Multiquip TLW-300SS User Manual

PARTS AND OPERATION MANUAL

OPERATION AND PARTS MANUAL

WHISPERWELD

TM

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 ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

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

TABLE OF CONTENTS

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

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)

r

Best Deal!

PARTS ORDERING PROCEDURES

Ordering parts has never been easier!

Choose from three easy options:

Order via Internet

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

N View Parts Diagrams
N Order Parts
N Print Specification Information

(Dealers Only)

:

If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.

com.

To obtain an MQ Account, contact you
District Sales Manager for more information.

January 1

Effective:

st

, 2006

Goto www.multiquip.com and click on

Order Par ts

Order via Fax

All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)

to log in and save!

(Dealers Only)

:

Order via Phone:

Non-Dealer Customers:

Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.

When ordering parts, please supply:

R Dealer Account Number
R Dealer Name and Address
R Shipping Address (if different than billing address)
R Return Fax Number
R Applicable Model Number
R Quantity, Part Number and Description of Each Part

Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*

Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*

Domestic (US) Dealers Call:

1-800-427-1244

International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.

R Specify Preferred Method of Shipment:
UPS/Fed Ex DHL

N Priority One Truck 
N Ground
N Next Day
N Second/Third Day

Note: Discounts Are Subject To Change

Note: Discounts Are Subject To Change

NOTICE

All orders are treated as Standard Orders and will

ship the same day if received prior to 3PM PST.

www.mqpower.com

WE ACCEPT ALL MAJOR CREDIT CARDS!

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

RULES FOR SAFE OPERATION

CAUTION:CAUTION:

CAUTION:

CAUTION: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

■

DO NOT operate or service this equipment before
reading this entire manual.

■

This equipment should not be operated by
persons under 18 years of age.

■

NEVER operate this equipment without proper
protective clothing, welding shield, ventilator,
steel-toed boots and other protective devices
required by the job.

■

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

■

High Temperatures – Allow the engine to cool before adding
fuel or performing service and maintenance functions. Contact

hot

with

■

The engine of this welder/AC generator requires an adequate
free flow of cooling air. Never operate the welder/AC generator
in any enclosed or narrow area where free flow of the air is

components can cause serious burns.

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.

■

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.

■

■

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
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

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

smoke around or near

bodily harm or even death.

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

CAUTIONCAUTION

CAUTION

CAUTION:CAUTION:

CAUTION:

CAUTION: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
for your protection. Always complete the grounding path from
the welder/AC generator to an external grounding source.

■

NEVER operate this welder/AC generator, or handle any
electrical equipment while standing in

while hands are wet, or in the rain. Dangerous electrical
shock could occur causing severe bodily harm or even death.

■

This welder/AC generator requires an adequate free flow of
cooling air. Never operate the welder/AC generator in any
enclosed or narrow area where free flow of the air is restricted.
If the air flow is restricted it will cause serious damage to the
welder/AC generator and may cause injury to people.

■

Arc rays can cause blindness. Always wear protective
shield when welding.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

:

ground terminal

water, while bare foot,

CAUTIONCAUTION

■

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.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

RULES FOR SAFE OPERATION

:

:

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

■

and
Also know the phone numbers of the nearest

■

NEVER touch output terminals or electrode during
operation. This is extremely dangerous. Always stop the
machine when contact with the output terminals and
welding electrode.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

■

Never connect the welder/AC generator to house wiring.
This is illegal and very dangerous. Electrical shock could
occur causing damage to the welder/AC generator and
bodily harm even death.

:

doctor

in the case of an emergency.

Maintenance Safety

■

■

■

■

■

■

■

Always know the location of the nearest

first aid kit

and

NEVER lubricate components or attempt service on a running
machine.

Always allow the machine a proper amount of time to cool
before servicing.

Keep the machinery in proper running condition.

Fix damage to the machine immediately and always replace
broken parts.

