DECALS
Table of Contents
P/N DCL160
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 9
BLW -400SSW — SPECIFICATIONS
Table of Contents
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conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric
reading of 29.92 inches and a temperature of 60 degrees F ahrenheit.
°°
°
°°
Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10
°°
°
F ahrenheit above the standard temperature of 60
°°
F.
F
PAGE 10 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
BLW -400SSW — GENERAL INFORMATION
Table of Contents
BL W -400SSW F AMILIARIZATION
Generator
The MQ Power Model BLW-400 welder/AC generator can
provide 400 amps of welding current with a single operator
or 200 amps of welding current simultaneously with two
operators. When used as a welder/AC generator it can
provide a maximum of 6,000 watts of power.
Control Panel
The
control panel
!
One GFCI 120 volt receptacle, 20 amp
!
One 120 volt receptacle, 30 amp
!
One 120/240 volt receptacle, 30 amp
!
Main Circuit Breaker 265V @25 amps
!
Circuit Protector Breaker (GFCI) 120V @20 amps
!
Idle Control Switch
!
Starter Switch
!
Warning Lamp Unit
!
Hour Meter
!
Ground T erminal
Engine Protection System
Engine protection fail safe features are provided in the event
of low oil pressure, high coolant temperature and failure of
the battery to charge. If any of the above conditions occur
while operating the welder/AC generator, it will cause a
complete unit shut down.
Battery Charge Indicator
This unit is equipped with a protective device that signals
an indicator and automatically stops the engine when the
battery cannot be charged by the alternator.
Water Temperature Indicator
This unit is equipped with an apparatus that signals an
indicator and automatically stops the engine when the cooling
water temperature becomes abnormally high. This apparatus
will not function properly if the machine is operated with
less than the proper amount of coolant.
is provided with the following:
Excitation System
The BL W -400SSW Welder/A C generator uses a brushless
exciter to create rated output electricity. This system will
use the mechanical energy generated by the 3600 RPM
engine to spin the rotor (or armature) inside the welder/AC
generator (or alternator end).
The motion created by the rotor (which holds copper coils)
spins inside a housing of permanent magnets called the
"STATOR". A magnetic field is created by the stator and
produces an electrical current.
Engine
The BL W -400SSW is powered by a 4-cycle KUBO TA
engine. This engine is designed to meet e v ery performance
requirement for welder/A C generator. Ref erence Table 1, page
10 for engine specifications.
In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.
Idle Control Switch
The BL W-400SSW W elder/AC generator is pro vided with an
automatic idle (engine) control capability for noise
suppression and fuel cost reduction. The automatic idle
control feature automatically engages under a no-load
condition.
When the Idle Control Switch is placed in the “ON” position,
the engine revolutions will be approximately 2200 rpm (lowspeed operation). When a load is connected to one of the
output receptacles, the engine speed will automatically
increase to about 3600 rpm (high-speed operation) within 10
seconds. Con versely, when the load is removed, the engine
speed will automatically drop back down to 2200 rpm within
10 seconds.
diesel
Oil Pressure Warning Indicator
If low oil pressure is detected while operating the welder/AC
generator, the engine protection system will shut down the
engine.
If this condition (low oil pressure) should occur , please refer
to the engine troubleshooting table (page 44) in this manual.
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 11
BLW -400SSW — DIMENSIONS
Table of Contents
PAGE 12 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
Figure 1. BLW-400SSW Dimensions
BLW -400SSW — TRAILER-SAFETY GUIDELINES
Table of Contents
CAUTION:
ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.
Explanation of Chart:
This section is intended to provide the user with trailer service and maintenance information. The service and maintenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury .
It is the purpose of this section to cover the major maintenance components of the trailer . The following trailer components will be discussed in this section:
"
Brakes
"
Tires
"
Lug Nut T orquing
"
Suspension
"
Electrical
"
Brake Troubleshooting T ables
Use the following definitions with reading Table 2.
