Operation and Maintenance Manual

Transcription

1 Vanguard OP-002B Equipment, Inc. Operation and Maintenance Manual Weld-Deck welding package CPW S2 / includes Slewing Canopy (037-08OP-003A) S/N CB UP (Weld-Deck) To be used with Cummins Operation and Maintenance Manual

2 VANGUARD EQUIPMENT, INC EAST PINE ST TULSA, OKLAHOMA 74116, USA / : S/N CB UP (Weld-deck)

3 Table of Contents FOREWORD... 1 LITERATURE INFORMATION... 1 MACHINE DESCRIPTION... 1 SAFETY... 1 OPERATION... 1 MAINTENANCE... 2 MAINTENANCE INTERVALS... 2 CALIFORNIA PROPOSITION CERTIFIED ENGINE MAINTENANCE... 2 SAFETY SECTION... 2 SAFETY SIGNS AND LABELS... 2 Do Not Operate (1)... 5 Electrical Shock (2)... 5 Do Not Weld on the Machine (3)... 7 Hot Surface (4)... 8 Hot Fluid Under Pressure (5)... 9 Electrical Shock (6) Volt DC system (7)...11 Drain Air Receiver Daily (11)...15 ETHYL ETHER CYLINDER...16 Batteries...17 GENERAL HAZARD INFORMATION...18 PRESSURE AIR AND WATER...19 TRAPPED PRESSURE...19 FLUID PENETRATION...19 CONTAINING FLUID SPILLAGE...19 INHALATION...20 Exhaust...20 Asbestos Information...20 DISPOSE OF WASTE PROPERLY...20 CRUSHING PREVENTION AND CUTTING PREVENTION...20 BURN PREVENTION...21 Coolant...21 Oils...21 Batteries...21 FIRE PREVENTION AND EXPLOSION PREVENTION...21 General...21 Battery and Battery Cables...23 Wiring...24 Lines, Tubes and Hoses...24 Ether...25 Fire Extinguisher...25 Fire Safety...25 Fire Extinguisher Location...26 ELECTRICAL CABLES AND WIRE-HARNESSES...26 ELECTRICAL STORM INJURY PREVENTION...26 BEFORE STARTING GENSET-ENGINE...26 GENSET-ENGINE STARTING...26 BEFORE OPERATING EQUIPMENT...27 VISIBILITY INFORMATION...27 OPERATION...27 MACHINE OPERATING TEMPERATURE RANGE...27 MACHINE OPERATION...28 MACHINE PARKING...28 GENSET ENGINE STOPPING...28 SOUND LEVEL INFORMATION...28 S/N CB UP (Weld-deck) i

4 Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives...28 VIBRATION...28 GUARDS (OPERATOR PROTECTION)...28 PRODUCT INFORMATION SECTION (CPW S2)...29 GENERAL INFORMATION...29 Equipment Information Section...29 Restrictions to Application and Configuration...32 IDENTIFICATION INFORMATION...32 PLATE LOCATIONS AND FILM LOCATIONS...32 CE MARK...33 ISO SYMBOLS (MODEL USAGE)...34 DECLARATION OF CONFORMITY...35 EMISSIONS CERTIFICATION FILM...36 OPERATION SECTION...37 MOUNTING AND DISMOUNTING...37 BATTERY DISCONNECT SWITCH...38 OPERATOR CONTROLS...39 Emergency Stop...39 Control Panel Illumination Button...40 Genset Stop/Run/Start Switch...40 Rated/Idle Switch...41 Ether Starting Aid...41 Genset Engine Gauges and Indicators...42 Main Supply AC Circuit Breaker...44 Main Supply AC Meters...45 Three Phase Equipment Circuit Breakers and Receptacles Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) Standard Receptacles Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) Optional Receptacles...50 Single Phase Equipment Ground Fault Circuit Interrupters (GFCI) Connecting To...51 AIR COMPRESSOR...52 Air Compressor Start/Stop Switch...52 Compressed Air Pressure Gauge...53 Compressed Air Receiver Drain Valve...54 Compressed Air Supply Line Tee...54 Air Receiver Relief Valve...55 Air Compressor and tank...55 WELDER DOGHOUSE ENCLOSURE...56 BEFORE STARTING GENSET-ENGINE...57 Welding deck...57 Welder Doghouse...57 Genset...57 Control/Distribution Center...58 GENSET COLD WEATHER OPERATION...59 Winterfronts...60 GENSET-ENGINE STARTING...60 Starting Above 0 C (32 F)...60 Cold Weather Starting Below 0 C (32 F) with Ether Starting...61 Genset Engine Starting with Jump Start Cables...62 Use of Jump Start Cables...62 Starting Procedure After Extended Shutdown or Oil Change...63 After Starting the Engine...63 AC POWER-UP...64 Ground Fault Circuit Interrupters (GFCI) 60 Hz Test Daily...65 Ground Fault Circuit Interrupters (GFCI) 50 Hz Test Daily...66 GENSET SHUTDOWN...67 S/N CB UP (Weld-deck) ii

5 MACHINE PARKING...68 TRANSPORTATION INFORMATION...68 Shipping the Carrier-Mounted Weld-Deck...68 Towing the Carrier...68 MAINTENANCE SECTION...70 TORQUE SPECIFICATIONS...70 Torques for Standard Fasteners...71 Torques for Metric Fasteners...71 Torques for Vibration Isolator Mounts...72 Maintenance Welding to the Weld-deck...73 RECOMMENDED SERVICE INTERVALS MINIMUM SERVICE...74 Break-in Periods Hours or Daily Hours or 3 Months Hours or 6 Months...75 All Other Service Intervals...76 GENSET FREQUENCY CONFIGURATION 60HZ AND 50HZ MODES Hz Mode Hz Mode...79 SINGLE PHASE FRONT-MOUNTED EQUIPMENT RECEPTACLES INSTALLATION...82 ENGINE LUBRICATING OIL AND FILTER CHANGE...84 COOLING SYSTEM: CORE - CLEAN...86 COOLING SYSTEM: SERVICE...87 AIR CLEANER SERVICE...87 AIR COMPRESSOR...88 AIR COMPRESSOR MOTOR BEARINGS...88 TROUBLESHOOTING...90 GENERAL INFORMATION...90 ENGINE FAULTS:...90 Engine Won t Crank...91 Engine Won t Start...92 Engine Will Not Idle...93 Engine Will Not Go to Full Speed (Run)...93 Batteries fail to charge (low DC voltage) VDC Alternator Overcharging (High DC voltage)...95 NO OR LOW 480 VAC THREE PHASE SUPPLY VOLTAGE...96 MAIN BREAKER WILL NOT SET VAC OR 240 VAC GROUND FAULT INTERRUPTER (GFCI) CIRCUIT BREAKERS WILL NOT SET...97 ELECTRICAL SCHEMATICS VAC, 60 Hz Supply Schematic VDC Controls Schematic...99 COMPRESSOR FAULTS APPENDICES: EQUIPMENT MODULES OPERATION AND MAINTENANCE MANUALS APPENDIX A AIR CLEANER SERVICE APPENDIX B AIR COMPRESSOR APPENDIX C AC GENERATOR AND VOLTAGE REGULATOR APPENDIX D ENGINE DIAGNOSTIC TROUBLE CODES APPENDIX E ENGINE DIGITAL DISPLAY APPENDIX F SLEWING CANOPY APPENDIX G GENSET ENGINE S/N CB UP (Weld-deck) iii

6 Foreword Literature Information This manual should be stored in the genset compartment's literature holder in the left door (closest to the radiator end). This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information. This manual also contains supplemental operation and maintenance manuals supplied by the original equipment manufacturers that detail specific procedures that must be followed in addition to the information outlined in the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. The latest version of this publication is available for downloaded from the internet at Read, study and keep this manual with the machine. Machine Description Vanguard s Continuously Powered Welding (CPW) Package attachment is a modular, self powered design that can be mounted to a variety of carriers pipelayers, crawler tractors, etc. or on a self contained skid-mount. It provides clean, stable alternating current (AC) to power a variety of welding power units and auxiliary equipment. The CPW S2-s-s2 (or series 2) unit can be configured to provide either 480/ VAC at a frequency of 60Hz, or 415/240VAC at a frequency of 50Hz. The primary use of this machine is for petroleum-product pipeline construction. The operator should read, understand, and follow both the carrier s and the CPW s operating and maintenance instructions. The operator must comply with all pipeline-construction procedures, regulations, and safety precautions. This equipment is to be operated by qualified personnel only. The daily service/inspection procedure should be performed before start-up. Note: Refer to the specific module s Compressor, Engine, Generator, Welding Power-unit operation and maintenance manuals for detailed information on the operation of the respective module. Safety The safety sections list basic safety precautions. In addition, these sections identify the text and locations of warning signs and labels used on the machine. Read and understand the basic precautions listed in the safety sections before operating or performing lubrication, maintenance and repair on this machine. This equipment is to be operated and serviced by qualified personnel only. To become familiar with the basic safety precautions and warning sign locations and wording, at a minimum they must read and understand the safety section before operating or performing lubrication, maintenance and repair on this equipment. Do not attempt to bypass any of the safety equipment or instrumentation on this equipment. Do not attempt to operate this equipment with any of the safety equipment or instrumentation bypassed. Certain conditions and precautions are peculiar to pipeline construction operations. The following represents the minimum considerations for safe operation of this equipment. Operation The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, machine controls, and transportation information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the equipment. Additional operation and maintenance information for key components such as the genset engine, genset alternator, and air compressor, etc., are included in the Original Equipment Manufactures' manuals contained in the appendices of this manual. These Original Equipment Manufactures' manuals should also be read and understood before operating or performing lubrication, maintenance and repair on this machine OP-002B S/N CB UP (Weld-deck) 1

7 Maintenance The maintenance section is provided for quick, general reference only. They do not outline all of the inspection and service procedures that MUST be performed to the various modules. Refer to the specific module s Compressor, Engine, Generator, etc. operation and maintenance manuals for complete and detailed information on the care of the respective module. The maintenance sections are guides to equipment care. The Maintenance Interval Schedules (MIS) list the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval. Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals charts might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily. California Proposition 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Certified Engine Maintenance Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89). Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may be emission related and should not be altered unless approved by Vanguard. Safety Section Safety Signs and Labels There are several specific safety signs on this equipment. The exact location of the hazard and the description are reviewed in this section. Become familiarized with all safety signs. Make sure that all of the safety signs are legible. Clean or replace the safety signs if you cannot read the words. Replace the illustrations if the illustrations are not visible. Use a cloth, water, and mild soap to clean the safety signs. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall. Do not use pressure washers to clean the safety signs. Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Vanguard Equipment can provide new safety signs OP-002B S/N CB UP (Weld-deck) 2

8 OP-002B S/N CB UP (Weld-deck) 3

9 OP-002B S/N CB UP (Weld-deck) 4

10 Do Not Operate (1) WARNING! Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your dealer for replacement manuals. Proper care is your responsibility. Safety message (1) is located on main door of the control/distribution center A Figure 1: Do not operate (1) Electrical Shock (2) WARNING! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. High voltage poses an electrocution hazard; this equipment must be operated by qualified personnel only. DO NOT OPEN the inner main panel door unless you are a qualified service technician, and are familiar with the dangers of high voltage. DO NOT REMOVE the rear access cover unless you are a qualified service technician, and are familiar with the dangers of high voltage. The main electrical lines coming into the bottom of the main supply AC circuit breaker (CB1) from the genset are LIVE, and HIGH VOLTAGE is present on the main incoming lines WHENEVER the genset is running, EVEN WHEN THE MAIN CIRCUIT BREAKER (CB1) IS DE-ENERGIZED (O) OP-002B S/N CB UP (Weld-deck) 5

11 Safety message (2) is located on outer main door, and on the inner main panel door of the control/distribution center. Safety message (2) is also located on the rear access panel on the control/distribution center A B A Figure 2: Electrical Shock (2) OP-002B S/N CB UP (Weld-deck) 6

12 Do Not Weld on the Machine (3) Notice The Do not weld on, or modify this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Improper welding or modifications to this machine could seriously damage the Genset Engine. See the Maintenance Welding to the Weld-deck section in the Operation and Maintenance Manual. Information message (3) is located on main door of the control/distribution center. Message (3) is also located on the Genset Enclosure Door. Message (3) is also located at the front of the Weld-Deck, under the Access-ways A B A Figure 3: Do Not Weld on the Machine (3) OP-002B S/N CB UP (Weld-deck) 7

13 Hot Surface (4) WARNING! Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin. Keep away from hot surfaces. Safety message (4) is located on top of the Genset Enclosure close to exhaust muffler (three places) A A Figure 4: Hot Surface (4) OP-002B S/N CB UP (Weld-deck) 8

14 Hot Fluid Under Pressure (5) WARNING! Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance. Safety message (5) is located beside the radiator fill opening, on top of the Genset Enclosure A A Figure 5: Hot Fluid Under Pressure (5) OP-002B S/N CB UP (Weld-deck) 9

15 Electrical Shock (6) WARNING! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. Safety message (6) is located on the Genset Enclosure service door. Message (6) is also located on the Genset Enclosure service panel, and on the generator electrical connection box inside of the Genset Enclosure B A (6) (6) Figure 6 Electrical Shock (6) OP-002B S/N CB UP (Weld-deck) 10

16 24 Volt DC system (7) Notice The Genset Engine operates on a 24Volt DC electric system. This includes the batteries, charging, starter-motor, and control system. Do not attempt to connect to another system that operates on a different voltage than 24 Volts DC. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury, or could seriously damage the Genset Engine. Information message (7) is located on the Genset Enclosure service panel, battery/charging system access A Figure 7: 24 Volt DC system (7) A OP-002B S/N CB UP (Weld-deck) 11

17 Improper Connections for Jump Start Cables (8) Warning! Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. Refer to the Operation and Maintenance Manual for the correct jump starting procedure. Safety message (8) is located on the Genset Enclosure service panel, battery/charging system access. Message (8) is also located inside the enclosure on the Genset Engine air filter, above the batteries A A (8) Figure 8: Improper Connections for Jump Start Cables (8) OP-002B S/N CB UP (Weld-deck) 12

18 Fan Do Not Touch (9) Warning! Rotating Fan, do not touch. Serious injury can occur if body parts come into contact with the rotating fan. Keep body parts, and loose clothing away from the rotating fan at all times. Keep objects away from moving fan blades. The fan blades will throw objects or cut objects. Safety message (9) is located inside the Genset Enclosure on both sides of the Radiator Fan Guard. Message (9) is also located at the top and on the side near the Fan Guard around the Generator A A (9) (9) Figure 9: Fan Do Not Touch (9) OP-002B S/N CB UP (Weld-deck) 13

19 Do Not Smoke (10) Warning! Explosion Hazard! Do Not Smoke inside the Genset Enclosure. Ether cylinder present, do not smoke inside the genset compartment. Do not smoke while changing ether cylinders. Safety message (10) is located inside the Genset Enclosure on both sides of the Engine. (10) (10) (10) Figure 10: Do Not Smoke (10) OP-002B S/N CB UP (Weld-deck) 14