Dispose of hazardous waste properly. Examples of potentially
hazardous waste are used motor oil, fuel, coolant and fuel
filters.

DO NOT use plastic containers to dispose of hazardous
waste.

DO NOT pour waste, oil, coolant or fuel directly onto the
ground, down a drain or into any water source.

. Know the location of the nearest telephone.

fire department

. This information will be invaluable

fire extinguisher

ambulance

,

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

ledoMSS003-WLB

epyTrotarenegepytdleif,gnivlover,sselhsurB

tnerruCdetaRA082

egatloVdetaRV52/V2.13

TLW-300SS — SPECIFICATIONS

snoitacificepS.1elbaT

snoitacificepSredleW

aRA003~53

taRmpr0063/PH8.81

tnerruCfoegn

elcyCytuD%001/%05

ycneuqerFzH06

deepSmpr0063

tuptuO.xaMWk5.01

tuptuOdetaRWk0.01

egatloVV042/021

ledoMBE227DATOBUK

epyTlacitrev,elcyC4

srednilyCfo.oNsrednilyc3

ekortSxeroB)mm86xmm76(.ni86.2x.ni46.2

tuptuOde

tnemecalpsiD)cc917(.ni.uc9.34

snoitacificepSrotareneG

snoitacificepSenignE

gnitratScirtcelE

yticapaCtnalooC)sretil1.2(.lag55.

OebuL)sretil51.3(.lag38.

yticapaCli

noitpmusnoCleuF

yticapaCleuF)sret

epytleuFleuFleseiD2#

yrettaBHA54-V21

.lag66.gnidleW rh/)L5.2(

.lag41.1rewoPCA rh/)L3.4(

il63(lag5.9.xorppA

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

°°

°

Fahrenheit above the standard temperature of 60

°°

F.

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 Model TLW-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

control panel

The



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



Ground Terminal

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.

is provided with the following:

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
engine. This engine is designed to meet every performance
requirement for welder/AC generator. Reference Table 1, page
10 for engine specifications.

In keeping with MQ Power's policy of constantly improving
its products, the specifications quoted herein are subject to
change without prior notice.

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

diesel

Battery Charge Indicator

This unit is equipped with a protective device that signals
an indicator and automatically stops the engine when the
battery cannot be charged by the alternator.

Water Temperature Indicator

This unit is equipped with an apparatus that signals an
indicator and automatically stops the engine when the cooling
water temperature becomes abnormally high. This apparatus
will not function properly if the machine is operated with
less than the proper amount of coolant.

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.

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:CAUTION:

CAUTION:

CAUTION:CAUTION:

ALWAYS make sure the trailer is in good
operating condition. Check the tires for
proper inflation and wear. Also check the
wheel lug nuts for proper tightness.

Explanation of Chart:

This section is intended to provide the user with trailer ser­vice and maintenance information. The service and main­tenance guidelines referenced in this section apply a wide
range of trailers. Remember periodic inspection of the trailer
will ensure safe towing of the equipment and will prevent
damage to the equipment and personal injury.

It is the purpose of this section to cover the major mainte­nance components of the trailer. The following trailer com­ponents will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



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

CELL

TRLR-10W SDW225,

SGW250,TLW300

TRLR-10 DCA10, TLG12,

DCA-15

TRLR-10XF DCA10, TLG-12,

DCA15, TLW-300

TRLR-225W WELDERS,

DA7000SS

TRLR-BLW400 BLW-400 NO ELECTRIC 2700LBS W/MAST 154"

TRLR-50X DCA-25 NO NO 2700LBS 124" 55" 800LB.

TRLR-50XF DCA-25 41 GAL NO 2700LBS 124" 55" 800LB.

TRLR-70W D CA -45, -60, 70 NO SURGE 7000LBS 186" 77" 2000LB.

TRLR-70X DCA-45, -60, 70 OPT SURGE 7000LBS 13 8" 66" 2000LB.

TRLR-70XF DCA -45, -60, 70 53 GAL SURGE 70 00LBS 138" 66" 2000LB.

