ESAB Installation 494461-1 Installation guide

Brand: ESAB

Model: Installation 494461-1

Category: Welding System

Type: Installation guide

This manual is also suitable for

Installation Instructions Idle Device Kit 494461494461-1

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

Owner’s 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

Under 300 Amp

300 to 400 Amp

Over 400 Amp

Filter

Shade

No.

3or4

4or5

5or6

4or5

5or6

6or8

Filter

Shade

No.

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-

facturer’s 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

This page intentionally left blank.

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 494461-1 Installation guide

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Model: Installation 494461-1

Category: Welding System

Type: Installation guide

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Installation Instructions Idle Device Kit 494461494461-1

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