MULTIQUIP SmartStick DLW500ESA4 User manual

TM
OPERATION MANUAL
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
MODEL DLW500ESA4
WELDER/GENERATOR
(ISUZU 4LE2T DIESEL ENGINE)
INSTRUCTION MANUAL NO. D6844301434
Revision #0 (01/13/23)
To find the latest revision of this publication
or associated parts manual, visit our
website at: www.multiquip.com

PAGE 2 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
PROPOSITION 65 WARNING

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 3
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip Inc. at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free
at 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.

PAGE 4 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
TABLE OF CONTENTS
DLW500ESA4
Welder-Generator
Proposition 65 Warning ........................................... 2
Reporting Safety Defects......................................... 3
Safety Information .............................................. 5-12
Specifications (Welder-Generator) ........................ 13
Specifications (Fuel Consumption)........................ 14
Dimensions............................................................ 15
Installation ........................................................ 16-17
General Information............................................... 18
Welding Polarity And Duty Cycle ........................... 19
Welding Terms ....................................................... 20
Components Welder/Generator........................ 21-22
Engine Components.............................................. 23
Power Receptacles................................................ 24
Control Panel.................................................... 25-27
Inspection ......................................................... 28-30
Setup ................................................................ 31-33
Local Operation ............................................... 34-45
Remote Operation ........................................... 46-48
Maintenance..................................................... 49-62
Welder-Generator Fault Codes......................... 63-64
Engine Diagnostic Fault Codes ...................... 65-66
Welder-Generator Troubleshooting................... 67-68
Generator Wiring Diagram..................................... 69
Generator Reference Designators/Connectors ..... 70
Engine Wiring Diagram.......................................... 71
Controller Wiring Diagram ..................................... 72
Battery Charger Wiring Diagram ........................... 74
Engine Block Heater Wiring Diagram .................... 75
NOTICE
Specifications are subject to change without notice.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 5
SAFETY INFORMATION
DO NOT operate or service the equipment before reading
the entire manual. Safety precautions should be followed
at all times when operating this equipment.
Failure to read and understand the safety
messages and operating instructions could
result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you
about potential hazards that could injure you or others.The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION
or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
Lethal Exhaust Gas Hazards
Explosive Fuel Hazards
Burn Hazards
Symbol Safety Hazard
Welding Hazards
EMF Hazards
Fire Hazards
Electric Shock Hazards
Pacemaker Hazards
Implant Hazards
Flying Sparks Hazards

PAGE 6 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
SAFETY INFORMATION
GENERAL SAFETY
CAUTION

NEVER operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.

NEVER operate this equipment when not
feeling well due to fatigue, illness or when
under medication.

NEVER operate this equipment under the influence of
drugs or alcohol.
NOTICE

This equipment should only be operated by trained and
qualified personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.

Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
NEVER
use accessories or attachments that are not
recommended by Multiquip for this equipment. Damage
to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest
fire extinguisher.
ALWAYS know the location of the nearest
first aid kit.
ALWAYS know the location of the nearest phone or
keep
a phone on the job site.
Also, know the phone numbers
of the nearest ambulance, doctor and
fire department.
This information will be invaluable in the case of an
emergency.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 7
SAFETY INFORMATION
WELDER SAFETY
DANGER

NEVER install or operate the welder-
generator in an explosive atmosphere or
near combustible materials. An explosion
or fire could result causing severe bodily
harm or even death.

Flying sparks can cause injury. Wear a face
shield to protect eyes and face.

Remove all flammables within 35 ft (10.7 m)
of welding arc. If this is not possible, tightly
cover them with approved covers.

Do not weld where flying sparks can strike flammable
material.

Hot metal from air arc cutting and gouging
can cause fire or explosion. DO NOT cut or
gouge near flammables.

Welding on closed containers, like tanks, drums or
pipes, can cause them to blow up. DO NOT weld on
closed containers unless they are properly prepared
according to AWS F4.1 (see Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping from American Welding Society
Standards). Check and be sure area is safe before doing
any welding.

Protect yourself and others from flying sparks and hot metal.
Wear oil-free protective garments like leather gloves,
heavy shirt, cuffless trousers, high shoes and a cap.

