Denyo DLW-300LS - User Manual

Questions and Answers

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Benjamin MartinezAug 18, 2025
What to do if my Denyo DLW-300LS Welding System has no arcing or weak arcing?
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  Matthew GardnerAug 18, 2025
  If you're experiencing no arcing or weak arcing with your Denyo Welding System, consider these potential causes and solutions: * Loose or disconnected wires: Visually check and repair. * Poor contacting at wire terminal: Pull the lead wire and check the connection. * Faulty generator, control device (FE-50), transistor (IGBT), rectifier (Re1), current regulator (VR1), DC reactor, or condenser (C1, 2): Replace the faulty component. * Inadequate welding cable: Replace the welding cable with one of adequate length and thickness. * Faulty output terminals: Replace and repair the output terminals.
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Courtney JacksonAug 21, 2025
What to do if my Denyo DLW-300LS engine overheats?
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  Michael OrtegaAug 21, 2025
  If your Denyo Welding System engine is overheating, consider the following: * Low oil level: Add oil to the FULL mark on the dipstick. * Overload: Reduce the load on the system. * Poor ventilation: Ensure there is adequate space around the machine, with at least 1 clearance on all sides. * Low coolant level: Check and replenish the cooling water.
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Melissa SullivanAug 25, 2025
What to do if my Denyo DLW-300LS has no AC output?
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  johnhughesAug 26, 2025
  If your Denyo Welding System isn't producing AC output, here's what you can check: * Loose or disconnected wires: Visually check and repair. * Poor contacting at wire terminal: Pull the lead wire and check the connection. * Faulty control device (AVR) or rotor: Replace the control device (AVR) or the rotor. * Low engine speed: Adjust and repair to achieve the correct engine speed. * Tripped circuit breaker: Replace the circuit breaker. * Layer short-circuit in armature: Replace the armature.
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Linda GarnerAug 28, 2025
What causes abnormal noise in Denyo DLW-300LS Welding System?
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  Mackenzie HuntAug 28, 2025
  Abnormal noise in your Denyo Welding System can stem from several sources: * Faulty engine: Repair the engine. * Damaged rotor: Replace the rotor. * Loose or damaged bolts: Tighten the bolts. * Damaged bonnet: Repair the bonnet.
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Amanda HensleyAug 31, 2025
What causes a Denyo Welding System battery to become flat quickly?
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  Ryan GutierrezAug 31, 2025
  A Denyo Welding System battery that quickly goes flat may be due to: * A faulty charging generator: Replace the charging generator. * A faulty regulator: Replace the regulator. * A faulty starter switch: Replace the starter switch. * A burned main fuse (65A): Replace the fuse.
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Heather DiazSep 3, 2025
Why does Denyo Welding System engine remain at high or slow speed?
- K
  kimjonesSep 3, 2025
  If your Denyo Welding System engine speed is consistently too high or too low, check these items: * Loose or disconnected wires: Visually check and repair them. * Poor contacting at wire terminal: Pull the lead wire and check the connection. * Faulty control panel, e mode selector switch (SW1), current trans (CT-AC,DCCT), control device (FE-50), geared motor (GM), or burned fuse (F): Replace the faulty component.
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Stephanie DavisSep 7, 2025
Why Denyo DLW-300LS Welding System engine has abnormal color of emission?
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  Jennifer MathisSep 7, 2025
  Abnormal exhaust color in a Denyo Welding System can be caused by: * Bad quality fuel: Replace the fuel. * Clogged air cleaner: Clean the air cleaner element.
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Michael FullerSep 10, 2025
What causes low power and sudden shutdown of Denyo Welding System engine?
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  Carrie ReyesSep 12, 2025
  A sudden shutdown of the Denyo Welding System engine with low power can be attributed to: * Lack of fuel: Replenish the fuel supply. * Clogged air cleaner: Clean the air cleaner element. * Faulty emergency shutdown switch: Check the oil quantity. * [Not mentioned in the extract]: Check for water quantity. * [Not mentioned in the extract]: Check the fan belt. * [Not mentioned in the extract]: Check the radiator for clogging.
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Justin NicholsNov 14, 2025
Why Denyo DLW-300LS Welding System engine does not start?
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  Taylor SanchezNov 14, 2025
  If your Denyo Welding System engine won't start, several issues could be the cause: * Loose or disconnected wires: Visually check and repair. * Poor contacting at wire terminal: Pull the lead wire and check connection. * No fuel flow: Check the fuel tank, fuel filter, and water separator, removing any foreign matter. If the filter is clogged, change it. * Air or water in the fuel system: Bleed air. * Fuel cock/water separator cock closed: Open the fuel cock/water separator cock. * Over-discharged battery: Charge or replace the battery. * Faulty starter switch or starter: Replace the starter switch or starter. * Broken pre-heat circuit: Repair the circuit. * Burned fuse (F3 5A, main fuse 65A): Replace the fuse. * Faulty emergency unit or safety relay: Replace the emerge...