20 Drain Air Receiver Daily (11) Warning! Explosion Hazard! Drain Air Receiver Daily. Failure to drain moisture will corrode Air Receiver material and lead to Air Receiver failure. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. Safety message (11) is located at the front of the Weld-Deck, under the Access-ways, above the air receiver drain valve (if an air receiver is installed) A Figure 11: Drain Air Receiver Daily (11) OP-002B S/N CB UP (Weld-deck) 15

21 ETHYL ETHER CYLINDER Warning! Explosion hazard! When maintaining or troubleshooting these systems, always make sure that you are in a well ventilated area away from heat, open flames, or sparks. Wear goggles when testing to avoid eye injury. Make sure that openings of the valve, tube, or atomizer are pointed away from yourself while testing. The ethyl ether used in this starting fuel for these systems is extremely flammable, toxic, harmful, or fatal if swallowed, do not induce vomiting. Call physician immediately. If fuel enteres eyes or fumes irritate eyes, they should be washed with large quantites of clean water for 15 minutes. A physician, preferably an eyan eye specialist, should be contacted. Do not store cylinders in temperatures above 160 f. Contents are under pressure. Do not incierate, puncture, or attempt to remove center core valve or side safety valve from cylinder Figure 12: Ethyl Ether Cylinder; typical note located on ether cylinder on Genset Engine A OP-002B S/N CB UP (Weld-deck) 16

22 Batteries Warning! Poison! Explosion Hazard! Keep out of reach of children. Do not tip. Do not open battery! Shield eyes. Explosive gases can cause blindness or injury. No sparks, flames or smoking. Sulfuric Acid can cause blindness or severe burns. Keep vent caps tight and level. FLUSH EYES IMMEDIATELY WITH WATER. Get medical help fast. CAUTION: For safe jumpstarting, follow instructions in owners manual or if not available, seek assistance. Contains lead: return, recycle A B Figure 13: Danger/Poison; typical note located on both batteries inside the Genset Enclosure OP-002B S/N CB UP (Weld-deck) 17

23 General Hazard Information Before you service the equipment or before you repair the equipment, attach a Do Not Operate tag or similar tag to the start switch or controls. Know the width of your equipment in order to maintain proper clearance near fences, boundary obstacles, etc. This attachment adds significant rearward length to the carrier, be especially aware of the additional length when turning and maneuvering the machine. This attachment adds significant weight to the rear of the machine, which will change the weightbalance point (center of gravity). Be especially aware of the additional weight when climbing steep slopes or loading for transport. Additional front-mounted counter weight is available from Vanguard Equipment. Follow all safety regulations, procedures and precautions that govern the work site, including: wearing a hard hat, protective glasses and other protective equipment in order to accommodate job conditions. Do not wear loose clothing or jewelry that can catch on controls or other parts of the equipment. Keep all equipment free from foreign material. Check the deck, walkways and any steps. Remove debris, oil, tools and other items. Secure all loose items that are not part of the machine; tools, lunchboxes, water bottles, etc. Know the appropriate work site hand signals. Also, know the personnel that are authorized to give the hand signals. Accept signals from one person only. Do not smoke when do not smoke inside the genset compartment. Do not smoke while changing ether cylinders. Also, do not smoke if ether cylinder gas may be present. The ethyl ether used in this starting fuel for these systems is extremely flammable and can easily be ignited by a lighted cigarette, resulting in bodily harm or death. Never put maintenance fluids into glass containers. Drain all liquids into a suitable container. When you discard liquids, obey all local regulations. Use all cleaning solutions with care. Report all necessary repairs. Do not allow unauthorized personnel on the machine. Unless you are instructed otherwise, perform the maintenance with the following conditions: The carrier is parked on level ground as per the manufacturer's instructions. If the equipment is not installed onto a carrier, the shipping legs are installed and the weld-deck is on stable, level ground. All walkways are extended. The genset-engine is stopped. The genset-engine start switch is in the OFF position. The disconnect switch is in the Off (O) position and the key is removed. The air tank, if present, is fully drained. Note: The shipping legs must be removed prior to moving the carrier. SHIPPING LEG A Figure 14: Shipping leg OP-002B S/N CB UP (Weld-deck) 18

24 Pressure Air and water Pressurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hot water could result in personal injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. The maximum air pressure for cleaning purposes must be reduced to 205 kpa (30 psi) when the nozzle is deadheaded and the nozzle is used with an effective chip deflector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kpa (40 psi). Trapped Pressure Pressure can be trapped in a hydraulic system. Trapped pressure can cause sudden equipment movement. Use caution if you disconnect hydraulic lines or fittings. High pressure oil that is released can cause a hose to whip. High pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death. Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure. When you check for a leak, use a board or cardboard. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must obtain treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids. Obey all local regulations for the disposal of liquids OP-002B S/N CB UP (Weld-deck) 19

25 Inhalation Exhaust Use caution. Exhaust fumes can be hazardous to your health. If you operate the machine in an enclosed area, adequate ventilation is necessary. 16 Asbestos Information Equipment and replacement parts that are shipped from Vanguard are asbestos free. Use only genuine OEM replacement parts. If any replacement parts that contain asbestos are used, follow the manufacturer's handling guidelines and procedures as outlined in their instruction documentation. Obey environmental regulations for the disposal of asbestos. Stay away from areas that might have asbestos particles in the air. Dispose of Waste Properly Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. Crushing Prevention and Cutting Prevention Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running. Never jump across the starter solenoid terminals in order to start the engine. Unexpected machine movement could result. Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement. Stay clear of all rotating and moving parts OP-002B S/N CB UP (Weld-deck) 20

26 If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed. Keep objects away from moving fan blades. The fan blade will throw objects or cut objects. When you strike a retainer pin with force, the retainer pin can fly out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear protective glasses when you strike a retainer pin. Chips or other debris can fly off an object when you strike the object. Make sure that no one can be injured by flying debris before striking any object. Burn prevention Do not touch any part of an operating engine. Allow machine systems to cool before any maintenance is performed. Relieve all pressure in the air system, in the oil system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings, or related items are disconnected. Coolant At operating temperature, the engine coolant is hot and the engine coolant is under pressure. The radiator and all lines to the engine contain hot coolant or steam. Any contact with hot coolant or with steam can cause severe burns and personal injury. Allow cooling system components to cool before the cooling system is drained. Only check the coolant level after the engine has been stopped; use the sight gauge on the radiator. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Allow cooling system components to cool before you drain the cooling system. Oils Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also do not allow hot components to contact the skin. Batteries Batteries give off flammable fumes which can explode. Do not smoke when you observe the battery electrolyte levels. Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses when you work with batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. Fire Prevention and Explosion Prevention General All fuels, most lubricants, and some coolant mixtures are flammable OP-002B S/N CB UP (Weld-deck) 21

27 To minimize the risk of fire or explosion, the following actions are recommended. Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine when a fire hazard exists. Contact your dealer for service. Do not operate a machine with a fluid leak. Repair leaks and clean up fluids before resuming machine operation. Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. A fire may cause personal injury or death. Remove flammable material such as leaves, twigs, papers, trash, and so on. These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine. Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of fire suppression equipment, in case a fire should occur. Clean all flammable materials such as fuel, oil, debris, etc. from the machine. Do not operate the machine to the any flames. Keep shields in place. Exhaust shields (if equipped) protect hot exhaust components from oil spray or fuel spray in a break in a line, in a hose, or in a seal. Exhaust shields must be installed correctly. Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material. Empty and purge the lines and tanks. Then clean the lines and tanks with a nonflammable solvent prior to welding or flame cutting. Ensure that the components are properly grounded in order to avoid unwanted arcs. Dust that is generated from repairing nonmetallic components may be flammable and/or explosive. Repair such components in a ventilated area away from open flames or sparks. Use suitable Personal Protection Equipment (PPE). Inspect all lines and hoses for wear or deterioration. Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to the recommended torque. Damage to the protective cover or insulation may provide fuel for fires. Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials. Use caution when you are fueling a machine. Do not smoke while you are fueling a machine. Do not fuel a machine near open flames or sparks. Always stop the engine before fueling. Fill the fuel tank outdoors. Properly clean areas of spillage. Never store flammable fluids in the operator compartment of the carrier vehicle OP-002B S/N CB UP (Weld-deck) 22

28 Battery and Battery Cables The following actions are recommended to minimize the risk of fire or an explosion related to the battery. Do not operate a machine if battery cables or related parts show signs of wear or damage. Contact your dealer for service. Follow safe procedures for engine starting with jump-start cables. Improper jumper cable connections can cause an explosion that may result in injury. Refer to Operation and Maintenance Manual, Genset Engine Starting with Jump Start Cables for specific instructions. Do not charge a frozen battery. This action may cause an explosion. Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter in order to check the battery charge. Daily inspect battery cables that are in areas that are visible. Inspect cables, clips, straps, and other restraints for damage. Replace any damaged parts. Check for signs of the following, which can occur over time due to use and environmental factors: Fraying Abrasion Cracking Discoloration Cuts on the insulation of the cable Fouling or build up of unwanted material Corroded terminals, damaged terminals, and loose terminals Tighten all loose wires before you operate the machine. Replace damaged battery cable(s) and replace any related parts. Eliminate any fouling, which may have caused insulation failure or related component damage or wear. Ensure that all components are reinstalled correctly. An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface. A battery cable short produces heat from the battery current, which may be a fire hazard. An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface. This action may result in an unsafe condition for servicing the machine. Repair components or replace components before servicing the machine. Warning! Fire Hazard! Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in fires. Replace cables and related parts that show signs of wear or damage. Contact your dealer OP-002B S/N CB UP (Weld-deck) 23

29 Wiring Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine. Fraying Signs of abrasion or wear Cracking Discoloration Cuts on insulation Other damage Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This action will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation. Attaching electrical wiring to hoses and tubes that contain flammable fluids or combustible fluids should be avoided. Consult your dealer for repair or for replacement parts. Keep wiring and electrical connections free of debris. Lines, Tubes and Hoses Do not bend high pressure lines. Do not strike high pressure lines. Do not install bent lines, bent tubes, or bent hoses. Do not install damaged lines, damaged tubes, or damaged hoses. Repair loose lines, loose tubes, and loose hoses. Repair damaged lines, damaged tubes, and damaged hoses. Use the appropriate backup wrenches in order to tighten all connections to the recommended torque. Leaks can cause fires. Contact VEI for replacement parts. Check lines, tubes and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Do not use your bare hands to check for leaks. Always use a board or cardboard to check for leaks. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Replace the affected parts if any of the following conditions are present: End fittings are damaged or leaking. Outer coverings are chafed or cut. Wires are exposed. Outer coverings are swelling or ballooning. Flexible parts of the hoses are kinked or crushed. Outer covers have exposed embedded armoring. End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this action will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes, and hoses OP-002B S/N CB UP (Weld-deck) 24

30 Do not operate a machine when a fire hazard exists. Repair any lines that are corroded, loose, or damaged. Leaks may provide fuel for fires. Consult your dealer for repair or for replacement parts. Use genuine OEM parts or the equivalent, for capabilities of both the pressure limit and temperature limit. Ether Ether (if equipped) is commonly used in cold-weather applications. Ether is flammable and poisonous. Follow the correct cold engine starting procedures. Refer to the Operation and Maintenance Manual, Ether Starting Aid. Do not spray ether manually into an engine if the machine is equipped with a thermal starting aid for cold weather starting. Use ether in ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray. Do not store ether cylinders in living areas or in the operator compartment of a machine. Do not store ether cylinders in direct sunlight or in temperatures above 40 C (102 F). Keep ether cylinders away from open flames or sparks. Dispose of used ether cylinders properly, and only in an approved place. Do not puncture an ether cylinder. Do not burn ether cylinders. Keep ether cylinders away from unauthorized personnel. Fire Extinguisher A fire extinguisher is typically carried on the vehicle carrier. As an additional safety measure, keep a fire extinguisher on the machine. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the fire extinguisher s instruction-plate. Note: Keep access and walkway clear; do not mount any accessory equipment in a manner that obstructs the access or walkways. If an additional extinguisher is required on the weld-deck, mount one in a convenient and readily accessible location, such as the free deck-space to the rear of the control/distribution center beside the transformer, or in the space between the tractor and the welding power-unit enclosure. Consider installation of an aftermarket Fire Suppression System, if the application and working conditions warrant the installation. Fire Safety Note: Locate secondary exits and how to use the secondary exits before you operate the machine. Note: Locate fire extinguishers and how to use a fire extinguisher before you operate the machine. If you find that you are involved in a machine fire, your safety and that of others on site is the top priority. The following actions should only be performed if the actions do not present a danger or risk to you and any nearby people. At all times you should assess the risk of personal injury and move away to a safe distance as soon as you feel unsafe. Move the machine away from nearby combustible material such as fuel/oil stations, structures, trash, mulch and timber. Lower any implements and turn off the engine as soon as possible. If you leave the engine running, the engine will continue to feed a fire. The fire will be fed from any damaged hoses that are attached to the engine or pumps. Use the emergency Stop button on the welder package, refer to Operation and Maintenance Manual, Emergency Stop for specific instructions. If possible, turn the battery disconnect switch to the OFF position. Disconnecting the battery will remove the ignition source in the event of an electrical short. Disconnecting the battery will eliminate a second ignition source if electrical wiring is damaged by the fire, resulting in a short circuit. Notify emergency personnel of the fire and your location. If your machine is equipped with a fire suppression system, follow the manufacturer's procedure for activating the system. Note: Fire suppression systems need to be regularly inspected by qualified personnel. You must be trained to operate the fire suppression system. Use the on-board fire extinguisher, per the instructions on the fire extinguisher s instruction-plate, use the following procedure: 1. Pull the pin. 2. Aim the extinguisher or nozzle at the base of the fire. 3. Squeeze the handle and release the extinguishing agent OP-002B S/N CB UP (Weld-deck) 25

31 4. Sweep the extinguisher from side to side across the base of the fire until the fire is out. Remember, if you are unable to do anything else, shut off the machine before exiting. By shutting off the machine, fuels will not continue to be pumped into the fire. Use the emergency Stop button on the welder package to shut off the machine. If the fire grows out of control, be aware of the following risks: Tires on wheeled machines pose a risk of explosion as tires burn. Hot shrapnel and debris can be thrown great distances in an explosion. Tanks, accumulators, hoses, and fittings can rupture in a fire, spraying fuels and shrapnel over a large area. Remember that nearly all of the fluids on the machine are flammable, including coolant and oils. Additionally, plastics, rubbers, fabrics, and resins in fiberglass panels are also flammable. Fire Extinguisher Location Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher. Obey the recommendations on the instruction plate. Mount the fire extinguisher in the accepted location per local regulations. Keep access and walkway clear, do not mount any accessory equipment in a manner that obstructs the access or walkways. Electrical cables and wire-harnesses Do not bend electrical cables or wire-harnesses to a tighter radius than already installed. Do not strike electrical cables or wire-harnesses. Do not kink electrical cables or wire-harnesses. Do not install kinked electrical cables or wire-harnesses. Do not install damaged electrical cables or wire-harnesses. Note: Only qualified personnel should work on electrical equipment, including electrical cables or wire-harnesses. Follow established safety procedures when working on electrical equipment, including stopping the genset and locking out operator controls as described in the "General Hazard Information" section above. Replace electrical cables or wire-harnesses with the same electrical rating, properties, and specifications as the original. Contact your dealer or Vangurd for replacement parts. Replace electrical cables or wire-harnesses if any of the following conditions are present: The outer covering is chafed or cut. The insulation is chafed, cut, or damaged in any way. Signs of burning or arcing through the outer covering/insulation are present. The electrical cable or wire-harness has been crushed by a heavy object. Make sure that all clamps and guards are installed correctly. During operation, this will help prevent vibration and rubbing against other parts. Electrical Storm Injury Prevention When lightning is striking or threatening to strike near the vicinity of the machine, the operator should never attempt the following procedures: Mount the machine. Dismount the machine. If you are in the operator s station during an electrical storm, stay in the operator s station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine. Before Starting Genset-Engine Start the engine only from the control/distribution center s control panel. Do not short across the battery terminals and do not short across the batteries; serious damage to the electrical system could result. Before you move the equipment, make sure that no personnel are underneath the machine, around the machine, or on the machine. Make sure the area is free of personnel. Genset-Engine Starting OP-002B S/N CB UP (Weld-deck) 26

