Denyo GAW-185ES2 Instruction Manual
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Denyo GAW-185ES2 Instruction Manual

Denyo GAW-185ES2 Instruction Manual

Soundproof gasoline engine-driven dc welder
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Reference No. D18413 01204
Soundproof Gasoline Engine-Driven DC Welder
Instruction manual
GAW-185ES2
For ensuring safety, make sure to read this manual prior to use of the machine.
For ensuring safety, be sure to observe precautions given under headings
DANGER and
CAUTION.
For ensuring safety, keep this manual in a place of easy access, to permit reference to it whenever it is needed.
Denyo
Co., Ltd.

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Summary of Contents for Denyo GAW-185ES2

  • Page 1 Reference No. D18413 01204 Soundproof Gasoline Engine-Driven DC Welder Instruction manual GAW-185ES2 For ensuring safety, make sure to read this manual prior to use of the machine. For ensuring safety, be sure to observe precautions given under headings DANGER and CAUTION.
  • Page 2 Thank you very much for your recent selection of a Denyo product. This is a noise isolated engine welder & generator combined machine (hereinafter called "machine"). (See Page for the specification.) For handling of the machine and for working with the welder and generator functions of the machine, observe applicable laws (Electricity Enterprises Law, Electric Engineering Technicians Law, Occupational Health and Safety Law, Fire Services Act, Noise Control Law, etc.) as well as their...
  • Page 3 If you any doubt arises or if you want to learn more about maintenance of the machine, please do not hesitate to contact us. When you contact us for an inquiry, please give us the type and serial number of the machine. The serial number is stamped on the main nameplate.

  • Page 4: Table Of Contents

    Contents For safe use of the machine 1. Names of component Knowledge to be acquired before use of the machine ..8 1-1 External appearances and names of components ..............8 1-2 Names of internal components (Control Panel / Left Side ) ............9 1-3 Names of internal components ....................

  • Page 5: For Safe Use Of The Machine

    For safe use of the machine GAW-185ES2 For safe use of the machine Although the machine has been designed and produced with safety fully taken into account, it is essential to observe the precautions given in this instruction manual in the use of the machine.
  • Page 6 Warning label is attached to the position shown in the figure below to the machine body. ● Keep clean always warning nameplate. ● If a warning nameplate is lost or damaged, please order to DENYO by nameplate number that is described below in () immediately. Please paste again to the specified location.
  • Page 7 For safe use of the machine GAW-185ES2 DANGER : Electric shock • Never touch electrical components such as output terminal and internal wiring while the machine is running. For cable connection or for inspection and maintenance of the machine, be sure to turn OFF the circuit breaker and stop the engine, before starting such a work.
  • Page 8 For safe use of the machine GAW-185ES2 CAUTION : Burn injury Never open the following places while the machine is running and also immediately after termination of running. (1) Radiator water filler cap If the water filler cap is opened while the machine is running, steam or hot water will jet out, and is extremely dangerous.
  • Page 9 For safe use of the machine GAW-185ES2 CAUTION : Casualty caused by battery (1) Casualty caused by battery electrolyte Be careful so as not to allow entry of battery electrolyte (dilute sulfuric acid) into eyes and not to allow its attachment to the skin or clothes. If it entered eyes or attached to the skin, immediately wash it off using plenty of water.

  • Page 10: External Appearances And Names Of Components

    Names of components GAW-185ES2 1. Names of components 1-1 External appearances and names of components ① Operation panel ⑥ Handle (rope fitting) ⑪ Wheel stopper ② Fuel Gauge ⑦ Air inlet ③ Fuel filler port ⑧ Exhaust port ④ Lifting lug ⑨...

  • Page 11: Operation Panel And Names Of Components

    Names of components GAW-185ES2 1-3 Operation panel and names of components Name *Digital monitor (*Model GAW-150ES2D only) Welding current regulator Arc force regulator Voltage reduction device switch AC Power output switch Starter switch Choke knob Slow down switch Welding output terminal...
  • Page 12 Names of components GAW-185ES2 1-4 Digital display monitor ①Welding current meter ②Set / actual current indicator ③ODO meter (section hour meter function) ④Display switching button ⑤Frequency indicator (1) Welding current meter ・Welding current meter displays the actual current value and the current setting of the welding output.
  • Page 13 Names of components GAW-185ES2 (3) Time interval meter（TRIP） ・Time interval meter is built with "A" and "B". When it is in the "ON" position starter switch, each time you press the display switching button, the display screen will be switched in the order of "ODO" → "TRIP A" → "TRIP B".

  • Page 14: Precautions For Conveyance Of The Machine

    Periodic inspection and maintenance GAW-185ES2 2. Conveyance and installation 2-1 Precautions for conveyance of the machine CAUTION : Removal (1) Falling during hoisting Handle (rope fitting) • Use the lifting lug located at the center of the roof panel for hoisting Lifting lug the machine.

  • Page 15: Precautions For Installation Of The Machine

    Periodic inspection and maintenance GAW-185ES2 2-2 Precautions for installation of the machine DANGER : Poisoning caused by exhaust gas • The exhaust gas from the engine contains substances that are hazardous to human bodies. Do not run the machine in a place of inferior ventilation such as tunnel and indoors.

