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MULTIQUIP DLW400ESA4 Operation Manuals

Welder/generator (kubota d902e4bwdde2 diesel engine)
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OPERATION MANUAL
TM
MODEL DLW400ESA4
WELDER/GENERATOR
(KUBOTA D902E4BWDDE2 DIESEL ENGINE)
Revision #0 (03/14/18)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

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Summary of Contents for MULTIQUIP DLW400ESA4

  • Page 1 OPERATION MANUAL MODEL DLW400ESA4 WELDER/GENERATOR (KUBOTA D902E4BWDDE2 DIESEL ENGINE) Revision #0 (03/14/18) To find the latest revision of this publication, visit our website at: www.multiquip.com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING Diesel engine exhaust and some of PAGE 2 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 3: Reporting Safety Defects

    1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov; or write to: Administrator NHTSA 1200 New Jersey Avenue, SE Washington, DC 20590 You can also obtain information about motor vehicle safety from http://www.safercar.gov. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 3...

  • Page 4: Table Of Contents

    Generator Wiring Diagram ........52 Generator Wiring Diagram (Reference Designators) .. 53 Engine Wiring Diagram .......... 54 Error Codes ............55 Troubleshooting ..........56-58 NOTICE Specifications are subject to change without notice. PAGE 4 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 5: Parts Ordering Procedures

    ❒ 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! DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 5...

  • Page 6: Safety Information

    Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY. Pacemaker Hazards NOTICE Addresses practices not related to personal injury. Implant Hazards Flying Sparks Hazards Fire Hazards Electric Shock Hazards PAGE 6 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 7 Also, know the phone numbers of the nearest ambulance, doctor and fi re department. This information will be invaluable in the case of an emergency. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 7...
  • Page 8 „ DO NOT use welder-generator to thaw frozen pipes. „ Remove stick electrode from holder or cut off welding wire at contact tip when not in use. PAGE 8 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 9 „ ALWAYS store welder-generator properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 9...
  • Page 10 This can take several hours to burn off the accumulated unburned fuel. PAGE 10 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 11 NOTICE „ ALWAYS make certain that proper power or extension cord has been selected for the job. See Cable Selection Chart in this manual. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 11...
  • Page 12 „ ALWAYS keep the battery charged. If the battery is not charged, combustible gas will build up. „ ALWAYS recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gasses. PAGE 12 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 13: Safety Information

    „ When the life cycle of this equipment is over, remove battery (if equipped) and bring to appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 13...

  • Page 14: Specifications

    Refer to Table 3 for simultaneous use of AC power and DC welding. DO NOT overload unit when AC and DC voltages are used simultaneous. Main circuit breaker will trip when overload condition exist. PAGE 14 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 15: Specifications (Fuel Consumption)

    (llters/hr.) (1.47) (2.04) (3.36) (5.00) DC welding current at 100% Fuel Consumption High DC Weld Amperes at 100% duty cycle [A] Figure 1. Fuel Consumption Chart DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 15...

  • Page 16: Dimensions

    Power Source Professionals. SIDE VIEW Figure 2. Dimensions FRONT VIEW Table 6. Dimensions Reference Letter Dimension in. (mm) 28.35 (720) 21.06 (535) 13.42 (341) 60.6 (1,539) 31.50 (800) 34.84 (885) PAGE 16 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 17 NOTES DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 17...

  • Page 18: Installation

    IF THE WELDER-GENERATOR IS PROVIDING ELECTRIC POWER TO A BUILDING VIA A TRANSFER SWITCH IT MUST BE CONNECTED GROUND CABLE TO A GROUND ROD. REFERENCE NEC 250 Figure 3. Welder-Generator Grounding Application PAGE 18 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 19 Electric shock can occur when vibrators electrician. are used. Pay close attention to handling when operating vibrators and always use rubber boots and gloves to insulate the body from a short circuit. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 19...

  • Page 20: General Information

    Use the cable selection chart (Table 9) as a „ AC Voltmeter guide for selecting proper extension cable size. „ Idle Stop Time Regulator Control „ Idle Stop Select Switch „ GFCI Sensing Module PAGE 20 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 21: Welding Polarity And Duty Cycle

    30 ~ 350 Dual Mode Continuous 30 ~ 175 The DLW400ESA4 welder has a 100% duty cycle @ 350 amps (single mode) or 175 amps (dual mode) DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 21...