Be alert that welding sparks and hot materials from
welding can go through small cracks and openings to
adjacent areas.

Be aware that welding on a ceiling, floor, bulkhead or
partition can cause fire on hidden side.

Connect welding cable to the work as close to welding
area as practical to prevent welding current from traveling
long, possibly unknown paths and causing electric shock,
sparks and fire hazards.

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.
DO NOT touch output terminals during operation.
Contact with output terminals during operation can cause
electrocution, electrical shock or burn.

Remove any combustibles, such as a butane lighter or
matches, from your person before doing any welding.

After completion of work, inspect area to ensure it is free
of sparks, glowing embers and flames.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and
NFPA 51B for hot work and have a fire watcher and
extinguisher nearby.
WARNING

Keep your head out of the fumes. Use enough ventilation
or exhaust at the arc, or both, to keep the fumes and
gases from your breathing zone and the general area.
In a large room or outdoors, natural ventilation may be
adequate if you keep your head out of the fumes.
DO NOT
get too close to the arc. Use corrective lenses
if necessary to stay a reasonable distance away from
the arc.

Use natural drafts or fans to keep the fumes away from
your face.
Welding wire can cause injury. Do not press
gun trigger until instructed to do so. Do
not point gun toward any part of the body,
other people or any metal when threading
welding wire.

Have only qualified people remove doors, panels,
covers or guards for maintenance and troubleshooting
if necessary.

Reinstall doors, panels, covers or guards when servicing
is finished and before starting engine.
NEVER disconnect any
emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.

PAGE 8 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
SAFETY INFORMATION
CAUTION

Electric current flowing through any
conductor causes localized Electro
Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables
and welding machines.

Wearers of pacemakers and other
implanted medical devices should keep
away from welding equipment when in use.

Implanted medical device wearers should
consult their doctor and the device
manufacturer before going near arc
welding, spot welding, gouging, plasma
arc cutting or induction heating operations.

Exposure to EMF fields in welding may have other health
effects which are now not known.

All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
• Route the electrode and work cables together. Secure
them with tape when possible.
• NEVER coil the electrode lead around your body.
• DO NOT place your body between the electrode and
work cables. If the electrode cable is on your right side,
the work cable should also be on your right side.
• Connect the work cable to the workpiece as close as
possible to the area being welded.
• DO NOT work next to the welder-generator.
NOTICE
Electromagnetic energy can interfere
with sensitive electronic equipment such
as microprocessors, computers and
computer-driven equipment such as robots.
Be sure all equipment in the welding area
is electromagnetically compatible.
To reduce possible interference, keep weld cables as short
as possible, close together and down low, such as on
the floor. Locate welding operation 100 meters from any
sensitive electronic equipment.Be sure welder-generator
is installed and grounded according to this manual.
If interference still occurs, the operator must take extra
measures, like moving the welder-generator, using shielded
cables, using line filters or shielding the work area.
NEVER
lubricate components or attempt service on a
running machine.

Overheating can damage equipment.Turn off or unplug
equipment before starting or stopping engine. Low
voltage and frequency caused by low engine speed can
damage electric devices. Ensure engine speed is correct
during operation.

Overloading shortens the life of the welder-generator.
Use the machine with appropriate AC and DC current
and appropriate duty cycle.
ALWAYS
ensure welder-generator is on level ground
before use.
ALWAYS
keep the welder-generator in proper running
condition.

Fix damage to welder-generator and replace any broken
parts immediately.
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.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 9
SAFETY INFORMATION
ENGINE SAFETY
DANGER

The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.

The engine of this equipment
requires an adequate free
flow of cooling air. NEVER
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING

DO NOT place hands or fingers inside engine
compartment when engine is running.

NEVER operate the engine with heat shields or guards
removed.

Keep fingers, hands, hair and clothing away
from all moving parts to prevent injury.

DO NOT remove the radiator cap or coolant
drain plug while the engine is hot. High
pressure boiling water or coolant will gush
out and severely scald any persons in the
general area of the welder-generator.

DO NOT remove the engine oil drain plug while
the engine is hot. Hot oil will gush out of the engine
crankcase and severely scald any persons in the general
area of the welder-generator.
CAUTION

NEVER touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
NEVER
run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filter
frequently to prevent engine malfunction.
NEVER tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.

