CIGWELD 636804 Quick guide

DOC No: EDW0005 Date: 16-July-97
Issue No: 2
ENGINE DRIVEN WELDER
GENERATING SET
MPM 12/400 I-KA
(Part Number 636804)

1
GENERAL USE INSTRUCTIONS
Read the instructions carefully; proceed according to the regulations in use in the
country where the machine will operate.
TRANSPORTATION
Y The machine must be fixed securely to the motor vehicle if it has to be moved to the
place of use. Raise the machine using the lifting eye if the model provides it;
otherwise, lift it using a forklift, taking care that the weight is well balanced on the
two forks. Keep well clear during these operations; furthermore, we suggest not to
keep the machine suspended for long.
Y If the machine is mounted on a wheels trolley or trailer, be sure the machine is stable
and secure before use.
CAUTION
Y Note: The generating set or the welder is furnished WITHOUT lubricating oil.
Provide the machine with "10 W 40" multi-grade oil indicated for temperatures
from - 20°C to 40° C in the quantity indicated in the engine SPECIFICATION
section.
Y Note: If the machine is fitted with a water cooled engine fill the radiator circuit with a
solution made up by 50% water and 50% antifreeze liquid in the quantity indicated in
the engine SPECIFICATION section.
Y Note: The generating set is furnished with a flat battery and without acid. Fill it using
sulphuric acid in a 30% - 40% concentrated solution to cover the elements. During
this operation, we suggest the operator use protective gloves and goggles; accidental
skin contact with the sulphuric acid solution must be washed up immediately with
cold water and, if necessary, a doctor must be consulted.
Y Note: Do not disconnect battery cables when the engine runs. This could result in
serious damage to the machine.
Y Note: BEFORE OPERATING THE MACHINE the neutral, or the equivalent
winding point, MUST be connected effectively to earth using an earth stake (without
any switch or other device that may interrupt the electrical connection) from the earth
stud available on the machine, and identified by the symbol:
Y
Y Note: for normal transportation, follow the instructions as specified in the
TRANSPORTATION section.

2
RUNNING IN
For the first 50 hours of operation of the machine do not employ more than 70% of the
maximum power indicated in the technical specifications.
STARTING AND WORKING
1- Make the earth connection (see the USE INSTRUCTIONS).
2- If the machine model IS NOT equipped with a earth leakage circuit breaker the
available socket is intended ONLY for connecting the machine to a switchboard
equipped with all protection devices imposed by current law regulations.
3- Check the state and efficiency of the cables.
4- Make sure that all the switches and electric connections are in the right position for
starting (see USE INSTRUCTIONS and CONTROL PANEL DESCRIPTIONS).
5- Use the machine in well ventilated places, taking care that the exhaust gas and the
welding fumes produced (where welders are used) do not stagnate. Keep the machine
away from walls or other obstacles in order to avoid air or gas recycling. If the
machine is employed in closed places, use forced ventilation in order to ensure proper
air recycling.
6- While welding, eyes and body must be protected by gloves, mask and appropriate
clothes.
7- Fuel refill must not be made while smoking or close to flames. This operation must
be done when the engine is switched off.
8- Do not over fill the tank and clean up any spillage.
9- Check daily for loss of fuel or lubricating oil.
10-For machines provided with a liftable canopy engage the canopy securing brackets
where fitted.
WARNING
Y Do not connect the machine to the commercial electric network.
Y Do not work close to flammable materials or where there is explosive gas or vapours.
Y Do not work in confined or poorly ventilated places.
Y Do not touch the exhaust muffler or adjacent components.
Y Do not carry out service operations while the engine is running.
Y Any service on the electrical circuit must be done when the engine is stopped and only
by qualified technicians.
Y Keep clear of moving parts of the engine while it is operating and do not approach the
machine with loose fitting clothing.
SERVICE AND CLEANING
We suggest frequent cleaning of the machine since the presence of dirt can compromise
efficiency.
The frequency of this operation depends on the environment in which the machine is
used. We advise to pay special care to the service of::
OIL LEVEL, OIL FILTER, AIR FILTER, FUEL FILTER, COOLING LIQUID
LEVEL, RADIATOR, VENTILATION DUCTS AND INTAKES, BATTERY
ENGINE USE AND SERVICE manual and the SPECIFICATION section to know
how and when it is useful to do it. The extraordinary service operations not mentioned
herein require the aid of specialised technicians (see the Engine Dealers list).