1. Fuel Cell - Provides an adequate amount of fuel for
the equipment in use. Fuel cells must be empty when
transporting equipment.
2. Braking System - System employed in stopping the
trailer . Typical braking systems are electric, surge, hydraulic, h ydraulic-surge and air.
3. GVWR- Gross Vehicle Weight Rating (GVWR), is the
maximum number of pounds the trailer can carry, including the fuel cell (empty).
4. Frame Length - This measurement is from the ball
hitch to the rear bumper (reflector).
5. Frame Width - This measurement is from fender to
fender.
6. Jack Stand - Trailer support device with maximum
pound requirement from the tongue of the trailer .
7. Coupler - Type of hitch used on the trailer for towing.
8. Tire Size - Indicates the diameter of the tire in inches
(10,12,14, etc.), and the width in millimeters
(175,185,205, etc.). The tire diameter must match the
diameter of the tire rim.
9. Tire Ply - The tire ply (lay ers) number is rated in letters;
2-ply,4-ply,6-ply, etc.
10. Wheel Hub - The wheel hub is connected to the trailer’s
axle.
11. Tire Rim - Tires mounted on a tire rim. The tire rim must
match the size of the tire.
12. Lug Nuts - Used to secure the wheel to the wheel hub.
Always use a torque wrench to tighten down the lug
nuts. See Table 4 and Figure 5 or lug nut tightening and
sequence.
13. Axle - Indicates the maximum weight the axle can support in pounds, and the diameter of the axle expressed
in inches (see Table 3). Please not that some trailers
have a double axle. This will be shown as 2-6000 lbs.,
meaning two axles with a total weight capacity of 6000
pounds.
14. Suspension - Protects the trailer chassis from shocks
transmitted through the wheels. Types of suspension
used are leaf, Q-flex, and air ride.
15. Electrical - Electrical connectors (looms) are provided
with the trailer so the brake lights and turn signals can
be connected to the towing vehicle.
16. Application - Indicates which units can be employed
on a particular trailer.
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 13
BLW -400SSW — TRAILER-SPECIFICATIONS
Table of Contents
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PAGE 14 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
BLW-400SSW — TRAILER-SPECIFICATIONS
Table of Contents
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BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 15
BLW -400SSW —TRAILER SAFETY GUIDELINES
Table of Contents
Brakes
If your trailer has a braking system, the brakes should be
inspected the first 200 miles of operation. This will allow
the brake shoes and drums to seat properly. After the first
200 mile interval, inspect the brakes every 3,000 miles. If
driving over rough terrain, inspect the brakes more
frequently.
Electric Brakes
Electrically actuated brakes (Figure 2) are similar to
hydraulic brakes. The basic difference is that hydraulic
brakes are actuated by an electromagnet.
Listed below are some of the advantages that electric
brakes have over hydraulic brakes:
"
Brake system can be manually adjusted to provide
the corrected braking capability for varying road and
load conditions
"
Brake system can be modulated to provide more or
less braking force, thus easing the brake load on the
towing vehicle
"
Brake system has very little lag time between the time
the vehicle’s brakes are actuated and the trailer’s br akes
are actuated
"
Brake system can provide an independent emergency
brake system
Remember in order to properly synchronize the tow vehicle’s
braking to the trailer’s braking, can only be accomplished
by road testing. Brake lockup, grabbiness or harshness is
due to lack of synchronization between the tow vehicle
and the trailer being towed or under-adjusted brakes.
Before any brake synchronizations adjustments can be
made, the trailer brakes should be burnished-in by applying
the brakes 20-30 times with approximately a 20 m.p.h.
decrease in speed, e.g. 40 m.p.h. to 20 m.p.h. Allow ample
time for brakes to cool between application. This allows
the brake shoes to slightly be seated into the brake drum
surface.
Figure 2 displays the major electric brake components that
will require inspection and maintenance. Please inspect
these components as required.