State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.

Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.

PAGE 10 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
SAFETY INFORMATION
FUEL SAFETY
DANGER

DO NOT add fuel to equipment if it is placed inside truck
bed with plastic liner. Possibility exists of explosion or
fire due to static electricity.

DO NOT start the engine near spilled fuel or combustible
fluids. Gasoline fuel is extremely flammable and its
vapors can cause an explosion if ignited.

ALWAYS refuel in a well-ventilated area, away from
sparks and open flames.

ALWAYS use extreme caution when working with
flammable liquids.

DO NOT fill the fuel tank while the engine is running
or hot.

DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.

Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.

NEVER use fuel as a cleaning agent.

DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine
ELECTRICAL SAFETY
DANGER
Turn welder-generator and all circuit breakers
OFF
before performing maintenance on the generator or
making contact with output receptacles.
NEVER insert any objects into the
output receptacles during operation.
This is extremely dangerous. The
possibility exists of electrical shock,
electrocution or death.
Backfeed to a utility system can cause
electrocution and/or property damage.
NEVER connect the welder-generator
to a building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician
in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing
serious
injury or even death.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water
while AC or DC power from the
generator is being transferred to a load.
NEVER use damaged or worn
cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
NEVER grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.

Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the generator.
NOTICE
ALWAYS
make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 11
SAFETY INFORMATION
Grounding Safety
DANGER

These welder-generators are equipped with a grounding
terminal at the base of the pipe frame. Electrical
grounding requirements can differ by State, Province,
District, Municipality, and unique application settings.

For portable and vehicle-mounted welder-generators,
Multiquip recognizes the guidance provided in NEC
Handbook Article 250.34 Parts A and B, and 29 CFR
1926.404 (f) (3) (i). If a more definitive earth-to-ground
safeguard is required, please consult a qualified
electrician and reference appropriate National Electrical
Code (NEC) guidelines in establishing an exterior
grounding point

NEVER use gas piping as an electrical ground.
BATTERY SAFETY
DANGER

DO NOT drop the battery. There is a possibility that the
battery will explode.

DO NOT expose the battery to open flames,
sparks, cigarettes, etc.The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.

DO NOT charge battery if frozen. Battery can explode.
When frozen, warm the battery to at least 61°F (16°C)
WARNING

ALWAYS wear safety glasses when
handling the battery to avoid eye irritation.
The battery contains acids that can cause
injury to the eyes and skin.

Use well-insulated gloves when picking up the battery.

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.
If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin
, rinse skin or clothing
immediately with plenty of water.

If the battery liquid (dilute sulfuric acid) comes into
contact with eyes
, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
ALWAYS disconnect the
NEGATIVE battery terminal
before performing service on the generator.
ALWAYS
keep battery cables in good working condition.
Repair or replace all worn cables.
TRANSPORTING SAFETY
CAUTION
NEVER
allow any person or animal to stand underneath
the equipment while lifting.
NOTICE

Before lifting, make sure that the equipment parts (lifting
bail) is not damaged and screws are not loose or missing.
ALWAYS
make sure crane or lifitng device has
been properly secured to the lifting bail (hook) of the
equipment.
ALWAYS shutdown engine before transporting.
NEVER lift the equipment while the engine is running.

Tighten fuel tank cap securely and close fuel cock to
prevent fuel from spilling.

Use adequate lifting cable (wire or rope) of sufficient
strength.

PAGE 12 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
SAFETY INFORMATION
Use one point suspension hook and lift straight upwards.

DO NOT lift machine to unnecessary heights.

ALWAYS tie down equipment during transport by
securing the equipment with rope.
ENVIRONMENTAL SAFETY/
DECOMMISSIONING
NOTICE
Decommissioning is a controlled process used to safely
retire a piece of equipment that is no longer serviceable.
If the equipment poses an unacceptable and unrepairable
safety risk due to wear or damage or is no longer cost
effective to maintain (beyond life-cycle reliability) and is to
be decommissioned (demolition and dismantlement),be
sure to follow rules below.

DO NOT pour waste or oil directly onto the ground, down
a drain or into any water source.

