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1. MPM 12 400 I KA Part Number 636804 DOC No EDW0005 Date 16 Julv 97 Issue No 2 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 accide
2. 20x20 shock absorber N GO OGS18760 Rectifier assembly N Ne OGS18872 Left plate rectifier w OGS18873 Right plate rectifier W OGS 18708 Front and cover 15 GLIUWELLU SPARE PARTS LIST MPM 12 400 I KA Part Number 636804 Ordering no Denomination OGS19498 Front plate OGS10057 Plate for earth fault protection OGS839 25A earth fault protection OGS 13933 Protection OGS632 16A circuit breaker OGS13191 Protection OGS 19483 400V 20A three phase socket OGS 19482 230V 15A single phase socket OGS322 300V F S voltmeter OGS11688 Fuel meter OGS12163 Switch assemblv OGS18225 Socket for remote control and wire feeder 14 poles OGS910 CC CV switch assemblv OGS912 Hourmeter OGS16959 Water temperature lamp OGS10264 Batterv charge lamp OGS15380 Glow plug lamp OGS19458 Oil pressure lamp OGS17519 Pin OGS17521 Grub screw OGS18844 Potentiometer knob OGS18728 Plate OGS909 1K potentiometer OGS14370 115V ac relav OGS14197 24V ac relay OGS 12763 Terminal board assembly OGS 16505 DAS automatic stop for engine protection OGSO336 12V relav OGS13407 Amperometric transformer OGS16267 Cover OGS16265 Left hand cover 16 GI
3. 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 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 re
4. 03 62281755 South Australia Mac Pac Sales amp 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 A JJ PQ N EIER Er J 46 o Q o h aa OS VUTS R Oe ia O OTTE E 730 SENA J w A jIgnition key O Arc force regulator B Single phase voltmeter P Basic Cellulose switch C Hourmeter Q Wire feeder connector 14 pin D Water temperature lamp R 230V single phase outlet E Battery charge lamp S 400V
5. TIG welding connected the Electrode Lead to the negative terminal see Y on page 7 and the work lead to the positive terminal see W on page 7 7 1 CONSTANT VOLTAGE CV MODE Set the CC CV mode switch to the mode CV position Connect wire feeder cable to 14 pin remote control socket If a remote control pendant is plugged into the remote control socket of the wirefeeder then set the REMOTE CONTROL switch to the REMOTE position Set the REMOTE CONTROL switch to the PANEL position if a remote pendant is not used Note When a remote control pendant is fitted see Q on page 7 the Welding current voltage control is switched out of the circuit and remote control pendant has full control over the welding voltage For GMAW MIG welding connected the Electrode Lead to the positive terminal see W on page 7 and the work lead to the negative terminal see X on page 7 10 8 1 USE OF ENGINE DRIVEN WELDER AS A GENERATING SET Start the engine ass described in section 4 1 Switch the ELCB lever up to setting I ON Switch the single phase 16A CB lever up to setting I ON The single phase voltmeter see I on page 7 reads approximately 170V when the engine is at idle speed 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 approxim
6. DO NOT disconnect the battery from the Engine Driven Welder when the engine is running as this action will cause the alternator regulator to fail 12 MPM 12 400 I KA Part Number 636804 82 iz gez rz ez 6S 4 Je q lt lt A K 9 0 MPM 12 400 I KA Part Number 636804 CIGWELD SPARE PARTS LIST MPM 12 400 I KA Part Number 636804 Ordering no Description OGS 19493 Stator OGS18512 Stator protection OGS 18486 Engine connection flange OGS11446 Stator tie rod OGS 18699 Flange with bearing seat OGS10175 Fan OGS 18764 Fan cover OGSO905 Circlip MO l G lA av LAILA OGS903 Bearing 100 45 25 2RS OGS 18368 Shaft with rotor OGS14339 Flex plate N OGS 18369 Panel io OGS 18576 Electronic panel GS9603 A P OGS993 Amperometric relay Nn OGSOO79 Diode heatsink assv ON OGS16259 Solenoid support SI OGS991 60x60x 150 solenoid oo OGS12673 Shaft for solenoid o OGS12674 Wire for solenoid N OGS588 Fuse holder N OGS 12284 8A fuse N N OGS18310 Bowden support N W OGS18724 Resistor support N F OGS12776 100 Ohm 75 W resistor N Nn OGS 18723 Shunt N ON OGS846 Resistor tie rod N SI OGS17245
7. UWELLU SPARE PARTS LIST MPM 12 400 I KA Part Number 636804 Ordering no Denomination OGS16266 Right hand cover OGS17255 Frame OGS12786 Reactor OGS18869 Plate OGS836 Welding outlet OGS886 Plug for welding outlet OGS 16940 3x60uF capacitor OGS 16896 Plate for capacitor OGS 16934 Plate for capacitors OGS11410 Pin OGS12531 Tie rod OGS 12532 Washer OGS11621 60kg gas spring filter OGS 15526 Plate for canopy OGS 10267 1 gas rubber wire holder OGS11707 Insulator OGS18370 Panel OGS 18427 Stator bracket OGS927 50x50 shock absorber OGS 16468 Fuel prefilter OGS 19499 Air filter support OGS 15246 Fuel tank OGS 16271 Fuel filter cap OGS 16272 Fuel prefilter OGSO923 Fuel drain cap OGS15613 Fuel level gauge OGS425 43Ah 12V Batterv OGS14247 Positive batterv charging clip OGS14248 Negative batterv charging clip OGS11726 Batterv clamp OGS948 Tie rod 17 GLIUWELLU SPARE PARTS LIST MPM 12 400 I KA Part Number 636804 Ordering no Denomination OGS16190 Batterv cover OGS16191 Silencer OGS18308 Silencer extension OGS14300 Rubber puffer OGS11312 Dia 16 rubber wire holder OGS13493 50x35 shock absorber OGS17749 En
