Multiquip TLW-300SS User Manual

4.7 (3)

OPERATION AND PARTS MANUAL

WHISPERWELDTM SERIES

MODEL TLW-300SS WELDER/AC GENERATOR

(KUBOTA D722EB DIESEL ENGINE)

Revision # 2 (04/07/10)

To find the latest revision of this publication, visit our website at: www.mqpower.com

THIS MANUAL MUST ACCOMPANYTHE EQUIPMENT AT ALLTIMES.

PROPOSITION 65WARNING

Diesel engine exhaust and some of

PAGE 2 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

NOTE PAGE

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 3

Proposition 65 Warning ...........................................

 

2

Table of Contents ....................................................

 

4

Parts Ordering Procedure .......................................

5

Rules for Safe Operation .....................................

6-7

Operation and Safety Decals ...............................

8-9

Specifications ........................................................

 

10

General Information ..............................................

 

11

Dimensions ...........................................................

 

12

Trailer Safety Guidelines ..................................

13-17

Trailer Wiring Diagram...........................................

 

18

Towing ...................................................................

 

19

Controls and Indicators ....................................

 

20-21

Output Terminal Overview .....................................

22

Installation .............................................................

 

23

Preset ...............................................................

 

24-26

Instrumentation .....................................................

 

27

Load Application ...................................................

 

28

Welder Operation Instructions .........................

29-30

Engine Operation Instructions ..............................

31

Maintenance ....................................................

 

32-33

Gen. Wiring Diagram (S/N 5308736~Below) ........

34

Gen. Wiring Diagram (S/N 5308737~Above) .......

35

Engine Wiring Diagram

(S/N 5308736~Below)

.... 36

Engine Wiring Diagram

(S/N 5308737~Above)

... 37

Troubleshooting-Engine

...................................

38-40

Troubleshooting-Welder

........................................

41

Explanation of Codes in Remarks Section............

42

Spare Parts ...........................................................

 

43

TLW-300SS WELDER/

 

AC GENERATOR

 

 

Generator Assembly ........................................

 

44-46

Control Box Assembly ......................................

 

46-49

Control Parts Assembly, part 1 ........................

50-51

Control Parts Assembly, part 2 ........................

52-53

Engine and Radiator Assembly........................

54-55

Battery Assembly .............................................

 

56-57

Muffler Assembly .............................................

 

58-59

Fuel Tank Assembly .........................................

 

60-61

Enclosure Assembly.........................................

 

62-65

Rubber Seals Assembly

...................................

66-67

Decal Assembly ...............................................

 

68-69

TABLE OF CONTENTS

KUBOTA D722EB ENGINE

Crankcase Assembly .......................................

70-71

Oil Pan Assembly .............................................

72-73

Cylinder Head Assembly ..................................

74-75

Gear Case Assembly .......................................

76-77

Air Cleaner Assembly.......................................

78-79

Inlet Manifold Assembly ...................................

80-81

Exhaust Manifold Assembly .............................

82-83

Rocker Arm Valve Assembly ............................

84-85

Head Cover Assembly .....................................

86-87

Dip Stick Assembly...........................................

88-89

Main Bearing Assembly ...................................

90-91

Camshaft Assembly .........................................

92-93

Piston and Crankshaft Assembly .....................

94-95

Flywheel Assembly ..........................................

96-97

Fuel Camshaft Assembly .................................

98-99

Nozzleholder Assembly................................

100-103

Nozzleholder Glow Plug Assembly ..............

104-105

Injection Pump Assembly .............................

106-107

Injection Pump Comp. Assembly .................

108-109

Fuel Filter Assembly ....................................

110-111

Fuel Pump Assembly ...................................

112-113

Governor Assembly .....................................

114-115

Speed Control Plate Assembly ....................

116-117

Stop Solenoid Assembly ..............................

118-119

Starter Assembly .........................................

120-121

Starter Comp. Assembly ..............................

122-123

Dynamo Assembly .......................................

124-125

Water Flange Assembly ...............................

126-127

Water Pump Assembly .................................

128-129

Water Pipe Assembly ...................................

130-131

Starter Switch Assembly ..............................

132-133

Piston Kit and Accessories ...........................

134-135

Terms and Conditions - Sale...............................

136

NOTE

Specification and part number are subject to change without notice.