3
For service intervals consult the ENGINE USE AND SERVICE manual and the
SPECIFICATION.
ADJUSTMENTS AND REGULATIONS
All necessary controls are located on the main control panel and are properly explained
in the section FRONT PANEL DESCRIPTION.
We advise the operator against tampering with the engine or the internal electrical
components.
Note: Modification of the normal parameters can compromise the reliability of the
machine.
PROLONGED STANDING PERIODS
If the machine has to be stopped for a long period (more than one year), we suggest to
leave the motor oil and the fuel in and the water in the radiator in order to avoid
oxidising effects.
When the machine is to be used, the liquids must be replaced, the battery must be
charged; the belts, pipes and rubber hoses must be checked and a visual inspection of the
electrical connections must be done.
SCRAPPING
In order to preserve the environment, it is advised to dispose of the oil, fuel and battery
in an approved manner. For the complete range of materials, see the list below:
FERROUS and NON-FERROUS MATERIALS:
steel, cast iron, aluminium, copper, brass are used in the structure of engine,
alternator, transformers, etc.
PLASTIC MATERIALS:
rubber, bakalite, epovit, lexan are used for the instruments, engine pipes,
junction boxes and connectors, fuel tank, fuel cap, wheels, anti-vibration
dampers, condenser housings, fans, belts, filters and hoses.
ELECTRONIC MATERIALS:
various components, diodes, resistors, electronic panels.
VARIOUS MATERIALS:
rock wool, sound proofing materials.
LIQUIDS:
fuel, gasoline, cooling liquids, battery acid.

POWER PLANT INFORMATION
MPM 12/400 I-KADescription
636804Part number
WELDING GENERATOR D.C.
18V to 40VCV mode
30A to 400ACC mode
IP 23Mechanical protection
FInsulation class
70VDC open circuit voltage
5 minutesDuty cycle period
30A to 400ARange of continuous control
350A @ 34VRated output at 60% duty cycle
400A @ 36VMaximum power
AUXILIARY GENERATOR
50 HzFrequency
10kVA @ 230VSingle phase power
12kVA @ 400VThree phase power
AsynchronousGenerator type
RECOMMENDED MANUAL METAL ARC WELDING ELECTRODE
6.0mmIron powder
6.0mmCellulose
6.0mmGeneral purpose & low hydrogen
Maximum Electrode DiameterElectrode Description
4
TECHNICAL SPECIFICATION

ENGINE
15 hoursAverage operating hours
275 gram/kW/hourAverage fuel consumption
77 dBAcoustic pressure @ 4 metre
89 dBAcoustic pressure @ 1 metre
97 dB(A)Acoustic energy emission
12V - 43 AhBattery
ElectricStarter
5.1 LitresOil capacity
36.5 LitresFuel tank capacity
WaterCooling
3000 rpmEngine speed
25 HPDiesel engine output
1124 cc.Displacement
3Number of cylinders
Kubota D 1105-EMake/Type
DIMENSIONS AND WEIGHT
460 KgWeight
1590mm x 730mm x 920 mmDimensions (Length x Width x Height)
5

