ESAB Installation Instructions Idle Device Kit 494461494461-1 Installation guide

Category
Welding System
Type
Installation guide

This manual is also suitable for

Installation Instructions
Idle Device Kit
494461
494461-1
Combined Instructions For Use On:
MA-3525DD 500005-1
MA-3525DD 500005A-1
MA-3525DD 500005B-1
MA-5040DD S-6436A-1
MA-5040DD S-6436B-1
OWNER’S MANUAL Number 430429-089
Revised December 1, 1997
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
IMPORTANT: Readtheseinstructionsbeforeinstalling, operating, or servicing this system.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERSKEEPAWAY UNTIL CONSULTINGYOURDOCTOR. DO NOTLOSETHESEINSTRUCTIONS.READOPERATING/INSTRUC-
TION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
trainingbefore using thisequipment. Anyone not having extensive training inwelding and cutting practices shouldnot attempt toweld.Certain
of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled:
SAFETY IN WELDING AND CUTTING. This publication and
other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touchingliveelectrical partscan causefatal shocks
or severe burns. The electrode and work circuit is
electricallylive wheneverthe output ison. Theinput
power circuit and machine internal circuits are also
livewhenpowerison.Insemiautomaticorautomatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself fromwork and groundusing dryinsulating mats
or covers.
4. Disconnect input power or stop engine before installing or serv-
icing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to coolit or lay it down on the ground or the worksurface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do notuseworn,damaged, undersized,orpoorly splicedcables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Useonlywell-maintainedequipment.Repairorreplacedamaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
ARC WELDING can be hazardous.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering
Torch brazing
Oxygen cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc welding
(stick) electrodes
Welding or Cutting
Operation
Gas metal-arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gastungstenarc welding(TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in., 4 to 6.4 mm
Over 1/4 in., 6.4 mm
Electrode Size
Metal Thickness
or Welding Current
All
All
All
All
All
All
Under 300 Amp
300 to 400 Amp
Over 400 Amp
Filter
Shade
No.
2
3or4
3or4
4or5
5or6
4or5
5or6
6or8
10
12
14
Filter
Shade
No.
11
12
12
12
12
12
12
14
9
12
14
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
May 8, 1996 2-1
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work-
piece, and hot equipment cancause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields rec-
ommended.
2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pres-
sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protectcompressedgascylindersfromexcessiveheat,mechani-
cal shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
themtoastationarysupportorequipmentcylinderracktoprevent
falling or tipping.
3. Keep cylinders awayfrom anywelding orother electricalcircuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Readand follow instructions oncompressed gascylinders, asso-
ciated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
FUMES AND GASES can be hazardous
to your health.
Weldingproducesfumesandgases.Breathingthese
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manu-
facturers instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and raysof the arc canreact with vaporsto
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
2-2 May 8, 1996
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant inthe radiatorcan bevery hotand under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety inWelding andCutting, ANSIStandard Z49.1,fromAmerican
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safetyand Health Standards, OSHA29 CFR1910, fromSuperinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
CuttingofContainersThatHaveHeldHazardousSubstances,Ameri-
can Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code forSafety inWelding andCutting, CSAStandardW117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Pro-
tection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteriescontainacidandgenerateexplosivegases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and ) on batteries.
MOVING PARTS can cause injury.
Moving parts,such as fans,rotors, and beltscan cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for mainte-
nance and troubleshooting as necessary.
4. Toprevent accidental startingduring servicing,disconnectnega-
tive (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Donot addfuel whilesmokingor ifunitisnearanysparksoropen
flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
4. Do not overfill tank allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment,
Biological Effects
of Power Frequency Electric & Magnetic Fields Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): ... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize or avoid potential risks.
To reduce magnetic fields in the workplace, use the following procedures:
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away from body as
practical.
WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
May 8, 1996 2-3
This page intentionally left blank.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
2-4 May 8, 1996
SECTION I
INSTRUCTIONS FOR MA-3525DD
For MA-5040DD Instructions See Section II
430429-089S1
December 1, 1997 Revised
This page intentionally left blank.
430429-089S1
December 1, 1997 Revised
INSTALLATION INSTRUCTIONS
for
MA-3525DD
These instructions are for the installation of an idle device kit on a 3-cylinder Deutz diesel engine. These
engines are on Model MA-3525DD. Since this is a Dual Usage Kit, extra parts will be found.