  • Page 22: Welding Terms

    PAGE 22 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 23: Components (Welder/Generator)

    NEVER block this 8. Fuel Drain Plug – Remove this plug to drain fuel from opening. fuel tank Reference Table 4 for fuel tank capacity. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 23...

  • Page 24: Components (Welder/Generator)

    Use only the recommended oil type. See Table 4 for engine oil capacity. 5. Oil Filter — Spin-on type, filters oil contaminants. Replace filter as recommended in the maintenance section of this manual. PAGE 24 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 25: Components (Engine)

    Loosen clips on side of air filter canister to gain access to filter element. Replace with manufacturer's recommended type air cleaner only. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 25...

  • Page 26: Power Receptacles

    50 ft. CAUTION: Equipment damage can result from low voltage „ L6-30R — Provides 250 VAC @30 amps „ CS6369 — Provides 125/250 VAC @50 amps (Dual Voltage receptacle. PAGE 26 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 27: Control Panel

    LEDs indicating the amount of fuel in the fuel tank. 10. Single/Dual Selector Switch – Place this switch in the desired welding mode. DO NOT switch under load. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 27...

  • Page 28: Control Panel

    10. Starter Switch — Place ignition key in RUN position, then press engine start button to start engine. 4. Time Regulator Control – Indicates the amount of PAGE 28 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 29: Inspection

    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. Wipe up any spilled fuel immediately. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 29...

  • Page 30: Inspection

    When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%. NEVER place hands near the belts or fan while the welder-generator set is running. PAGE 30 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 31: Inspection/Setup

    The possibility exists of electrical shock or short circuit which could cause a fire resulting in severe bodily harm and damage to the Figure 14. Battery equipment. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 31...

  • Page 32: Setup

    Operation) or Table 17 (Dual Mode Operation). Figure 16. Welding Cable Connections (Electrode Type Correct) 5. Attach the clamp holder to the electrode as shown in Figure 16 and Figure 17. PAGE 32 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 33 1. Connect the welding cables from the welder-generator NR-232MP Wire Connect to negative (–) terminal to the wire feeder as shown in Figure 18. Figure 18. CV Setup (Wire Feeder) DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 33...

  • Page 34: Operation

    Figure 19. Circuit Breakers 2. Place the fuel valve lever (Figure 20) in the ON position. FUEL VALVE LEVER Figure 23. Ignition Key (RUN Position) Figure 20. Fuel Valve Lever (ON) PAGE 34 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 35 (noise), oil leakage, fuel leakage, cooling water leakage and air leakage. Also, verify if any alarm lights are lit. If any abnormal conditions exits, turn the engine OFF and correct the problem. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 35...
  • Page 36 Ø (~200A) (140Ax2) 2400 2200 Figure 31. E-Mode Selector Switch (CC Mode) 2000 2000 4000 6000 8000 10000 12000 Preset Welding (kW) Figure 32. E-Mode Engine Variable Control PAGE 36 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 37 In addition this control can be used to fine tune the arc based on the specific application being used. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 37...
  • Page 38 Figure 40. Current/Voltage Regulator Control Knob (Voltage Adjust) 5. The selected voltage will be displayed on the DC weld Figure 39. E-Mode Selector Switch (CV Mode) meter (Figure 41). PAGE 38 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 39 „ AC Load Lamp – If lamp is blinking, indicates that the ON/OFF power switch of a power tool connected to the Figure 44. Time Regulator GFCI receptacle has been left in the ON position. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 39...
  • Page 40 CLAMP HOLDER the work surface. ENGINE RESTART TAP #2 WORK WORK WORK Figure 46. Restart Signal (Welder Side) PAGE 40 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 41: Operation

    Figure 49. E-Mode Selector Switch EMERGENCY SHUTDOWN PROCEDURE (Variable/Low Position) Place the ignition key (Figure 50) in the STOP position. 3. Let the engine run at idle speed for 5 minutes. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 41...