  • Page 16: Pre-Operational Inspection

    Periodic inspection and maintenance GAW-185ES2 3. Operation Pre-operational inspection DANGER : Personal injury ▪ There are components rotating at high speed in the welder. ▪ Make sure to stop the engine, before starting maintenance and inspection of the welder. Personal injury may arise due to roll-in of your hands by rotating components, if you fail to observe the precautions given above.
  • Page 17 Periodic inspection and maintenance GAW-185ES2 [Caution]: Do not mix engine oil of different kinds. It is because properties of the engine oil may become inferior, if engine oil of different kinds is mixed together. - 31 -...
  • Page 18 Periodic inspection and maintenance GAW-185ES2 (2) Check of fuel level CAUTION : Fire ▪ Fuel and oil are combustible materials. Never bring any fire close to the welder. Do not use the welder in a place where the welder exposed to sparks of welding or of a sander. Do not perform fueling while you are smoking or while the welder is running.
  • Page 19 Periodic inspection and maintenance GAW-185ES2 (3) Open the fuel cock (4) Check the spark plug Do not touch the spark plug, cable and cap, while the engine is running. Make sure to stop the engine, before check the spark plug and using a plug removal tool.
  • Page 20 Periodic inspection and maintenance GAW-185ES2 (7) Connection and check of battery cables Connect battery cables in correct polarity. If connection is made in incorrect polarity (reversing of + and -), electric components will be damaged, even if such an error occurred only for a short length of time.

  • Page 21: Startup And Running

    Periodic inspection and maintenance GAW-185ES2 Startup and running Make sure that no obstacle is located in the range of 1 m from the welder, and send a signal to the people located around the welder, before starting the engine. Furthermore, lock the engine while it is running, so that operation by anybody having no knowledge on the welder or welder operating skill is disabled.
  • Page 22 Periodic inspection and maintenance GAW-185ES2 Push Push - 36 -...
  • Page 23 Periodic inspection and maintenance GAW-185ES2 [Caution]: Do not turn the starter switch while the engine is running. ▪ If abnormal vibration or abnormal noise was observed, stop the engine and carry out inspection. Moreover, check for emission of black smoke or white smoke.

  • Page 24: Stopping

    Periodic inspection and maintenance GAW-185ES2 Stopping (1) The engine revolution drops when the slow down switch is push to the “ON” position. Continue cool-down running for about 5 minutes in this state. (2) Stop the engine by turning the starter switch to the “STOP” position.

  • Page 25: After Stopping

    Periodic inspection and maintenance GAW-185ES2 After stopping (1) In case it is intended that the welder will not be used for a certain length of time, be sure to remove the starter switch key, and keep it in the specified position with care exercised not to lose it.

  • Page 26: Protective Devices

    Periodic inspection and maintenance GAW-185ES2 Protective devices The welder is equipped with protective devices indicated below that act against errors during running. When any of these protective devices is activated, immediately stop running of the welder and carry out troubleshooting of the abnormal point.

  • Page 27: Warning On Matters To Be Observed Prior To Operation

    Periodic inspection and maintenance GAW-185ES2 4. Welder operation Warning on matters to be observed prior to operation DANGER : Make sure to observe the following instructions for avoiding serious accidents resulting in injury or death. (1) Observe laws and regulations and your in-house standards for working power sources on the input side, setup of place of installation, handling of high-pressure gases, storage and piping, storage of products after welding, disposal of waste and others.
  • Page 28 Periodic inspection and maintenance GAW-185ES2 (4) For welding of the ceiling, floor, wall or the like, remove hidden combustible materials. (5) Be sure to tighten and insulate cable joints. (6) Connect the cable on the base metal side to as close as possible to the welding point.
  • Page 29 Periodic inspection and maintenance GAW-185ES2 CAUTION : Wear protective equipment for protecting you and other people against fumes and gases produced during welding. ▪ Health hazard may arise, if fumes and gases produced during welding is inhaled. ▪ Suffocation may occur due to shortage of air, if welding work is performed in a small space.
  • Page 30 Periodic inspection and maintenance GAW-185ES2 CAUTION : Examine the following matters for preventing electromagnetic hazards. Furthermore, examine the following matters again if any electromagnetic hazard occurs. ▪ Large current that rapidly changes during welding flows to the welder and weldment, and it may hinder nearby equipment by electromagnetic noise.

  • Page 31: Selection Of Welding Cable

    Periodic inspection and maintenance GAW-185ES2 Selection of welding cable The longer the welding cable and the larger the current, a welding cable of larger size is required. Prepare a cable of appropriate size as selected out of the following table depending on the required welding current and cable length.
  • Page 32 Periodic inspection and maintenance GAW-185ES2 Deposit welding, arc welding Reversed (+) ------- Welding electrode holder of thin sheets, arc welding of polarity (-) -------- Ground (base metal) stainless steel, air gouging - 46 -...

