INSTRUCTION MANUAL Soundproof Engine Welder/Generator MODEL : TLW-300 SSY (50Hz)(60Hz) A Caution: Do not attempt to operate this machine until you have Read and understood completely All instructions and Guidelines contained. Atall times, keep this manual readily available for operators and service engineer. Denyo Co., Ltd. HEAD OFFICE NO. 2,4-CHOME, KAMITAKADA, NAKANO-KU, TOKYO, JAPAN TEL. 03(3228" )1111 FAX. 03(5380)7171CONTENTS Please Use the Machine in Accordance with the following Instructions ‘Symbol mark in this Manuel SAFETY PRECAUTIONS, Instrumentation Names - 3. Operation Procedures — 31 The following checks before start-up must be ubdertaken 3.2 Starting and operating 3.3 Stopping the engine 3.4 Operating precautions 3.5 Emergency stop devices 4. Operation of the welder ~~. 4.1 Connection and polarities of welding cable 4.2 Selection of welding cable 4.3. Adjustment of weldingcurrent 4.4 Slowdown unit -—~. 4.5 Dutyoycle -. 4.6 Inwelding operation — 4.7 ACpower supply —-. 5. Earth leakage Relay ( Option Parties ) ~~~ 6. Lubricating Oll Cooling Water and Fuel - 6.1 Engine Oil - 6.2 Engine Cooling Water - 6.3 Fuel 7. Maintenance - rE 7.4 Required Maintenance for the Initial 50 Hours. 7.2 Maintenance Check Every 100 Hours of Operation 7.3 Maintenance Check Every 260 Hours of Operation 7.4 Maintenance Check Every 300 Hours of Operation 7.5 Maintenance Check Every 400 Hours of Operation 7.6 Maintenance Check Every 500 Hours of Operation 7.7 Maintenance Check Every 1000 Hours of Operation 7.8 Other Checks and Maintenance 7.9 Maintenance Check List ~ 8. Troubleshooting 9. Storage of Machine 10. Major specifications - 11. Generator Wiring Diagram 12. Engine Wiring Diagram - 13. Outline Drawing ---Please use the Machine in Accordance with the following Instructions. + This INSTRUCTION MANUAL" gives a detailed description of the operation, routine inspection, maintenance and trouble-shooting of the welder/generator, and other items required for proper operation. ‘+ Please read this manual carefully, especially the contents and caution symbols. ‘+ While the gonerator is in i's place of operation, please keep the instruction manual in a place readily available to operators and service engineers. For the detailed operation and maintenance of the ENGINE, please refer to the “Engine Operation Manual” , supplied by the engine manufacturer. aa IN Geration Serial_No. AD, Your Machine: [NOTE]: There may be a difference between the specifications detailed in this manual and the actual performance of the machine due to modifications of the machine, ‘Symbol mark in this Manual Z\ dancer: indicates an imminently hazardous situation which. If not avoided. will result in death or serious injury. Z\ caution: indicates a potentially hazardous situation Which, if not avoided, may result in minor or moderate injury or property-damage. [ NOTICE ] = Notice is used to notify people of installation, operation, or Maintenance information which is important but not hazard- related.SEFETY PRECAUTIONS AN DANGER A DANGER: AN DANGER AN DANGER : A DANGER : ENSURE GOOD VENTILATION : FIRE PREVENTION Exhaust from the engine contains substance harmful to the hut body. Sufficient change of air is necessary when the machine is used in places with poor ventilation, such as in a tunnel or indoors. Do not direct exhaust to passers-by or houses. Fuel and oil are inflammable. Never fail to keep inflammable material ‘away from the machine, never smoke while refueling and never refuel during operation. : WATCH OUR FOR ELECTRIC SHOCKS Do not touch output terminals during operation, This is extremely dangerous when your hands fare wet. Stop the machine when you touch the terminals for connection and other purposes.” NO CONNECTION TO HOUSE WIRING Connecting to house wiring is illegal and very dangerous because it may cause electric shocks and damage the generator. CONFIRM CONNECTION Damaged cables and insufficient tightening of connection screws may cause damage to the machine and electric shocks. Repair damaged cables and ensure connections are tight.A DANGER : A CAUTION Z\ caution DURING OPERATING Do not open any of the following items while the generator is running and immediately after the generator has stopped. 1. Radiator Cap ‘Only perform these checks when the engine is cold, to avoid injury. Do not, at anytime, when the engine is stil hot, remove the radiator cap. Opening the radiator cap when the engine is hot will result in boiling water gushing out of the radiator which will scald nearby people. 2. Cooling Water Drain Plug Opening the cooling water drain plug when the engine is hot will resulf in boiling water gushing out of the engine which will scald nearby people. 3. Engine Oil Drain Plug Opening the engine oil drain plug when the engine is hot will result in boiling oil gushing out of the engine which will scald nearby people. 