PAGE 4 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

www.mqpower.com

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

 

 

 

 

 

 

 

Choose from three easy options:

 

 

 

 

 

 

 

 

 

 

 

 

Effective:

 

 

 

 

 

 

 

 

 

 

 

 

January 1st, 2006

Best Deal! Order via Internet (Dealers Only):

 

 

If you have an MQ Account, to obtain a Username

 

 

 

Order parts on-line using Multiquip’s SmartEquip website!

 

 

 

 

 

 

 

and Password, E-mail us at: parts@multiquip.

 

 

 

 

N View Parts Diagrams

 

 

com.

 

 

 

 

N Order Parts

 

 

To obtain an MQ Account, contact your

 

 

 

 

N Print Specification Information

 

 

District Sales Manager for more information.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Goto www.multiquip.com and click on

 

 

Use the internet and qualify for a 5% Discount

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

on Standard orders for all orders which include

 

 

 

 

 

 

Order

Parts

to log in and save!

 

 

 

 

 

 

 

 

 

 

 

 

complete part numbers.*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: Discounts Are Subject To Change

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Order via Fax (Dealers Only):

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fax your order in and qualify for a 2% Discount

 

 

 

 

 

 

 

 

All customers are welcome to order parts via Fax.

 

on Standard orders for all orders which include

 

 

 

 

 

 

 

 

 

 

 

 

 

Domestic (US) Customers dial:

 

complete part numbers.*

 

 

 

 

 

 

1-800-6-PARTS-7 (800-672-7877)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Note: Discounts Are Subject To Change

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Order via Phone: Domestic (US) Dealers Call:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1-800-427-1244

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Non-Dealer Customers:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

International Customers should contact

 

 

 

Contact your local Multiquip Dealer for

 

 

 

 

 

 

 

 

 

their local Multiquip Representatives for

 

 

 

parts or call 800-427-1244 for help in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Parts Ordering information.

 

 

 

locating a dealer near you.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

When ordering parts, please supply:

R

Dealer Account Number

R Specify Preferred Method of Shipment:

R

Dealer Name and Address

UPS/Fed Ex

DHL

R

Shipping Address (if different than billing address)

N Priority One

Truck

R

Return Fax Number

N Ground

 

N Next Day

 

R

Applicable Model Number

 

N Second/Third Day

 

 

 

 

RQuantity, Part Number and Description of Each Part

NOTICE

All orders are treated as Standard Orders and will ship the same day if received prior to 3PM PST.

WE ACCEPT ALL MAJOR CREDIT CARDS!

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 5

CAUTION:

Failure to follow 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 TLW-300SS Welder/AC Generator:

GENERAL SAFETY

DONOToperateorservicethisequipmentbefore readingthisentiremanual.

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 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.

NEVER use accessories or attachments, which are not recommended by MQ Power for 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.

RULES FOR SAFE OPERATION

NEVER touch the hot exhaust manifold, muffler or cylinder. Allow these parts to cool before servicing engine or welder/AC generator.

HighTemperatures – Allow the engine to cool before adding fuel or performing service and maintenance functions. Contact with hot components can cause serious burns.

The engine of 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 engine and may cause injury to people. The engine gives off DEADLY carbon monoxide gas.

■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 smoke around or near the machine. Fire or explosion could result from fuel vapors, or if fuel is spilled on a hot engine.

NEVER operate the welder/AC generator in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death.

Topping-off to filler port is dangerous, as it tends to spill fuel.

PAGE 6 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

CAUTION:

This welder/AC generator is a source of providing LETHAL high voltages. Never permit unqualified personnel-especially children to operate the welder/AC generator.

This welder/AC generator is equipped with a ground terminal 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 water,while bare foot, 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:

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.

RULES FOR SAFE OPERATION

CAUTION:

Never use damaged or worn cables when connecting power tools or equipment to the welder/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 drain 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 fire extinguisher and first aid kit. Know the location of the nearest telephone. Also know the phone numbers of the nearest ambulance, doctor and fire department. This information will be invaluable in the case of an emergency.

Maintenance Safety

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.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 7

OPERATION AND SAFETY DECALS

Machine Safety Decals

The TLW-300SS welder/AC generator is equipped with a number of safety decals.These decals are provided for operator safety and maintenance information.The illustration below shows these decals as they appear on the machine.Should any of these decals become unreadable, replacements can be obtained from your dealer.

