Airworks Twister T60 Installation & Operation Manual
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Airworks Twister T60 Installation & Operation Manual

Welder/generator
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A division of Airworks Compressors and Mobile Equipment Corp
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TWISTER
T40/T60
WELDER/GENERATOR
INSTALLATION
&
OPERATION MANUAL
REVISED 09/18
Unit Serial Number __________________________
Engine SN _________________________
Compressor SN ____________________
Control Box SN _____________________

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Summary of Contents for Airworks Twister T60

  • Page 1 A division of Airworks Compressors and Mobile Equipment Corp TWISTER T40/T60 WELDER/GENERATOR INSTALLATION & OPERATION MANUAL REVISED 09/18 Unit Serial Number __________________________ Engine SN _________________________ Compressor SN ____________________ Control Box SN _____________________...

  • Page 2: Table Of Contents

    Table of Contents Operating Instructions ..........................1 Basic Installation/Operation ........................1 Safety ............................... 2 Maintenance ............................4 Starting/Shutdown Procedures ........................ 5 Coolant Fill Instructions (Cold Weather Kit) .................... 6 Troubleshooting ............................8 Caring For Your Twister .......................... 11 Warranty Policy ............................12 Drawings ..............................

  • Page 3: Operating Instructions

    Twister is more than 6 feet from the fuel tank, the pump should be relocated closer to the fuel tank. An auxiliary fuel pump is available from Airworks, part number ATO110 for long runs (more than 6 feet) or high lift (more than 3 feet).

  • Page 4: Safety

    Do not attempt to modify any component. g) Do not operate with cover or doors removed. h) Do not use replacement or service parts other than Airworks recommended components. Compressor may start at any time discount power before serving. Safety Features...
  • Page 5 Lubrication and Filters Use only Airworks certified and approved fluids and filters. Compressor may be under pressure; ensure pressure is released and unit is switched off and unloaded before servicing, remove fill cap slowly – stop if pressure is present until compressor unloads.

  • Page 6: Maintenance

    Routine Maintenance You must follow the maintenance schedule and use only Airworks genuine replacement parts to maintain your system and warranty. The most critical aspect of maintenance is proper air filtration and clean oil. If any particulate matter enters the compressor through the air inlet or other means, they can contaminate roller bearings, gears and rotors in the compressor.

  • Page 7: Starting/Shutdown Procedures

    Value Lash Settings Cold Kobota Z482 Intake 0.007 / Exhaust 0.007 Yanmar 3TNV Intake 0.008 / Exhaust 0.008 Twister Starting Procedure Diesel Engines Turn ignition key to the left and hold for 15 seconds. This primes the fuel pump and engages the pre-heater.

  • Page 8: Coolant Fill Instructions (Cold Weather Kit)

    Coolant Fill Instructions – For Use with Cold Weather Kit Cold weather option ties chassis cooling system into Twister cooling system. NEVER OPEN THE COOLING SYSTEM WHILE HOT! Perform a visual check of both the chassis engine and the Twister coolant expansion bottle with both engines cold.
  • Page 9 RPM. The cut out and cut in pressure of the compressor can be adjusted on the pressure switch (clockwise to increase pressure). Consult your Airworks dealer if you have any questions before attempting adjustment.

  • Page 10: Troubleshooting

    Run the system, if possible, to determine the problem. c) Do not perform test procedures that are harmful to people or equipment. d) Perform repairs using the correct parts and procedures. e) Consult your local dealer or Airworks Compressors Corp. Symptom: Compressor does not produce adequate air...
  • Page 11 Symptom: Engine stalls when compressor starts Check and correct the following: a) Engine fuel filter or air filter plugged - replace b) Fuel pump functioning c) Air compressor is under pressure – allow to unload d) Operating speed is too low – adjust as required (1800 rpm) e) Blow down valve operating properly Compressor switched on, building pressure (should be off to start) g) Positive air shut off valve tripping (optional –...
  • Page 12 Symptom: Oil blows out of compressor air filter on shut down Check and correct the following: a) Unit shut down while compressor under load b) check inlet control valve seal – repair as required Symptom: Engine Smoking Lack of Power Check and correct the following a) Check coolant level b) Air in fuel filter...

  • Page 13: Caring For Your Twister

    Caring for Your Twister Your Twister is designed to provide many thousands of hours of working life. By following the listed procedures you will ensure this happens and protect your investment, up time and warranty. Every 25 hours  Check fluid levels ...

