CIGWELD 636804 Guide rapide

DOC No: EDW0005 Date: 16-July-97

Issue No: 2

ENGINE DRIVEN WELDER

GENERATING SET

MPM 12/400 I-KA

(Part Number 636804)

GENERAL USE INSTRUCTIONS

Read the instructions carefully; proceed according to the regulations in use in the

country where the machine will operate.

TRANSPORTATION

The machine must be fixed securely to the motor vehicle if it has to be moved to the

place of use. Raise the machine using the lifting eye if the model provides it;

otherwise, lift it using a forklift, taking care that the weight is well balanced on the

two forks. Keep well clear during these operations; furthermore, we suggest not to

keep the machine suspended for long.

If the machine is mounted on a wheels trolley or trailer, be sure the machine is stable

and secure before use.

CAUTION

Note: The generating set or the welder is furnished WITHOUT lubricating oil.

Provide the machine with "10 W 40" multi-grade oil indicated for temperatures

from - 20°C to 40° C in the quantity indicated in the engine SPECIFICATION

section.

Note: If the machine is fitted with a water cooled engine fill the radiator circuit with a

solution made up by 50% water and 50% antifreeze liquid in the quantity indicated in

the engine SPECIFICATION section.

Note: The generating set is furnished with a flat battery and without acid. Fill it using

sulphuric acid in a 30% - 40% concentrated solution to cover the elements. During

this operation, we suggest the operator use protective gloves and goggles; accidental

skin contact with the sulphuric acid solution must be washed up immediately with

cold water and, if necessary, a doctor must be consulted.

Note: Do not disconnect battery cables when the engine runs. This could result in

serious damage to the machine.

Note: BEFORE OPERATING THE MACHINE the neutral, or the equivalent

winding point, MUST be connected effectively to earth using an earth stake (without

any switch or other device that may interrupt the electrical connection) from the earth

stud available on the machine, and identified by the symbol:

Note: for normal transportation, follow the instructions as specified in the

TRANSPORTATION section.

RUNNING IN

For the first 50 hours of operation of the machine do not employ more than 70% of the

maximum power indicated in the technical specifications.

STARTING AND WORKING

1- Make the earth connection (see the USE INSTRUCTIONS).

2- If the machine model IS NOT equipped with a earth leakage circuit breaker the

available socket is intended ONLY for connecting the machine to a switchboard

equipped with all protection devices imposed by current law regulations.

3- Check the state and efficiency of the cables.

4- Make sure that all the switches and electric connections are in the right position for

starting (see USE INSTRUCTIONS and CONTROL PANEL DESCRIPTIONS).

5- Use the machine in well ventilated places, taking care that the exhaust gas and the

welding fumes produced (where welders are used) do not stagnate. Keep the machine

away from walls or other obstacles in order to avoid air or gas recycling. If the

machine is employed in closed places, use forced ventilation in order to ensure proper

air recycling.

6- While welding, eyes and body must be protected by gloves, mask and appropriate

clothes.

7- Fuel refill must not be made while smoking or close to flames. This operation must

be done when the engine is switched off.

8- Do not over fill the tank and clean up any spillage.

9- Check daily for loss of fuel or lubricating oil.

10-For machines provided with a liftable canopy engage the canopy securing brackets

where fitted.

WARNING

Do not connect the machine to the commercial electric network.

Do not work close to flammable materials or where there is explosive gas or vapours.

Do not work in confined or poorly ventilated places.

Do not touch the exhaust muffler or adjacent components.

Do not carry out service operations while the engine is running.

Any service on the electrical circuit must be done when the engine is stopped and only

by qualified technicians.

Keep clear of moving parts of the engine while it is operating and do not approach the

machine with loose fitting clothing.

SERVICE AND CLEANING

We suggest frequent cleaning of the machine since the presence of dirt can compromise

efficiency.

The frequency of this operation depends on the environment in which the machine is

used. We advise to pay special care to the service of::

OIL LEVEL, OIL FILTER, AIR FILTER, FUEL FILTER, COOLING LIQUID

LEVEL, RADIATOR, VENTILATION DUCTS AND INTAKES, BATTERY

ENGINE USE AND SERVICE manual and the SPECIFICATION section to know

how and when it is useful to do it. The extraordinary service operations not mentioned

herein require the aid of specialised technicians (see the Engine Dealers list).

For service intervals consult the ENGINE USE AND SERVICE manual and the

SPECIFICATION.