PAGE 8 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

Multiquip TLW-300SS User Manual

OPERATION AND SAFETY DECALS

P/N DCL160

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 9

 

 

TLW-300SS — SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

Table 1. Specifications

 

 

 

 

 

 

 

Welder Specifications

 

 

 

 

 

 

Model

BLW-300SS

 

 

 

 

 

 

Type

Brushless, revolving, field type generator

 

 

 

 

 

 

Rated Current

280A

 

 

 

 

 

 

Rated Voltage

31.2V / 25V

 

 

 

 

 

 

Range of Current

35~300A

 

 

 

 

 

 

Duty Cycle

50% / 100%

 

 

 

 

 

 

 

Generator Specifications

 

 

 

 

 

 

Frequency

60 Hz

 

 

 

 

 

 

Speed

3600 rpm

 

 

 

 

 

 

Max. Output

10.5kW

 

 

 

 

 

 

Rated Output

10.0kW

 

 

 

 

 

 

Voltage

120/240 V

 

 

 

 

 

 

 

Engine Specifications

 

 

 

 

 

 

Model

KUBOTA D722EB

 

 

 

 

 

 

Type

4 Cycle, vertical

 

 

 

 

 

 

No. of Cylinders

3 cylinders

 

 

 

 

 

 

Bore x Stroke

2.64 in. x 2.68 in. (67 mm x 68 mm)

 

 

 

 

 

 

Rated Output

18.8HP/3600 rpm

 

 

 

 

 

 

Displacement

43.9 cu. in. (719 cc)

 

 

 

 

 

 

Starting

Electric

 

 

 

 

 

 

Coolant Capacity

.55 gal. (2.1 liters)

 

 

 

 

 

 

Lube Oil Capacity

.83 gal. (3.15 liters)

 

 

 

 

 

 

Fuel Consumption

Welding .66 gal. (2.5L)/hr

 

 

AC Power 1.14 gal. (4.3L)/hr

 

 

 

 

 

 

 

 

 

Fuel Capacity

Approx. 9.5 gal (36 liters)

 

 

 

 

 

 

Fuel type

#2 Diesel Fuel

 

 

 

 

 

 

Battery

12V45AH

 

 

 

 

 

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient 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 Fahrenheit.

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 Fahrenheit above the standard temperature of 60° F.

PAGE 10 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS — GENERAL INFORMATION

TLW-300SS FAMILIARIZATION

Generator

The MQ Power ModelTLW-300SS welder/AC generator can provide 280 amps of welding current. When used as a generator, can provide a maximum of 10 kilowatts of power.

Control Panel

The control panel is provided with the following:

One GFCI 120 volt receptacle, 20 amp

One 120 volt receptacle, 30 amp

One 120/240 volt receptacle, 30 amp

Circuit Protector Breaker (GFCI) 120V @20 Amps

Idle Control Switch

Main Circuit Breaker, 42A

Starter Switch

Warning Lamp Unit

Hour Meter

GroundTerminal

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.

WaterTemperature 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.

Oil Pressure Warning Indicator

In the event of low oil pressure (engine), this welder/AC generator is equipped with an engine protection fail safe system . 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 28) in this manual.

Excitation System

The TLW-300SS Welder/AC 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 pf permanent magnets called the "STATOR". A magnetic field is created by the stator and produces an electrical current.

Engine

The TLW-300SS is powered by a 4-cycle KUBOTA diesel engine.This engine is designed to meet every performance requirement for welder/AC generator.ReferenceTable 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.

Figures 2 and 3 (pages 13-14) show the basic controls and indicators for the TLW-300SS Welder/AC generator.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 11

TLW-300SS — DIMENSIONS

Figure 1. TLW-300SS Dimensions

PAGE 12 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS —TRAILER-SAFETY GUIDELINES

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 NutTorquing

Suspension

Electrical

Brake Troubleshooting Tables

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, hydraulic-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 (layers) 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.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 13

TLW-300SS — TRAILER-SPECIFICATIONS

 

 

 

Table 1. Specifications

 

 

 

MODEL

APPLICATION

FUEL

BRAKE

GVWR

FRAME

FRAME

JACK

 

 

CELL

SYSTEM

 

LENGTH

WIDTH

STAND

TRLR-10W

SDW225,

NO

NO

1900LBS

96"

50"

800LB.