Electric Brake Adjustment
1. Place the trailer on jack stands. Make sure the jack
stands are placed on secure level ground.
2. Check the wheel and drum for free rotation.
3. Remove the adjusting hole cover from the adjusting
slot at the bottom brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate
the star wheel of the adjuster assembly to expand the
brake shoes.
5. Adjust the brake shoes outward until the pressure of
the lining against the wheel drum makes the wheel
difficult to turn.
6. Rotate the star wheel in the opposite direction until the
wheel rotates freely with slight lining drag.
7. Replace the adjusting hole cover and lower the trailer
to the ground.
8. Repeat steps 1 through 6 on the remaining brakes.
PAGE 16 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
Figure 2. Electrical Brake Components
BLW -400SSW —TRAILER SAFETY GUIDELINES
Table of Contents
Tires/Wheels/Lug Nuts
Tires and wheels are a very important and critical
components of the trailer . When specifying or replacing the
trailer wheels it is important the wheels, tires, and axle are
properly matched.
CAUTION:
DO NOT attempt to repair or modify a
wheel. DO NOT install in inner tube to
correct a leak through the rim. If the rim
is cracked,
the air
pressure in
the inner tube may cause pieces
of the rim to explode (break off)
with great force and cause serious
eye or bodily injur y.
Tire Wear/Inflation
Tire inflation pressure is the most important factor in tire life.
Pressure should be checked cold bef ore operation DO NO T
bleed air from tires when they are hot. Check inflation
pressure weekly during use to insure the maximum tire life
and tread wear .
Table 3 (Tire Wear Troubleshooting) will help pinpoint the
causes and solutions of tire wear problems.
Suspension
The leaf suspension springs and associated components
(Figure 3) should be visually inspected every 6,000 miles for
signs of excessive wear, elongation of bolt holes, and
loosening of fasteners. Replace all damaged parts
(suspension) immediately . T orqued suspension components
as detailed in Tab le 4.
CAUTION:
NOTE
AL WAYS wear saf ety glasses when removing
or installing force fitted parts. Failure to
comply may result in serious injury.
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 17
Figure 3. Major Suspension Components
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Table of Contents
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BLW -400SSW —TRAILER SAFETY GUIDELINES
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SHACKLE BOLT
SPRING EYE BOLT
SHOULDER TYPE
SHACKLE BOLT
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LOCKING NUTS OR COTTER PINS ARE PROVIDED TO
-
RETAIN NUT
BOLT ASSEMBLY
.
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.
Lug Nut T orque Requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Star t all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure 4. DO NO T
torque the wheel lug nuts all the way down. Tighten
each lug nut in 3 separate passes as defined by Tab le 5.
3. After first road use, retorque all lug nuts in sequence.
Check all wheel lug nuts periodically.
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PAGE 18 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
Figure 4. Wheel Lug Nuts Tightening Sequence
NOTE
NEVER use an pneumatic air gun to
tighten wheel lug nuts.
BL W -400SSW —TRAILER-WIRING DIA GRAM
Table of Contents
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 19
BL W -400SSW —TRAILER-BRAKE TROUBLESHOOTING
Table of Contents
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PAGE 20 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
BLW-400SSW —TO WING
Table of Contents
Towing Safety Precautions
■
ALWAYS attach trailer's safety chain to bumper of towing
vehicle.
CAUTION :
■
ALWAYS make sure the vehicle and trailer directional,
Check with your county or state safety
towing regulations department before
towing your generator. Vehicle towing
codes and regulations can vary from state
to state.
To reduce the possibility of an accident while transporting
the generator on public roads, always make sure the trailer
(Figure 5) and the towing vehicle are in good operating
condition and both units are mechanically sound.
The following list of suggestions should be used when towing
your generator:
■
Make sure the hitch and coupling of the towing vehicle are
rated equal to, or greater than the trailer "gross vehicle weight
rating" (GVWR).
