Owner s Guide for. *24 Months engine warranty on Vanguard powered sets

Transcription

1 Owner s Guide for WELD n WORK Engine Driven Welder Generators *24 Months engine warranty on Vanguard owered sets We are leased to advise that your ADVANCED POWER Welding Set is covered by warranty for a eriod of 36 months* from the date of its original urchase. Refer to the engine oeration manual for additional engine warranty details. This warranty is subject to the terms and conditions of the resective manufacturers and covers defects occurring under normal oerating conditions caused by faulty materials or workmanshi. Excluded from this warranty are normal maintenance items, consumable arts and equiment subjected to misuse, abuse, lack of maintenance or damage due to unauthorised servicing. For warranty service, the equiment must be returned, freight re-aid to an authorised Advanced Power service agent. Should you require warranty service or maintenance, lease contact MPower on AWARD WINNERS FOR EXCELLENCE IN DESIGN OF GENERATORS

2 Imortant Information for all owners of ADVANCED POWER Engine Driven Welding Sets Thank you for urchasing an ADVANCED POWER Welder Generator. We have reared this handbook to make it easier and safer for you to use and care for your Welder Generator. Please read this handbook carefully as it contains imortant information which may revent serious ersonal injury or equiment damage. Please read this leaflet in conjunction with the additional engine maintenance information which can be found in the accomanying engine owners manual. Your ADVANCED POWER Welder Generator has been run, tested and tuned for otimum erformance at the factory rior to desatch. All etrol and oil has been drained for safe transort uroses. DO NOT START YOUR WELDER- GENERATOR until you correctly FILL ENGINE CRANKCASE WITH OIL. DO NOT ADJUST THE ENGINE SPEED. HINTS FOR SAFE OPERATION AND BEST PERFORMANCE n FILL CRANKCASE WITH OIL as recommended in the engine owner s manual. Check oil level daily. DO NOT USE FRICTION MODIFIED OILS. n USE ONLY FRESH QUALITY FUEL in your Advanced Power Welder Generator. DO NOT use fuel that has been stored for several weeks. n DO NOT ADJUST OPERATING SPEED. This has been factory set. Alteration will vary the outut voltage and frequency, which will cause damage to your aliances and/or generator and void your warranty. n ONLY ONE SECTION OF THE SET CAN BE OPERATED AT ANY ONE TIME. i.e. Welder or Alternator. n DO NOT DISCONNECT THE LOW OIL SENDER LEAD/WIRE. THIS WILL CAUSE DAMAGE TO YOUR GENERATOR WELDER AND VOID THE UNITS WARRANTY n DO NOT OPERATE YOUR etrol/ diesel DRIVEN WELDER-GENERATOR AT LESS THAN 1/3 FULL LOAD for long eriods. Light loading can cause glazing of the cylinder bore, and cause increased carbon build u in combustion chambers. After long eriods of oeration at light loads, the generator should be oerated for 5 minutes at 75% load or more of its rated caacity to diserse carbon build-u in the combustion chamber. 2