 

SGW250,TLW300

 

 

 

 

 

FULL TILT WHEEL

TRLR-10

DCA10, TLG12,

NO

NO

1900LBS

96"

50"

800LB.

 

DCA-15

 

 

 

 

 

FULL TILT WHEEL

TRLR-10XF

DCA10, TLG-12,

52 GAL

NO

1900LBS

96"

50"

800LB.

 

DCA15, TLW-300

 

 

 

 

 

FULL TILT WHEEL

TRLR-225W

WELDERS,

NO

NO

2200LBS

85"

42"

800LB.

 

DA7000SS

 

 

 

 

 

FULL TILT WHEEL

TRLR-BLW400

BLW-400

NO

ELECTRIC

2700LBS

W/MAST 154"

55"

800LB.

 

 

 

 

 

W/O 124"

(78" TALL)

FULL TILT WHEEL

TRLR-50X

DCA-25

NO

NO

2700LBS

124"

55"

800LB.

 

 

 

 

 

 

 

FULL TILT WHEEL

TRLR-50XF

DCA-25

41 GAL

NO

2700LBS

124"

55"

800LB.

 

 

 

 

 

 

 

FULL TILT WHEEL

TRLR-70W

DCA-45, -60, 70

NO

SURGE

7000LBS

186"

77"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-70X

DCA-45, -60, 70

OPT

SURGE

7000LBS

138"

66"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-70XF

DCA-45, -60, 70

53 GAL

SURGE

7000LBS

138"

66"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-100XF

DCA-100, 125

150 GAL

HYDRAULIC SURGE

7000LBS

190"

76"

2000LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-85/125

DCA-85, 100,

145 GAL

HYDRAULIC

10000LBS

186"

77"

2000LB.

 

125

 

 

 

 

 

FLAT PAD

TRLR-150XF

DCA-150, 180

200 GAL

HYDRAULIC SURGE

11160LBS

204"

84"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-220XF

DCA-220

250 GAL

HYDRAULIC SURGE

14000LBS

222"

83"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-300XF

DCA-300

250 GAL

HYDRAULIC SURGE

18000LBS

238"

83"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-400XF

DCA-400

350 GAL

ELECTRIC

18000LBS

238"

83"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-600XF

DCA-600, 800

550 GAL

AIR

30000LBS

384"

96"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

TRLR-800SX

DCA-600, 800

550 GAL

AIR

30000LBS

384"

96"

5000 LB.

 

 

 

 

 

 

 

FLAT PAD

PAGE 14 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS — TRAILER-SPECIFICATIONS

 

 

Table 1. Specifications (Con't)

 

 

 

MODEL

COUPLER

TIRES

WHEELS

AXLE

HUBS

SUSPENSION

ELECTRICAL

TRLR-10W

2" BALL CLASS

175-13C

13"X4.50"

2200# 2X2

5 LUG

3 LEAF

4 WIRE LOOM W/

 

2 ADJUSTABLE

 

 

 

 

 

4 POLE FLAT

TRLR-10

2"BALL CLASS

175-13C

13"X4.5"

2200#2X2

5 LUG

3 LEAF

4 POLE FLAT

 

2 ADJUSTABLE

 

 

 

 

 

 

TRLR-10XF

2"BALL CLASS

175-13C

13"X4.5"

2200#2X2

5 LUG

3 LEAF

4 POLE FLAT

 

2 ADJUSTABLE

 

 

 

 

 

 

TRLR-225W

2"BALL CLASS

175-13B

13X4.5"

2200#2X2

5 LUG

Q FLEX

4 POLE FLAT

 

2 ADJUSTABLE

 

 

 

 

 

 

TRLR-BLW

2"BALL CLASS

175-13C

13 X 4.5"

2200#2X2

5 LUG

3 LEAF

4 POLE FLAT

400

2 ADJUSTABLE

 

 

 

 

 

 

TRLR-50X

2" BALL CLASS

B78-13LRC

13"X4.50"

3500lbs.

5 LUG

4 LEAF

4 POLE RUBBER

 

 

 

 

2-3/8"

 

 

FLAT

TRLR-50XF

2" BALL CLASS

B78-13LRC

13"X4.50"

3500lbs.

5 LUG

4 LEAF

4 POLE RUBBER

 

 

 

 

2-3/8"

 

 

FLAT

TRLR-70W

2" BALL CLASS

205-14C

14"X5"

3500lbs.