■
ALWAYS inspect the hitch and coupling for wear. NEVER
tow a trailer with defective hitches, couplings, chains etc.
■
Check the tire air pressure on both the towing vehicle and
the trailer . Also check the tire tread wear on both vehicles.
■
ALWAYS make sure the trailer is equipped with a "Safety
Chain".
backup, brake, and trailer lights are connected and are
working properly .
■
The maximum speed (unless otherwise posted) for highway
towing is 45 MPH. Recommended off-road towing is not to
exceed 10 MPH or less, depending on type of terrain.
■
Place
while parked.
■
Place
prevent
■
Use the trailer's hand winch to adjust the height of the trailer ,
then insert locking pin to lock wheel stand in place, while
parked.
■
Av oid sudden stops and starts. This can cause skidding, or
jackknifing. Smooth, gradual starts and stops will improve
gas milage.
■
Avoid sharp turns to prevent rolling.
■
Remove wheel stand when transporting.
■
DO NOT transport generator with fuel in tank.
chocked blocks
support blocks
tipping
underneath wheel to prevent
underneath the trailer's bumper to
, while parked.
rolling,
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 21
Figure 5. Welder/AC Generator and Towing Trailer
BLW -400SSW — CONTROLS AND INDICAT ORS
Table of Contents
PAGE 22 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
Figure 6. Controls and Indicators
BLW -400SSW — CONTROLS AND INDICAT ORS
Table of Contents
Figure 6 shows the location of the controls and indicators. The
functions of each control or indicator is described below .
1. DC Current Selector/Single-Use to select current when
using welder for single operator .
2. Current Range Selector- Use to select for single or dual
welding operators.
3. DC Current Selector/Dual- Use to select current when
using welder for dual operators.
4. AC Voltmeter-Indicates the output of total voltage with
welder and/or generator .
5. AC Circuit Breaker - This 53 amp main circuit breaker will
shut down current if welder/generator is overloaded.
6. Engine Indicator Lamps- Lights red when the following
conditions occur:
!
Low Oil Pressure
!
High Water T emperature
!
Electrical System Is Not Charging Properly
7. Preheat Indicator-Indicates the engine is warmed up for
welding/adding load.
8. Ignition Switch – With key inserted turn clockwise to start
engine.
9. Hour Meter – Indicates number of hours machine has
been in use or hours engine was run.
10. Idle Switch- T urn on for rpms to automatically adjust rpms
when a load is added.
11. Fuel Gauge – Indicates the amount of fuel in the fuel tank.
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 23
BLW -400SSW — OUTPUT TERMINAL OVER VIEW
Table of Contents
Figure 8. Duplex Receptacle Detail
Figure 7. Output Terminal Panel
120 V olt Receptacle
One GFCI Duplex Nema 5-20R (120V, 20 Amp) receptacle
is provided on the output terminal. This receptacle can be
used anytime the generator is in operation. The receptacle
is controlled by the circuit breaker located on the control
panel.
The reset button is for the GFCI when the circuit is tripped.
Pressing the "Test Button" (See Figure 9) in the center of
this receptacle will check the GFCI function. The receptacle
should be tested at least once a month.
PAGE 24 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
Figure 9. GFCI Test Button
BLW-400SSW — OUTPUT TERMINAL OVERVIEW
Table of Contents
Output T erminal Panel Available V olta ges
The BLW-400SSW is a single phase generator only. It is
able to supply both 120 volt and 240 volt.
120V Hard Wire Hookup
The output terminal panel, when suppling single phase 120
volts, will provide two circuits available at 41.7 amps with
any two wires plus the ground. (See Figure 10 below.)
Maximum Amps
The BLW-400SSW can provide 41.7 amps at 120 or 240
volts. Do not exceed the maximum amps!
240V Hard Wire Hookup
The output terminal panel, when suppling single phase 240
volts, will provide one circuit available at 41.7 amps with
two wires plus the ground. (See Figure 11 belo w.)