FOR INSTALLATION ON A MA-5040DD, SEE SECTION ΙΙ
READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING
INSTALLATION
Figure 1 Idle Device Kit As It Appears Installed
On MA-3525DD
430429-089S1
December 1, 1997 Revised Page 1
1. Remove throttle cable from pivot on engine throttle arm and from control panel.
2. Remove pivot from engine throttle arm.
3. Attach solenoid mounting bracket to the gusset on the right engine foot. Referring to Figure 1A, mark two
holes asshown. Drilltwo holes 5/16" diameter. Attach thebracket using two 1/4"screws and keps nuts supplied.
4. Mount the solenoid to the mounting bracket using 1/4-20 screws, lockwashers, and nuts supplied. Place
one toothed washer between solenoid and bracket to assure a good electrical ground.
5. Attach tension spring supplied in kit to solenoid
plungerusingtwo1/4-28nutssupplied.Springbody
should be parallel to solenoid plunger stud. Center
spring on threads.
6.Push the pieceof tubingthroughtheunattached
end of the tension spring. (It is a tight fit but it will
go.)
7. Push the #6-50 mm screw through the tubing
and a 1/4" flat washer and attach it to the engine
throttle arm (the same hole the pivot was removed
from).
8.Adjust the solenoidlinkageby fully compressing
the solenoid, making sure the plunger is bottomed
out in the solenoid, and adjusting the tension spring
on the stud until the throttle arm is bottomed in its
low speed position and the tension spring is
stretched approximately 1/8" or less. The solenoid
position on the mounting bracket may have to be
altered to accomplish this.
Figure 2
Figure 1A
430429-089S1
Page 2 December 1, 1997 Revised
9.Mount the reedswitch assemblyon filter reactor (locatedattopof liftingyoke) in a verticalposition.Mount
the assembly using two 1/4" self-tapping screws supplied. Use the holes provided on the reactor assembly,
located on the engine starter side of the filter reactor. Refer to Figure 3 for correct positioning.
10. Installthe speed control toggle switch on the right-hand side of the weldercontrol panel wherethe throttle
lever was located. Drill the hole to 1/2" diameter. Mount the toggle switch in the hole with the keyway in the
switch pointing towards the bottom of the machine. Position the Speed Control label on the left side of the
switch.
Figure 3
430429-089S1
December 1, 1997 Revised Page 3
11. Refer to Figure 4. On the left-hand side of the lifting yoke, drilltwo 7/32" diameter holes located 10" above
the top of the welder frame, 17/64" from the left edge and 2-15/32" between centerlines. Also drill two 5/32"
diameterholeslocated3/4"fromtheleftedgeand14-3/16"abovethetopofthewelderframe,2-9/16"between
centers. Mount the idling device timer and the relay on the inside of the lifting yoke using two #10-24 screws
and lockwashers (timer) and #6 screws, flat and lockwashers, and nuts (relay) supplied.
12. Mount the AC current coil on the left side of the fuel tank tray between the lifting yoke and the output
terminal panel. Use the 5/16-18 screw, the large flat washer, and the 5/16 keps nut in the kit to mount the
current coil. If your machine does not have a hole in the fuel tank tray, drill a 3/8" diameter hole located per
Figure 5. Mount the current coil on the bottom side of the fuel tank tray with the flat washer next to the coil.
13. Wire the idle device system per connection diagram 494462, sheet 5, using the wires and wire ties
supplied in the kit. When connecting the black lead from the idle current coil to the yellow stator lead, it may
be necessary to cut or break off the tab portion of the piggyback lug on the stator lead so it will fit in the inline
quick-connect splicer supplied.