3 n When STARTING and STOPPING your Welder Generator, TURN OFF ALL CONNECTED APPLIANCES - ESPECIALLY INDUCTION MOTOR DRIVEN APPLIANCES such as refrigerators, water ums, air conditioners, worksho machinery and electronic aliances such as TV sets. Damage may occur to these aliances due to the high/low voltage outut from the generator under starting and stoing situations. n STOP ENGINE AND ALLOW TO COOL BEFORE FILLING WITH PETROL OR DIESEL. You may be seriously injured by fire or exlosion if fuel is silt and ignites. n ALLOW ALL SPILT PETROL TO EVAPORATE BEFORE STARTING OR RE-STARTING THE SET. n DO NOT SMOKE NEAR PETROL. n DO NOT OPERATE YOUR WELDER GENERATOR WITHOUT SUFFICIENT VENTILATION. Poisonous carbon monoxide gases - colourless and odourless - are contained in exhaust gases. n DO NOT OPERATE YOUR WELDER GENERATOR IN AN ENCLOSED AREA. Your Welder requires amle circulation of cooling air. n PROTECT YOUR WELDER GENERATOR FROM WATER AND RAIN. Water ingress will damage comonents and cause corrosion, voiding your Advanced Power warranty. n When using your Welder Generator to rovide ower for 240Volt AC aliances USE CORRECT SIZED FLEXIBLE POWER CABLES. Do not use light domestic extension leads for high ower loadings or over long distances. Damage to your aliances and/ or welder generator may result from excessive voltage dro in the cable. n NEVER CONNECT YOUR WELDER GENERATOR TO ANY WALL MOUNTED POWER OUTLET BY MEANS OF A CORD OR PLUG. This will create a POTENTIALLY FATAL SITUATION. ALL WIRING WORK associated with the connection of the generator to an existing ELECTRICAL INSTALLATION MUST BE CARRIED OUT BY A LICENSED ELECTRICAL CONTRACTOR and must be in accordance with individual state regulations. n Where aliances are to be directly lugged into the generator s 240 volt A.C. ower outlet it is recommended that OVER-CURRENT PROTECTIVE DEVICES BE INSTALLED in the active lead. n DO NOT EARTH WELDER - GENERATOR FRAME via an earth stake or other means. Refer to individual site, work lace or state regulations for welder generator EARTH STAKE requirements. n DAILY AIR CLEANER SERVICING IS RECOMMENDED in dusty conditions. Do not neglect oil changes and engine servicing requirements refer to age 6. WELDER GENERATOR STORAGE When your Welder Generator is to be stored for several weeks without use n Drain the carburettor by running the engine with the FUEL VALVE OFF until it stos. Ensure no aliance is connected to the Welder Generator during this oeration. n Pull start roe gently till slight resistance is felt to ensure the engine valves are closed. n Store in a DRY and CLEAN location. For longer storage rocedures, see the engine owners manual. n When transorting the Welder Generator always TURN OFF THE FUEL VALVE, if fitted. 3

4 OPTIONAL BATTERY OPTIONS AND ACCESSORIES All electric start sets are fitted with a battery mounting bracket and two leads. The otional battery is a heavy duty re-charged 12 VDC maintenance free, sealed gel, dee cycle battery. ELECTRIC START MODELS BATTERY INSTALLATION n Mount the battery into the rovided battery holder. Secure in lace by alying a gentle ressure with the battery holder clam nuts. n Making sure the start key is in the off osition, attach the red battery cable to the ositive (+) terminal of the battery. Then attach the black cable to the negative (-) terminal of the battery. n The engine will recharge your battery during normal oerating eriods. Should your battery need additional recharging due to lack of use, a regulated battery charger may be used. If this is necessary, disconnect the battery cables before connecting the charger. Ensure you connect the ositive and negative leads to the corresonding terminals at all times. Reversal of leads may cause damage to your equiment. Welding Leads (250am) Heavy Duty 4 Wheel Trolley Kit Earth Leakage & Weather Proof Outlets Lifting Eye 2 Wheel Trolley Kit (4 Wheel Kit Available) Battery For Electric Start Models Earth Stake Containment Tray 4