TRLR-100XF DC A -100, 125 150 GAL HYDRAULIC SURGE 7000LBS 190" 76" 2000LB.

TRLR-85/125 DCA-85, 100,

125

TRLR-150XF DC A -150, 180 200 GAL HYDRAULIC SURGE 11160LBS 204" 84" 5000 LB.

TRLR-220XF DCA-220 25 0 GAL HYD RAULIC SURGE 14000LBS 222" 83" 50 00 L B .

TRLR-300XF DCA-300 25 0 GAL HYD RAULIC SURGE 18000LBS 238" 83" 50 00 L B .

TRLR-400XF DCA-400 350 GAL ELECTRIC 18000LBS 238" 83" 5000 LB.

TRLR-600XF DCA -600, 800 550 GAL AIR 30000LBS 384" 96" 5000 LB.

TRLR-800SX DCA-600, 800 550 GAL AIR 30000LBS 384" 96" 5000 LB.

NO NO 1900LBS 96" 50" 800LB.

NO NO 1900LBS 96" 50" 800LB.

52 GAL NO 1900LBS 96" 50" 800LB.

NO NO 2200LBS 85" 42" 800LB.

145 GAL HYD RAULIC 10000LBS 186" 77" 2000LB.

BRAKE

SYSTEM

GVWR FRAME

LENGTH

W/O 124"

FRAME
WIDTH

55"

(78" TALL )

JACK

STAND

FULL TILT WHEEL

FULL TILT WHEEL

FULL TILT WHEEL

FULL TILT WHEEL

800LB.

FULL TILT WHEEL

FULL TILT WHEEL

FULL TILT WHEEL

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT PAD

FL AT 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

TRLR-10 2"BALL CLASS

TRLR-10XF 2"BALL CLASS

TRLR-225W 2"BALL CLASS

TRLR-BLW

400

TRLR-50X 2" BALL CLASS B78-13LRC 13"X4.50" 3500lbs.

TRLR-50XF 2" BALL CLASS B78-13LRC 13"X4.50" 3500lbs.

TRLR-70W 2" BALL CLASS

TRLR-70X 2" BALL CLASS

TRLR-70XF 2" BALL CLASS

TRLR-100XF ADJUSTABLE 2-5/6

TRLR-85/125 ADJUSTABLE 2-5/6

TRLR-150XF 3" BALL EYE 750-16 E

TRLR-220XF 3" E YE

TRLR-300XF 3" E YE

TRLR-400XF 3" EYE

TRLR-600XF 5TH WHEEL ST215/75R17.5H

TRLR-800AR 5TH WHEEL ST215/75R17.5H

2 ADJUSTABLE

2 ADJUSTABLE

2 ADJUSTABLE

2 ADJUSTABLE
2"BALL CLASS

2 ADJUSTABLE

3" ADJUSTABLE

3" ADJUSTABLE

3" ADJUSTABLE

OPT 3" EYE

OPT 3" EYE

ADJUSTABLE

ADJUSTABLE

ADJUSTABLE

175-13C 13"X4.50" 2200# 2X2 5 LUG 3 LEAF 4 WIRE LOOM W/

175-13C 13"X4.5" 2200#2X2 5 LUG 3 LEAF 4 P OLE FLAT

175-13C 13"X4.5" 2200#2X2 5 LUG 3 LEAF 4 P OLE FLAT

175-13B 13X 4.5" 2200#2X2 5 LUG Q FLEX 4 POLE FLAT

175-13C 13 X 4.5" 2200#2X2 5 LUG 3 LEAF 4 POLE FLAT

5 LUG 4 LEAF 4 POLE RUBBER

5 LUG 4 LEAF 4 POLE RUBBER

5 LUG 5 LEAF 4 POLE RUBBER

5 LUG 5 LEAF 4 POLE RUBBER

5 LUG 5 LEAF 4 WIRE LOOM

205-14C
BIAS (4)

205-14C
BIAS (4)

205-14C
BIAS (4)

205-15C
BIAS (4)

ST225/75R15D

RADIAL (4)

BIAS (4)

ST235/85R16E

RADIAL(4)

ST235/85R16E

RADIAL(6)

ST235/85R16E

RADIAL(6)

RADIAL (8)

RADIAL (8)

2-3/8"

2-3/8"

14"X5" 3500lbs.