14. Attach diode assembly to the solenoid. See Connection Diagram for orientation.
15. Ground wire attaches to solenoid mounting screws.
Figure 4
430429-089S1
Page 4 December 1, 1997 Revised
Figure 5
430429-089S1
December 1, 1997 Revised Page 5
Figure 6 - Parts List
430429-089S1
Page 6 December 1, 1997 Revised
494461 Kit - Idling Device 1 A
494461-1 Kit - Idling Device 1 B
1 493799 . Solenoid - 20 Lb. Pull 1 All
2 494463 . Bracket - Solenoid 1 A
494463-1 . Bracket - Solenoid 1 B
3 493350 . Holder - Fuse 1 All
4 16DA-4252-6 . Fuse - 8 Amp, MDL, Slow Blow 4 All
5 400562-45 . Spring - Tension 1 All
6 406735-4 . Screw - M6-1 x 50 1 All
7 W-11280-3 . Nut - 1/4-28, Hex, ST. (For Sol. Plunger) 2 All
8 402119-6 . Screw - 1/4-20 x 1, HHCS, ST. 4 All
9 50MS-732-0 . Nut - 1/4-20, Hex, Keps, ST. 4 All
10 W-11112-1 . Screw - #10-24 x 1/2 Rd. Hd. ST. 2 All
11 W-11254-3 . Washer - #10, LK, ST. 2 All
12 359414 . Timer - Idle Device, Assembly 1 All
13 491485 . Switch - Reed, Assembly 1 A
491485-1 . Switch - Reed, Assembly 1 B
14 490616-2 . Transformer - Current Assembly 1 All
15 5CW-1308-10 . Screw - 5/16-18 x 1-3/4, HHC, ST. 1 All
16 W-11242-24 . Washer - 2" O.D. 1 All
17 50MS-732-3 . Nut - 5/16-18, Hex, Keps, ST. 1 All
18 W-11236-4 . Screw - 1/4-20 x 1/2, HWH, SF-Tap, Type F 2 All
19 493826 . Label - Speed Contro
(Mounts on Control Panel) 1 All
20 407016 . Switch - Toggle, DPDT 1 All
21 W-11263-4 . Washer - LK, IET, 1/4 4 All
400778 . Terminal - Coupler, Insulated 4 All
22 490597-1 . Diode - Assembly 1 All
23 403056-8 . Relay - 12 V, DC 1 All
24 W-11110-4 . Screw - #6-32 x 1/2, Rd. Hd. ST. 3 All
25 W-11254-1 . Washer - #6, LK, ST. 3 All
26 W-11245-2 . Washer - #6, FL, Brs. 3 All
27 W-11287-2 . Nut - #6-32, Hex, SCR, ST. 2 All
28 W-11242-5 . Washer - FL, 1/4" 5 All
29 494464-1 . Sleeve - Brass 1 All
Not Illustrated
Item Part Description Qty Application
No Number per Code
Assy
Parts List for Figure 6
430429-089S1
December 1, 1997 Revised Page 7
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430429-089S1
Page 8 December 1, 1997 Revised
SECTION II
INSTRUCTIONS FOR MA-5040DD
For MA-3525DD Instruction See Section I
430429-089S2
December 1, 1997 Revised
This page intentionally left blank.
430429-089S2
December 1, 1997 Revised
INSTALLATION INSTRUCTIONS
for
MA-5040DD
These instructions are for the installation of an idle device kit on a 3-cylinder Deutz diesel engine. These
engines are on Model MA-5040DD or MA-400DD. Since this is a Dual Usage Kit, extra parts will be found.
FOR INSTALLATION ON A MA-3525DD, SEE SECTION Ι
READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING
INSTALLATION
Figure 1 Idle Device Kit As It Appears Installed
On MA-5040DD
430429-089S2
December 1, 1997 Revised Page 1
1. Refer to Figure 2. Mount the idle device timer and the relay on the inside of the mounting bracket using
two #10-24 screws and lockwashers (timer) and #6 screws, flat and lockwashers, and nuts (relay) supplied.
Also, mount the solenoid using 1/4-20 screws, lockwashers and nuts supplied. Place one toothed washer
between the bracket and solenoid base to assure a good electrical ground.
2. Drill two holes 5/16" in diameter lo-
cated 7-1/2" above the top of the welder
frame and 2" between centers and 1"
fromtheoutsideedgeasshowninFigure
2. Mount the bracket here using 1/4-20
screws,lockwashers,andnutssupplied.
Placeonetoothedwasherbetweenyoke
and bracket to assure a good electrical
ground.
3.Remove adjustmentrodfromengine
throttle arm.
4. Attach throttle bracket to throttle arm
usingthe6mmscrewanda1/4-20screw
and two nuts. One of the nuts is used as
a spacer. Refer to Figure 3.
5. Put small pivot of cable linkage as-
semblyinplaceonthebottomsideofthe
throttle bracket mount with #6 washers
and #6 x 1/2-inch long screw in kit.
6. Attach tension spring supplied in kit
tosolenoidplungerusingtwo1/4-28nuts
supplied. Center spring on screw.
7. Connect cable from throttle bracket
totensionspring,slippingloopoverhook
of spring. Linkage length adjustment
may be required. Small adjustment for
fine tuning can be accomplished by ad-
justing the nuts on the solenoid plunger.
Larger length adjustments will be re-
quiredandcan be madebyadjustingthe
cable length prior to installing. Loosen
the nuts on the clamp holding the loop in
the cable and pull more cable through.
To fine tune linkage, fully compress
solenoid plunger, making sure the
plunger is bottomed in the solenoid. Ad-
just cable length so that the speed con-
trol arm is against the high speed
adjustmentscrew(movedinthedirection
of lifting yoke) and the tension spring is
stretched approximately 1/8 inch.
Figure 2
430429-089S2
Page 2 December 1, 1997 Revised
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ESAB Installation Instructions Idle Device Kit 494461494461-1 Installation guide

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Welding System
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Installation guide
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