ADJUSTMENTS AND REGULATIONS

All necessary controls are located on the main control panel and are properly explained

in the section FRONT PANEL DESCRIPTION.

We advise the operator against tampering with the engine or the internal electrical

components.

Note: Modification of the normal parameters can compromise the reliability of the

machine.

PROLONGED STANDING PERIODS

If the machine has to be stopped for a long period (more than one year), we suggest to

leave the motor oil and the fuel in and the water in the radiator in order to avoid

oxidising effects.

When the machine is to be used, the liquids must be replaced, the battery must be

charged; the belts, pipes and rubber hoses must be checked and a visual inspection of the

electrical connections must be done.

SCRAPPING

In order to preserve the environment, it is advised to dispose of the oil, fuel and battery

in an approved manner. For the complete range of materials, see the list below:

FERROUS and NON-FERROUS MATERIALS:

steel, cast iron, aluminium, copper, brass are used in the structure of engine,

alternator, transformers, etc.

PLASTIC MATERIALS:

rubber, bakalite, epovit, lexan are used for the instruments, engine pipes,

junction boxes and connectors, fuel tank, fuel cap, wheels, anti-vibration

dampers, condenser housings, fans, belts, filters and hoses.

ELECTRONIC MATERIALS:

various components, diodes, resistors, electronic panels.

VARIOUS MATERIALS:

rock wool, sound proofing materials.

LIQUIDS:

fuel, gasoline, cooling liquids, battery acid.

POWER PLANT INFORMATION

MPM 12/400 I-KADescription

636804Part number

WELDING GENERATOR D.C.

18V to 40VCV mode

30A to 400ACC mode

IP 23Mechanical protection

FInsulation class

70VDC open circuit voltage

5 minutesDuty cycle period

30A to 400ARange of continuous control

350A @ 34VRated output at 60% duty cycle

400A @ 36VMaximum power

AUXILIARY GENERATOR

50 HzFrequency

10kVA @ 230VSingle phase power

12kVA @ 400VThree phase power

AsynchronousGenerator type

RECOMMENDED MANUAL METAL ARC WELDING ELECTRODE

6.0mmIron powder

6.0mmCellulose

6.0mmGeneral purpose & low hydrogen

Maximum Electrode DiameterElectrode Description

TECHNICAL SPECIFICATION

ENGINE

15 hoursAverage operating hours

275 gram/kW/hourAverage fuel consumption

77 dBAcoustic pressure @ 4 metre

89 dBAcoustic pressure @ 1 metre

97 dB(A)Acoustic energy emission

12V - 43 AhBattery

ElectricStarter

5.1 LitresOil capacity

36.5 LitresFuel tank capacity

WaterCooling

3000 rpmEngine speed

25 HPDiesel engine output

1124 cc.Displacement

3Number of cylinders

Kubota D 1105-EMake/Type

DIMENSIONS AND WEIGHT

460 KgWeight

1590mm x 730mm x 920 mmDimensions (Length x Width x Height)

The engine is warranted for twelve (12) months from date of purchase or one thousand (1000) hours

which ever is sooner. This warranty is limited to the replacement or repair, at Tutts workshop of any

parts proven defective, under normal use and service within the warranty period. For warranty

service outside a Tutts workshop, all travelling time and mileage incurred, will of necessity, be

charged to the owner of the equipment who ordered the off site warranty repair(s).

New engine warranty does not apply to maintenance items such as filters, hoses, belts, preheaters,

injection nozzles, packing and seals, etc.

To secure warranty for the engine ensure that the warranty certificate is fill in and mailed to the Tutts

state branch office (KUBOTAs Australian engine distributor).

1.2 ENGINE WARRANTY

Carefully follow the KUBOTA engine operation manual for safe operation and long service life of

this product.

1.1 INTRODUCTION

Tutts Branch Network Tutts (Sydney): 2 South St. Rydalmere NSW 2116

Tutts (Perth): 50 Great Eastern Hwy South Guildford WA 6055

Tutts (Brisbane): 39 Suscatand St Rocklea QLD 4106

Tutts (Melbourne): Gwelo St Tottenham VIC 3012

Tutts Dealer Network

Queensland: Andrew's Agricultural Centre Pty Ltd - Goranvale, Cairns Ph: (070) 565222