Contact your country's Department of
Public Works or recycling agency in your
area and arrange for proper disposal of
any electrical components, waste or oil
associated with this equipment.

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.
When the life cycle of this equipment is over, it is
recommended that the unit frame and all other metal
parts be sent to a recycling center.
Metal recycling involves the collection of metal from
discarded products and its transformation into raw
materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process
of recycling metal. Using a metal recycling center
promotes energy cost savings.
EMISSIONS INFORMATION
NOTICE
The gasoline engine used in this equipment has been
designed to reduce harmful levels of carbon monoxide
(CO), hydrocarbons (HC) and nitrogen oxides (NOx)
contained in gasoline exhaust emissions.
This engine has been certified to meet US EPA Evaporative
emissions requirements in the installed configuration.
Attempting to modify or make adjustments to the engine
emmission system by unauthorized personnel without
proper training could damage the equipment or create an
unsafe condition.
Additionally, modifying the fuel system may adversely affect
evaporative emissions, resulting in fines or other penalties.
Emission Control Label
The emission control label is an integral part of the emission
system and is strictly controlled by regulation(s).
The label must remain with the engine for its entire life.
If a replacement emission label is needed, please contact
your authorized engine distributor.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 13
SPECIFICATIONS (WELDER-GENERATOR)
Table 1. Welding Generator Specifications
CC Mode CV Mode
High Speed Low Speed High Speed Low Speed
Single Dual Single Dual Single Dual Single Dual
Rated Output 17.1 kW 7.5 kW 7.5 kW 4.9 kW 16.4 kW 6.6 kW 6.6 kW 4.1 kW
Rated Current 450 A 250 A 250 A 180 A 450 A 250 A 250 A 180 A
Rated Voltage 38.0 V 30.0 V 30.0 V 27.2 V 36.5 V 26.5 V 26.5 V 23.0 V
Duty Cycle 100% 100% 100% 100%
Rated Speed 1800 rpm 1200 rpm 1800 rpm 1800 rpm
Current Range 30~500 A 30~280 A 30~280 A 30~180 A — — — —
Voltage Range — — — — 14~40 V 14~29 V 14~29 V 14~24 V
Table 2. AC Generator Specifications
No. of Phases 1
Wires 3-Wires (Neutral Grounded)
Max. Output 14 kW (14 kVA)
Rated Output 12 kW (12kVA)
Rated Voltage 120/240 VAC
Amperage 116/58
Frequency 60 Hz
Power Factor 1
Rating Continuous
Receptacles (4) GFCI, 30 Amp Twist Lock (2)
50 Amp Twist Lock
Table 3. DC/AC Simultaneous Use
Electrode Size
(Dia. in.)
DC
Welding
Amps
AC
Output
(kW)
AC
Output (Amps)
120/240V
— — 14 116.6/58.3
3/32 80 14 116.6/58.3
1/8 130 14 116.6/58.3
5/32 170 14 116.6/58.3
3/16 220 11 91.6/45.8
7/32 270 9 75.0/37.5
1/4 320 7 58.3/29.1
5/16 370 5 41.6/20.83
Table 4. Engine Specifications
Model ISUZU 4LE2T
Type Vertical, 4-Cycle
Water Cooled, EGR
Rated Output 40.2 HP/1800 rpm
Displacement 133 cu. in. (2.179 L)
Cooling System Water-Cooled-Radiator
Starting System Electric Starting
Fuel Tank Capacity 17.7 gal. (67 L)
Fuel Type
No. 2 Diesel Fuel
Low Sulfur/Ultra LowSulfur
Diesel fuel
Cooling Water Capacity 2.35 gal. (8.9 L)
Lube Oil Capacity 2.75 gal. (10.4 L)
Lubricating Type Oil API Service Class
See Table 26 and Table 27
Battery 12 V 64Ah x 1
Dry Weight 1962 lbs. (890 kg)
Exhaust Gas-After Treatment DOC
NOTICE
This unit is a two function device, welder and AC
generator.The single-phase AC power source (14 kW)
can be used in conjunction with DC welding operations.
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 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
SPECIFICATIONS (FUEL CONSUMPTION)
Table 5. Fuel Consumption
No Load High (1800 rpm) Low (1200 rpm)
Fuel Consumption
gal/hr. (llters/hr.)
0.47
(1.77)
0.23
(0.87)
High (1800 rpm)
Amperes1113 225 338 450
Fuel Consumption
gal/hr. (llters/hr.)
0.60
(2.27)
0.84
(3.17)
1.15
(4.35)
1.59
(6.00)
Low (1200 rpm)
Amperes 63 125 188 250
Fuel Consumption
gal/hr. (llters/hr.)
0.30
(1.13)
0.41
(1.55)
0.56
(2.11)
0.75
(2.83)
1DC welding current at 100%
Figure 1. Fuel Consumption Chart
Fuel Consumption
Fuel Consumption
[gal/h]
High
Low
DC Weld Amperes at 100% duty cycle [A]