5 LUG

5 LEAF

4 POLE RUBBER

 

3" ADJUSTABLE

BIAS (4)

 

3"

 

 

FLAT

TRLR-70X

2" BALL CLASS

205-14C

14"X5"

3500lbs

5 LUG

5 LEAF

4 POLE RUBBER

 

3" ADJUSTABLE

BIAS (4)

 

3"

 

 

FLAT

TRLR-70XF

2" BALL CLASS

205-14C

14"X5"

3500lbs.

5 LUG

5 LEAF

4 POLE RUBBER

 

3" ADJUSTABLE

BIAS (4)

 

3"

 

 

FLAT

TRLR-100XF

ADJUSTABLE 2-5/6

205-15C

14"X5.5"

3500lbs

5 LUG

5 LEAF

4 WIRE LOOM

 

OPT 3" EYE

BIAS (4)

 

3"

 

 

 

TRLR-85/125

ADJUSTABLE 2-5/6

ST225/75R15D

14"x6"

(2)-6000lbs

6 LUG

7 LEAF

4 WIRE LOOM

 

OPT 3" EYE

RADIAL (4)

 

 

 

 

 

TRLR-150XF

3" BALL EYE

750-16 E

16"X7"

(2)-6000lbs

8 LUG

7 LEAF

4 WIRE LOOM

 

 

BIAS (4)

 

 

 

 

 

TRLR-220XF

3" EYE

ST235/85R16E

16"X7"

(2)-7000lbs

8 LUG

Q FLEX

4 WIRE LOOM

 

ADJUSTABLE

RADIAL(4)

 

 

 

 

 

TRLR-300XF

3" EYE

ST235/85R16E

16"X7"

(2)-6000lbs

8 LUG

Q FLEX

4 WIRE LOOM

 

ADJUSTABLE

RADIAL(6)

 

 

 

 

 

TRLR-400XF

3" EYE

ST235/85R16E

16"X7"

(3)-7000lbs.

8 LUG

Q FLEX

4 WIRE LOOM

 

ADJUSTABLE

RADIAL(6)

 

 

 

 

 

TRLR-600XF

5TH WHEEL

ST215/75R17.5H

16"X7"

(3)-10000lbs

8 LUG

7 LEAF

6 WIRE LOOM

 

 

RADIAL (8)

 

 

 

 

 

TRLR-800AR

5TH WHEEL

ST215/75R17.5H

16"X7"

(3)-10000lbs

8 LUG

AIR-RIDE

6 WIRE LOOM

 

 

RADIAL (8)

 

 

 

 

 

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 15

TLW-300SS —TRAILER SAFETY GUIDELINES

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 injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life. Pressure should be checked cold before operation DO NOT 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.

CAUTION:

Suspension

The leaf suspension springs and associated components (Figure 2) 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. Torqued suspension components as detailed in Table 4.

Figure 2. Major Suspension Components

NOTE

ALWAYS wear safety glasses when removing or installing force fitted parts. Failure to comply may result in serious injury.

PAGE 16 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS —TRAILER SAFETY GUIDELINES

Table 4. Suspension Torque Requirements

Item

Torque (Ft.-Lbs.)

 

 

3/8" U-BOLT

MIN-30 MAX-35

 

 

7/16" U-BOLT

MIN-45 MAX-60

 

 

1/2" U-BOLT

MIN-45 MAX-60

 

 

SHACKLE BOLT

SNUG FIT ONLY. PARTS MUST ROTATE FREELY.

SPRING EYE BOLT

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

 

RETAIN NUT-BOLT ASSEMBLY.

 

 

SHOULDER TYPE

MIN-30 MAX-50

SHACKLE BOLT

 

 

 

Lug NutTorque 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.Start all wheel lug nuts by hand.

2.Torque all lug nuts in sequence. See Figure 3. DO NOT torque the wheel lug nuts all the way down. Tighten each lug nut in 3 separate passes as defined by Table 5.

3.After first road use, retorque all lug nuts in sequence. Check all wheel lug nuts periodically.