32 If a warning tag is attached to the start switch or to the other controls, do not start the genset-engine. Also, do not move any other controls. Check that all of the louvers on the genset compartment are free of obstructions and debris. Move all hydraulic controls, if present, to the HOLD position before you start the engine. Diesel engine exhaust contains products of combustion which can be harmful to your health. Always start genset-engine and always operate the genset-engine in a well ventilated area. If you are in an enclosed area, vent the exhaust to the outside. Note: If starting engine after an oil change, or if the engine has been shut down for more than 30 days, refer to Starting Procedure After Extended Shutdown or Oil Change section of this manual. Before Operating Equipment Note: The shipping legs must be removed prior to moving the carrier. Clear all personnel from the equipment and from the area. Check for obvious signs of damage, lose bolts, lose equipment, and foreign objects or debris on and under the deck. Ensure all service panels and enclosure doors are secured in their working positions: genset enclosure doors and panels closed and latched, control-distribution center doors closed and latched, and welder doghouse doors fully open or fully closed and latched. Connect trailing equipment to a drawbar or to a hitch on the carrier only. Do not connect trailing equipment to the deck structure. Visibility Information Before you start the machine, perform a walk-around inspection in order to ensure that there are no hazards around the machine. While the machine is in operation, constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine. Your machine may be equipped with visual aids. Some examples of visual aids are Closed Circuit Television (CCTV) and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean. Adjust the visual aids using the procedures that are located in the carrier-vehicle's Operation and Maintenance Manual. This attachment adds significant rearward length to the carrier, be especially aware of the additional length when turning and maneuvering the machine. The installation of the weld-deck may restrict rearward vision, and it may not be possible to provide direct visibility to all areas around the machine. Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility. Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area. Examples of job site organization include the following: Operation Safety instructions Controlled patterns of machine movement and vehicle movement Workers that direct traffic to move when it is safe Restricted areas Operator training Warning symbols or warning signs on machines or on vehicles A system of communication Communication between workers and operators prior to approaching the machine Machine Operating Temperature Range The standard machine configuration is intended for use within an ambient temperature range -40 C (-40 F) to 50 C (122 F). Special configurations for different ambient temperatures may be available. Consult Vanguard or your dealer for additional information on special configurations OP-002B S/N CB UP (Weld-deck) 27

33 Machine Operation Follow the Operation instructions of the carrier-vehicle. Report any needed repairs that were noted during operation. Connect trailing equipment to a drawbar or to a hitch on the carrier-vehicle only. DO NOT connect trailing equipment to the weld-deck structure. Machine Parking Refer to the carrier s Operation and Maintenance Manual for specific machine parking instructions. Genset Engine Stopping Do not stop the genset-engine immediately after the machine has been operated under electrical-load. This can cause overheating and accelerated wear of engine components. After the electrical-load has been removed, allow the genset-engine to run at idle for 3 to 5 minutes before shutdown. This allows hot areas of the engine to cool gradually. Sound Level Information Hearing protection is prescribed for an operator of the Weld-deck Welding Package CPW S2. Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives Per the requirements under Noise in the Environment Directive 2000/14/EC, 2005/88/EC, Reg. 219/2009: The Weld-deck Welding Package CPW S2 is outside Article 12 and Article 13 definitions, but, as it is intended to be used outdoors in conjunction with other equipment that must bear LWA marking, maximum guaranteed sound power level has been calculated and the equipment is marked 114dB(A). Hearing protection is prescribed for an operator of the Weld-deck Welding Package CPW S2. Vibration When the machine is operated according to the intended use, the vibration data for the carrier-vehicle is unaffected by attachment of the CPW Package. Guards (Operator Protection) There are different types of guards that are used to protect the operator. The machine and the machine application determines the type of guard that should be used. A daily inspection of the guards is required in order to check for structures that are bent, cracked or loose. Never operate a machine with a damaged structure. The operator becomes exposed to a hazardous situation if the machine is used improperly or if poor operating techniques are used. This situation can occur even though a machine is equipped with an appropriate protective guard. Follow the established operating procedures that are recommended for your machine OP-002B S/N CB UP (Weld-deck) 28

34 Product Information Section (CPW s2) General Information Equipment Information Section AIR RECEIVER Weld-Deck Module Weld-Deck Module GENSET AIR COMPRESSOR A PACKAGE SERIAL NUMBER DOGHOUSE (WELDER MODULE) CONTROL/ DISTRIBUTION CENTER A Figure 15: Equipment modules (Crawler Tractor) FRONT MOUNT PLATFORM A OP-002B S/N CB UP (Weld-deck) 29

35 CPW S2 4-s2 Rear-mounted Welder Package Specification (Carrier-vehicle/Welding Gas and consumables/crane weights not included) (A) Transport width (catwalks stowed) 2743 mm 108 in (B) Working width (catwalks extended) 3232 mm in (C) Welding package height exhaust (transport) to ground (no carrier) 2680 mm in (D) Welding package height exhaust installed (working) to ground 3229 mm in (typical installation, D6N LGP tractor carrier vehicle) Additional height to ground, typical carrier installation mm 19.4 in (E) Overall length Welding package alone (catwalks stowed) 2642 mm 104 in (F) Overall length Welding package alone (catwalks extended) 2875 mm in Additional length Welding package bolt-on front catwalks +358 mm in Additional length D6N LGP mounted Welder Package with front mm in mount Knuckle-boom crane platform 8x bottle rack + Water holder + Propane holder (Crane weight/gas-bottles/water-jug not included) Weight Welding package alone (includes 4 x 456MP welders, Whoser 4468 kg 9850 lb pole, Compressed air system) D6M/N adapter plate). Weight less Compressed air system -708 kg lb D6M/N rear connector plate +209 kg +460 lb Weight D6M/N front mount Knuckle-boom crane platform/8x bottle 2858 kg 6300 lb rack + Water holder + Propane holder Genset module power rating Hz Hz Voltage output (200 Amp total service) 240/ 415/ 50Hz 120/ 240/ 480/ 60Hz Compressed air supply (If installed) 30 hp (22 kw) electric motor l/min; MPa 90 cfm; 250 psi OP-002B S/N CB UP (Weld-deck) 30

36 AIR RECEIVER Weld-Deck Module Weld-Deck Module GENSET PACKAGE SERIAL NUMBER DOGHOUSE (WELDER MODULE) CONTROL/ DISTRIBUTION CENTER A FRONT PLATFORM Module (If Equipped) AIR COMPRESSOR 037-T A Figure 16: Equipment modules (Flat-Deck Mount) OP-002B S/N CB UP (Weld-deck) 31

37 CPW S2 4 Flat-Deck-mounted Welder Package Specification (Carrier-vehicle/Welding Gas and consumables/crane weights not included) (A) Transport width (catwalks stowed) 2743 mm 108 in (B) Working width (catwalks extended) 3232 mm in (C) Welding package height exhaust (transport) to ground (no carrier) mm 81 in (D) Welding package height exhaust installed (working) to ground 3175 mm 125 in (typical installation, Panther T8 carrier vehicle) (E) Overall length Welding package alone (catwalks stowed) 2642 mm 104 in (F) Overall length Welding package alone (catwalks extended) 2875 mm in Weight Welding package alone (includes 4 x 456MP welders, Whoser 4334 kg 9555 lb pole, Compressed air system) D6M/N adapter plate). Weight less Compressed air system -708 kg lb Genset module power rating Hz Hz Voltage output (200 Amp total service) 240/ 415/ 50Hz 120/ 240/ 480/ 60Hz Compressed air supply (If installed) 30 hp (22 kw) electric motor l/min; MPa 90 cfm; 250 psi Restrictions to Application and Configuration To obtain the proper lubrication, a maximum slope should not exceed a grade of 119 percent or 50 degrees up and down angularity, and should not exceed 93 percent or 43 degrees side-to-side angularity. Do not exceed these limits. Do not exceed the angularity or slope grade limits of the carrier vehicle. Do not use this machine in explosive environments. Identification Information Plate Locations and Film Locations The attachment/component information plate is attached to the component to identify the model name/number and the serial number. It is not a Product Information Number (PIN). The attachment/component information plate is located under the left catwalk at the front of the machine per the illustration below. For quick reference, record this information in the spaces that are provided below OP-002B S/N CB UP (Weld-deck) 32

38 CE Mark This information is positioned on the attachment/component information plate located under the left catwalk at the front of the machine. For machines that are compliant to "2006/42/EC", the serial number (S/N), Model name/number (M/N), and Manufacture year information is stamped onto the "CE" plate. For quick reference, record this information in the spaces provided below: OP-002B S/N CB UP (Weld-deck) 33

39 ISO Symbols (Model Usage) The following list contains all of the ISO Symbols that appear in this publication. On: To identify the on position of a control. Off: To identify the off position of a control. Battery Disconnect: To identify the control that disconnects the battery from the electrical system. Engine Start: To identify the control used to start the engine. Engine Run: To identify the control position that indicates the engine, once started, will continue to operate. Engine Stop: To identify the control used to stop the engine. Engine-start aid: To identify the control that injects a pressurised ether gas into the combustion chamber to assist in starting the engine. Fast Operation: To indicate the fast or rated setting of the machine.. Slow Operation: To indicate the slow or idle setting of the machine. Pressure vessel: To identify the control for the compressed air (if equipped). Illumination: To identify the control for illuminating the control display lights. Battery charging condition: To identify the display that provides information about the battery charging condition. Engine Oil: To identify the display that provides information about the oil pressure in the engine lubrication system. Engine Coolant Temperature: To identify the display that provides information about the temperature in the engine cooling system. Hour meter: To indicate the number of hours the equipment has operated. Electrical Earth/Ground: Indentifies the Earth/Ground terminal connection OP-002B S/N CB UP (Weld-deck) 34

40 Declaration of Conformity Machines supplied with the "CE" plate are compliant to "2006/42/EC" and with EN OP-002B S/N CB UP (Weld-deck) 35

41 Emissions Certification Film Note: This information is pertinent in the United States, in Canada and in Europe. This label is located on the engine. This label lists EPA emission conformity for North America, and the EU emissions certificate number for Europe. For complete details on all Engine Identification tags and labels, refer to Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S A A EU emissions certificate number EPA emission conformity B Figure 17: Emissions Certification Film located on engine OP-002B S/N CB UP (Weld-deck) 36

42 Operation Section Mounting and Dismounting Warning! Crushing HazardDo not attempt to mount or dismount the machine between the machine and any object that may move. RETAINING LATCH A RETAINING LATCH A RETAINING LATCH (BOTH SIDES) STOW LATCH WHEN EXTENDING WALKWAYS A A Figure 18: Walkway retaining latches. Extend all walkways before mounting the machine. The walkways are latched together for transport; unbolt the retaining latches from the rear walkway, and bolt in the stowing position on each of the side walkways A A Figure 19: Typical welding package access; Walkways extended. Mount the machine only at locations that have steps and/or handholds. Dismount the machine only at locations that have steps and/or handholds. Before getting on the machine, clean the steps and handholds. Inspect the steps, handholds, and walkways. Make all necessary repairs OP-002B S/N CB UP (Weld-deck) 37

43 Face the machine whenever getting on, off, or moving around the machine. Maintain three-point contact with the steps/walkways and with the handholds. Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands. Do not a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount or dismount the machine while carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when entering or exiting the operator compartment. Ground personnel must be kept clear at all times and only approach the machine when signaled to do so by the operator. Battery Disconnect Switch The battery disconnect switch is in the genset enclosure behind the main door on the right (fuel pump) side of the weld-deck A A A Figure 20: Battery Disconnect Switch I ON Insert the battery disconnect switch key, and turn the battery disconnect switch key clockwise in order to activate the electrical system. The switch must be ON before you start the engine. O OFF Turn the battery disconnect switch key counterclockwise in order to shut off the entire electrical system. NOTE: Ensure the Genset Stop/Run/Start Switch is off for at least 30 seconds before turning the battery disconnect switch to OFF to allow proper engine control module (ECM) shut down. The battery disconnect switch and the genset Stop/Run/Start Switch serve different functions. When the battery disconnect switch is turned off, the entire electrical system is disabled. When only the engine start switch is turned off, the battery remains connected to the electrical system OP-002B S/N CB UP (Weld-deck) 38

44 Turn the battery disconnect switch key to the off (O) position and remove the battery disconnect switch key when you service the electrical system or you service any other components on the equipment. See also the General Hazard Information section in this manual. Turn the battery disconnect switch key to the off (O) position and remove the battery disconnect switch key when the equipment is left for an extended period of one month or longer. This procedure will prevent a short circuit from draining the battery. This procedure will also prevent the components from draining the battery. This procedure will also prevent the battery from being drained by vandalism. Operator Controls Emergency Stop A B Figure 21: Emergency Stop Button Genset Emergency Stop Located on the Control/Distribution Center, the button is RED in colour with a YELLOW surrounding collar. Push the RED emergency stop button to IMMEDIATELY trip the main breaker to cut the genset electrical power, and to IMMEDIATELY remove all 24VDC electrical power from the Control/Distribution Center, and to stop the genset, if any type of emergency condition exists. The RED emergency stop button must be pulled out to reset. Note: The emergency stop button cuts all 24 VDC voltage from the Control/Distribution Center, including engine crank control. Ensure that the emergency stop button is fully pulled out prior to starting the genset OP-002B S/N CB UP (Weld-deck) 39