8. ately 3000 rpm The returns to idle speed approximately 25 seconds after the auxiliary equipment is disconnected from the auxiliary outlets 9 1 STOPPING ENGINE Disconnect any load from the auxiliary outlets and the welding terminals of the Engine Driven Welder Wait approximately 1 minute then turn the ignition key to the 0 position and the motor will stop 11 10 1 ENGINE PROTECTION The DAS Engine Protection Device checks for low oil pressure no battery charge high water temperature and low fuel level conditions when the Engine Driven Welder is in operation When a low oil pressure no battery charge high water temperature or low fuel level condition occurs the DAS stops the engine and illuminates the corresponding lamp on the control expect for the low fuel level condition When the faulty condition has been removed the engine can be re started Note that if the low oil pressure no battery charge high water temperature or low fuel level condition is still present when after the engine is re started then the DAS Engine Protection Device will stop the engine after approximately one minute has elapsed 11 1 WARNING In order to preserve the engine performance CIGWELD strongly recommends that the maintenance schedule is adhered to as specified in the engine manufacturer Use and maintenance user manual Poor maintenance could result in a shorter operating life decreased performance and loss of engine warranty
9. ders 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 ca
10. el 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 TECHNICAL SPECIFICATION POWER PLANT INFORMATION MEM 12400 TKA WELDING GENERATOR D C Rated output at 60 duty cycle Range of continuous control DC open circuit voltage Mechanical protection AUXILIARY GENERATOR Frequency RECOMMENDED MANUAL METAL ARC WELDING ELECTRODE Electrode Description Maximum Electrode Diameter General purpose amp low hydrogen 6 0mm Cellulose 6 0mm Iron powder 6 0mm ENGINE MakerType Banery Acoustic energy emission Acoustic pressure 1 metre Acoustic pressure 4 metre Average fuel consumption Average operating hours DIMENSIONS AND WEIGHT Dimensions Length x Width x Height 1590mm x 730mm x 920 mm ENGINE WARRANTY AND SPARE PARTS 1 1 INTRODUCTION Carefully follow the KUBOTA engine operation manual for safe operation and long service life of this product 1 2 ENGINE WARRANTY To secure warranty for the eng
11. gine support OGS18302 Left engine support bracket OGS18303 Right engine support bracket OGS11817 3 8 cap OGS14775 Oil drain pipe OGS18309 Screw OGSO873 Washer OGSO872 M14 screw OGS 12728 Clip for pipe OGS18618 Filter support OGS18871 Plate OGS18870 Panel OGS 18425 Engine stator protection OGS 19496 Left plate for hook OGS 19497 Right plate for hook OGS 19495 Panel support hook OGS 19494 Hook OGS16119 Steel cable OGS 16278 Canopy OGSO881 Pivot shaft OGS16279 Instrument front cover OGS12529 Locking hook closed front cover OGS12526 Spring OGS12527 Plate OGS12528 Locking hook opened front cover 18 SPARE PARTS LIST MPM 12 400 I KA Part Number 636804 Ordering no Denomination OGS 16280 Air grate OGS 10530 Frame locking hook OGSOO90 Rubber OGS949 Jog wheel OGSO548 Adjustable clamp OGSO924 Brace OGS15247 Axle OGS10538 Wheel 19
12. ine ensure that the warranty certificate is fill in and mailed to the Tutts state branch office KUBOTAs Australian engine distributor 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 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 amp 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 amp Marine Pty Ltd Newtown Hobart Ph
13. mote 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 6 1 CONSTANT CURRENT CC MODE Set the CC CV mode switch to the mode CC position If using a remote control pendant plug remote pendant into the 14 pin remote control socket and set the REMOTE CONTROL switch to the REMOTE position Set the REMOTE CONTROL switch to the PANEL position if a remote pendant is not used Note When a remote control pendant is fitted see Q on page 7 the Welding current voltage control is switched out of the circuit and remote control pendant has full control over the welding current For MMAW stick welding connected the Electrode Lead to the positive terminal see W on page 7 and the work lead to the negative terminal see Y on page 7 Note Stick electrodes are generally connected to the positive terminal but if in doubt consult the electrode manufactures literature For GTAW
14. ntal 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 2 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 wel
15. re 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 ste
16. three phase outlet F Oil pressure lamp T 16A single phase circuit breaker G Glow plug lamp U ELCB 25A earth fault protection H Fuel meter V Serial number I Throttle switch Z Earth connection L CC CV mode select X Welding socket negative connection for CV WORK M Welding current control Y Welding socket negative connection for CC WORK N Remote control switch W Welding socket positive connection OPERATING INSTRUCTIONS 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 Ifa 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

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