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 15
DIMENSIONS
Table 6. Dimensions
Reference Letter Dimension in. (mm)
A 24.21 (615)
B 24.21 (615)
C 23.62 (600)
D 23.62 (600)
E 44.48 (1130)
F 80.11 (2035)
G 16.92 (430)
H 32.67 (830)
Figure 2. Dimensions
FRONT VIEW
H
TOP VIEW
MAXIMUM
3,030 lbs.
(1,374 kg)
LIFTING POINT
A
B
D
C
SIDE VIEW
G F
Power Source Professionals.
E

PAGE 16 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
INSTALLATION
Figure 3. Welder-Generator Grounding Application
Power Source Professionals.
REFERENCE
NEC 250-83
GROUND CABLE
8 FT / 2.4M (MINIMUM)
WELDER-GENERATOR
GROUND LUG
IF THE WELDER-GENERATOR IS PROVIDING
ELECTRIC POWER TO A BUILDING VIA A
TRANSFER SWITCH ITMUST BE CONNECTED
TO A GROUND ROD.
CONNECTING THE GROUND
Consult with local Electrical and Safety Codes for proper
connection based on condition of use.
EXAMPLE of how to ground the unit if the condition
of use requires such a device:
The ground terminal on the generator should always be
used to connect the generator to a suitable ground when
required.
The ground cable should be #8 size wire (aluminum)
minimum. If copper wire is used, #10 size wire minimum
should be used.
Connect one end of the ground cable terminal to the welder-
generator ground point (Figure 3). Connect the other end of
the ground cable to a suitable earth ground (ground rod).
NOTICE
Trailer-mounted welder-generators are the sole
responsibility of MQ Power.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 17
INSTALLATION
OUTDOOR INSTALLATION
If possible install the welder-generator in a area that is free
of debris, bystanders, and overhead obstructions. Make
sure the welder-generator is on secure level ground so
that it cannot slide or shift around.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected
from excessive moisture. Failure to do so will result in
deterioration of the insulation and will result in short circuits
and grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
INDOOR INSTALLATION
Exhaust gases from gas engines are extremely poisonous.
Whenever an engine is installed indoors the exhaust
fumes must be vented to the outside. The engine should
be installed at least two feet from any outside wall. Using
an exhaust pipe which is too long or too small can cause
excessive back pressure which will cause the engine to
heat excessively and possibly burn the valves.
PLACEMENT
This welder-generator should always be placed on a flat
level surface when it is running. DO NOT place the welder-
generator on slopes, the possibility exists that the unit could
slide.
WARNING
Pay close attention to ventilation when
operating the generator inside tunnels
and caves. The engine exhaust contains
noxious elements. Engine exhaust must
be routed to a ventilated area
DANGER
Electric shock can occur when vibrators
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.
WELDER-GENERATOR GROUNDING
If applicable ,to guard against electrical shock and possible
damage to the generator, it is important to provide a good
EARTH ground, (Figure 3).
Article 250 (Grounding) of the NEC handbook provides
guidelines for proper grounding. It specifies that the cable
ground shall be connected to the grounding system of the
building as close to the point of cable entry as practical.
NEC article 250 specifices the following grounding
requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper 10 AWG (5.3 mm2) or larger.
b. Aluminum 8 AWG (8.4 mm2) or larger.
2. When grounding of the generator (Figure 3) is required,
connect one end of the ground cable to the ground lug
on the generator. Connect the other end of the ground
cable to the ground rod (earth ground).
3. NEC article 250 specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
The Occupational Safety and Health Administration
(OSHA) and the National Electrical Code (NEC)
recommend that if the welder-generator is providing
electrical power to a structure (home, office shop,
trailer or similar) it must be connected to a grounding
electrode system, such as driven ground rod (Figure 3).
NOTICE
ALWAYS check with State, Province, District and
Municipalities for electrical grounding requirements
before using generator.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.