Table 5. Tire Torque Requirements

Wheel Size

First Pass

Second Pass

Third Pass

 

FT-LBS

FT-LBS

FT-LBS

 

 

 

 

12"

20-25

35-40

50-65

 

 

 

 

13"

20-25

35-40

50-65

 

 

 

 

14"

20-25

50-60

90-120

 

 

 

 

15"

20-25

50-60

90-120

 

 

 

 

16"

20-25

50-60

90-120

 

 

 

 

Figure 3. Wheel Lug Nuts Tightening Sequence

NOTE

NEVER use an pneumatic air gun to tighten wheel lug nuts.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 17

TLW-300SS —TRAILER-WIRING DIAGRAM

PAGE 18 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS —TOWING

Towing Safety Precautions

CAUTION :

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 4) 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".

ALWAYS attach trailer's safety chain to bumper of towing vehicle.

ALWAYS make sure the vehicle and trailer directional, 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 chocked blocks underneath wheel to prevent rolling, while parked.

Place support blocks underneath the trailer's bumper to prevent tipping, while parked.

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.

Avoid 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.

Figure 4. Welder/AC Generator and Towing Trailer

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 19

TLW-300SS — CONTROLS AND INDICATORS

Figure 5. Controls and Indicators

PAGE 20 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS — CONTROLS AND INDICATORS

Figure 5 shows the location of the controls and indicators.The functions of each control or indicator is described below.

1.Voltage Regulator- Controls theVoltage for welding/load.

2.ACVoltmeter- Indicated amount of voltage output.

3.Main Circuit Breaker- 2-pole, 42A will shut down current when welder/generator is overloaded.

4.No. 1 Circuit Breaker-(S/N 5308737~)- single pole circuit breaker will shut down current in the 240V/30A receptacle.

5.IgnitionSwitchwithKey- Used to start and preheat engine.

6.EngineWarning Indicators- Lights red when the following conditions occur:

Low Oil Pressure

High WaterTemperature

Electrical System Is Not Charging Properly

7.Hour Meter – Indicates number of hours machine has been in use or hours engine was run.

8.Idle Switch-Turn on for rpms to automatically adjust rpms when a load is added.

9.No. 3 Circuit Breaker-(S/N 5308737~)- single pole circuit breaker will shut down current in the 120V/20A receptacle.

10.No. 2 Circuit Breaker-(S/N 5308737~)- single pole circuit breaker will shut down current in the 120V/30A receptacle.

11.Positive Welding Output Terminal- Positive connection for welding.

12.NegativeWelding OutputTerminal-Negative connection for welding.

13.G.F.C.I. Ground Terminal- Used to ground GFCI receptacle.

14.G.F.C.I. Receptacle- 120V/20A receptacle for smaller power applications.

15.120V Receptacles- used for 20 or 30 amp power applications.

16.240V Receptacle- used for 30 amp power applications.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 21

TLW-300SS — OUTPUTTERMINAL OVERVIEW

Panel

 

120Volt 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 8) in the center of

 

this receptacle will check the GFCI function. The receptacle

Figure 7. Duplex Receptacle Detail

should be tested at least once a month.

Figure 8. GFCI Test Button

PAGE 22 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS — INSTALLATION

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.

CAUTION :

Pay close attention to ventilation when operating the welder/AC generator inside tunnels and caves. The engine exhaust contains noxious elements.

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.

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 :

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.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 23

TLW-300SS — PRE-SETUP

General Inspection Prior to Operation

The TLW-300SS utilizes 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 suitable 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 overload, a 2-pole, 42 amp, main circuit breaker is provided. In addition, three separate circuit breakers are provided for each receptacle. Be sure the circuit breakers are in the ‘OFF’ position prior to starting the engine.

Welding Cable

When welding, use the table below (Table 6) to measure the optimum amount of voltage and amperes when selecting the proper welding cable. The relationship between cable length and sectional area is to keep the line voltage drop within 4V.

Table 6. Welding Cable Sizes

Total Cable Length (ft)/

50

100

125

150

200

250

300

Current (A)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

#3

#3

#3

#3

#3

#3

#3

 

 

 

 

 

 

 

 

150

#3

#3

#3

#3

#2

#1

#1

 

 

 

 

 

 

 

 

200

#3

#3

#2

#1

#1/0

#2/0

#3/0

 

 

 

 

 

 

 

 

250

#3

#2

#1

#1/0

#2/0

#3/0

#3/0

 

 

 

 

 

 

 

 

DC Welding/AC Power

This unit will provide simultaneous use of DC welding power and AC Power. Use the table below (Table 7) when selecting electrode size for the amount of AC power provided.