5 PETROL ENGINE STARTING OPERATION 1 Fill crankcase with oil as nominated in engine manual. - Place your generator on level ground. - Remove lug or distick - Fill crankcase slowly to the oint of overflowing or correct level on distick. Relace lug or distick securely. 2 Pull engine over several times to ensure there has been no damage during transit. 3 Switch off electrical ower outlets. 4 Turn fuel valve ON. 5 Close choke - ush lever in direction of arrow. It is normal to use the choke when starting the generator from cold. 6 DO NOT ADJUST THROTTLE SETTING. It has been factory set and locked at the correct seed. 7 Set the ON/OFF switch to the ON osition. 8 RECOIL/ROPE START - Pull the starter handle until slight resistance is felt, then ull briskly. Allow roe to recoil slowly. ELECTRIC START - Press start button or turn key to start. Do not oerate starter for more than about 10 seconds at a time. Allow 60 seconds rest after 2 starting attemts. 9 When engine starts, rogressively OPEN THE CHOKE until engine runs smoothly. 10 Allow engine to warm u for about 3 minutes before alying high loadings to your welder. 11 If engine fails to start after several attemts, fuel flooding may have occurred. Oen the choke, try starting engine several times, then reeat starting rocedure. TO STOP ENGINE - Move start/sto switch or key to off osition DIESEL ENGINE STARTING OPERATION 1 Fill crankcase with oil as nominated in engine manual. - Place your generator on level ground. - Remove lug or distick - Fill crankcase slowly to the oint of overflowing or correct level on distick. Relace lug or distick securely. 2 Pull engine over several times to ensure there has been no damage during transit. 3 Set decomression lever if fitted 4 Turn fuel valve ON. 5 Set seed control to start setting, 50% (refer engine owner s manual) 6 Set the ON/OFF switch to the ON osition. 7 RECOIL/ROPE START - Pull the starter handle until slight resistance is felt, then ull briskly. Allow roe to recoil slowly. ELECTRIC START - Press start button or turn key to start. Do not oerate starter for more than about 10 seconds at a time. Allow 60 seconds rest after 2 starting attemts 8 Run engine at idle seed for 3 minutes to allow it to warm u. 9 Set seed control to run osition (Max) before alying load. (refer engine owner s manual) TO STOP ENGINE - Turn fuel valve to off osition, then turn ignition key to off osition. 5

6 n Each Authorised Service Centre is equied with secial service tools and trained mechanics to ensure exert service or reair on all engines Welder Alternator Trouble Shooting Guide Problems Causes Remedies Engine will not start 1) no/low fuel 2) fuel valve is closed 3) Start/sto switch is on start osition 4) Insufficient oil level 5) Faulty low oil sender Fill fuel tank Oen fuel valve Set to start osition Add oil to the correct level See authorised reair agent Generator excitation failure. High no-load voltage. Low no-load voltage. Correct no-load, but low loaded voltage. Correct no-load, but high loaded voltage. Unstable voltage. Noisy Generator. ENGINE & ALTERNATOR SERVICE IF ENGINE SERVICE OR REPAIR IS NEEDED, CONTACT AN AUTHORISED ENGINE SERVICE CENTRE. TO SERVE YOU PROMPTLY AND EFFICIENTLY, THE SERVICE CENTRE WILL NEED THE MODEL, TYPE AND ESPECIALLY THE SERIAL NUMBER OF YOUR ENGINE. COMPLY WITH ENGINE OWNERS MANUAL WHERE IT SPECIFIES MORE FREQUENT SERVICING Carry out servicing at indicated month or oerating hours, whichever occurs first. Daily 1) Low seed. 2) Faulty condenser. 3) Faulty windings. 1) Seed too high. 2) Condenser with high caacity. 1) Seed too low. 2) Faulty rotary diodes. 3) Breakdown in windings. 4) Condenser with low caacity. 1) Low loaded seed. 2) Load too large. 3) Condenser with low caacity. Check and adjust to factory Check and relace. Check windings resistance. Check and adjust RPM. Check and relace. Check and adjust RPM. Check and relace. Check windings resistance. Check and relace. Check and adjust RPM. Check and change. Check and relace. 1) High loaded seed. Check and adjust RPM. 1) Loose contacts. 2) Uneven rotation. 1) Damaged bearings. 2) Poor engine-alternator couling. n Major engine reairs should not be attemted without the roer tools and a thorough knowledge of engine reair rocedures. First month or first 20 hours Every 3 months or 40 hrs Check connections. Check for uniform RPM. Relace. Check and adjust. Every 6 months or 100 hrs Every year or 300 hrs Engine oil Insect Change Change Air cleaner element Insect Clean (1) Fuel filter cleaning Clean Sark lug maintenance (etrol engines) YES Taet clearance adjustment (if alicable) YES Combustion chamber cleaning YES Fuel tank cleaning YES Sark arrester (if alicable) Clean every 100 oerating hours. Fuel line Relace every 3 years. Alternator exciter brushes (if alicable) Insect Battery fluid - Electric start (if alicable) Insect NOTE: (1) Service more frequently when used in dusty areas. (2) Daily checks to be erformed by the oerator, all eriodic servicing to be carried out by an authorised service agent. 6