Summary

Foreword and Symbols

Introduction and Symbol Guide

Provides a brief introduction and explains hazard and caution symbols used in the manual.

Safety Precautions

General Hazard Warnings

Details risks including electric shock, fire, hot parts, and improper connections.

Machine Overview and Components

External and Internal Component Identification

Identifies external and internal parts, including diagrams and component lists.

Control Panel Layout and Functions

Details the function and layout of all controls and indicators on the main panel.

Transportation, Installation, and Initial Checks

Safe Transport and Lifting Guidelines

Provides instructions for moving, lifting, and placing the machine safely.

Installation Site Requirements

Specifies optimal installation conditions, including level ground and ventilation.

Battery Maintenance and Checks

Covers battery electrolyte level, gravity checks, and charging recommendations.

Battery Cable and Fan Belt Procedures

Details correct battery cable connection and fan belt inspection.

Prestart System Verification

Outlines essential checks of fuel level, engine monitor, and other indicators before starting.

Fluids, Fuel, and Consumption

Engine Oil and Cooling Water Management

Recommends oil types, viscosity, coolant, and capacities for engine maintenance.

Fuel Type and Consumption Data

Specifies recommended fuel, tank capacity, and details fuel consumption rates.

Starting and Operating the Welder

Engine Start-Up Sequence and Operation

Step-by-step guide for starting the engine and operational monitoring.

Stopping the Engine and Protection Systems

Engine Shutdown and Securing Procedures

Provides instructions for safely stopping the engine and securing the machine after use.

Automatic Air Bleeding Unit Use

Explains how to operate the automatic air bleeding unit for fuel system issues.

Machine Protection Systems Overview

Details built-in protection devices for engine, welding output, and electrical components.

Welder Operation and Adjustments

Welding Cables, Polarity, and Selection

Guides on connecting welding cables, selecting polarity, and choosing appropriate cable sizes.

Current Control, Modes, and e-Mode

Explains current adjustment, welding modes, and e-mode operation for performance optimization.

VRD, AC Power, and Earth Leakage Relay

Covers VRD, AC power supply usage, and earth leakage relay functions for safety.

Maintenance Procedures

Routine Maintenance Schedule and Tasks

Outlines periodic maintenance based on operating hours, including filters and air cleaner.

Filter and Separator Servicing

Provides detailed instructions for servicing oil filters, fuel filters, and water separators.

Air Cleaner and Condenser Service

Details air cleaner element cleaning/replacement and condenser replacement advice.

Troubleshooting and Storage

Common Issues and Solutions

Lists common problems like no arcing, no AC output, and engine start failures with causes and remedies.

Long-Term Storage Recommendations

Covers battery disconnection, electrolyte checks, and general inspection before storage.

Technical Specifications and Diagrams

Detailed Machine Specifications

Provides comprehensive technical data for welding output, AC power, and engine parameters.

Outline Drawings and Wiring Schematics

Illustrates machine layout, control panel, and electrical wiring diagrams.

Attachments and Accessories

Included Items and Documentation

Lists items included with the welder, such as manuals, keys, and fuses.

Denyo DLW-300LS Specifications

General

Rated Output (Welding Current)	300A
Frequency	50/60 Hz
Welding Current Range	50-300A
Rated Welding Current	300A
Duty Cycle	60%
Engine Model	Kubota D902
Insulation Class	F
Protection Class	IP23
Type	Engine Driven Welder
Power Supply	Diesel
Usable Electrode	2.6-6.0mm