  • Page 42: Maintenance

    Do not make any modification, changes or remove the emission control system and related parts. Please contact your nearest dealer or Multiquip Service Dept. for SCR maintenance. Use fully formulated antifreeze/coolant. Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H PAGE 42 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 43 (not to exceed 30 psi (207 kPa, 2.1 kgf/cm ) through the filter element from the inside out. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 43...

  • Page 44: Engine Oil

    For composite oil pans always install a new o-ring. (500 PPM) or Ultra CF, CF-4, CG-4, CH-4 or CI-4 Low Sulfur Fuel Sulfer Content < 0.0015% (15 PPM) PAGE 44 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 45 Top off the oil to the upper limit on the dipstick. Figure 57. Draining Radiator Coolant 3. Check hoses for softening and kinks. Check clamps for signs of leakage. 4. Remove and inspect radiator cap. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 45...
  • Page 46 DO NOT remove the radiator cap Figure 58. Radiator Cleaning until the unit has completely cooled. The possibility of hot! coolant exists which can cause severe burns. PAGE 46 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 47 1. Place fuel valve lever (Figure 61) in the CLOSED position. Figure 61. Fuel Valve Lever (CLOSED) DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 47...
  • Page 48 Hand-tighten only. Figure 63. Engine Stop Lever 6. Remove the air from the fuel system. Reference the Kubota Operation and Maintenance Manual, "Bleeding the Fuel System". PAGE 48 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 49 2. Place the main circuit breaker, CB1 (Figure 65) in the ON position. 40 A AC220V 25kA 40 A AC220V 25kA Figure 68. Circuit Breaker OFF (GFCI Test) Figure 65. Main Circuit Breaker ON (GFCI Test) DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 49...
  • Page 50 It is recommended that the GFCI sensing module be TEST tested when the welder-generator is initially uncrated. BUTTON RESET Then, the module should be tested daily at startup. BUTTON Figure 73. GFCI Receptacle Test PAGE 50 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 51 Figure 74. DC Weld Meter Error Codes either of these fuses are blown, check the wiring to determine if an electrical short circuit exists. Correct the problem before installing new fuses. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 51...

  • Page 52: Generator Wiring Diagram

    GENERATOR WIRING DIAGRAM (S/N573486 AND BELOW) PAGE 52 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 53: Generator Wiring Diagram (Reference Designators)

    ROTATION SENSOR GEARED MOTOR RESISTOR R2 A, B RESISTOR R4 A, B RESISTOR RELAY SOCKET OVER CURRENT RELAY TERMINAL BOARD GROUND TERMINAL FOR GFCI GFCI SENSING MODULE DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 53...

  • Page 54: Engine Wiring Diagram

    GENERATOR WIRING DIAGRAM (S/N573487 AND ABOVE) PAGE 54 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)

  • Page 55: Error Codes

    GEARED MOTOR RESISTOR R2 A, B RESISTOR R4 A, B RESISTOR RELAY RY1, 2 SOCKET OVER CURRENT RELAY TERMINAL BOARD GROUND TERMINAL FOR GFCI GFCI SENSING MODULE DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 55...

  • Page 56: Troubleshooting

    ENGINE WIRING DIAGRAM PAGE 56 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 57 [1] : An error condition displayed with an asterisk (*) cannot always be corrected via simple inspection. Please contact Multiquip Service Dept. or your MQ Service Dealer for assistance. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 57...
  • Page 58 Stop limit time varies with time idle stop is operated. Main AC circuit breaker (CB1) is Place Main AC circuit breaker (CB1) to the set to the ON position? OFF position. PAGE 58 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 59 AC circuit breakers are not set to Place all circuit breakers CB1, CB2, CB3, AC power is not available. and CB4 to the ON position. DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 59...
  • Page 60 If the side-door is open or exhaust vents are clogged, causing insufficient cooling; if Semiconductor is overheated? semiconductors are heated at an over-duty rate, output is limited to prevent such overheating. PAGE 60 — DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. #0 (03/14/18)
  • Page 61 NOTES DLW400ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (03/14/18) — PAGE 61...
  • Page 62 © COPYRIGHT 2018, MULTIQUIP INC. Multiquip Inc , the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

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