45 Control Panel Illumination Button A Figure 22: Control Panel Illumination B Press and hold the WHITE control panel illumination button in dark lighting conditions to turn on the panel display lights and illuminate the controls when the genset is stopped; the lights automatically turn on whenever the genset is running. Gauge lights include: DC voltmeter, AC voltmeter, AC ammeter, AC frequency meter. Two display LEDs illuminate the remaining gauges and the control switches. The genset engine Oil Pressure gauge, the Coolant Temperature gauge, and the Engine Digital Display are all backlight when the genset Stop/Run/Start Switch is in the RUN position however these gauges only indicate actual information when the genset engine is running. Genset Stop/Run/Start Switch STOP Turn the genset Stop/Run/Start switch to the STOP position in order to stop the genset; the main breaker if set will automatically trip as the genset slows to a stop. START Turn the genset Stop/Run/Start switch all the way clockwise to the START position in order to crank the Genset. Crank the Genset until the engine catches; this should take no more than 10 seconds. Note: Special cold start precautions must be taken for ambient temperatures below 0 ºC (32 ºF), refer to the Cold Weather section in this manual. Run Release the Stop/Run/Start switch as soon as the engine catches; the switch will self-return to the Run position A Figure 23: Genset Stop/Run/Start B Note: If the engine fails to start, the genset Stop/Run/Start switch must be returned to the STOP position in order to attempt to start the engine again; the Stop/Run/Start switch has an anti-restart feature built into it to prevent the switch from being turned to the Start position directly from the Run position OP-002B S/N CB UP (Weld-deck) 40

46 Rated/Idle Switch IDLE With the rated/idle switch in this position, the genset engine runs at an idle speed of approximately RPM. Use this position for start-up, warm-up, and during extended periods of running with no load. Note: Do not operate the engine at idle for long periods with the engine coolant temperature below the minimum recommended in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. RATED With the rated/idle switch in this position, the genset engine runs at full or rated speed; approximately z, Hz. Use this position when working. Note: The main breaker will only set when the genset rated/idle switch is in the RATED position. Ether Starting Aid A Figure 24: Genset Rated/Idle Switch B A B Figure 25: Genset Ether Starting Aid Ether Starting At temperatures below 0 C (32 F), a metered amount of ether will be injected into the intake when the ether starting aid button is released. Push and release the BLACK ether starting aid button while cranking the engine. Refer to the Cold Weather Starting Below 0 C (32 F) with Ether Starting Aid section this manual for complete operating instructions OP-002B S/N CB UP (Weld-deck) 41

47 Genset Engine Gauges and Indicators A C 5 6 Figure 26: Genset Engine Gauges and Indicators B Service Hour Meter (1) This gauge indicates the total operating hours of the genset. The service hour meter should be used to determine service hour maintenance intervals. Genset Engine Coolant (1) This gauge indicates the temperature of the genset engine coolant. Note: The genset engine will automatically shutdown if the Engine Control Module (ECM) detects that the coolant temperature exceeds 107 ºC (225 ºF). Genset Engine Oil Pressure (3) This gauge indicates the oil pressure of the genset engine. Note: The genset engine will automatically shutdown if the Engine Control Module (ECM) detects low oil pressure; 69 kpa (10 low idle, 207 kpa (30 rated speed. Battery Charge Meter (4) This gauge indicates the charge state genset is running, or by pressing the WHITE control panel illumination of the 24 Volt-DC batteries whenever the button when the genset is stopped OP-002B S/N CB UP (Weld-deck) 42

48 Engine Digital Display (5) This display shows the Genset Engine's operating parameters monitored by the Engine Control Module (ECM), as well as active and stored ECM trouble codes. The Engine Digital Display unit also powers and supplies all displayed engine information to the engine gauges (2), (3), and (4) above. Engine generated fault codes are shown in the display window as a numeric code. These codes can be cross referenced to identify the fault using the tables listed in the appendix Engine Diagnostic Trouble Codes; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. The alarm indication has ultra-bright alarm and shutdown LEDs (amber and red), these indicate the severity of the alarm and shutdown. AMBER indicates a warning or service issue, while the engine continues to run. RED indicates a fault that has triggered an engine shutdown and the fault needs to be rectified before the engine will run. Figure 27: Engine Digital Display Faceplate Features The display can show either a single parameter or a quadrant display showing four parameters simultaneously. The Engine Digital Display can be configured to show the readout information as desired, refer to the Original Equipment Manufacture appendix Engine Digital Display for complete set-up and operation information. Audible Alarm (6) This indicator provides an audible sound to alert the operator to a fault conditions. It has a temporary silencer button ( ) that silences the audible tone for 2 minutes on warnings and 30 seconds on shutdown. Note: The alarm will continue to repeat until the fault is cleared, or the genset Stop/Run/Start is switched to the STOP position. Turn the genset Stop/Run/Start switch to the STOP position to turn the unit off and prevent the batteries draining in the event of an ECM fault code shutdown OP-002B S/N CB UP (Weld-deck) 43

49 Main Supply AC Circuit Breaker Warning! Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. High voltage poses an electrocution hazard; this equipment must be operated by qualified personnel only. DO NOT OPEN the inner main panel door unless you are a qualified service technician, and are familiar with the dangers of high voltage. DO NOT REMOVE the rear access cover unless you are a qualified service technician, and are familiar with the dangers of high voltage. The main electrical lines coming into the bottom of the main supply AC circuit breaker (CB1) from the genset are LIVE, and HIGH VOLTAGE is present on the main incoming lines WHENEVER the genset is running, EVEN WHEN THE MAIN CIRCUIT BREAKER (CB1) IS DE-ENERGIZED (O). CB1 Figure 28: Main Supply AC Circuit Breaker B B CB1 Main Supply AC Circuit Breaker Use this circuit breaker to energize (I) or to de-energize (O) the main AC supply circuit. No power is available to the other AC circuits until this breaker is set (I). In order to reset the breaker, it must first be switched to (O) and then to (I). Note: The main supply AC circuit breaker can only be set when the genset is running at rated speed OP-002B S/N CB UP (Weld-deck) 44

50 B B Main Supply AC Meters Phase Selector Switch Figure 29: Main Supply AC Meters Phase Selector Switch Ф Main Supply AC Meters Phase Selector Switch Use this switch to select which leg of the three-phase (3Ф) load current is displayed on the main AC-supply A1 Ammeter. The positions 1, 2, 3 correspond to each leg of the three-phase supply, while position 0 turns the meters off. Switching between each of the 3 legs gives an indication of the load being applied to each individual AC-supply leg. Note: Turning the main supply AC meters phase selector switch to 0 only turns the main supply AC meters off, it does NOT turn the main supply power off. See the description for the main supply AC circuit breaker (CB1) above. Main Supply AC Meters A C Figure 30: Main Supply AC Meters OP-002B S/N CB UP (Weld-deck) 45

51 F1 Frequency Meter (1) This meter displays the frequency, in Hertz, of the incoming main supply power, either 60Hz or 50Hz. Refer to the Genset Frequency Configuration 60Hz and 50Hz Modes section in this manual for more detailed info. V1 Voltmeter (2) This meter displays the main incoming supply voltage, in Volts, being supplied to the load by the genset; Hz or 50Hz. Refer to the Genset Frequency Configuration 60Hz and 50Hz Modes section in this manual for more detailed info. A1 Ammeter (3) This meter displays the load current, in Amps, being drawn by the various components (welding power units, air compressor, and auxiliary equipment). The current indicated is dependent on the electrical load applied to the genset through the various electrical components connected. Note: The main AC-supply A1 Ammeter displays only one phase of the 3Ф supply at a time. The phase displayed is selected by main supply meter phase selector switch (Ф) Note: The displayed current is dependent on the load; if there is no load (all components are off) then the current will be zero OP-002B S/N CB UP (Weld-deck) 46

52 Three Phase Equipment Circuit Breakers and Receptacles 3Ф circuit breakers, CB10 - CB 15 CB15 CB14 CB13 CB12 CB11 CB B REAR OF CONTROL/ DISTRIBUTION CENTER RC 9 AIR COMPRESSOR (IF INSTALLED) RC 11 RC 8 RC 10 RC A A Figure 31: Three Phase Equipment Circuit Breakers and Receptacles Each of the three phase equipment circuit breakers energizes one of the three phase sub-circuits that exit the rear of the control/distribution center; in most cases a dedicated receptacle for one of the welding power units. Each circuit breaker will independently trip if an overload condition arises in its dedicated circuit. Move each of the three phase equipment circuit breakers to the ON position to energize its corresponding receptacle. Move each of the three phase equipment circuit breakers to the Off position to de-energize its corresponding receptacle: CB 10 Energizes receptacle RC 8 Welder 1. CB 11 Energizes receptacle RC 9 Welder 2. CB 12 Energizes receptacle RC 10 Welder 3. CB 13 Energizes receptacle RC 11 Welder 4. CB 14 Energizes receptacle RC 12 Welder 5. CB 15 Energizes the Air compressor circuit. Note: The Air Compressor may not be installed OP-002B S/N CB UP (Weld-deck) 47

53 60Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) Standard Receptacles CB16 60Hz, Single Phase circuit breakers with GFCIs, CB17 - CB B RC 6 RC 7 CB9 RC 1 RC 2 RC 3 RC 4 RC A CB8 CB7 CB6 CB5 CB4 CB A Figure 32: 60 Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) Each of the 60Hz single phase equipment circuit breakers energizes one of the dedicated 60Hz single phase receptacles on the front of the control/distribution center, refer to the Genset Frequency Configuration 60Hz Mode in the Maintenance and Lubrication section of this manual for 60Hz configuration set-up instructions. Each circuit breaker will independently trip if an over current condition arises in its dedicated circuit. Each of the 60Hz single phase equipment circuit breakers incorporates a Ground Fault Circuit Interrupter (GFCI). A GFCI is a device whose function is to interrupt the electric circuit to a load when a fault current to ground exceeds a predetermined value, that is less than that required to operate the over current protective device of the supply circuit. GFCIs are designed to shut off electric power when the current going into the electric equipment does not equal the amount of current returning to the GFCI. A GFCI interrupts the unbalanced current flow in a fraction of a second, to prevent electrocution. GFCIs only protect against unbalanced current flow type faults, some current must be returned through another path for the GFCI to trip. GFCIs do not protect against line to line or line to neutral contact hazards such as result OP-002B S/N CB UP (Weld-deck) 48

54 from bare connectors or terminals, etc. Note: GFCI should be tested daily, refer to the Ground Fault Circuit Interrupters (GFCI) Test Daily section of this manual. Move each of the 60Hz single phase equipment circuit breakers to the ON position to energize its corresponding receptacle. Move each of the 60Hz single phase equipment circuit breakers to the Off position to de-energize its corresponding receptacle, if required. The output for each receptacle is: RC 1 120V/20A/60Hz supply. CB 3 Energizes receptacle RC 1. RC 2 120V/20A/60Hz supply. CB 4 Energizes receptacle RC 2. RC 3 120V/20A/60Hz supply. CB 5 Energizes receptacle RC3. RC 4 120V/20A/60Hz supply. CB 6 Energizes receptacle RC 4. RC 5 120V/20A/60Hz supply. CB 7 Energizes receptacle RC 5. RC 6 240V/30A/60Hz supply. CB 8 Energizes receptacle RC 6. RC 7 240V/30A/60Hz supply. CB 9 Energizes receptacle RC 7. CB 16 Energizes the transformer which supplies the above sub-circuits (CB 3 through CB 9). Note: Both CB 16 and the sub-circuit breakers (CB 3 through CB 9) must be energized in order to obtain voltage through receptacles RC1 through RC OP-002B S/N CB UP (Weld-deck) 49

55 50Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) Optional Receptacles 50Hz, Single Phase circuit breakers, CB17 - CB 23 60Hz panel shown. Contact Vanguard for available 50 Hz front panels B CB17 CB18 CB19 CB20 CB21 CB22 (GFCI) CB23 (GFCI) A Figure 33: 50 Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) Each of the 50Hz single phase equipment circuit breakers energizes one of the dedicated 50Hz single phase receptacles, available optional receptacle plates, on the front of the control/distribution center. Refer to the Genset Frequency Configuration 50Hz Mode in the Maintenance and Lubrication section of this manual for 50Hz configuration set-up instructions. Each circuit breaker will independently trip if an over current condition arises in its dedicated circuit. Each of the 50Hz single phase equipment supply-power buss circuit is protected by a feeder circuit breaker, CB 22 and CB 23. The individual feeder circuit breaker CB 22 or CB 23 will trip if the combined load results in an over current condition in its dedicated circuit. Each of the individual feeder circuit breakers, CB 22 and CB 23, incorporates a Ground Fault Circuit Interrupter (GFCI). A GFCI is a device whose function is to interrupt the electric circuit to a load when a fault current to ground exceeds a predetermined value, that is less than that required to operate the over current protective device of the supply circuit. GFCIs are designed to shut off electric power when the current going into the electric equipment does not equal the amount of current returning to the GFCI. A GFCI interrupts the unbalanced current flow in a fraction of a second, to prevent electrocution. GFCIs only protect against unbalanced current flow type faults, some current must be returned through OP-002B S/N CB UP (Weld-deck) 50

56 another path for the GFCI to trip. GFCIs do not protect against line to line or line to neutral contact hazards such as result from bare connectors or terminals, etc. Note: GFCI should be tested daily, refer to the Ground Fault Circuit Interrupters (GFCI) Test Daily section of this manual. Move each of the 50Hz single phase equipment circuit breakers to the ON position to energize its corresponding receptacle. Move each of the 50Hz single phase equipment circuit breakers to the Off position to de-energize its corresponding receptacle, if required. The output for each receptacle is: RC V/15A/50Hz supply. CB 17 Energizes receptacle RC 13. RC V/15A/50Hz supply. CB 18 Energizes receptacle RC 14. RC V/15A/50Hz supply. CB 19 Energizes receptacle RC 15. RC V/15A/50Hz supply. CB 20 Energizes receptacle RC 16. RC V/15A/50Hz supply. CB 21 Energizes receptacle RC 17. CB22 240V/63A/50Hz supply with GFCI. CB 22 Energises power buss circuit for CB 17, CB 18, CB 19. Provides GFCI protection for for receptacles RC 13, RC 14, RC 15. CB23 240V/40A/50Hz supply with GFCI. CB 23 Energises power buss circuit for CB 20, CB 21. Provides GFCI protection for for receptacles RC 16, RC 17. Note: Both CB 22 and CB 23 together with the sub-circuit breakers (CB 17 through CB 21) must be energized in order to obtain voltage through receptacles RC13 through RC 17. Single Phase Equipment Ground Fault Circuit Interrupters (GFCI) Connecting To Notice All electrical sub-circuits connected to the single phase front-mounted equipment receptacles should be made by a qualified electrician. Failure to make correctly wired connections to the GFCI could result in the inability to set the GFCI due to a perceived ground fault by the GFCI. The single phase equipment circuit breakers CB 3 through CB 9 for 60Hz operation, or CB 22 and CB 23 are equipped with ground fault circuit interrupters (GFCI). Electrical connections to any of the front-mounted receptacles must not cause current to flow back through an alternate ground path: For 60 Hz operation: Equipment or circuits connected to receptacles RC 1 through RC 5 for 60Hz operation must have the neutral connected through the corresponding receptacles neutral. Equipment or circuits connected to receptacles RC 6 and RC 7 for 60Hz operation must have the neutrals connected through the corresponding receptacles neutral AND they must be grounded through the receptacle, DO NOT use a separate grounding path. For 60 Hz operation: Equipment or circuits connected to receptacles RC 13 through RC 17 for 50Hz operation, must have the neutral connected through the corresponding receptacles neutral OP-002B S/N CB UP (Weld-deck) 51