  • Page 33: Adjustment Of Welding Current

    Periodic inspection and maintenance GAW-185ES2 Adjustment of welding current (1) Adjust welding current with the welding current regulator. [Caution]: If two different welders are run simultaneously as connected to a common base metal in different polarity, the voltage between holders rises to a level produced by addition of voltages from two welders and electric shock may arise.

  • Page 34: Slow Down Unit

    Periodic inspection and maintenance GAW-185ES2 Slow down unit (1) This unit is provided for noise prevention and fuel saving during running without load. It executes control as described below in the state where the slow down switch is “ON.” 1) When welding is suspended for a while in the state where the welder keeps running, the engine...

  • Page 35: Duty Cycle

    Periodic inspection and maintenance GAW-185ES2 Dutry cycle No matter how tough a person may be, he will be exhausted if he keeps working without rest. This welder is not of a design that withstands continuous use when it is used as a welder, from the viewpoints of job contents and economy.

  • Page 36: Voltage Reduction

    Periodic inspection and maintenance GAW-185ES2 welding work. [Caution]: Do not use this welder for any purpose other than welding. Voltage reduction (1) This unit is assist in the reduction of electrical shock to personnel involved in welding activities. It reduces open circuit voltage to safe value before and after the welding operation.

  • Page 37: Simultaneous Use Of Welding Power Supply And Ac Power Supply

    Periodic inspection and maintenance GAW-185ES2 Select a grounding rod and perform grounding work so that the grounding resistance is no higher than 100 by Class D grounding work specified in the Electrical Equipment Technical Specification. Select a grounding lead wire of size that corresponds to the generator capacity based on the Electrical Equipment Technical Specification.
  • Page 38 Periodic inspection and maintenance GAW-185ES2 5. Periodic inspection and maintenance DANGER : Personal injury • There are components rotating at high speed in the machine. • Make sure to stop the engine, before starting maintenance and inspection of the machine.

  • Page 39: General Inspection And Maintenance Prior To Operation

    Periodic inspection and maintenance GAW-185ES2 5-1 General inspection and maintenance prior to Operation (1) Check for loose, missing, damaged bolt/nuts or other fasteners. (2) Check for engine oil level and fill. (3) Check for fuel or oil leakage. 5-2 Initial 20-hour inspection and maintenance...

  • Page 40: Inspection And Maintenance Of Once Every 50 Hours

    Periodic inspection and maintenance GAW-185ES2 5-3 Inspection and maintenance of once every 50 hours (1) Cleaning of air cleaner element Remove the cover and element. Wash the element in a non-flammable or high point solvent and squeeze thoroughly. Soak the element in the clean mixed oil and squeeze out of the excess oil, then reinstall the element and cover.

  • Page 41: Inspection And Maintenance Of Once Every 300 Hours

    Periodic inspection and maintenance GAW-185ES2 tester of 500V, to check whether there is more than 1M . Do not use the insulation resistance by the insulation resistance tester that exceeds 500V. There is a possibility that the control device will be broken if you use it.

  • Page 42: Engine Malfunction And Action To Be Taken

    Long-term storage of the machine GAW-1850ES2 6. Troubleshooting Causes for troubles and actions to be taken against them Almost all the troubles can be prevented by proper handling and by implementation of inspection and maintenance. If any trouble arises, take actions with reference made to the following description. 6-1 Engine malfunction and actions to be taken If the engine malfunctions, take appropriate actions based on the following chart.

  • Page 43: Troubleshooting Chart

    Long-term storage of the machine GAW-1850ES2 6-2 Troubleshooting chart Trouble phenomenon Probable cause Action No arc is produced. Faulty cable connection • Check cable connection. Faulty generator main unit • Repair or replace the generator. Failed control unit SCR • Replace SCR Failed Reactor •...

  • Page 44: 7. Long-Term Storage Of The Machine

    Long-term storage of the machine GAW-1850ES2 7. Long-term storage of the machine Observe the following instructions for permitting the machine to exhibit its superior performance for an extended period of time. (1) Check for oil leakage and fuel leakage, and check bolts and nuts for looseness. (2) Disconnect the battery cable from the (-) terminal of the battery, for storage of the machine for a long time.

  • Page 45: External Dimensions And Appearance Drawing

    Conveyance and installation GAW-185ES2 8. Servicing data 8-1 External dimensions and appearance drawing - 59 -...

  • Page 46: Specification

    Conveyance and installation GAW-185ES2 8-2 Specification Type GAW-185ES2 Rated output 4.58 Rated voltage 26.8 Rated current Duty cycle Current regulating range 30 – 150 Applicable welding rod φ2.0 – φ4.0 Number of phases Single phase Rated output Rated voltage Rated current...

  • Page 47: Generator Wiring Diagram

    Conveyance and installation GAW-185ES2 8-3 Generator wiring diagram - 61 -...

  • Page 48: Engine Wiring Diagram

    Conveyance and installation GAW-185ES2 8-4 Engine wiring diagram - 62 -...

  • Page 49: Attachment

    Conveyance and installation GAW-185ES2 8-5 Attachment Instruction manual Engine instruction manual Starter key Plug wrench - 63 -...

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