3"

14"X5" 3500lbs

3"

14"X5" 3500lbs.3"5 LUG 5 LEAF 4 POLE RUBBER

14"X5.5" 3500lbs

3"

14"x6" (2)-6000lbs 6 LUG 7 LE A F 4 WIRE LOOM

16"X7" (2)-6000lbs 8 LUG 7 LEAF 4 WIRE LOOM

16"X7" (2)-7000lbs 8 LUG Q FLEX 4 WIRE LOOM

16"X7" (2)-6000lbs 8 LUG Q FLEX 4 WIRE LOOM

16"X7" (3)-7000lbs. 8 LUG Q FLEX 4 WIRE LOOM

16"X7" (3)-10000lbs 8 LUG 7 LEAF 6 WIRE LOOM

16"X7" (3)-10000lbs 8 LUG AIR-RID E 6 WIRE LOOM

4 POLE FLAT

FLAT

FLAT

FLAT

FLAT

FLAT

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.

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.

CAUTION:

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)

metI ).sbL-.tF(euqroT

TLOB-U"8/353-XAM03-NIM

TLOB-U"61/706-XAM54-NIM

TLOB-U"2/106-XAM54-NIM

TLW-300SS —TRAILER SAFETY GUIDELINES

stnemeriuqeReuqroTnoisnepsuS.4elbaT

SHACKLE BOLT

SPRING EYE BOLT

SHOULDER TYPE

SHACKLE BOLT

SNUG FIT ONLY.PARTS MUST ROTATE FREELY

LOCKING NUTS OR COTTER PINS ARE PROVIDED TO

-

RETAIN NUT

BOLT ASSEMBLY

.

.

05-XAM03-NIM

Lug Nut Torque 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.

stnemeriuqeReuqroTeriT.5elbaT

eziSleehWssaPtsriF

SBL-TF

ssaPdnoceS

SBL-TF

ssaPdrihT

SBL-TF

"2152-0204-5356-05

"3152-0204-5356-05

"4152-0206-05021-09

5152-0206-05021-09

"

"6152-0206-05021-09

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 :CAUTION :

CAUTION :

CAUTION :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
while parked.

■

Place
prevent

■

Use the trailer's hand winch to adjust the height of the trailer,
then insert locking pin to lock wheel stand in place, while
parked.

■

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.

chocked blocks

support blocks

tipping

underneath wheel to prevent

underneath the trailer's bumper to

, while parked.

rolling,

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 the Voltage for welding/load.

2. AC Voltmeter- 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. Ignition Switch with Key- Used to start and preheat engine.

6. Engine Warning Indicators- Lights red when the following

conditions occur:



Low Oil Pressure



High Water Temperature



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. Negative Welding Output Terminal-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 — OUTPUT TERMINAL OVERVIEW

Figure 7. Duplex Receptacle Detail

Figure 6. Output Terminal Panel

120 Volt 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
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 :CAUTION :

CAUTION :

CAUTION :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 :CAUTION :

CAUTION :

CAUTION :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.

Circuit Breakers

To protect the welder/AC generator from an overload,

42 amp,
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.

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.