4. Do not touch while operating the generating set, the engine cooling fan and other place of high temperature like the exhaust pipe, engine and radiator. Even when the machine is stopped, take care that the machine has cooled down enough before touching the engine and the like. Battery As the battery contains combustible gas, take extreme care in handling the battery. If you are careless, like dropping the battery, there is a risk that the battery may explode. In carrying out maintenance or inspection check, recharging and using booster cables, extreme care should be taken to ensure safety. :Strictly Prohibited Do not expose the battery to naked flames, sparks, cigarettes and like, As the battery contains flammable liquid and gas.A CAUTION :There is a risk of an explosion if you do not charge the battery A CAUTION A CAUTION : as there will be build-up of combustible gas. The recharging process and handling the battery should be done in an area that is exposed to an air current, to avoid the risk of a dangerous concentration of combustible gas. In case the battery liquid (dilute sulphuric acid) happens to ‘come in contact with clothing or skin, you must immediately rinse it out by using a lot of water. If the battery liquid comes. into contact with your eyes, wash it out with lot's of water and seek medical attention immediately. When welding operation, use a helmet or a hand-shield-mask in order to protect an operator's eyes from arc and to protect his face, neck, and ears from radiant t energy directly emanated from arc. stit Select a protective lens with the appropriate tinting.1. Preparations * This machine has undergone stringent factory tests and inspections to ‘ensure the machine performs in accordance with its specifications, before been shipped to the end user. * As with any piece of motorized machinery, excessive use of a brand new machine may shorten the life of the machine. Therefore, it is Tecommended for the initial 50 hours of machine usage, special care is required for this break-in period. * Upon receipt of the machine, please perform a maintenance check of the machine BEFORE USE, so as to further ensure there are no major matfunctions or damage to the machine that occurred during transit. * We recommend the machine be placed upon a level surface, where there is not excessive dust or moisture, 1.1, When using the machine in places where there is inadequate ventilation, make sure the following care is taken: DANGER : Ensure good ventilation Exhaust from the engine contains substances harmful to the human body. Sufficient change of air is necessary when the machine is used in places with poor ventilation, such as in a tunnel or indoors. Do not direct exhaust to passers-by or houses. 1.2. Caution in Machine Transporting DANGER : In cases where wheels are fixed to the generator, for better mobility, make sure blocks are used stop the generator from moving when operating and transporting the generator. AN baNceR : When transporting and loading (unloading) the machine, you must use the balanced centre-point lifting hook which is situated on the top panel of the machine. ZN DANGER : Caution should be taken in transporting the machine to a particular job site. It is advisable when lifting the machine to use the balanced centre-point lifting hook.. Trucks and the like should be ‘used as a means of transportation. When loaded on a truck be sure to use the bar on the front and back of the machine, as a means to affix the machine during eet Liteine tot \,1.3. Notice for installation. [Notice ] : [Notice] : [ Notice ] [Notice] : [Notice] : [Notice] : Make sure the generator is placed on a secure and level surface. In case of using the generator on an inclined surface, the allowable inclination angle is up to around 20 degrees. ‘Avoid using the generator in places of high humidity. Avoid using the generator in places where the surrounding temperature is likely to rise over 40 degrees Celsius. Avoid using the generator in places where there is excessive dust, noxious gases and explosive gases. Provide adequate space for machine Inspection and maintenance. Do not have any obstacles within a 1 meter from the machine. Failing to do so, may cause the machine to overheat. 1.4. Caution During Operating. While operating the welder/generator set, you should check the instruments on the control panet (eg voltmeter, indicator lamp, etc. to make sure the machine is working correctly), on a timely basis. CAUTION : DURING OPERATING Do not open any of the following items while the welder/generator is’ running and immediately: after the welder/generator has stopped. 1. Radiator Cap Only perform these checks when the engine is cold, to avoid injury. Do not, at anytime, when the engine is still hot remove the radiator cap. Opening the radiator cap when the engine is hot will result in boiling water gushing out of the radiator which will scald nearby people. 2. Cooling Water Drain Plug Opening the cooling water drain plug when the engine is hot will result in boiling water gushing out of the engine which will scald nearby people. 3, Engine Oil Drain Plug Opening the engine oil drain plug when the engine is hot will result in boiling gushing out ef the engine will scald nearby people. 