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.
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 40 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.
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.
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 ...................................................................................................
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. Death or serious injury may arise, if the machine is used with these precautions ignored. Safety precautions are described in this manual as ranked using signal words indicated below.
For safe use of the machine GAW-185ES2 Mounting position of the warning nameplate 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.
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. • When the machine or your body is wet, it is extremely dangerous. Never touch the machine in such a state.
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. Therefore, never open the water filler cap while the machine is running. Wait for at least 10 minutes after termination of running, before opening the cap.
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. In case of entry to eyes, submit to medical treatment. Casualty to eyes and burn may result otherwise.
Names of components GAW-185ES2 1.
Names of components GAW-185ES2 1-3 Operation panel and names of components No.
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. Welding current meter displays the actual current value during welding. The welding current meter displays the setting value under welding stop.
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". When each interval time is displayed, hold down the display switching button. The display time is reset and return to 0. ・Please use as a time meter of periodic inspection and maintenance for such as oil change.
Periodic inspection and maintenance GAW-185ES2 2. Conveyance and installation 2-1 Precautions for conveyance of the machine CAUTION: Removal (1) Falling during hoisting • Use the lifting lug located at the center of the roof panel for hoisting the machine. Furthermore, do not walk in to the space underneath the machine in the hoisted state. • Do not hoist the machine by the handle (rope fitting). The handle will come off and the machine will fall if the machine is hoisted by the handle.
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. If it is necessary to run the machine in such a place, provide sufficient ventilation using ventilating equipment or the like.
Periodic inspection and maintenance GAW-185ES2 3. Operation 3-1 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. Carry out inspection described below prior to operation.
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.
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. ▪ If the fuel or oil has spilt, fully wipe it off.
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. Fuel Filler Port Red mark Cap Spark Plug Gap Filter Fuel gauge Gasket Fuel Cock Close Open (5) Check of pipe joints Check pipe joints for looseness, oil leakage. Carry out repair or replacement, if any abnormality is found.
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. [Caution]: Connect battery cables in the state where the starter switch key is removed. Applying small amount of grease to battery terminals will prevent corrosion to terminals.
Periodic inspection and maintenance 3-2 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. ▪ Select the using frequency by the frequency select switch located inside the door.
Periodic inspection and maintenance GAW-185ES2 Push Push - 36 -
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. ▪ Keep all the doors closed and keep the side door locked during running. If any door is kept open, the welder may be damaged due to inclusion of foreign matters.
Periodic inspection and maintenance 3-3 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. (3) If the engine fails to stop even when starter switch is turned to the “STOP” position, use one out of two methods indicated below for forcibly stopping the engine. (4) After the engine has stopped.
Periodic inspection and maintenance 3-4 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. (2) Turn the fuel filter cock to the “CLOSE” position. (3) Disconnect the welding cable. Disconnect cables and plugs from AC power outlets. (4) Keep refueling the fuel tank.
Periodic inspection and maintenance 3-5 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.
Periodic inspection and maintenance GAW-185ES2 4. Welder operation 4-1 Warning on matters to be observed prior to operation DANGER: Make sure to observe the following instructions for avoiding serious accidents (1) (2) (3) (4) resulting in injury or death.
Periodic inspection and maintenance (4) (5) (6) (7) (8) GAW-185ES2 For welding of the ceiling, floor, wall or the like, remove hidden combustible materials. Be sure to tighten and insulate cable joints. Connect the cable on the base metal side to as close as possible to the welding point. Do not weld a gas pipe containing gas. Do not weld an enclosed tank or pipe. Locate fire extinguishers near the welding work area for emergency use.
Periodic inspection and maintenance CAUTION: (1) (2) (3) (4) (5) (6) (2) (3) (4) (5) 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.
Periodic inspection and maintenance CAUTION: GAW-185ES2 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. (1) Do not share the ground for the base metal and welder with the ground for other equipment.
Periodic inspection and maintenance 4-2 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.
Periodic inspection and maintenance Reversed polarity GAW-185ES2 (+) ------- Welding electrode holder (-) -------- Ground (base metal) - 46 - Deposit welding, arc welding of thin sheets, arc welding of stainless steel, air gouging
Periodic inspection and maintenance 4-4 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. Therefore, such a situation that one worker holds two holders of two different welders should be avoided absolutely.
Periodic inspection and maintenance 4-5 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 revolution changes to a low level automatically (2500 min-1) after elapse of a fixed length of time (about 9-10 seconds).
Periodic inspection and maintenance 4-6 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. Duty cycle indicated below explains this situation. It is the same for manual welding. 10 minutes * Usage rate represents the ratio of the load time in a 10-minute period.
Periodic inspection and maintenance GAW-185ES2 welding work. [Caution]: Do not use this welder for any purpose other than welding. 4-8 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. (2) The voltage reduction switch in the “ON” position, welding no load voltage become below 27V. Upon arc strike, normal selected voltage becomes available.
Periodic inspection and maintenance GAW-185ES2 Select a grounding rod and perform grounding work so that the grounding resistance is no higher than 100Ω 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.
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. Personal injury may arise due to roll-in of your hands by rotating components, if you fail to observe the precautions given above.
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 (1) Change of engine oil Engine oil be replaced at an early period of either one month or after 20 hours after the start of operations. 1) Remove the engine oil drain plug, and fully discharge the engine oil.
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. 【Mixed oil ratio, kerosene 3 : engine oil 1】 Air cleaner element Part No.
Periodic inspection and maintenance GAW-185ES2 tester of 500V, to check whether there is more than 1MΩ. 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. If you need to use the insulation resistance tester that exceeds 500V, take off all connector which is connecting to control unit.
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. (See the instruction manual for the engine for details.
Long-term storage of the machine GAW-1850ES2 6-2 Troubleshooting chart Revolution control Single phase AC power supply Welding Trouble phenomenon Probable cause Action No arc is produced. Welding current regulator fails to work. Failed welding current regulator Faulty cable connection Failed board of control unit • Replace the welding regulator. • Check cable connection • Replace board No voltage (AC 100V) is produced, and no power is generated.
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. (3) The battery discharges naturally when it is shelved for a long time.
Conveyance and installation GAW-185ES2 8.
Conveyance and installation GAW-185ES2 8-2 Specification Single phase AC power supply DC welding power supply Type GAW-185ES2 Rated output Rated voltage Rated current Duty cycle Current regulating range Applicable welding rod Number of phases Rated output Rated voltage Rated current Frequency Rated revolution Power factor kW V A % A mm kVA V A Hz -1 min Name Engine Type Number of cylinders – Bore × Stroke Total displacement Rated output Used fuel Fuel tank capacity Lubricating oil total volume Lu
Conveyance and installation GAW-185ES2 8-3 Generator wiring diagram - 61 -
Conveyance and installation GAW-185ES2 8-4 Engine wiring diagram - 62 -
Conveyance and installation GAW-185ES2 8-5 Attachment Instruction manual Starter key Engine instruction manual Plug wrench - 63 -