7 WELDER SERVICE Your Advanced Power welder is designed to rovide many years of trouble free oeration. All servicing of the welder must be carried out by an Authorised Service Centre. WELDING ENSURE ALL A.C. AUXILIARY AND BATTERY CHARGING CABLES ARE DISCONNECTED COMPLETELY FROM THE TERMINALS ON THE WELDER-GENERATOR BEFORE WELDING. The Selector Knob on the Control Panel allows adjustment of welder amerage to rovide otimum current for each size electrode and tye of job. If the job requires less ams for satisfactory welding, connect the cable to the low terminal and then adjust the Selector Knob to rovide the correct current. If the job requires more ams, connect the cable to the high terminal and then adjust the Selector Knob to obtain the current required. A thermal overload rotection device is fitted which intervenes in case of overload by cutting off welder outut. After aroximately 1 minute, normal oeration will be automatically restored. Allow your generator/welder to warm u (arox 3 minutes) before you start welding and after any welding allow your generator welder to run (aroximately 1 minute) to cool down before turning it off. WELDING TERMINALS The female terminals on the welder accet the loose sulied male terminals which should be fitted to the ends of the welder cables. The rimary welding cable (connected to the rod holder) must be lugged into one of the welding outlets as marked. These relate to the maximum welding current available from that articular outlet and are designed to corresond with the control setting ranges on the Control Panel. For welding, the EARTH terminal must be connected to the earth cable which at all times must be clamed to the material been welded. DO NOT ATTEMPT TO WELD CONTINUOUSLY. THE THERMAL OVERLOAD PROTECTION DEVICE WILL INTERVENE. IF THIS OCCURS REGULARLY IT MAY CAUSE DAMAGE TO THE UNIT. 1 PHASE A.C. GENERATOR POWER ENSURE THE WELDING CABLES ARE DISCONNECTED COMPLETELY FROM THE TERMINALS ON THE WELDER/GENERATOR BEFORE USING A.C. POWER. Set the Selector Knob to the GEN or (Generator) osition and then lug the aliance cable into the normal A.C. socket rovided. Refer to the settings shown on the Control Panel. DO NOT OPERATE 2 OPTIONS AT ONE TIME. DO NOT REMOVE ANY BATTERY CONNECTIONS WHILE ENGINE IS RUNNING. BATTERY CHARGING (If Fitted) Your welder generator is fitted with a 12 VDC trickle charger. To charge your battery, ensure your welder generator is turned off and connect the battery using aroriate battery leads. Make sure the red lead connects to the ositive (+) terminal of the battery and black to the negative (-). Start your welder generator and your battery is now been charged. Not suitable for batteries above 100 am hour. NOTE, outut is not regulated and connection of small batteries for long eriods of time may cause damage to the battery. 7

8 OPERATOR SAFETY A welder generator set must not be transorted with any fuel in the fuel tank or carburetor in any vehicle. Fumes are a health hazard and there is always the danger of fire. NOTE: ALL NUTS AND BOLTS SHOULD BE CHECKED FOR TIGHTNESS ON A REGULAR BASIS. WELD n WORK WELDER GENERATOR FINAL QUALITY INSPECTION MODEL... ALT... SERIAL No... DATE... Engine Alternator / Welder Standard/Weather-roof Outlets Mounting Frame A/V Mounts Namelate Stamed & Fitted Engine to Alternator Assembly Engine/Alternator to Frame Assembly Paint Finish Test Procedure Fuel & Oil Drained Labels Correct & Secure All Bolts Tensioned Nyloc Nuts Correctly Fitted All Documents Included Electrical Connections Battery Charge & Fuse Protection Signed:... This certificate to be comleted and signed by the erson resonsible for the final test and insection rocedure and acked with the comleted generator set. M+H Power Systems Pty Ltd 10 Williamson Road, Ingleburn, NSW 2565 T: F: E: ortables@mower.com.au ABN APOGwnw-500E 9-11