  • Page 14: Warranty Policy

    If the warranty registration form has not been received by Airworks within 2 months from the date of purchase then the warranty period will be deemed to commence 30 days from date of shipment from Airworks.
  • Page 15 Airworks at time of installation. Disclaimer and Warranty Service a) Any labour costs incurred in excess of Airworks set labour rates are not covered. b) Any travel time or labour costs incurred by unauthorized personnel are not covered by this warranty.

  • Page 23: Engine

    T WI S T E R T 4 0 / T 6 0 E N G I N E ( 1 ) C o o l a n t D r a i n C o c k ( 1 0 ) O i l D r a i n F i t t i n g A T E 0 1 2 A T E 0 4 9 ( 2 ) I n t a k e Ma n i f o l d...

  • Page 24: Compressor

    T 4 0 / T 6 0 C O MP R E S S O R ( 1 ) A i r E n d A T C 0 0 1 - A ( T 4 0 ) A T C 0 0 1 - B ( T 6 0 ) ( 2 ) A i r F i l t e r A T C 0 0 2...
  • Page 26 A division of Airworks Compressors and Mobile Equipment Corp WELDER/GENERATOR OPERATION MANUAL AWG-DW4K REVISED 05/18 Serial Number ______________________________...
  • Page 27 Introduction Read Before Using WARNING: Improper use of equipment could cause serious injury or death. Prior to using this equipment carefully read, understand and observe all instructions in this manual and the engine manual. This is an industrial-type electric welder/generator. This equipment is potentially hazardous and could cause physical injury or even death if improperly used, before attempting to operate this equipment: ...
  • Page 28 Before calling for service, please have the generator model and serial number ready. This information is displayed on the serial number tag, which is adhered to the generator. Contact our service department using the following information: Airworks Compressors Corp. 14503 115 Avenue Edmonton, Alberta, Canada...
  • Page 29 Safety Information Operating Safety DANGER: Explosion hazard.  Never operate welder/generator in an explosive atmosphere or near combustible materials.  Keep welder/generator, engine, fuel and other combustibles away from sparks, open flame, and burning objects.  Do not smoke near engine. ...
  • Page 30 CAUTION: Risk of severe burn.  Do not touch the engine, exhaust pipes, or any engine component until cool.  Do not remove radiator cap when engine is hot. Contents are hot and under pressure. CAUTION: Moving parts can cause injury. ...
  • Page 31 Engine Safety Operator safety Refer to engine manufacturer’s documentation for additional engine safety and operating information. Welding Safety Operator Safety DANGER: Explosion hazard. Sparks, spatter, temperature, and open flame can cause an explosion.  Ensure the work area is free from combustible and explosive materials, fumes, and gases.
  • Page 32  ALWAYS wear appropriate protective clothing, shoes, and other protective devices, as required by the job.  ALWAYS wear appropriate eye, respiratory, and hearing protection.  ALWAYS be aware of the welding environment, paying particular attention to combustibles, fumes, and gases. ...
  • Page 33 Storage and Maintenance Safety DANGER: Corrosive material. Battery acid will cause severe burns and blindness.  Use extreme care when handling or servicing batteries.  Never service batteries while generator is operating.  Wear appropriate eye and hand protection.  Upon contact with skin or eyes, flush with water and seek medical help immediately.
  • Page 34 Operation Before Starting Safety Before operating the welder/generator:  Read and be familiar with this instruction manual.  Read and follow all safety instructions.  Read and follow instructions in the engine manufacturer’s documentation. Location CAUTION: Engine exhaust is hot and can damage materials and other equipment. ...
  • Page 35 Operating the generator Operation as a welder 1. Before operating the welder, follow all instructions in the “Before starting” section. 2. Refer to engine manufacturer’s instructions and start the engine, operate on high speed while welding. 3. Ensure the welding leads are plugged into the proper jacks in the front panel – the positive lead in the positive jack;...
  • Page 36 Appendix A Eye Filter Shades Table A.1 Eye protection filter shade selection for welding or cutting (goggles or helmet). Guideline only, consult shade manufacturer for more info. Welding or Cutting Operation Electrode Size, Metal Filter Shade Number Thickness, or Welding Current Torch soldering Torch brazing 3 or 4...

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