PAGE 18 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
When used in single mode applications, Multiquip’s Model
DLW500ESA4 Whisper Weld™ is a 500 amp DC welder.
Dual mode applications provide 250 amps at each of the
A and B welding terminals.
This unit incorporates a brushless revolving field
simultaneous power generator, featuring stable arc
characteristics, excellent vibration resistance and durability.
The unit also incorporates an AC power source (14 kW)
which provides power for tools, submersible water pumps
and other industrial and construction machinery.
In addition, this unit features incredibly quiet operation
and can be operated at night or in restricted noise level
locations.
This instruction manual provides information necessary
for proper handling and operation of the welder/generator.
Please read the manual to ensure maximum operation and
long service life.
CONTROL PANEL
The control panel is provided with the following components:
DC Weld Meter
Hour Meter
Display Change Button
Idle Stop Monitor
Fuel Guage
Warning Lamp/Hour Display Button
Welding Regulation Control A/B
Current Voltage Regulator Control A/B
Single-Dual Selector Switch
Welding Mode Selector Switch CC/CV
E-Mode Selector Switch
Operation Lamp
Engine Start Button
Starter Switch
60 Amp Main Circuit Breaker
AC Voltmeter
Idle Stop Time Regulator Control
Idle Stop Select Switch
GFCI Sensing Module
GENERAL INFORMATION
OUTPUT TERMINAL PANEL
120 VAC GFCI Receptacle (5-20R)
120V Twist-Lock Output Receptacle (L5-30R)
240V Twist-Lock Output Receptacle (L6-30R)
120/240V Output Twist-Lock Receptacle (CS6369)
20 Amp 2P Circuit Breaker
30 Amp 1P Circuit Breaker
30 Amp 2P Circuit Breaker
Ground Terminal
OPTIONS
The welder-generator has the following options:
TRLRMP/TRLRMPXF Trailers
Trailer Tool Box
Cable Carrier
Wired Remote Control
Block Heater
Fuel Heater
Battery Tender
This welder-generator is powered by a 4 cylinder, 4-cycle
liquid-cooled Isuzu 4LE2T diesel engine. This engine is
designed to meet every performance requirement for the
generator. Reference Table 4 for engine specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
EXTENSION CABLES
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 11) as a
guide for selecting proper extension cable size.

DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23) — PAGE 19
WELDING POLARITY AND DUTY CYCLE
WELDING POLARITY
Polarity indicates the direction of the current flow in that
circuit. Since DC current moves in only one direction,
polarity is important because the flow of current must be
changed depending on the application.
By changing the polarity, the greatest amount of heat can
be concentrated where it is most needed. With straight
polarity (electrode negative), more heat is directed to
the workplace. When using reverse polarity (electrode
positive), more of the heat generated is directed to the
electrode. Reference Figure 19.
DUTY CYCLE
Duty cycle is based on a 10-minute welding period.
Exceeding the duty cycle will have an affect on the welding
process. The amperage will start dropping off and the
welding process will not have the proper amperage required
to proceed. If the duty cycle is exceeded, damage can occur
to the welding machine.
The 10-minute duty cycle period means 100% welding. If
the duty cycle is 70%, then you can only weld for seven
minutes and the machine must cool down for three
minutes (Reference Table 7).
NOTICE
When high quality welding is required DO NOT use AC
power side of unit.
NOTICE
The American Welding Society sets all regulations
and procedures for the welding industry. All welders
are subject to the same regulations.
Table 7. 10-Minute Duty Cycle
Duty
Cycle %
Welding
ON Time (Min.)
Cool Down
Time (Min.)
Welding
Current
(Amps)
Single Mode (High Speed)
1001Continuous N/A 30 ~ 450
90 9 1 470
80 8 2 480
70 7 3 500
Dual Mode (High Speed)
1001Continuous N/A 30 ~ 250
90 9 1 260
80 8 2 270
70 7 3 275
1The DLW500ESA4 welder has a 100% duty cycle @ 450 amps (single
mode) or 250 amps (dual mode).
Table 8. 10-Minute Duty Cycle
Duty
Cycle %
Welding
ON Time (Min.)
Cool Down
Time (Min.)
Welding
Current
(Amps)
Single Mode (Low Speed)
1001Continuous N/A 30 ~ 250
90 9 1 260
80 8 2 270
70 7 3 280
Table 9. 10-Minute Duty Cycle
Duty
Cycle %
Welding
ON Time (Min.)
Cool Down
Time (Min.)
Welding
Current
(Amps)
Dual Mode (Low Speed)
1001Continuous N/A 30 ~ 180
90 9 1 190
80 8 2 195
70 7 3 200