Table 7. DC Weldng/AC Power Capacity

WELDING ELECTRODE SIZE

AC POWER SOURCE CAPACITY

 

 

0

10.5kW

 

 

3/32" to 1/8"

3.5kW

 

 

5/32"

2.5kW

 

 

3/16"

1.5kW

 

 

7/32" to 1/4"

0.8kW

 

 

PAGE 24 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

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 inserted all the way, but without being screw into the filler hole, verify that the oil level is maintained between the two notches (Figure 9) on the dipstick. See Table 8 for proper selection of engine oil.

Figure 9. Engine Oil Dipstick

TLW-300SS — PRE-SETUP

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 :

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.

Coolant

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

Kubota Engine Operator's Manual for further details.

Table 8. Recommended Motor Oil

Temperature Range

Type Oil

104° F ~ 23° F

SAE 30W or SAE 40W

(40° C ~ -5°C)

23° F ~ 5° F

SAE 20W or SAE 10W

(-5° C ~ -15°C)

Below 5° C (-15°)

SAE 10W

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 25

TLW-300SS — PRE-SETUP

CAUTION :

When adding coolant or antifreeze to the radiator, do not remove the radiator cap until the unit has completely cooled.

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.

Table 9. Coolant Capacity

Engine and Radiator

0.55 Gal.

 

 

Reserve Tank

0.27 Gal.

 

 

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 Kubota Engine Operator's Manual.

The fan belt tension is proper if the fan belt (Figure 10) bends 7 to 9 mm (0.28to 0.35 in.) when depressed with the thumb as shown in Figure 5 below.

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.

Table 10. Anti-Freeze Operating Temperatures

Vol %

Freezing Point

Boiling Point

 

 

 

 

Anti-Freeze

°C

°F

°C

°F

 

 

 

 

 

 

40

-24

-12

106

222

 

 

 

 

 

50

-37

-34

108

226

 

 

 

 

 

NOTE

When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%.

Figure 10. Fan Belt Tension

CAUTION :

Never place hands near the belts or fan while the welder/AC generator is running.

Air Cleaner

Periodic cleaning/replacement is necessary. Inspect it in accordance with the Kubota Engine Operator's Manual.

Battery

This unit is of negative ground. DO NOT connect in reverse. 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.

PAGE 26 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS — INSTRUMENTATION

CAUTION :

Idle Control Switch

When using a combination of dual receptacles, total load should not exceed the rated capacity of the welder/AC generator set.

Power Outlets

The welder/AC generator has the following single-phase 60

Hz, 120/240 volt receptacles.

Single Phase

One Duplex NEMA (GFCI) 5-20R (120V, 20 Amp)

One Twist Lock-Non-NEMA CS6369

One Twist Lock NEMA L14-30R (120/240V, 25 Amp)

One Twist Lock NEMA L5-30R (120V, 25 Amp)

Main Circuit Breaker

This 42 amp breaker protects the welder/AC generator from short circuiting or overloading from the 60 Hz single-phase load.

Protection Breakers

Each receptacle has individual breakers to protect them from an overload. The main circuit breaker is also for receptacle number 1, L14-30R; number 2 breaker is for the CS6369; the number 3 breaker is for the L5-30R; and the number 4 breaker is for the GFCI receptacle.

The TLW-300SS Welder/AC generator is provided 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. Conversely, when the load is removed, the engine speed will automatically drop back down to 2200 rpm within

10 seconds.

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.

Fuel Gauge

The fuel gauge is located next to the control panel on the left side.

GFCI Receptacle

Before connecting a load to the generator's GFCI receptacle, push the "Test Button" on the front of receptacle before connecting the load, to confirm that the receptacle is functioning correctly.

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 27

Single Phase Load

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 the wattage is influenced by the efficiency, power factor and starting system of the equipment.

NOTE

If wattage is not given on the equipment's name plate, approximate 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.

Table 11. Power Factor By Load

Type Of Load

Power Factor

 

 

Single-phase induction motors

0.4 - 0.75

 

 

Electric heaters, incandescent

1.0

lamps

 

 

 

Fluorescent lamps, mercury lamps

0.4 - 0.9

 

 

Electronic devices, communication

1.0

equipment

 

 

 

Common power tools

0.8

 

 

When connecting a resistance load such as an incandescent lamp or electric heater, a capacity of up 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.