4. Do not touch while operating the welding/generating set, the engine cooling fan and other places of high temperature like the exhaust pipe, engine and radiator. Even when-the machine is stopped, take care that the machine has cooled down enough before touching the engine and the like.1.5. Battery. Proper maintenance of the battery is extremely important to ensure ‘smooth starting and long service life. Check the specific gravity, level of electrolyte and output voltage every 50 hours or once every month. [Notice ] [ Notice ] A CAUTION Z\ caution AN CAUTION A CAUTION : If the specific gravity is 1.28 ( at 20 °C ), the battery is adequately charged. If the specific gravity is 1.245 or less recharging is necessary. The electrolyte must always cover the plates. If the plates are exposed to air for a long time, damage will result. Apply a thin coat of grease, to ensure a good connection. : As the battery contains combustible gas, take extreme care in handling the battery. if you are careless, like dropping the battery, there is a risk that the battery may explode. In carrying out maintenance or inspection check, recharging and using booster cables, extreme care should be taken to ensure safety. Strictly Prohibited Do not expose the battery to naked flames, sparks, cigarettes and the like, as the battery contains flammable liquid and gas. ‘There is a risk of an explosion if you do not charge the Battery as there will be a build-up of combustible gas. The recharging process and handling the battery should be done in an area that is exposed to an air current, to avoid the risk of a dangerous concentration of combustible gas. : In case the battery liquid ( diluted sulphuric acid ) happens to come in contact with clothing or skin, you must immediately rinse it out by using-a lot of water. If the battery liquid comes into contact with your eyes, wash it out with lot's of water and seek medical attention immediately.2. Instrumentation Names. zZ 2.1. Outline Draw and Name of Instrument. 4. Control panel 6. Bar { for rope ) 14. Water drain 2. Fuellevel gauge 7. Airintake * 42. Oildrain 3. Fuel tank inlet 8. Exhaust 43. Radiator inlet 4. Lifting hook/lug 9. Ventilation 14. Wheel (option) 5. Door latch 10.Fuel drain 2.2. Name of Components 1. Alternator 2. Diesel Engine Air Cleaner Fuel Tank Fuel Filter Oil Inlet Oil Filter Oil Level Gauge . Radiator 10.Radiator Reserve Tank 14.Battery 42.Junetion Terminal 13.Fuse O@NBMRE2.3.Control Panel and Name of Instruments. 1. Current Regulator Current Range Selector Switch Circuit Breaker Single Phase Output Respectable (option ) Indicator Lamp Unit (oil pressure, cooling water, battery charging and pre-heat ) A.C. Voltmeter Idling Control Switch Starter Switch . Earth Leakage Relay ( option ) 10. Hour Meter 11.DC Welding Output Terminal (+,-) 12. There Phase Output Terminal 13. Earth Terminal for Earth Leakage Relay ( option ) 14. Single Phase Output Terminal 3. Operating Procedures. 3.1. The following checks before start-up must be undertaking. (1) Oil Check ‘* Be sure to check the oil level before start-up everyday. The oil level must be maintained between the two level notches on the dipstick. If the oil level is below the lower notch, immediately replenish the oil, so that the oil level lies between the two notches on the dipstick. Do not overfill, so that the oil level is greater than the upper notch, as this may cause the oil seals of the engine to fail, causing an oil leak. * When checking the oil level, be sure to check if the oil is clean and viscous. If the oil is not clean, drain the oil by removing the oil drain plug and then re-fit the oil plug and replenish the oil * After a specified amount of engine oil is supplied, run the engine for several minutes and then stop it to re-check the oil level again. 2 PEN ©2N® Engine Oil Capacity 3.45 Liters Engine Oil Usage 1.50 Liters: [ Notice ] : Use only high quality lubricating oil with classification CC and CD. [Notice |": Grades of lubricating oil ( service classifications ) CA, CB, CC, CD — Diesel Engine Classification. [Notice } : Selection of engine oil viscosity. Use oil with viscosity most suitable to the temperature under which the machine is iused. For example, SAE30 ( oil for summer time use ), SAE20 ( oil for wintertime use ) and SAE10W-30 ( oil for all season use ). Oil with viscosity not susceptible to temperature are recommended.