/)tf(htgneLelbaClatoT

)A(tnerruC

05001521051002052003

a 2-pole,

main

circuit breaker is provided. In addition, three

seziSelbaCgnidleW.6elbaT

0013#3#3#3#3#3#3#

0513#3#3#3#2#1#1#

0023#3#2#1#0/1#0/2#0/3#

0523#2#1#0/1#0/2#0/3#0/3#

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.

yticapaCrewoPCA/gndleWCD.7elbaT

EZISEDORTCELEGNIDLEWYTICAPACECRUOSREWOPCA

0Wk5.01

"8/1ot"23/3Wk5.3

"23/5Wk5.2

"61/3Wk5.1

"4/1ot"23/7Wk8.0

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

TLW-300SS — PRE-SETUP

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.

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 :CAUTION :

CAUTION :

CAUTION :CAUTION :

Coolant

Never fill the fuel tank while the engine is
running or in the dark. Fuel spillage on a
hot engine can cause a fire or explosion.
If fuel spillage occurs, wipe up the spilled
gasoline completely to prevent fire
hazards.

Figure 9. Engine Oil Dipstick

F°32~F°401

)C°5-~C°04(

F°5~F°32

)C°51-~C°5-(

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

egnaRerutarepmeTliOepyT

for further details.

liOrotoMdednemmoceR.8elbaT

W04EASroW03EAS

W01EASroW02EAS

oleBW01EAS

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

)°51-(C°5w

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Day-to-day addition of coolant or antifreeze is done from the
reserve tank. See Table 9 for engine, radiator and reserve
tank coolant capacities. Make sure the coolant level in the
reserve tank is always between the "H" and the "L" markings.

:

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

yticapaCtnalooC.9elbaT

rotaidaRdnaenignE.laG55.0

Cleaning the Radiator

The radiator may overheat if the fins become overloaded
with dust or debris. Periodically clean the radiator fins with
compressed air.

Fan Belt Tension

A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect and adjust it in
accordance with the

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

TLW-300SS — PRE-SETUP

Kubota Engine Operator's Manual

.

knaTevreseR.laG72.0

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.

serutarepmeTgnitarepOezeerF-itnA.01elbaT

tnioPgnizeerFtnioPgnilioB

%loV

ezeerF-itnA

C°F°C°F°

0442-21-601222

0573-43-80

NOTE

1622

Figure 10. Fan Belt Tension

CAUTION :CAUTION :

CAUTION :

CAUTION :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

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.

Kubota Engine Operator's Manual.

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

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

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.

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :

TLW-300SS — INSTRUMENTATION

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

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 a u t o m a t i c a l l y
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.

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.

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

TLW-300SS — LOAD APPLICATION

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.

daoLyBrotcaFrewoP.11elbaT

daoLfOepyTrotcaFrewoP

CAUTION:

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:

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

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

Before connecting this welder/AC
generator to any building’s electrical
system, a licensed electrician must install
an isolation (transfer) switch. Serious
injury or death may result without this
transfer switch.

srotomnoitcudniesahp-elgniS57.0-4.0

tnecsednacni,sretaehcirtcelE

spmal

m,spmaltnecseroulF9.0-4.0

tnempiuqe

slootrewopnommoC8.0



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.

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

spmalyrucre

noitacinummoc,secivedcinortcelE

0.1

0.1

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).

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 11. Electrode Cable Connection

(Correct)

YTIRALOPDOHTEMGNIDLEWSNOITACILPPALACIPYT

)+(

...

ytiraloPthgiartS

)-(yollareppocrofgnidlewcrA

ytiraloPesreveR

+(

...

)

Figure 12. Electrode Cable Connection

(Incorrect)

snoitacilppAgnidleW.21elbaT

pmalCdnuorG

)lateMesaB(

redloHedortcelE...

redloHedortcelE...)+(

setalpniht

pmalCdnuorG

)lateMesaB(

larenegrofslairetamleetsgnidleW

.setalpssenkcihtdna,serutcurts

fognidlewcra,gnidlewpu-dliuB

leetssselniatsfognidlewcrA

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.

elcyCytuD.31elbaT

)%(elcyCytuD00108

)spmA(tnerruCsselro082003

CAUTION :CAUTION :

CAUTION :

CAUTION :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.

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.

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.

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