57 Air Compressor An air compressor may be installed, check the specific weld-deck A Figure 34: Air Compressor (if installed) Note: Refer to the Air Compressor Operation/Maintenance Manual for detailed operation and maintenance instructions; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Air Compressor Start/Stop Switch A B Figure 35: Air Compressor Start/Stop Switch Air Compressor Start/Stop Switch Turn the air compressor start/stop switch to ON (I) to start the air compressor and leave the switch in this position for normal work. Turn the air compressor start/stop switch to OFF (O) to stop the OP-002B S/N CB UP (Weld-deck) 52

58 compressor when not in use. The air compressor start/stop switch can be left in the on (I) for the duration of a job when the compressor is in use; it will automatically start-up as soon as the main supply AC circuit breaker (CB 1) is set. Note: Depending on the compressor run-mode, the compressor will automatically unload or shut-off once the set airreceiver pressure has been reached; consult the Equipment Operation section of this manual. Compressed Air Pressure Gauge Figure 36: Compressed Air Pressure Gauge Tank mounted A Compressed Air Pressure Gauge This gauge displays the compressed air pressure, in PSI and in MPa, stored in the air receiver OP-002B S/N CB UP (Weld-deck) 53

59 Compressed Air Receiver Drain Valve Front Left Side FRO NT Drain Valve on underside of deck. Warning Film on side of deck A Air Receiver Drain Valve, shown OPEN to drain A Left Side FRO NT Warning! Explosion Hazard! Drain Air Receiver Daily. Failure to drain moisture will corrode Air Receiver material and lead to Air Receiver failure. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. Air Receiver Drain Valve shown CLOSED for working A Figure 37: Compressed Air Receiver Drain Valve and "Drain Tank Daily" Warning Film Compressed Air Receiver Drain Valve The compressed air receiver is fitted with a drain valve on the underside of the deck. The compressed air receiver drain valve is used to drain water from the air receiver that accumulates during normal use. The compressed air receiver drain valve is also used to drain the compressed air from the receiver when not in use. Ensure that compressed air receiver drain valve is closed prior to starting the air compressor. Note: The compressed air receiver must be fully drained of air at the end of each work day. Compressed Air Supply Line Tee A Figure 38: Compressed Air Supply Line Tee OP-002B S/N CB UP (Weld-deck) 54

60 Compressed Air Supply Line Tee Two 1-inch NPT pipe connections are provided for air supply to outboard auxiliary equipment. (1) A 1-inch NPT ball valve (female, open). (2) a 1-inch NPT ball valve with straight connection (male, capped). Note: Use appropriate lines and fittings that have adequate pressure ratings to carry the MPa (250 psi) working pressure of the compressed air supply. Air Receiver Relief Valve Genset Figure 39: Air Receiver Relief Valve A Air Receiver Relief Valve To guard against over pressure, the air receiver is fitted with a relief valve. The air receiver relief valve is located on top of the air receiver, towards the genset side. The air receiver relief valve is set to vent the air receiver if the compressed air pressure reaches 1.9 MPa (275 psi); no operator intervention is required. Note: If the air receiver relief valve does vent, it will be necessary to drain all of the air out of the air receiver using the compressed air receiver drain valve in order to fully reseat the air receiver relief valve. Air Compressor and tank 1. Check the compressor s oil level through the sight gauge; add oil if required. Note: The compressor automatically shuts down in the event of low oil pressure. Figure 40: Air Compressor Oil Level Sight Gauge 2. Check that the air-vent valve on the air tank is closed. Sight Gauge A 3. The air tank is fitted with drain valve on the underside of the deck, check that it closed OP-002B S/N CB UP (Weld-deck) 55

61 Welder Doghouse Enclosure A A Figure 41: Welder Doghouse Enclosure, door latched open, door latched closed The Welder Doghouse Enclosure houses up to four welding power units. The welder doghouse enclosure s door folds up and slides back into the top of the doghouse enclosure. The doghouse enclosure s door latches in place in either the open or the closed position. The welding power units can be operated with the door of the welder doghouse enclosure in either the open or closed position; ensure the door is secured in either the open or closed position when working A A Figure 42: Welder Power Units on extendable trays with latches The welding power units are secured to extendable trays in the welder doghouse enclosure. The trays latch in place in the retracted position. Unlatch the trays and slide the trays completely out to service the welder power units. Ensure the trays are fully retracted and securely latched whenever the equipment is in use. NOTE: Do not move or operate the weld-deck with the welder doghouse enclosure s trays in the extended position OP-002B S/N CB UP (Weld-deck) 56

62 Before Starting Genset-Engine Make a thorough walk-around inspection and specific module checks: Welding deck 1. Fully extend the catwalks all around the deck. 2. Check for obvious signs of damage, lose bolts, lose equipment, and foreign objects or debris on and under the deck. Welder Doghouse 1. Open up the folding door on the Doghouse and slide it all the way back, pushing it firmly into its spring latch; ensure that it latches securely. 2. Ensure that the two slide-out trays holding the welding machines are securely latched in the retraced position. 3. Check that the rubber isolators on the Doghouse are undamaged and that all the bolts are tight. Genset Figure 43: Genset prestart checks A A 1. The Genset is fuelled by the carrier s fuel tank, check that there is adequate fuel to run the Genset and carrier for the intended operation (a full tank per day). 2. Check all of the louvers on the Genset compartment to ensure that they are free of obstructions and debris. 3. Open the main service doors on the right hand side (genset side) and check the general appearance of the Genset. Perform a visual inspection, checking for obvious signs of damaged or loose components and wires, loose or worn radiator hoses, worn or damaged isolators, etc. Check that there are no foreign objects such as rags, tools, etc., present in the compartment. Check the rubber isolators on the feet of the engine and alternator, and at the base of the radiator are undamaged and that all the bolts are tight. Check that the radiator cooling fins are free from dirt and debris, blow out with compressed air if necessary. Note: The access panels on the left or turbo side of the engine should be removed to perform a complete visual inspection. 4. Check that the Engine Harness is firmly secured to the Engine Control Module (ECM) (1), tighten the centre holdingscrew if required. Note: Do not start the genset engine if the harness is not connected to the ECM as damage to the engine may result OP-002B S/N CB UP (Weld-deck) 57

63 Warning! Pressurized system! Only remove the radiator filler cap when the engine is cool, then loosen cap slowly to relieve the pressure. To prevent the possibility of personal injury, do not remove the cap on a hot engine. Wait until the coolant temperature is below 50 C (120 F) before removing the radiator pressure cap. Refer to Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Removing the filler cap is not necessary to check the coolant level. Use the sight glass (2) at the top of the radiator for checking the daily coolant level. With the engine temperature below 50 C (120 F), use the sight-gauge (2) to check that the coolant level fully covers the sight gauge. Top up the radiator via its fill cap through the small access door. Note: View the sight gauge from the access panels on the left or turbo side of the engine. Note: Low coolant level or high coolant temperature will result in an engine fault condition, automatically shutting down the engine. 6. Check the engine oil level using the dipstick (3), top up as required via the oil fill (4). Refer to Operation and Maintenance Manual, Engine Oil Level - Check for more information. Note: Low engine oil pressure will result in an engine alarm condition, automatically shutting down the engine. 7. Ensure the battery switch (5) is at the ON (I) position; in the ON position, the switch key will not be able to be removed. 8. Close the genset s main service doors. Control/Distribution Center 1. Ensure that the Emergency stop button (1) is fully pulled out. 2. Open the full main door and ensure that all of the required circuit breakers are set; refer to the following sections of this manual: Three Phase Equipment Circuit Breakers and Receptacles, 60Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) Standard Receptacles, and 50Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) Optional Receptacles Note: Only energise the single phase equipment circuit breakers required for the intended operational frequency. 3. Close the main door. 4. Open the window-door on the control/distribution center to access the operator controls. Push the WHITE LAMP button (2). The two LED lamps (3), the AC power meters (4) and the DC voltmeter (5) should light-up. The DC voltmeter (5) should indicate approximately 24VDC. If the lights do not work, and no voltage is shown on the DC voltmeter, then recheck that the RED emergency stop button (1) is pulled out fully and that the battery switch in the engine compartment is in the ON (I) position. If DC voltage is still not present, check the DC fuses as described in the Troubleshooting section in this manual. 5. Check that the Rated/Idle switch (6) Hare/Turtle is in the Idle position ( ) A Figure 44: Control/Distribution Center prestart checks 6. Return to the control/distribution center and move the genset Stop/Run/Start switch (7) to the stop position ( ) OP-002B S/N CB UP (Weld-deck) 58

64 Genset Cold Weather Operation It is possible to operate the genset-engine in extremely cold environments, if properly prepared and maintained. Satisfactory performance of the genset-engine in low ambient temperature conditions requires modification of the engine, the surrounding equipment, operating practices, and maintenance procedures. The correct engine coolant lubricating oil and fuels must be used for the cold weather range in which the engine is being operated. Refer to Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ), Cold Weather section for recommendations for critical engine fluids; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. A 750W/120VAC coolant heater (1), and a 150W/120VAC oil heater (2) are fitted to the standard engine. Both plug into an external 120VAC power source. Contact Vanguard equipment for optional heaters. 1 2 Figure 45: Genset Fluid Heaters A A Other provisions for operating cold weather must also be taken into account, such as but not limited to: battery heaters, fuel heater, etc. Refer to CUMMINS Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ) Cold Weather section in the appendices at the end of this manual for complete details. Note: To reduce the possibility of damage to the lubricating oil pan, due to the composite materials used in the manufacture of the lubricating oil pan, under no circumstances should an external heat source be applied directly or indirectly to the lubricating oil pan OP-002B S/N CB UP (Weld-deck) 59

65 Winterfronts The genset enclosure can be fitted with Winterfronts, contact Vanguard Equipment, Inc. Winterfronts can be used on the genset enclosure to reduce air flow through the radiator core. This can reduce the time required to warm the engine and help maintain the engine coolant temperature. The engine coolant temperature specifications are in the Maintenance Specification section of the CUMMINS Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Adjust the Winterfronts to maintain the engine coolant temperature above the CUMMINS Minimum Recommended Operating Temperature of 71ºC (160ºF); do not exceed the maximum operating temperature. Note: The genset automatically shuts down if the engine coolant exceeds 100ºC (210ºF). Genset-Engine Starting Starting Above 0 C (32 F) 1. For additional steps and procedures for starting in temperatures below 0 C (32 F, refer to the Cold Weather Starting Below 0 C (32 F) with Ether Starting section in this manual. 2. To stop the Genset, once it has been started, turn the Stop/Run/Start switch (1) to the stop position ( ). If any type of emergency condition exists, use the RED emergency stop button (2) to IMMEDIATELY trip the main breaker to cut the genset electrical power and to stop the genset. 3. Ensure that all of the pre-startup checks in the Before Starting Genset-Engine section of this manual have been made. 4. Ensure that the main service doors on genset are closed. 5. With the Rated/Idle switch (3) is at idle ( ) move the genset Stop/Run/Start switch (1) to start ( ). Release the Stop/Run/Start switch after the engine starts. Note: Return the Stop/Run/Start switch to stop ( ) after cranking the engine for 15 seconds, and then retry starting. Note: After every 30 seconds of engine cranking, allow the starter-motor to cool for two minutes. Note: The genset engine will automatically shutdown if the oil pressure drops below 138 kpa (20 psi). 6. If the engine does not start after three attempts, check the fuel supply system. Absence of blue or white exhaust smoke during cranking indicates no fuel is being delivered. 7. Once the engine starts, observe the oil pressure at idle. The oil pressure should stabilize at approximately 10 psi (69 kpa). 8. Idle the engine three to five minutes before switching the Rated/Idle switch (3) to rated ( ). Note: Do not operate the engine at idle for long periods with the engine coolant temperature below the Minimum Recommended Operating Temperature of 71ºC (160ºF), refer to CUMMINS Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of this manual. 9. Observe the oil pressure at Rated speed. The oil pressure should stabilize between approximately 40 to 60 psi (276 to 414 kpa). 10. Observe the coolant temperature to ensure that it is not too high. Note: The Genset will automatically shutdown if the coolant temperature reaches 100 ºC (210 ºF) A Figure 46: Genset-Engine Starting OP-002B S/N CB UP (Weld-deck) 60

66 11. Observe the engine operation Walk completely around the machine and check for unusual operation unusual noises or vibration, coolant or oil leaks including inside the Genset compartment Listen for any unusual noises and IMMEDIATELY stop the genset and investigate if any are present.. Stop the Genset and correct any deficiencies as required. Figure 47: Observe engine operation Most failures give an early warning. Look and listen for changes in performance, sound, or engine appearance that can indicate service or engine repair is needed. Some changes to look for are: Engine misfires Vibration Unusual engine noises Sudden changes in engine operating temperatures or pressures Excessive smoke Loss of power An increase in oil consumption An increase in fuel consumption Fuel, oil, or coolant leaks. 12. Close the Genset compartment doors and ensure the handles are securely latched. Note: Use caution when closing the main service doors while the Genset is running, as the cooling air flowing into the compartment will tend to suck the doors in while being closed. Cold Weather Starting Below 0 C (32 F) with Ether Starting 1. Refer to the above sections Genset Cold Weather Operation and Winter-fronts. 2. Follow the procedure outlined in the Starting Above 0 C (32 F) section of this manual. Follow the steps below if required. 3. While cranking the engine, push the Ether Starting Aid button ( ) to inject metered amounts of starting fluid. Figure 48: Ether Starting Aid A B Note: Do not use excessive amounts of starting fluid when starting the engine; too much fluid will cause damage to the engine. Note: Never hold the Ether Starting Aid button in for more than five seconds OP-002B S/N CB UP (Weld-deck) 61

67 Note: Use the Ether Starting aid during start-up while cranking the engine only, do not push the button once the engine is running. Significant damage to the engine could occur if the button is pushed while the engine is running. Note: Refer to the Ether Starting Aid Cylinder Replace section of this manual in order to change the ether starting aid cylinder. 4. Release the Stop/Run/Start switch after the engine starts. Genset Engine Starting with Jump Start Cables Warning! Explosion Hazard! Batteries give off flammable fumes that can explode resulting in personal injury. Prevent sparks near the batteries; they could cause vapors to explode. Do not allow the jump start cable ends to contact each other or the machine. Do not smoke when checking battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear eye protection when starting a machine with jump start cables. Improper jump start procedures can cause an explosion resulting in personal injury. Always connect the battery positive (+) to battery positive (+), and battery negative ( ) to battery negative ( ). Jump start only with an energy source with the same voltage as the stalled machine. Notice When starting from another machine, make sure that the machines do not touch. This could prevent damage to the engine bearings and electrical circuits. Severely discharged maintenance free batteries do not fully recharge from the alternator after jump starting. The batteries must be charged to proper voltage with a battery charger. Many batteries though to be unusable are still rechargeable. This machine has a 24 volt starting system. Use only the same voltage for jump starting. Use of a welder or higher voltage damages the electrical system. Use of Jump Start Cables 1. Determine the failure of the engine to start. 2. On a stalled machine, turn the Stop/Run/Start switch (Starter Switch) to the stop position. Turn off any accessories. 3. On a stalled machine, turn on the battery disconnect switch. 4. Move the machines together in order for the cables to reach. DO NOT ALLOW THE MACHINES TO CONTACT. 5. Stop the engine on the machine that is the electrical source. When you use an auxiliary power source, turn off the charging system. 6. The batteries on this machine are located inside the genset enclosure, on the turbo-side (starter-side) of the engine, and are accessible via the genset service-panel on the inner deck-side of the enclosure. 7. Check the battery caps for correct placement and for correct tightness. Make these checks on both machines. Make sure the batteries in the stalled machine are not frozen. Check the batteries for low electrolyte. 8. Connect the positive jump start cable to the positive cable terminal of the discharged battery. 9. Batteries in series may be in separate compartments. Use the terminal that is connected to the starter solenoid. Trace this cable in order to make sure that the cable is connected to the starter. 10. Connect the positive jump start cable to the positive terminal of the electrical source. Use the procedure from step 9 in order to determine the correct terminal. 11. Connect one end of the negative jump start cable to the negative terminal of the electrical source OP-002B S/N CB UP (Weld-deck) 62