(2) Check the Cooling Water. In checking and replenishing the cooling water, make sure that the engine is cold. Check that the reserve water tank (sub-tank) water level is between the high (H) and low (L) lines of the level gauge. When the cooling water in the reserve tank is at a low level, immediately refill it. The radiator when it's water level is low will automatically draw on the water from the reserve tank. [Notice ] : When refilling the engine's cooling water, be sure to use tap water. Do not use river or rain water as it may cause trouble for the engine cooling system. (3) Check the Fan Belt. Check the belt for tension and elongation and adjust them as required. Concurrently, check that the belt has not been damaged and immediately replace it if any abnormality is noted on the belt Perform the adjustment and replacement as directed in the “Instruction Manual" provided by the Engine Manufacturer. Fan Belt Part No. : 060 20 114 80 (4) Check the Fuel. ‘©. Check the fuel level by looking at the fuel gauge. If the level is low refill the fuel tank. [ Notice ] : Only use ASTM No.2 Diesel Fuel or Heavy oil which the __engine Manufacturer recommends. Do not use substitute oils and kerosene as the quality. is unknown and the octane (cetane) number is low. Use JIS Special No.3 Diesel Fuel for temperatures below -15°C. * From time to time, it is important to drain the fuel tank, as contaminants will build up at the bottom of the fuel tank. Unplug the fuel tank. Unplug the fuel tank drain at the side of the generator base and replug the drain to refill with fresh supply of diesel fuel.~ [ Notice ] : The fuel inlet has drain hole for overflow of fuel and rain. When refueling, be sure to remove dust, mud, etc that will build up around the fuel inlet. If this is not done, the fuel inlet will choke up and there is a greater change of contaminants entering the fuel tank. 10 RESERVE WATER TANK csA Danger : FIRE PREVENTION Fuel and oil are inftarimable. Never fal to keep inflammable material away from the machine, never smoke while refueling and never refuel during operation. (6) Battery Check. + Always ensure the level of battery fluid is always maintained above the low level mark. If the battery fluid level is low, distilled water should be immediately supplied to the battery [ Notice ] : Do not refill the battery over the upper level mark. Always remember to tighten the battery cap properly after refilling the battery. (6) Battery Cable Connection. ‘+ Make sure the battery cable is properly connected to the battery terminals (+) and (-) [Notice] : If the cable is connected incorrectly, damage to the electrical parts will result in a short period. BATTERY * Always check or connect the battery cable connection when the starter key switch is in the off position. * [Notice ] : Do not connect the cables to the battery terminal when the starter switch is "ON", because electric sparks will be produced. This may injure the operator and cause damage to the machine's electrical components. [Notice ] : It is recommended that a thin film of grease be applied to the battery terminals to ensure a good connection and the prevention of corrosion of the battery terminals. An insufficient or poor connection may cause poor starting of the machine and other malfunctions to occur. (7) Fuel Filter Cock. «Tum the fuel filter cock lever from:the close position to the ‘open position. (8) Check the Wiring. «Inspect the wiring to ensure that all wire connections are not : loose and that no wires are worn out. << If any wor out or damaged wires or connections are noticed either repair it or replace it immediately. (8) Check the Piping and Hose Connections. § * Check that all piping and hose connections are not loose. If these connections are loose and not rectified, oil leakages and cooling water leakage may occur during operation. Make sure all loose connections are rectified. ‘© Check that all hoses are not worn out. If'a hose is found to be worn out or damaged, repair or replace it immediately ul3.2, Starting and Operating ‘* Before starting the machine, the pre-starting safety checks must be completed. In addition, do a general survey of the area surrounding the machine making sure the area is safe, air vents of the machine are not blocked an the exhaust can freely be discharged. The machine can be started, once the people surrounding the machine have been notified that the machine is going to be used. [ Notice] : In cold operating conditions, use suitable cooling water and lubricating oil for improved starting and prevention of any troubles. The battery must always be maintained at full charging level. (1) Insert the key into the “Starter Switch” and tum it to the "Run” position. When the key is in the “Run” position, the indicator lamp will come on. During the starting procedure, Run-Pre-heat the indicator lamp acts as a “Pre-heat 27 indicator.” (2) Once the indicator lamp goes off, turn the key to the “Start” position ‘to start the engine. As soon as the engine starts, release the key whereby the key will automatically return to the "Run" position (3) After the engine starts, let the machine idle for § ~ 10 minutes to warm-up. [ Notice ] : After the engine is started, check to see that the oll Pressure lamp and battery charging lamp are off. If one of these lamps is on, check the machine after the engine is turned off. (Refer to the Operation Manual for details) [Notice ] : While the engine is operating. do not tum the starter switch on. Note, if the engine does not start within 10 seconds after the key is tumed to the “Start” position, wait for at Jeast 30 seconds and repeat