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 ........................................... |
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Table of Contents .................................................... |
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Parts Ordering Procedure ....................................... |
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Rules for Safe Operation ..................................... |
6-7 |
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Operation and Safety Decals ............................... |
8-9 |
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Specifications ........................................................ |
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10 |
General Information .............................................. |
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11 |
Dimensions ........................................................... |
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Trailer Safety Guidelines .................................. |
13-17 |
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Trailer Wiring Diagram........................................... |
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18 |
Towing ................................................................... |
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19 |
Controls and Indicators .................................... |
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20-21 |
Output Terminal Overview ..................................... |
22 |
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Installation ............................................................. |
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Preset ............................................................... |
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24-26 |
Instrumentation ..................................................... |
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Load Application ................................................... |
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28 |
Welder Operation Instructions ......................... |
29-30 |
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Engine Operation Instructions .............................. |
31 |
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Maintenance .................................................... |
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32-33 |
Gen. Wiring Diagram (S/N 5308736~Below) ........ |
34 |
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Gen. Wiring Diagram (S/N 5308737~Above) ....... |
35 |
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Engine Wiring Diagram |
(S/N 5308736~Below) |
.... 36 |
Engine Wiring Diagram |
(S/N 5308737~Above) |
... 37 |
Troubleshooting-Engine |
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38-40 |
Troubleshooting-Welder |
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41 |
Explanation of Codes in Remarks Section............ |
42 |
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Spare Parts ........................................................... |
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43 |
TLW-300SS WELDER/ |
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AC GENERATOR |
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Generator Assembly ........................................ |
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44-46 |
Control Box Assembly ...................................... |
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46-49 |
Control Parts Assembly, part 1 ........................ |
50-51 |
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Control Parts Assembly, part 2 ........................ |
52-53 |
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Engine and Radiator Assembly........................ |
54-55 |
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Battery Assembly ............................................. |
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56-57 |
Muffler Assembly ............................................. |
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58-59 |
Fuel Tank Assembly ......................................... |
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60-61 |
Enclosure Assembly......................................... |
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62-65 |
Rubber Seals Assembly |
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66-67 |
Decal Assembly ............................................... |
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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!
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Choose from three easy options: |
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Effective: |
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January 1st, 2006 |
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Best Deal! Order via Internet (Dealers Only): |
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If you have an MQ Account, to obtain a Username |
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Order parts on-line using Multiquip’s SmartEquip website! |
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and Password, E-mail us at: parts@multiquip. |
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N View Parts Diagrams |
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com. |
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N Order Parts |
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To obtain an MQ Account, contact your |
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N Print Specification Information |
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District Sales Manager for more information. |
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Goto www.multiquip.com and click on |
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Use the internet and qualify for a 5% Discount |
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on Standard orders for all orders which include |
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Order |
Parts |
to log in and save! |
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complete part numbers.* |
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Order via Fax (Dealers Only): |
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Fax your order in and qualify for a 2% Discount |
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All customers are welcome to order parts via Fax. |
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on Standard orders for all orders which include |
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Domestic (US) Customers dial: |
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complete part numbers.* |
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1-800-6-PARTS-7 (800-672-7877) |
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Note: Discounts Are Subject To Change |
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Order via Phone: Domestic (US) Dealers Call: |
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1-800-427-1244 |
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Non-Dealer Customers: |
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International Customers should contact |
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Contact your local Multiquip Dealer for |
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their local Multiquip Representatives for |
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parts or call 800-427-1244 for help in |
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Parts Ordering information. |
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locating a dealer near you. |
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When ordering parts, please supply: |
R |
Dealer Account Number |
R Specify Preferred Method of Shipment: |
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Dealer Name and Address |
UPS/Fed Ex |
DHL |
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Shipping Address (if different than billing address) |
N Priority One |
Truck |
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Return Fax Number |
N Ground |
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N Next Day |
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Applicable Model Number |
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N Second/Third Day |
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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)
OPERATION AND SAFETY DECALS
P/N DCL160
TLW-300SS DC WELDER/ AC GENERATOR— OPERATION AND PARTS MANUAL— REV. #2 (04/07/10) — PAGE 9
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TLW-300SS — SPECIFICATIONS |
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Table 1. Specifications |
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Welder Specifications |
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Model |
BLW-300SS |
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Type |
Brushless, revolving, field type generator |
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Rated Current |
280A |
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Rated Voltage |
31.2V / 25V |
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Range of Current |
35~300A |
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Duty Cycle |
50% / 100% |
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Generator Specifications |
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Frequency |
60 Hz |
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Speed |
3600 rpm |
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Max. Output |
10.5kW |
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Rated Output |
10.0kW |
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Voltage |
120/240 V |
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Engine Specifications |
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Model |
KUBOTA D722EB |
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Type |
4 Cycle, vertical |
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No. of Cylinders |
3 cylinders |
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Bore x Stroke |
2.64 in. x 2.68 in. (67 mm x 68 mm) |
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Rated Output |
18.8HP/3600 rpm |
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Displacement |
43.9 cu. in. (719 cc) |
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Starting |
Electric |
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Coolant Capacity |
.55 gal. (2.1 liters) |
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Lube Oil Capacity |
.83 gal. (3.15 liters) |
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Fuel Consumption |
Welding .66 gal. (2.5L)/hr |
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AC Power 1.14 gal. (4.3L)/hr |
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Fuel Capacity |
Approx. 9.5 gal (36 liters) |
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Fuel type |
#2 Diesel Fuel |
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Battery |
12V45AH |
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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
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Table 1. Specifications |
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MODEL |
APPLICATION |
FUEL |
BRAKE |
GVWR |
FRAME |
FRAME |
JACK |
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CELL |
SYSTEM |
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LENGTH |
WIDTH |
STAND |
TRLR-10W |
SDW225, |
NO |
NO |
1900LBS |
96" |
50" |
800LB. |
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SGW250,TLW300 |
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FULL TILT WHEEL |
TRLR-10 |
DCA10, TLG12, |
NO |
NO |
1900LBS |
96" |
50" |
800LB. |
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DCA-15 |
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|
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)