68 12. Make the final connection. Connect the negative cable to the frame of the stalled machine. Make this connection away from the battery, the fuel, the hydraulic lines, or moving parts. 13. Start the engine on the machine that is the electrical source. Also you can energize the charging system on the auxiliary power source. 14. Allow the electrical source to charge the batteries for two minutes. 15. Attempt to start the stalled engine. Refer to the Operation and Maintenance Manual, Engine Starting section. 16. Immediately after the stalled engine starts, disconnect the jump start cables in reverse order. 17. Conclude with a failure analysis on the starting charging system. Check the stalled machine, as required. Check the machine when the engine is running and the charging system is in operation. Starting Procedure After Extended Shutdown or Oil Change Complete the following steps after each oil change, or after the engine has been shut down for more than 30 days to make sure the engine receives the correct oil flow through the lubricating oil system. 1. Follow the procedure outlined in the Starting Above 0 C (32 F) section of this manual. The engine will not start until the minimum cranking oil pressure is detected by the ECM. It can take more cranking time to start the engine after an extended shut down or oil change. 2. Monitor the oil pressure for several minutes after the engine starts. At Idle, the oil pressure should stabilize at approximately 10 psi (69 kpa). At Rated, the oil pressure should stabilize between approximately 40 to 60 psi (276 to 414 kpa). After Starting the Engine 1. Observe the oil pressure gauge to ensure that adequate oil pressure is achieved. At Idle, the oil pressure should stabilize at approximately 10 psi (69 kpa). At Rated, the oil pressure should stabilize between approximately 40 to 60 psi (276 to 414 kpa). 2. Allow the oil pressure to stabilize before switching the Stop/Run/Start switch to run ( ). Note: Do not idle the engine for excessively long periods. Long periods of idling, more than 10 minutes, can cause poor engine performance. Note: Do not operate the engine at idle for long periods with the engine coolant temperature below the Minimum Recommended Operating Temperature of 71ºC (160ºF), refer to Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Check the genset-engine s oil level after the engine has warmed up. Add or remove oil as required. 4. Check the air filter s service indicator (1), located just upstream of the turbo air inlet C Figure 49: Monitor genset oil pressure 5. Check the operation of the Top Spin air pre-cleaner (2) when the genset-engine is running at rated speed ( ), the spinner-blades must turn freely while the housing-body remains stationary. 2 1 Figure 50: Monitor genset air filter B A OP-002B S/N CB UP (Weld-deck) 63

69 AC Power-UP Notice A B Figure 51: Emergency Stop Push the RED emergency stop button to IMMEDIATELY trip the main breaker and stop the Genset if any type of emergency condition exists. The emergency stop button can be used with the control door open or closed. It must be manually pulled out to reset before the engine can be restarted. Refer to the Emergency Stop section of this manual. 1. Follow the procedure outlined in the Starting Above 0 C (32 F) section of this manual. 2. Once the Genset is warmed up and no deficiencies have been observed, the genset can be switched to rated speed 3. Move the Rated/Idle switch (1) to the Rated ( ) position. The genset will be running at RATED speed (1800 RPM for 60 Hz, 1500 RPM for 50 Hz); if it is not, refer to the Troubleshooting section in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Observe the oil pressure at rated speed. The oil pressure should stabilize between approximately 40 to 60 psi (276 to 414 kpa). 5. Move the main AC breaker CB 1 (2) to the set (I) position, and observe the white AC meters for correct voltage and frequency, refer to the Genset Frequency Configuration 60Hz and 50Hz Modes section of this manual; there will be no AC current (AMPS) indicated unless there is an electrical load such as the compressor or welding machines. If the main breaker does not set, refer to the Troubleshooting section in this manual. 6. If an air compressor is installed, turn the black compressor run switch to run (I) to start the compressor if required; turn it to off (O) to stop the compressor. Close and latch the window door. 7. Test the Ground Fault Circuit Interrupters (GFCI) as outlined in the Ground Fault Circuit Interrupters (GFCI) Test Daily section below. Figure 52: AC Power Up 8. The CPW weld deck is now ready for work, and requires no further operator involvement under normal circumstances. However, it is recommended to routinely check the system gauges every hour or so to ensure normal functionality OP-002B S/N CB UP (Weld-deck) B

70 Ground Fault Circuit Interrupters (GFCI) 60 Hz Test Daily To ensure that they are functioning properly, the ground fault circuit interrupters (GFCI) must be tested at the start of each working day, or whenever there is an unusual occurrence such as a severe electrical storm. 60Hz, Single Phase circuit breakers with Ground Fault Circuit Interrupters, CB17 - CB B RC 6 RC 7 RC 1 RC 2 RC 3 RC 4 RC 5 Figure 53: 60 Hz GFCI test buttons A A GFCI TEST BUTTONS GFCI TEST BUTTONS GFCI TEST BUTTONS GFCI TEST BUTTONS 1. With the genset running and the main breaker (CB1) set, ensure that all of the 60 Hz auxiliary-supply circuit breakers (CB3 through CB9, and CB16) are set. 2. With a load such as a light plugged into a front mounted receptacle RC1 through RC7 and turned on (or a multimeter can also be used to indicate the supply voltage). Press the GFCI test button. The GFCI circuit breaker should trip and the light must go out, or the voltage reading goes to zero. If the light does not go out, or the voltage does not go to zero, then there is a problem with the GFCI and it must be replaced by a qualified electrician. Note: Replace GFCIs using only the same style and current rating; contact VEI or refer to the Parts Manual, Weld-Deck Welding Package CPW S2-4 for suitable replacement parts information. 3. Reset the GFCI by turning the circuit breaker switch to ON. 4. Repeat the test for each front-mounted receptacle. Note: If a GFCI trips without pressing its test button with any type of load test-load or normal operating load plugged into its corresponding receptacle, then there is a problem with the load or the connected circuit which must be checked and corrected by a qualified electrician OP-002B S/N CB UP (Weld-deck) 65

71 Ground Fault Circuit Interrupters (GFCI) 50 Hz Test Daily To ensure that they are functioning properly, the ground fault circuit interrupters (GFCI) must be tested at the start of each working day, or whenever there is an unusual occurrence such as a severe electrical storm. 50Hz feeder circuit breakers, CB 22 and CB 23, with Ground Fault Circuit Interrupters B 60Hz panel shown. Contact Vanguard for available 50 Hz front panels. GFCI TEST BUTTONS GFCI TEST BUTTONS Figure 54: 50 Hz GFCI test buttons A 1. With the genset running and the main breaker (CB1) set, ensure that all of the 50 Hz auxiliary-supply circuit breakers (CB17 through CB23) are set. 2. Each of the individual 50Hz feeder circuit breakers, CB22 and CB 23, incorporates a Ground Fault Circuit Interrupter (GFCI). With a load such as a light plugged into a front mounted receptacle and turned on (or a multimeter can also be used to indicate the supply voltage). Press the GFCI test button on the corresponding feeder circuit breaker: CB22 feeds receptacles RC13 through RC15, CB23 feeds receptacles RC116 and RC17. The GFCI circuit breaker should trip and the light must go out, or the voltage reading goes to zero. If the light does not go out, or the voltage does not go to zero, then there is a problem with the GFCI and it must be replaced by a qualified electrician. Note: Replace GFCIs using only the same style and current rating; contact VEI or refer to the Parts Manual, Weld-Deck Welding Package CPW S2-4 for suitable replacement parts information. 3. Reset the GFCI by turning the circuit breaker s switch to ON. 4. Repeat the test for each front-mounted receptacle OP-002B S/N CB UP (Weld-deck) 66

72 Note: If a GFCI trips without pressing its test button with any type of load test-load or normal operating load plugged into its corresponding receptacle, then there is a problem with the load or the connected circuit which must be checked and corrected by a qualified electrician. Genset shutdown 1 2 Figure 55: Genset-Engine Shutdown B 1. Switch the Rated/Idle switch (1) to idle ( ), CB1 will automatically trip due to under frequency. Allow the engine to idle 3 to 5 minutes to cool down before shutting it off after a full-load operation. This allows adequate cool down of engine pistons, cylinders, bearings, and turbocharger components. 2. After the cool down period, move the genset Stop/Run/Start switch (2) to stop ( ) OP-002B S/N CB UP (Weld-deck) 67

73 Machine Parking Refer to the carrier s Operation and Maintenance Manual for specific machine parking instructions. Transportation Information Do not transport the machine with the walkways extended. RETAINING LATCH A RETAINING LATCH A RETAINING LATCH (BOTH SIDES) LATCH BOLTED UNDERSIDE A A Figure 56: Secure walkway using retaining latches. 1. Fold the walkways up, and secure using the retaining latches that are bolted to the underside of the left- and right-hand side walkways. The rear walkway is latched to the two side walkways. 2. Obey all jurisdictional transportation laws that apply. Refer to the Equipment Information Section of the Weld-Deck s Operation and Maintenance Manual for Weld-deck weights and dimensions. Shipping the Carrier-Mounted Weld-Deck Ship the carrier-mounted machine as per the instructions in the carrier s Operation and Maintenance Manual., keeping in mind the additional weight of the weld-deck. Note: Refer to the Equipment Information Section of the Weld-Deck s Operation and Maintenance Manual for Weld-deck weights and dimensions. Towing the Carrier Note: DO NOT connect to any part of the weld-deck for towing purposes of any kind. DO NOT connect trailing equipment to the weld-deck structure. Refer to the carrier s Operation and Maintenance Manual for correct towing procedures. Connect any trailing equipment to a carrier-mounted drawbar or to a carrier-mounted hitch on the carrier only OP-002B S/N CB UP (Weld-deck) 68

74 Shipping the Weld-Deck Uninstalled Note: Refer to the Equipment Information Section of the Weld-Deck s Operation and Maintenance Manual for Weld-deck weights and dimensions. 1. If transporting the weld-deck separate from the carrier (uninstalled), install the weld-deck s two shipping legs. SHIPPING LEG Figure 57: Shipping leg A 2. A forklift can be used to load the weld-deck. Forklift access is provided at the transport beams (1, 2). 1 2 Figure 58: Forklift access B 3. Alternatively, the weld-deck can be hoisted using the deck strong points (3, 4, 5) and a spreader bar to evenly distribute the weight. The balance point, or Centre Of Gravity (C of G) lies left/right in line with strong point 5 and approximately 45 inches (114 cm) front/back from the line between strong points 3 and 4 towards 5. Note: A spreader bar MUST be used to hoist the weld-deck to prevent serious damage to the genset and welder-doghouse modules. Contact Vanguard Equipment, Inc. to order an appropriate spreader bar. NOTE: Enclosure not shown, leave enclosure in place when hoisting Figure 59: Hoisting strong points A OP-002B S/N CB UP (Weld-deck) 69

75 A B A B Figure 60: Weld-deck shipping distribute and secure the load A Evenly distribute the load by alternating the direction of consecutive weld-decks. One faces forward, the next faces rearward (A, B) and repeat. 4. Secure the weld-deck(s) to the transport deck with appropriately sized chains (6, 7), etc. Note: Refer to the Equipment Information Section of the Weld-Deck s Operation and Maintenance Manual for Weld-deck weights and dimensions. Maintenance Section Torque Specifications Notice Be very careful never to mix metric with U.S. customary (standard) fasteners. Mismatched or incorrect fasteners causes machine damage or malfunction and can result in personal injury. When replacing nuts, bolts, or hardware in general, always use the same measurement and strength type as the original. Note: The information listed below is for general layout fasteners only. Consult the specific modules' operation and maintenance manuals Compressor, Engine, Generator, etc. in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4 for detailed information on the fasteners used in the respective module. Note: The center mounting bolt and nut on the vibration isolators have specific torque values which are different than the torques for standard fastener. Refer to the Torques for Vibration Isolator Mounts table in this section of this manual OP-002B S/N CB UP (Weld-deck) 70

76 Torques for Standard Fasteners The following tables show general torques for bolts, and for nuts. The components have a rating of at least SAE Grade 5. Tread Size N m Torques for Bolts and for Nuts. Standard Torques 1/4 inch 12 ± 3 9 ± 2 5/16 inch 25 ± 6 18 ± 4.5 3/8 inch 47 ± 9 35 ± 7 7/16 inch 70 ± ± 11 1/2 inch 105 ± ± 15 9/16 inch 160 ± ± 20 5/8 inch 215 ± ± 30 3/4 inch 370 ± ± 37 7/8 inch 620 ± ± 60 1 inch 900 ± ± /8 inch 1300 ± ± /8 inch 2400 ± ± /2 inch 3100 ± ± 250 Torques for Metric Fasteners The following tables show general torques for bolts, and for nuts. The components have a rating of at least SAE Grade 8.8. Metric Tread Size Torques for Metric Thread Bolts and Nuts. N m lb-ft Standard Torques M6 12 ± 3 9 ± 2 M8 28 ± 7 20 ± 5 M10 55 ± ± 7 M ± ± 15 M ± ± 22 M ± ± 22 M ± ± 44 M ± ± 75 M ± ± 150 M ± ± 225 lb-ft OP-002B S/N CB UP (Weld-deck) 71

77 Torques for Vibration Isolator Mounts Note: The following tables show the required torque values for the nuts and for the bolts that mount the equipment modules to the vibration isolator (the center mounting bolt and nut). The components have a rating of at least SAE Grade 5. Refer to the Torques for Standard Fasteners tables for the values required to secure the vibration isolators to the weld-deck. Equipment Module Isolator Location (Center Bolt and Nut Tread Size) Torques for Vibration Isolator Mounts. N m Isolator Mounts Torques Genset-Engine (5/8 inch) Radiator Mount, Control/Distribution Center (5/8 inch). 1 Stabilizer Mount: Radiator, Control/Distribution Center, Welder Doghouse (1/2 inch). 1 lb-ft Install locknut and tighten to snug-fit overload washers onto isolator s inner tube sleeve (ensure zero-clearance). Tighten locknut an additional 1/8th turn (45 ) to a max of 3/16th turn (65 max), do not over tighten. Air Compressor, Welder Doghouse (5/8 inch). 1 Genset Roll Link Bushing (5/8 inch) Note: Special installation procedure required; refer to the Parts Manual for correct replacement instructions OP-002B S/N CB UP (Weld-deck) 72