the starting procedure again. LP p sea SP ON/Idling Note : During winter or when the surrounding air temperature is cold, in situations where a load start is required, turn the key to the “Run-pre-heat position’, you ‘must wait until the engine indicator lamp goes off.” 12[Notice ] : After the engine has started, if you continue to hold the key in the start position, damage will be caused to the starter. The key switch must be retumed to the “Run’ position within 10 seconds of starting the engine. In situations where the sounds of the engine furning over cannot be heard in trying to start the machine, repeat the starting procedure from the beginning in accordance with the ‘Operation Manual, after about 30 seconds. If the machine. fails to start despite repeating the starting procedure, there is obviously some problem with the machine, Therefore a through check is required (eg: fuel has run out, forgetting to turn the fuel cock to the open position, excessive air in the fuel system and battery leakage) (4) Carefully check the engine for abnormal vibration (noise), oil leakage, fuel leakage, cooling water leakage and air leakage. If the machine is operating normally, set the "Circuit breaker” to the ON position in order to Supply electricity to the load. {Notice ] : While the machine is operating, do not have any obstacles within a 1 meter radius from the machine. Failing to do so, may cause the machine to overheat. [ Notice]: Do not have any of the doors of the machine open while operating. The main problems with leaving the doors of the machine open during operating are the effect in the internal cooling air-flow of the machine and alien substances (eg dust and dirt) will be drawn into the machine, Note : How to Use the Automatic Air Vent Device When the engine stops due to running out of fuel, take off the fuel filter or fuel piping, and re-start the-machine in accordance with the following instructions. (a) Refuel the fuel tank and open the fuel filter cock. (b) Turn the starter switch to'.the “Start” position whereby when the engine starter turns over, the automatic air vent device will expel the air inside the fuel system. (©) After 10 to 20 seconds of turning the engine over, the automatic air vent device would have expelied all the air out of the fuel system. At this point, the engine will be able to start. 133.3. Stopping the Engine (1) Tum the load side's circuit breaker to. the "OFF" position. (2) Turn the circuit breaker on the welding/generating set to the "OFF” position and let the engine to cool down. After the five minute idling period is over, turn the key to the “OFF” position, (3) Remove the key out of the starter switch. Make sure the key, when the machine is not use, is kept in safe. (4) Tum the fuel filter cock to the “Close” position, (6) Disconnect the wiring and plug(s) from the AC Power connections. (6) Make sure the machine is not exposed to moisture. It is important that the machine be kept dry when not in use. (7) To keep the machine in goed. working order, do not leave the machine exposed to the elements and cover it using a sheet, when the machine is not been used. [ Notice } : In the unlikely occurrence of the engine not stopping when the key is tumed to the “OFF” position, there is a way to stopping the machine. Please refer to the following diagram and ‘explanation. In order to stop the machine in this of situation, you must turn the fuel filter cock to 'the “Close” position. Closing the fuel filter OFF CIRCUIT BREAKER *. cock cuts the supply of the fuel to the engine and the engine will take a few minutes to come to a stop. This should only be done in case of an emergency.3.4. Operating Precautions (1) Always read the meters and lamps on the control panel. ‘* While the welding/generating set is running, periodically check the readings of the meters on the control panel. Specifically, check that these meters show the machine is running correctly or not and the alarm lamps are on or not. * When the machine is running correctly, the alarm lamps will show the c following. ‘GENERATOR-LOAD Rated load No Load ‘Alarm Lamp All All Readings OFF OFF [ Notice]: If any of the alarm lamps are illuminated or the meters show abnormal readings while operating the machine, immediately stop the engine. Proceed to check and inspect the source of the problem. @y Hour eter Hour meter will always be working as soon as the engine is turned on. + Use the "Hour meter’ to plan maintenance for the generator. HOUR METER (3) Others + While the generator is running, check the following: [ Notice ] : Make a periodic check of the.exhaust discharge, which will make the operator aware of arly abnormalities in the exhaust discharge. [ Notice ] : Check for leakages of lubricant oil, fuel, cooling water and exhaust gases. [ Notice ] : Be aware of the noise produced by the machine. If any strange noises/sounds are noticed there may be a problem. [ Notice } : if any abnormalities are noted, immediately stop the machine and investigate the cause of the abnormality.