- Innisfail Ph: (070 616466

- Tully Ph: (070) 681311

Fishabout Pty Ltd - Mackay Ph: (079) 534752

Dore Power Equipment Pty Ltd - Roma Ph: (076) 221883

New South Wales: SJ & ML Foster - Moree Ph: (067) 525 488

Clares Diesel Service Pty Ltd - Coffs Harbour Ph: (066) 525121

Kentan Pty Ltd - Hexham, Newcastle Ph: (049) 648275

Tasmania: Diesel & Marine Pty Ltd - Newtown, Hobart Ph: (03) 62281755

South Australia: Mac Pac Sales & Service Pty Ltd - Wingfield, Adelaide Ph: (08) 82431422

1.3 SPARE PARTS

KUBOTA engine:Contact Tutts (in Australia) for spare parts and service assistance. Specify the

engine model number, serial number, name of part (with code number), Engine

Driven Welder model name (with code number) and manufacturers name when you

contact your KUBOTA Dealer. KUBOTA guarantees an efficient technical support

throughout Australia and New Zealand.

Generator and equipment: Contact your local CIGWELD Distributor for spare parts. Specify the

Engine Driven Welders model number, serial number and name of part

(with code number) when ordering spare parts. Refer to the Spare Parts

List from page 13.

ENGINE WARRANTY

AND SPARE PARTS

FRONT PANEL DESCRIPTIONS

Welding socket : positive connection

Remote control switch

Welding socket : negative connection

for CC-WORK

Welding current control

Welding socket : negative connection

for CV-WORK

CC/CV mode select

Earth connection

Throttle switch

Serial number

Fuel meter

ELCB (25A earth fault protection)

Glow plug lamp

16A single phase circuit breaker

Oil pressure lamp

400V three phase outlet

Battery charge lamp

230V single phase outlet

Water temperature lamp

Wire feeder connector 14 pin

Hourmeter

Basic / Cellulose switch

Single phase voltmeter

Arc force regulator

Ignition key

1.1 EQUIPMENT

GROUNDING CONNECTION

This machine has auxiliary power capability and grounding of the frame and case is

recommended. Refer to your local Supply Authority or Australian Standard AS3000 for

detailed earthing instructions. Connect the earth wire to the Earth connection located

on the front of the machine.

2.1 EARTH FAULT PROTECTION

Supply Authorities recommend that protection devices immediately disconnect all power

in the event of an earthing fault. This equipment is fitted with a Earth Leakage Circuit

Breaker (ELCB) that interrupts the auxiliary power circuit within 0.2 seconds when the

earth leakage is greater than 30 mA.

If a fault occurs in equipment connected to the auxiliary power supply, the outer casing

may become live and result in serious injury. The Engine Driven Welder must be

properly earthed. Refer to your local Supply Authority or Australian Standard AS3000

for detailed earthing instructions. The user is responsible for connecting this Engine

Driven Welder to earth.

3.1 USE AND TESTING OF EARTH FAULT PROTECTION

Switch the ELCB lever up to setting I (ON). Test by pressing the test button while the

engine is running. This will result in the ELCB tripping resulting the lever returning to

setting 0 (OFF). Reset to setting I (ON).

If the ELCB trips repeatedly while operating auxiliary equipment, have the equipment

tested by a qualified electrical tradesperson.

OPERATING INSTRUCTIONS

4.1 STARTING ENGINE

Check that engines fuel tank has been filled with diesel and the sump has been filled with

lubricating oil as specified in the Engine Manual.

Position the ignition key on the first step for preliminary heating of the glow plugs, the

glow plug light illuminates. When glow plug light turns off, start the engine by moving

key completely clockwise.

After starting the engine, allow it to warm up by waiting 10s minute before loading the

Engine Driven Welder.

Do not move the throttle control lever.

5.1 USE OF ENGINE DRIVEN WELDER AS A WELDER

Insert welding cable plugs into relevant sockets.

Set the current/voltage control knob on the front panel to the desired value on the

Engine Driven Welder. Take care that the REMOTE CONTROL switch is in 0 (OFF)

position.

Set the Arc Force control to I(ON) or 0(OFF) position.

Remote current control can be achieved by using a remote control device.

When operating with remote control switch the remote switch control to position I

(ON) and connect the cable of the remote control unit to the 14 pin remote control

socket.

Connected the Electrode Lead to the positive terminal and the work lead to the

negative terminal.

Note: Stick electrodes are generally connected to the positive terminal but if in doubt

consult the electrode manufactures literature.

In standby mode, ie not welding or supplying power to auxiliary outlets, the engine idles

at approximately 2000 rpm.

When an arc is struck or the unit is supplying power to auxiliary outlets then the engines

speed increases to approximately 3000 rpm. The returns to idle speed approximately 25

seconds after welding has ceased.

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