Figure 10. Hard Wire Hookup for
120 Volt
BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 25
Figure 11. Hard Wire Hookup for
240 Volt
NOTE
When using plural single phase
voltages, make sure to balance
the load on each of the single
phase legs.
BLW -400SSW — INSTALLATION
Table of Contents
Outdoor Installation
Install the welder/AC generator in a location where it will not
be exposed to rain or sunshine. Make sure the Welder/AC
generator is on secure level ground so it cannot slide or
shift around. Also install the welder/AC generator so the
exhaust will not be discharged in the direction of nearby
homes.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation, and will result in short circuits.
Foreign materials such as dust, sand, lint and abrasive
materials will cause excessive wear to engine and alternator
parts.
Indoor Installation
Exhaust gases from diesel engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust fumes
must be vented to the outside. The engine should be installed
at least two feet from any outside wall. Using an exhaust
pipe which is too long or too small can cause excessive
back pressure and cause the engine to heat excessively.
BLW -400SSW — INSTALLATION
Eliminate the danger of deadly carbon monoxide gas.
Remember that exhaust fumes from any diesel engine are
very poisonous if discharged in a closed room, but harmless
if allowed to mix with the outside air. If the welder/AC
generator is installed indoors, you must make provisions for
venting the engine exhaust to the outside of the building.
CAUTION :
CAUTION :
Pay close attention to ventilation when
operating the welder/AC generator inside
tunnels and caves. The engine exhaust
contains noxious elements.
An electric shock may happen when
vibrators are used. Pay close attention to
handling when operating vibrators and
always use rubber boots and gloves to
insulate the body from a electrical shock.
PAGE 26 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
BLW-400SSW — PRE-SETUP
Table of Contents
General Inspection Prior to Operation
The BLW-400SSW utiliz es a welder/AC generator that has
been thoroughly inspected and accepted prior to shipment
from the factory. However, be sure to check for damaged
parts or components, or loose nuts and bolts, which could
have occurred in transit.
Ground
The nut and ground terminal on the welder/AC generator
should always be used to connect to a suitab le ground. The
ground path should be of #8 size wire.
Connect the terminal of the ground wire between the lock
washer and the nut and tighten the nut fully. Connect their
end of the wire to a suitable ground.
Circuit Breakers
To protect the welder/AC generator from an ov erload,
53 amp,
pole, 25 amp breaker is provided f or the G.F.C.I. receptacles .
Make sure to switch both circuit breakers to the "OFF"
position prior to starting the engine.
Extension Cable
When electric power is to be provided to various tools or loads at
some distance from the welder/AC gener ator , e xtension cords
are normally used. Cables should be sized to allow for distance
in length and amperage so that the voltage drop between the
welder/AC generator and point of use (load) is held to a
minimum. Use the cable selection chart (T ab le 7 ) as a guide for
selecting proper cable size.
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BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 27
BLW-400SSW — PRE-SETUP
Table of Contents
Lubrication Oil
Fill the engine crankcase with lubricating oil through the filler
hole, but do not overfill. Make sure the welder/AC generator
is level. With the dipstick inser ted all the way, but without
being screw into the filler hole, verify that the oil level is
maintained between the two notches (Figure 12) on the
dipstick. See Table 8 for proper selection of engine oil.
Fuel
Fill the fuel tank with clean diesel fuel. Do not fill the tank
beyond capacity.
Pay attention to the fuel tank capacity when replenishing
fuel. Refer to the fuel tank capacity listed on page 10
Specification Table 1.
The fuel tank cap must be closed tightly after filling. Handle
fuel in a safety container. If the container does not have a
spout, use a funnel.
CAUTION :
Coolant
Never fill the fuel tank while the engine is
running or in the dark. Fuel spillage on a
hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled
gasoline completely to prevent fire
hazards.