PAGE 20 — DLW500ESA4 WELDER/GENERATOR • OPERATION MANUAL — REV. # 0 (01/13/23)
DEFINITIONS OF WELDING TERMS
1. Weld – The unification of metallic parts by heating and
allowing the metals to flow together or by hammering
or compressing with or without previous heating.
2. Straight Polarity – A term for direct current electrode
negative.
3. Reverse Polarity – A term for direct current electrode
positive.
4. Manual Welding – A welding operation performed
and controlled completely by hand.
5. AC or Alternating Current – AC is the kind of
electricity, which reverses its direction periodically.
For 60 cycle current, the current goes in one direction
and then in the other direction 60 times in the same
second, so that the current changes its direction 120
times in one second.
6. DC or Direct Current – DC is the kind of electricity,
which only flows in one direction. The flow of electricity
is from the power source to the application. In welding,
an arc welding process wherein the power supply is at
the arc is direct current.
7. ARC Force – An adjustment that allows the operator
to fine tune the arc characteristics according to job
requirements.
8. ARC Length – The distance from the end of the
electrode to the point where the arc makes contact
with the work surface.
9. ARC Voltage – The voltage across the welding arc.
10. ARC Blow – The deflection of an electric arc from its
normal path because of magnetic forces.
11. Base Metal (Material) – The metal (material) to be
welded, brazed, soldered, or cut.
12. E-Mode – Improves fuel efficiency by allowing the
operator to weld with engine at idle speed at up to
240 amps (single mode). Reduces operating costs
and noise levels.
13. Covered Electrode – A composite fill metal electrode
consisting of a core of a bare electrode or metal-cored
electrode to which a covering sufficient to provide a slag
layer on the weld metal has been applied.
The covering may contain materials providing
such functions as shielding from the atmosphere,
deoxidization, and arc stabilization and can serve as
a source of metallic additions to the weld.
14. Fillet Weld – A weld of triangular cross section joining
two surfaces approximately at right angles to each
other in a lap joint, T-joint or corner joint.
15. Tack Weld – A weld made to hold parts of a weldment
for proper alignment until the final welds are made.
16. Shade Number – This number pertains to the
lightness or darkness of the lens in the welding helmet.
Lens number range from 2 to 14 where 2 would be the
lightest lens and 14 would be the darkest lens.
17. CC or Constant Current – In this mode the
amperage or current stays constant, but the direct
current voltage will change depending on the arc
length. This mode is applied to SMAW, FCAW and
GTAW processes.
18. CV or Constant Voltage – In this mode the direct
current voltage stays constant, but direct current
amperage will change slightly. This mode is applied
to GMAW, FCAW and GTAW.
19. Parallel Connection – Simply connect the positive
terminals together, then connect the negative terminals
together. Make sure that the machines are located as
close together as possible.
Welding cables should be sized appropriately to handle
the additional amperage. Rheostats must be set at
the same amperage or as close as possible. (Note:
Unlike competitive models, no parallel box is needed
with Multiquip's welder-generators.)
WELDING PROCESSES
SMAW – Shielded-Metal Arc Welding
FCAW – Flux-Cored Arc Welding
GMAW – Gas-Metal Arc Welding
GTAW – Gas-Tungsten Arc Welding
ACAC – Air Carbon Arc Cutting
WELDING TERMS