78 Maintenance Welding to the Weld-deck Notice Do not use the welding power units on a weld-deck to perform any welding on the same weld-deck. The use of welding power units on one weld-deck to perform welding on a different weld-deck is permissible. Notice Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder. Notice Do not attempt to start or run the weld-deck genset with the main ground at the rear of the control/distribution center disconnected. Turn off the engine. Turn the battery disconnect switch to the Off (O) position. Note: Welding must only be done with Engine Control Module (ECM) connectors and power supply connects disconnected. Electrical arc welding will destroy the engine ECM. DISCONNECT THE ECM BEFORE WELDING. Always completely disconnect and isolate the main ground at the rear of the control/distribution center at point A or at point B prior to welding on the equipment. Ensure that all of the precautions covered in the Fire Prevention and Explosion Prevention section of this manual have been followed. Take adequate precautions to ensure that a fire will not occur as a result of welding. Always have an appropriate, fully charged fire extinguisher at hand when performing any welding. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Protect any wiring harnesses and components from the debris and the spatter which is created from welding. Ensure that the ECM connectors and power supply connects are reconnected after completion of welding on the machine. Ensure that the main ground at the rear of the control/distribution center point A, point B has been reconnected after completion of welding on the machine. A 4 2 Figure 61: Disconnect the ECM before welding A B Figure 62: Disconnect main ground at the rear of the control/distribution center before welding A OP-002B S/N CB UP (Weld-deck) 73

79 Recommended Service Intervals Minimum Service Ensure that all safety information, warnings and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Notice The procedures listed below are provided for quick, general reference only. They do not outline all of the inspection and service procedures that MUST be performed to the various modules. Refer to the specific module s Compressor, Engine, Generator, etc. operation and maintenance manuals for complete and detailed information on the care of the respective module); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. Break-in Periods GENSET ENGINE The new Cummins engine associated with this manual does not require a break-in procedure. Refer to the Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. AIR COMPRESSOR Compressors are factory filled with CHAMPLUB hydrocarbon based recip lubricant. This is an ISO 100 non-detergent industrial lubricant with rust and oxidation inhibitors specially formulated for reciprocating compressors. It is recommended this compressor be maintained using this oil for ambient temperatures above 32 F. Refer to the COMPRESSOR OIL SPECIFICATIONS section in the Air Compressor Operation Maintenance Manual in the appendices of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. 1. Normal break-in period of the air compressor is 25 hours. 2. For the first 100 hours of compressor operation, a careful and regular check of the oil level should be made. Maintain oil level at the full line. 10 Hours or Daily AIR CLEANER Check condition (service indicator on filter), and replace as required. Description Vanguard Part Number Quantity PRIMARY AIR ELEMENT SAFETY AIR ELEMENT PRECLEANER-AIR SPINNER (Check with engine running at Rated speed. Spinner must be turning freely; body stationary) Fluid levels: Check fluid levels for each piece of installed equipment. Refer to the Operation section for each component for instructions on checking fluid levels (Genset, Air Compressor). Follow Maintenance Schedule as outlined in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4 Note: Refer also to the Before Starting Genset-Engine section of this manual OP-002B S/N CB UP (Weld-deck) 74

80 Note: Refer also to the Ground Fault Circuit Interrupters (GFCI) Test Daily section of this manual. Note: Refer also to the Compressed Air Receiver Drain Valve section of this manual. Note: See also the specific module s Compressor, Engine, Generator, etc. operation and maintenance manual in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Hours or 3 Months Note: See also specific module s Compressor, Engine, Generator, etc. operation and maintenance manuals in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. CUMMINS DIESEL ENGINE QSB6.7 Description OEM Part Number Quantity ENGINE OIL Refer to the Engine OEM s operation and maintenance manual in the appendices of this manual for oil specification. LUBRICATING OIL FILTER Cummins Part Number: ENGINE COOLANT Fleetguard /Nelson Part Number: LF3970 Refer to the Cummins Engine OEM s operation and maintenance manual in the appendices of Weld-Deck s Operation and Maintenance Manual for Coolant Recommendations and Specifications. FUEL FILTER (PRIMARY) Cummins Part Number: Fleetguard /Nelson Part Number: FF5612 Fuel Filter (Prefilter with WIF Sensor) Cummins Part Number: Fleetguard /Nelson Part Number: FS19732 FAN BELT Cummins Part Number: QUARTS or 4.6 US GALLONS or 17.5 LITERS 1 28 QUARTS or 7 US GALLONS or 26.5 LITERS Follow Maintenance Schedule as outlined in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Hours or 6 Months Note: See also specific module s Compressor, Engine, Generator, etc. operation and maintenance manuals in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. AIR COMPRESSOR Description Vanguard Part Number Quantity OIL (hydrocarbon based lubricant for ambient temperatures above 0 C (32 F)) (synthetic lubricant for high temperature applications)) COMPRESSOR BELTS Batteries - Check CATERPILLAR 9X /3 QUARTS or 1.6 US GALLONS or 6 LITERS Follow Maintenance Schedule as outlined in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S OP-002B S/N CB UP (Weld-deck) 75

81 All Other Service Intervals See the specific module s Compressor, Engine, Generator, etc. operation and maintenance manuals in the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. Genset Frequency Configuration 60Hz and 50Hz Modes Shock/Electrocution Hazard! Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could cause serious injury or death. DO NOT OPEN the inner main panel door unless you are a qualified service technician, and are familiar with the dangers of high voltage. The main electrical lines coming into the bottom of the main supply AC circuit breaker (CB1) from the genset are LIVE, and HIGH VOLTAGE is present on the main incoming lines WHENEVER the genset is running, EVEN WHEN THE MAIN CIRCUIT BREAKER (CB1) IS DE-ENERGIZED (O). The genset can be configured to provide either 480/ VAC at a frequency of 60Hz, or 415/240VAC at a frequency of 50Hz. Note: A different Single Phase Front-Mounted Equipment Receptacle Plate is required for 60Hz and 50Hz operation, and no voltage will be present in the front-mounted equipment receptacles if the wrong plate is used. Refer to the section Single Phase Front-Mounted Equipment Receptacles Installation in the Maintenance Section of this manual for changing over between the different receptacle plates. Note: To avoid possible equipment damage, ensure that only equipment with the correct voltage and frequency ratings are connected to the supply receptacles. Follow the steps below to configure the unit for the desired AC electrical output. 1. Open the inner panel by turning the three securement latches clockwise approximately 1/2 turn B Figure 63: Inner panel securement latches 2. The Genset frequency selector switch SS60/SS50 (1) is located on the inner panel, in the upper rear quadrant. 3. Refer to the 60Hz Mode or the 50Hz Mode below for the set-up procedure for the desired operation mode OP-002B S/N CB UP (Weld-deck) 76

82 A Figure 64: Genset frequency selector switch SS60/SS50 (1) C 60Hz Mode 1 SS60 position for 60 Hz operation Figure 65: 60Hz setting for Genset frequency selector switch SS60/SS50 (1) 1. Ensure the genset Stop/Run/Start switch is in the STOP ( ) position. 2. Turn the Genset frequency selector switch SS60/SS50 (1) counterclockwise to the SS60 position to set the Genset rated speed for 60Hz operation OP-002B S/N CB UP (Weld-deck) 77

83 3. Ensure the correct Single Phase Front-Mounted Equipment Receptacle plate is installed. Voltage will be present in the front-mounted equipment receptacles if the wrong plate is used. Refer to the section Single Phase Front- Mounted Equipment Receptacles Installation in the Maintenance Section of this manual for changing over the different front mounted receptacle plates. 60Hz receptacle plates have 7 outlet receptacles. The 60Hz receptacles are labeled: 120V/20A RC1 CB3 120V/20A RC2 CB4 120V/20A RC3 CB5 120V/20A RC4 CB6 120V/20A RC5 CB7 240/30A RC6 CB8 240/30A RC7 CB9 50Hz receptacle plates have 5 outlet receptacles. The 50Hz receptacles are labeled: 240V/15A RC13 CB17 240V/15A RC14 CB18 240V/15A RC15 CB19 240V/15A RC16 CB20 240V/15A RC17 CB21 Figure 66: Identifying Front-Mounted Equipment Receptacles type A 4. Close the inner panel and secure it by turning the three securement latches counterclockwise approximately 1/2 turn until they stop and fully latch the panel. 5. Start the genset and engergise the main breaker as per the Genset-Engine Starting and the AC Power-UP sections in this manual. 6. Check the genset output on the Main Supply AC Meters, turn the Main Supply AC Meters Phase Selector Switch to verify the output on each of the three phase legs L1, L2, L3. a. The Main Supply AC voltage should be 480VAC ± 20VAC. Adjust the voltage regulator on the genset alternator to obtain the correct voltage; refer to the Operation and Maintenance Manual AC Generator for troubleshooting information; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2. Note: The STABILITY and the UNDER-FREQ ADJUST potentiometers do not normally need to be adjusted for this procedure. Adjust the VOLTAGE ADJUST potentiometer to change the generator output voltage. Clockwise increases the generator output voltage, counterclockwise lowers the output voltage. The other two potentiometers do not require adjustment A A Figure 67: Genset Voltage Regulator adjustment OP-002B S/N CB UP (Weld-deck) 78

84 b. The frequency meter should display 60Hz ± 3Hz. The genset frequency range is controlled by the engine ECM and is non-adjustable. If the frequency is out of range, verify that the engine RPM on the Engine Digital Display reads 1800 RPM ± 4 RPM. 7. Once the Supply AC voltage and frequency have been verified, with the genset running at rated speed, energise the Main Supply AC Circuit Breaker (CB1). Verify the output of the fronted mounted equipment receptacles; refer to the section 60Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) Standard Receptacles in this manual for the correct voltage outputs. The CPW s2 is now configured to supply 480/ VAC at a frequency of 60Hz, the welder receptacles RC8, RC9, RC10, RC11, RC12 and the compressor connection do not require any additional adjustment. Note: To avoid possible equipment damage, ensure that only equipment with the correct voltage and frequency ratings are connected to the supply receptacles. 50Hz Mode 1 SS50 position for 50 Hz operation A Figure 68: 50Hz setting for Genset frequency selector switch SS60/SS50 (1) 1. Ensure the genset Stop/Run/Start switch is in the STOP ( ) position. 2. Turn the Genset frequency selector switch SS60/SS50 (1) clockwise to the SS50 position to set the Genset rated speed for 50Hz operation OP-002B S/N CB UP (Weld-deck) 79

85 3. Ensure the correct Single Phase Front-Mounted Equipment Receptacle plate is installed. Voltage will be present in the front-mounted equipment receptacles if the wrong plate is used. Refer to the section Single Phase Front- Mounted Equipment Receptacles Installation in the Maintenance Section of this manual for changing over between the different receptacle plates. 50Hz receptacle plates have 5 outlet receptacles. The 50Hz receptacles are labeled: 240V/15A RC13 CB17 240V/15A RC14 CB18 240V/15A RC15 CB19 240V/15A RC16 CB20 240V/15A RC17 CB21 60Hz receptacle plates have 7 outlet receptacles. The 60Hz receptacles are labeled: 120V/20A RC1 CB3 120V/20A RC2 CB4 120V/20A RC3 CB5 120V/20A RC4 CB6 120V/20A RC5 CB7 240/30A RC6 CB8 240/30A RC7 CB9 Figure 69: Identifying Front-Mounted Equipment Receptacles type A 4. Close the inner panel and secure it by turning the three securement latches counterclockwise approximately 1/2 turn until they stop and fully latch the panel. 5. Start the genset and engergise the main breaker as per the Genset-Engine Starting and the AC Power-UP sections in this manual. 6. Check the genset output on the Main Supply AC Meters, turn the Main Supply AC Meters Phase Selector Switch to verify the output on each of the three phase legs L1, L2, L3. a. The Main Supply AC voltage should be 415VAC ± 15VAC. Adjust the voltage regulator on the genset alternator to obtain the correct voltage using a multimeter set to VAC or the Voltmeter (V1) on the Control Distribution Centre; refer to the Main. Refer to the Operation and Maintenance Manual AC Generator for troubleshooting information; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2.. Note: The STABILITY and the Adjust the VOLTAGE ADJUST potentiometer to change the generator output voltage. Clockwise increases the generator output voltage, counterclockwise lowers the output voltage. The other two potentiometers do not require adjustment A A Figure 70: Genset Voltage Regulator adjustment OP-002B S/N CB UP (Weld-deck) 80

86 UNDER-FREQ ADJUST potentiometers do not normally need to be adjusted for this procedure. b. The Frequency Meter (F1) should display 50Hz ± 3Hz. The genset frequency range is controlled by the engine ECM and is non-adjustable. If the frequency is out of range, verify that the engine RPM on the Engine Digital Display reads 1500 RPM ± 4 RPM. 7. Once the Supply AC voltage and frequency have been verified, with the genset running at rated speed, energise the Main Supply AC Circuit Breaker (CB1). Verify the output of the fronted mounted equipment receptacles; refer to the section 50Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) in this manual for the correct voltage outputs. The CPW s2 is now configured to supply 415/240VAC at a frequency of 50Hz, the welder receptacles RC8, RC9, RC10, RC11, RC12 and the compressor connection do not require any additional adjustment. Note: To avoid possible equipment damage, ensure that only equipment with the correct voltage and frequency ratings are connected to the supply receptacles OP-002B S/N CB UP (Weld-deck) 81

87 Single Phase Front-Mounted Equipment Receptacles Installation Different Single Phase Front-Mounted Equipment Receptacle plates are required for operation at the two different AC voltage supply frequencies, 50 Hz or 60Hz. Voltage will not be present in the front-mounted equipment receptacles if the wrong plate is used for the 50Hz or 60Hz operation. 1. Ensure the genset Stop/Run/Start switch is in the STOP ( ) position. Attach a Do Not Operate tag or similar tag to the start switch or controls. 2. Remove the ten (10) 1/4x20UNC bolts securing the Front-Mounted Equipment Receptacle plate. Remove the ten (10) 1/4x20UNC bolts securing the Front- Mounted Equipment Receptacle plate. 60Hz receptacle plate shown with 7 outlet receptacles. The 60Hz receptacles are labeled: 120V/20A RC1 CB3 120V/20A RC2 CB4 120V/20A RC3 CB5 120V/20A RC4 CB6 120V/20A RC5 CB7 240/30A RC6 CB8 240/30A RC7 CB A 50Hz receptacle plates (not shown) have 5 outlet receptacles. The 50Hz receptacles are labeled: 240V/15A RC13 CB17 240V/15A RC14 CB18 240V/15A RC15 CB19 240V/15A RC16 CB20 240V/15A RC17 CB21 Figure 71: Front-Mounted Equipment Receptacle plate removal B 3. Disconnect the quick connector (50Hz-plates) or connectors (60Hz-plates) between the Front-Mounted Equipment Receptacle plate and the control/distribution center. The 50Hz Front-Mounted Equipment Receptacle plate uses the single quick-connector labeled "TB1", while the 60Hz Front-Mounted Equipment Receptacle plate uses the two quick-connectors labeled "TB2" and "TB3". Note: The quick-connectors are not interchangeable, TB1 cannot be plugged into TB2 or TB3, andtb2 cannot be plugged into TB OP-002B S/N CB UP (Weld-deck) 82