Figure 12. Engine Oil Dipstick
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Use only drinkable tap water. If hard water or water with
many impurities is used, the inside of the engine and radiator
may become coated with deposits and cooling efficiency
will be reduced.
An anticorrosion additive added to the water will help prevent
deposits and corrosion in the cooling system. See the
Kobota Engine Operator's Manual
for further details.
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PAGE 28 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
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BLW-400SSW — PRE-SETUP
Table of Contents
CAUTION
Day-to-day addition of coolant or antifreeze is done from the
reserve tank. See Table 9 for engine, radiator and reserve
tank coolant capacities. Make sure the coolant level in the
reserve tank is always between the "H" and the "L" markings.
Operation in Freezing Weather
When operating in freezing weather , be certain that the proper
amount of antifreeze has been added. See Table 10 for
antifreeze operating temperatures.
:
When adding coolant or antifreeze to the
radiator, do not remove the radiator cap
until the unit has completely cooled.
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Cleaning the Radiator
The radiator may overheat if the fins become overloaded
with dust or debris. Periodically clean the radiator fins with
compressed air .
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect and adjust it in
accordance with the
The fan belt tension is proper if the fan belt (Figure 5) bends
7 to 9 mm (0.28- to 0.35 in.) when depressed with the thumb
as shown in Figure 13 below.
CAUTION :
Kubota Engine Operator's Manual
Figure 13. Fan Belt Tension
Never place hands near the belts or fan
while the welder/AC generator is running.
.
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BLW-400SSW-WELDER/AC GENERATOR— PARTS & OPERATION MANUAL— REV. #1 (06/15/01) — PAGE 29
Periodic cleaning/replacement is necessar y. Inspect it in
accordance with the
Battery
This unit is of negative ground. DO NO T connect in rev erse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level is not
properly maintained. Add only distilled water when
replenishment is necessary.
The battery is sufficiently charged if the specific gravity of
the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Check to see whether the battery cables are loose. Poor
contact may result in poor starting or malfunctions, always
keep the terminals firmly tightened. Coating the terminals
with a thin film of grease will help to inhibit corrosion.
Kobota Engine Operator's Man ual.
BLW -400SSW — LO AD APPLICATION
Table of Contents
Single Phase Load
CAUTION:
Always be sure to check the nameplate on the welder/AC
generator and equipment to insure the wattage, amperage
and frequency requirements are satisfactorily supplied by
the welder/AC generator for operating the equipment.
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require 130—
150% more wattage than the rating on the nameplate, as
An inadequate size connecting cable which cannot carry
the required load can cause a voltage drop which can burn
out the appliance or tool and overheat the cable.
the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
The idle control is operated at minimum load capacity of
100W. If the load capacity is less than 100W, change the
idle control switch to the "OFF" position.
NO TE
If wattage is not given on the
equipment's name plate, approximate
CAUTION:
wattage may be determined by
multiplying nameplate voltage by the
nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this welder/AC generator is 1.0. See
Table 11 below when connecting loads.
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
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be used. Use Table 12 below for proper welding electrode
size for power capacity.
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Motors and motor-driven equipment draw
much greater current for starting than
during operation.
Before connecting this welder/AC
generator to any building’s electrical
system, a licensed electrician must install
an isolation (transfer) switch. Serious
injury or death may result without this
transfer switch.
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When connecting a resistance load such as an
0.1
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to the generating set’s rated output (kW) can be used.
!
When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
!
When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
PAGE 30 — BLW-400SSW- WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #1 (06/15/01)
With AC loads of more than 150W (such as lighting
equipment, motor-powered tools, submersible water pumps,
etc.), the engine runs at high speed. When a no load condition
is produced, the engine automatically slows down.
Turn the idle control switch to the “ON” (up) position when
AC loads of more than 150W are connected. Turn the idle
control switch to the “OFF” (down) position when AC loads
of less than 100W or when a magnetic switch is used.
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