TLW-300SS — LOAD APPLICATION

CAUTION:

Motors and motor-driven equipment draw much greater current for starting than during operation.

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 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.

CAUTION:

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.

When connecting ordinary power tools, a capacity of up to the generating set’s rated output (kW) multiplied by 0.8 can be used.

PAGE 28 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

TLW-300SS—WELDER OPERATING INSTRUCTIONS

Welding Cables and Polarities

Connect the welding cables (Figure 11) to the welder's output terminals located on the control panel. The output terminals have (+) and (-) polarities. Select the appropriate polarities according to the application (See Welding Applications, Table 12).

Figure 11. Electrode Cable Connection

(Correct)

NOTE

ALWAYS attach terminal connectors at the end of each cable. NEVER connect exposed or frayed wires (Figure 12) directly to the terminals. Exposed wiring may cause shocks or di-electric breakdown from poor contact.

Figure 12. Electrode Cable Connection

(Incorrect)

Table 12. Welding Applications

POLARITY

 

WELDING METHOD

TYPICAL APPLICATIONS

 

 

 

 

(+) ... Ground Clamp

Welding steel materials for general

Straight Polarity

 

(Base Metal)

structures, and thickness plates.

 

 

 

 

(-) ...

Electrode Holder

Arc welding for copper alloy

 

 

 

 

 

(+) ...

Electrode Holder

Build-up welding, arc welding of

 

thin plates

Reverse Polarity

 

 

 

 

 

(+) ... Ground Clamp

Arc welding of stainless steel

 

 

 

(Base Metal)

 

 

 

 

 

 

 

TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 29

TLW-300SS—WELDER OPERATING INSTRUCTIONS

Duty Cycle

The welder is rated at 100% duty cycle at 280 amps.

However, the duty cycle depends upon the welding current. Select the appropriate duty cycle from Table 13 to prevent overload.

Table 13. Duty Cycle

Duty Cycle (%)

100

80

 

 

 

Current (Amps)

280 or less

300

 

 

 

CAUTION :

Always wear welding shield with correct filter shade when welding.

FIVE ESSENTIALS FOR PROPER

WELDING PROCEDURES

Besides the steady sizzling sound that a correct arc produces, the shape of the molten pool and the movement of the metal at the rear of the pool serve as a guide in checking weld quality.

In a correctly made deposit, the ripples produced on the bead will be uniform and the bead will be smooth, with no overlap or undercut.

1. Correct Electrode Size

The correct choice of electrode size involves consideration of a variety of factors. Such as the type, position, and preparation of the joint, the ability of the electrode to carry high current values without injury to the weld metal or loss of deposition efficiency. The mass of work metal and its ability to maintain its original properties after welding, the characteristics of the assembly with reference to effect of stresses set up by heat application, the practicability of heat treatment before and/or after welding, the specific requirements as to welding quality and the cost of achieving the desired results.

2. Correct Current

If current on equipment is too high or too low, you are certain to be disappointed in your weld. If too high, the electrode melts too fast and your molten pool is large and irregular. If too low, there is not enough heat to melt the base metal and your molten pool will be too small, will pile up, and look irregular.

3. Correct Arc Length

If the arc is too long or voltage too high the metal melts off the electrode in large globules which wobble from side to side as the arc wavers, giving a wide, spattered and irregular bead– with poor fusion between original metal and deposited metal.

If the arc is too short or voltage too low, there is not enough heat to melt the base metal properly and the electrode quite often sticks to the work. This gives a high, uneven bead, having irregular ripples and poor fusion.

4. Correct Travel Speed

When your speed is too fast: your pool does not last long enough, impurities and gas is locked in. The bead is narrow and ripples pointed. When speed is too slow: the metal piles up, the bead is high and wide, with a rather straight ripple.

5. Correct Electrode Angle

The electrode angle is of particular importance in fillet welding and deep groove welding. Generally speaking, when making a filet weld, the electrode should be held so that it bisects the angle between the plates and is perpendicular to the line of weld. If under cut occurs in the vertical member lowers the angle of the arc and directs the arc toward the vertical member.

PAGE 30 — TLW-300SS WELDER/AC GENERATOR — OPERATION AND PARTS MANUAL — REV. #2 (04/07/10)

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