88 4. Connect the replacement Front-Mounted Equipment Receptacle plate to the corresponding control/distribution center's quick-connector receptacle or quick-connector receptacles: the 50Hz Front-Mounted Equipment Receptacle plate uses the single quick-connector labeled "TB1", while the 60Hz Front-Mounted Equipment Receptacle plate uses the two quick-connectors labeled "TB2" and "TB3". Note: The quick-connectors are not interchangeable, TB1 SINGLE CONNECTOR "TB1" = 50Hz TWO CONNECTORS "TB2" AND "TB3" = 60Hz 60Hz receptacle plate shown with 7 receptacles and two quickconnectors A 50Hz receptacle plates (not shown) have 5 receptacles and one quick-connector. cannot be plugged into TB2 or TB3, andtb2 cannot be plugged into TB3. 5. Carefully lay the quick-connector cords back inside the control/distribution center, and reinstall the Front-Mounted Equipment Receptacle plate with the ten (10) 1/4x20UNC bolts. Torque the 1/4x20UNC bolts to 12±3 N m (9±2 lb ft). 6. Ensure the correct operational frequency is selected as per the instructions in the Genset Frequency Configuration 60Hz and 50Hz Modes section. 7. Start the genset and engergise the main breaker as per the Genset-Engine Starting and the AC Power-UP sections in this manual. 8. Verify the output of the fronted mounted equipment receptacles, for 60Hz operation refer to the section 60Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) Standard Receptacles, for 50Hz operation refer to section 50Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) Optional Receptacles in this manual. The unit is ready for operation at the Figure 72: Front-Mounted Equipment Receptacle quick-connectors OP-002B S/N CB UP (Weld-deck) 83

89 Engine Lubricating Oil Level - Check Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Notice Do not under fill or overfill engine crankcase with oil. Either condition can cause engine damage. Never operate the engine with oil level below the L (low) mark or above the H (high) mark shown on the dipstick (1), poor engine performance or engine damage can occur. 2 1 The engine oil level gauge relies on gravity. The engine must be level when checking the oil level to make sure the measurement is correct. Shut off the engine for an accurate reading. Wait at least 15 minutes after shutting off the engine to check the oil level. This allows time for the oil to drain into the oil pan. Use the engine Oil Level Gauge dipstick (1) to check the oil level. Maintain the oil level in the operating area on the engine oil level gauge. The operating area is between the L (low) mark or above the H (high) mark. Remove the oil fill cap (2) if necessary to add oil. Clean the oil fill cap and reinstall onto the engine. Refer to the Engine Lubricating Oil and Filter Change section for the steps required to drain the engine oil. Engine Lubricating Oil and Filter Change Figure 73: Oil Level check A Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Notice Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the equipment. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Notice Do not under fill or overfill engine crankcase with oil. Either condition can cause engine damage. Never operate the engine with oil level below the L (low) mark or above the H (high) mark shown on the dipstick (1), poor engine performance or engine damage can occur OP-002B S/N CB UP (Weld-deck) 84

90 1. Remove the brass cap under the deck from the drain fitting (1). 2 d 1 1 Install a drain hose under the deck onto (1) B Figure 74: Oil and filter change A 2. Install a drain hose (not shown) under the deck onto the drain fitting (1). The drain fitting is 3/8" NPT. 3. Operate the engine until the coolant temperature reaches 140 F (60 C) as indicated on the Genset Coolant Gauge ( ). 4. Shut off the engine 5. Drain the oil immediately to be sure all the oil and suspended contaminants are removed from the engine. Open shutoff valve (2). Allow the oil to drain into a suitable container. Use a container that can hold at least 21 Quarts (20 L) of oil. 6. When the oil has completed draining from the crankcase, close shutoff valve (2). Remove the drain hose. Install the brass cap under the deck from the drain fitting (1). 7. Replace the engine Lubricating Oil Filter as per the instructions outlined in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Cooling System Do not remove the cooling system filler cap (pressure cap) from a hot engine. Wait until the coolant temperature is below 50 C (120 F) before removing the filler cap. Heated coolant spray or stream can cause personal injury. Notice Never use a sealing additive to stop leaks in the coolant system. This can result in coolant system plugging and inadequate coolant flow, causing the engine to overheat. Notice Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool below 50 C (120 F) before adding coolant OP-002B S/N CB UP (Weld-deck) 85

91 The cooling system radiator is contains two separate cooling cores. The Charge Air Cooling (CAC) core cools the intake combustion air from the turbocharger, and the engine coolant radiator core (RAD) cools the engine. Cooling System: Core - Clean On a cool engine with the coolant temperature is below 50 C (120 F), inspect the cooling system radiator cores for debris. Clean the radiator cores, if necessary. Use compressed air, high-pressure water, or steam to remove dust and debris from the radiator core. However, the use of compressed air is preferred. 1 2 CAC RAD A A 1 2 COOLING FAN A A (CAC): Charge Air Cooler (RAD): engine coolant radiator (1): Filler Cap (pressure cap) (2): Sight Gauge (3): Drain Valve Figure 75: Genset Cooling System - Components OP-002B S/N CB UP (Weld-deck) 86

92 Cooling System: Service Coolant is toxic. Keep away from children and pets. To service the cooling system (Check, Drain, Flush), follow the instructions outlined in the Cummins Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Air Cleaner Service Notice Never operate the engine without the complete air cleaner assembly installed. Intake air must be filtered to prevent dirt and debris from entering the engine and causing premature wear or engine damage. Precleaner Indicator Air Cleaner Housing Dust Ejector Figure 76: Monitor genset air filter B A The red flag in the Indicator window gradually rises as the filter cartridge loads with dirt. After changing or replacing the cartridge, reset the indicator by pushing its reset button. For detailed air cleaner service instructions, refer to the Air Cleaner Service manual in the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Note: Service the primary filter element only when the Air Cleaner Restriction indicator showing fully RED. Do not open the filter compartment unless it is time for service. Opening the filter compartment can cause dirt to get into the clean side of the filter housing. Note: Extremely short air filter life can result if the precleaner system malfunctions. If air filter life is drastically reduced from typical for the operating conditions, consult your Dealer. Notice Service the engine air filters with the engine stopped. Engine damage could result. Never operate the engine without the complete air cleaner assembly installed. Intake air must be filtered to prevent dirt and debris from entering the engine and causing premature wear or engine damage. Note: Do not use the air filter for longer than one year OP-002B S/N CB UP (Weld-deck) 87

93 Air Compressor An air compressor may be installed, check the specific weld-deck A Figure 77: Air Compressor (if installed) Note: Refer to the Air Compressor Operation Maintenance Manual for detailed operation and maintenance instructions; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Air Compressor Motor Bearings Standard grease fittings are provided at each end shield to permit the re-lubrication of the bearings. The lubrication interval, quantity of grease, and lubrication specification are all stamped on the motor nameplate. Note: Excessive lubrication, i.e. a quantity of grease greater than that recommended on the motor nameplate, can result in the increase of bearing temperatures leading to reduced bearing life operating hours OP-002B S/N CB UP (Weld-deck) 88

94 This Page Intentionally Left Blank OP-002B S/N CB UP (Weld-deck) 89

95 Troubleshooting Notice This equipment is to be operated and serviced by qualified personnel only. Refer to the Safety section of this manual. Do not attempt to bypass any of the safety equipment or instrumentation on this equipment. Do not attempt to operate this equipment with any of the safety equipment or instrumentation bypassed. General Information The following faults are some of the typical problems that can be anticipated during normal operation of the CPW S2-4 Weld-Deck. The solutions listed are some of the acceptable corrections to those problems Engine Faults: The CPW S2-4 Weld-Deck incorporates the use of an electronic digital display, Engine Digital Display. Many of the engine faults that occur will result in fault codes to assist with identifying the problem. See the Engine Digital Display in the Operation section of this manual. Refer to the Engine Diagnostic Trouble Codes; see the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Engine Won t Crank 2. Engine Won t Start 3. Engine Will Not Idle 4. Engine Will Not Go to Full Speed (Run) 5. Batteries fail to charge (low DC voltage) 6. 24VDC Alternator Overcharging (High DC voltage) 7. No or Low 480 VAC Three Phase Supply Voltage 8. Main Breaker Will Not Set VAC or 240 VAC Ground Fault Interrupter (GFCI) Circuit Breakers Will Not Set 10. Electrical Schematics 11. Compressor Faults Note: See also the CUMMINS Operation and Maintenance Manual QSB4.5 and QSB6.7 Engine (Bulletin ); see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S OP-002B S/N CB UP (Weld-deck) 90

96 Engine Won t Crank 5 (SS2) 2 1 3, A Figure 78: Engine Won t Crank Troubleshooting numbered callouts reference numbered problem list below A Possible cause 1 Red emergency stop button (PB1) NOT pulled all the way out. Solution Pull the red emergency stop button (PB1) all the way out 2 Automotive style fuse (FU1) blown. Check and replace with spare fuse of same rating 3 Jumper (1J1) on blue terminal strip between terminals #82 and #83 loose or missing. Check loose connections. Replace missing jumper. 4 Loose wires. Check wire numbers: #82, #83, #84, #46; the wire at the starter solenoid on the turbo-side of the genset engine and at terminal #46. Note: The same wire number can be used on more than one wire in the same circuit. 5 Faulty Stop/Run/Start switch (SS2). Replace defective switch. 6 Bad starter motor or starter solenoid Replace genset engine s starter motor. 7 Engine fault. Refer to The Engine Digital Display unit to determine fault code. See the Engine Digital Display in the Operation section of this manual. Refer to the Engine Diagnostic Trouble Codes; see the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S LS1 inner door switch not closed Verify inner door closed. If ok, check LS1 wiring and switch for defects. 9 Low or dead batteries Verify 24VDC at the panel Battery Charge Meter (Minimum 9 VDC). Check connections. Check battery charge capacity OP-002B S/N CB UP (Weld-deck) 91

97 Engine Won t Start A Figure 79: Engine Won t Start Troubleshooting numbered callouts reference numbered problem list below A Possible cause Solution 1 No fuel Fill fuel tank. Check fuel lines for restrictions. Check fuel supply line shut-off valve if equipped is open. Refer to genset engine s Operation and Maintenance Manual for instructions on priming (see fuel filter replacement section). 2 Fuel line not primed. Prime fuel with lift pump lever; refer to genset engine s Operation and Maintenance Manual for instructions on priming (see fuel filter replacement section). 3 Automotive style fuse (FU4) blown. Check and replace with spare fuse of same rating 4 Loose wiring Check wires #6, #85 in control box. Check that the Engine Harness is firmly secured to the Engine Control Module (ECM), see the Before Starting Genset-Engine section. 5 Faulty control relay (CR1) Replace control relay (CR1) module, located behind Timer (TR1). 6 Engine fault. Refer to The Engine Digital Display unit to determine fault code. See the Engine Digital Display in the Operation section of this manual. Refer to the Engine Diagnostic Trouble Codes; see the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S OP-002B S/N CB UP (Weld-deck) 92

98 Engine Will Not Idle (SS2) B Figure 80: Engine Will Not Idle Troubleshooting numbered callouts reference numbered problem list below A Possible cause Solution 1 Engine fault. Refer to The Engine Digital Display unit to determine fault code. See the Engine Digital Display in the Operation section of this manual. Refer to the Engine Diagnostic Trouble Codes; see the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S Loose wires. Check wires #8, #111, in control box. Check that the Engine Harness is firmly secured to the Engine Control Module (ECM), see the Before Starting Genset-Engine section. 3 Defective Run/Idle switch (SS2) Check for correct operation. Replace. Engine Will Not Go to Full Speed (Run) Possible cause 1 Incorrect Genset Frequency Configuration. Solution Refer to the Genset Frequency Configuration 60Hz and 50Hz Modes section. 2 Engine fault. Refer to The Engine Digital Display unit to determine fault code. See the Engine Digital Display in the Operation section of this manual. Refer to the Engine Diagnostic Trouble Codes; see the appendices at the end of the Weld- Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S OP-002B S/N CB UP (Weld-deck) 93

99 Batteries fail to charge (low DC voltage) A Figure 81: Batteries fail to charge (low DC voltage) Troubleshooting numbered callouts reference numbered problem list below Possible cause Solution 1 24VDC alternator not charging. Check 24VDC alternator circuit breaker (CB30) located besides 24VDC alternator and starter on turbo side of genset engine; reset lever must be in. Improper jump starting possible cause. 2 Faulty or loose battery connections or cables. Check all battery cables and connections. 3 Faulty batteries. Replace batteries. Maintenance free batteries are originally supplied, and require no maintenance or inspection. Refer to documentation accompanying other battery types for maintenance instructions. Note: Always recycle a battery, never discard a battery. 4 Faulty 24VDC alternator. If 24VDC alternator circuit breaker (CB30) not tripped, possible faulty alternator, refer to genset engine s Operation and Maintenance Manual OP-002B S/N CB UP (Weld-deck) 94

100 24VDC Alternator Overcharging (High DC voltage) A Figure 82: 24VDC Alternator Overcharging (High DC voltage)troubleshooting numbered callouts reference numbered problem list below Possible cause Solution 1 Batteries have failed. Check condition of batteries, replace batteries if required. Maintenance free batteries are originally supplied, and require no maintenance or inspection. Refer to documentation accompanying other battery types for maintenance instructions. Note: Always recycle a battery, never discard a battery. 2 Faulty 24VDC alternator. Refer to genset engine s Operation and Maintenance Manual OP-002B S/N CB UP (Weld-deck) 95

101 No or Low 480 VAC Three Phase Supply Voltage Refer to the Operation and Maintenance Manual AC Generator for troubleshooting information; see the appendices at the end of the Weld-Deck Operation and Maintenance Manual, Weld-Deck welding package CPW S2-4. Main Breaker Will Not Set 3, A Figure 83: Main Breaker Will Not Set Troubleshooting numbered callouts reference numbered problem list below A Possible cause Solution 1 Automotive style fuse (FU5) blown. Check and replace with spare fuse of same rating 2 Defective Panel micro-switch (LS1) Check correct operation, adjust to ensure inner door activates LS1. 3 Loose wires Check wires #74, #75, #76, #86, #87, #88, #89 4 Speed sensors (ER1, ER2) Defective. Check operation of ER1 at 50Hz, ER2 at 60Hz. 5 Genset frequency selector switch SS60/SS50 defective. Check continuity across wires #74 and #76 for 60Hz operation, and across wires #75 and #76 for 50Hz operation. Replace if defective. 6 Main Breaker (CB1) or Main Breaker Shunt Trip defective. Replace defective component OP-002B S/N CB UP (Weld-deck) 96