The engine is warranted for twelve (12) months from date of purchase or one thousand (1000) hours
which ever is sooner. This warranty is limited to the replacement or repair, at Tutts workshop of any
parts proven defective, under normal use and service within the warranty period. For warranty
service outside a Tutts workshop, all travelling time and mileage incurred, will of necessity, be
charged to the owner of the equipment who ordered the off site warranty repair(s).
New engine warranty does not apply to maintenance items such as filters, hoses, belts, preheaters,
injection nozzles, packing and seals, etc.
To secure warranty for the engine ensure that the warranty certificate is fill in and mailed to the Tutts
state branch office (KUBOTAs Australian engine distributor).
1.2 ENGINE WARRANTY
Carefully follow the KUBOTA engine operation manual for safe operation and long service life of
this product.
1.1 INTRODUCTION
Tutts Branch Network Tutts (Sydney): 2 South St. Rydalmere NSW 2116
Tutts (Perth): 50 Great Eastern Hwy South Guildford WA 6055
Tutts (Brisbane): 39 Suscatand St Rocklea QLD 4106
Tutts (Melbourne): Gwelo St Tottenham VIC 3012
Tutts Dealer Network
Queensland: Andrew's Agricultural Centre Pty Ltd - Goranvale, Cairns Ph: [phone]
- Innisfail Ph: (070 616466
- Tully Ph: [phone]
Fishabout Pty Ltd - Mackay Ph: [phone]
Dore Power Equipment Pty Ltd - Roma Ph: [phone]
New South Wales: SJ & ML Foster - Moree Ph: [phone]
Clares Diesel Service Pty Ltd - Coffs Harbour Ph: [phone]
Kentan Pty Ltd - Hexham, Newcastle Ph: [phone]
Tasmania: Diesel & Marine Pty Ltd - Newtown, Hobart Ph: [phone]
South Australia: Mac Pac Sales & Service Pty Ltd - Wingfield, Adelaide Ph: [phone]
1.3 SPARE PARTS
KUBOTA engine:Contact Tutts (in Australia) for spare parts and service assistance. Specify the
engine model number, serial number, name of part (with code number), Engine
Driven Welder model name (with code number) and manufacturers name when you
contact your KUBOTA Dealer. KUBOTA guarantees an efficient technical support
throughout Australia and New Zealand.
Generator and equipment: Contact your local CIGWELD Distributor for spare parts. Specify the
Engine Driven Welders model number, serial number and name of part
(with code number) when ordering spare parts. Refer to the Spare Parts
List from page 13.
6
ENGINE WARRANTY
AND SPARE PARTS

7
FRONT PANEL DESCRIPTIONS
Welding socket : positive connection
W
Remote control switch
N
Welding socket : negative connection
for CC-WORK
Y
Welding current control
M
Welding socket : negative connection
for CV-WORK
X
CC/CV mode select
L
Earth connection
Z
Throttle switch
I
Serial number
V
Fuel meter
H
ELCB (25A earth fault protection)
U
Glow plug lamp
G
16A single phase circuit breaker
T
Oil pressure lamp
F
400V three phase outlet
S
Battery charge lamp
E
230V single phase outlet
R
Water temperature lamp
D
Wire feeder connector 14 pin
Q
Hourmeter
C
Basic / Cellulose switch
P
Single phase voltmeter
B
Arc force regulator
O
Ignition key
A

1.1 EQUIPMENT
GROUNDING CONNECTION
^ This machine has auxiliary power capability and grounding of the frame and case is
recommended. Refer to your local Supply Authority or Australian Standard AS3000 for
detailed earthing instructions. Connect the earth wire to the Earth connection located
on the front of the machine.
2.1 EARTH FAULT PROTECTION
^ Supply Authorities recommend that protection devices immediately disconnect all power
in the event of an earthing fault. This equipment is fitted with a Earth Leakage Circuit
Breaker (ELCB) that interrupts the auxiliary power circuit within 0.2 seconds when the
earth leakage is greater than 30 mA.
^ If a fault occurs in equipment connected to the auxiliary power supply, the outer casing
may become live and result in serious injury. The Engine Driven Welder must be
properly earthed. Refer to your local Supply Authority or Australian Standard AS3000
for detailed earthing instructions. The user is responsible for connecting this Engine
Driven Welder to earth.
3.1 USE AND TESTING OF EARTH FAULT PROTECTION
^
Switch the ELCB lever up to setting I (ON). Test by pressing the test button while the
engine is running. This will result in the ELCB tripping resulting the lever returning to
setting 0 (OFF). Reset to setting I (ON).
^ If the ELCB trips repeatedly while operating auxiliary equipment, have the equipment
tested by a qualified electrical tradesperson.
8
OPERATING INSTRUCTIONS

4.1 STARTING ENGINE
^ Check that engines fuel tank has been filled with diesel and the sump has been filled with
lubricating oil as specified in the Engine Manual.
^ Position the ignition key on the first step for preliminary heating of the glow plugs, the
glow plug light illuminates. When glow plug light turns off, start the engine by moving
key completely clockwise.
^ After starting the engine, allow it to warm up by waiting 10s minute before loading the
Engine Driven Welder.
^ Do not move the throttle control lever.
5.1 USE OF ENGINE DRIVEN WELDER AS A WELDER
^ Insert welding cable plugs into relevant sockets.
^ Set the current/voltage control knob on the front panel to the desired value on the
Engine Driven Welder. Take care that the REMOTE CONTROL switch is in 0 (OFF)
position.
^ Set the Arc Force control to I(ON) or 0(OFF) position.
^ Remote current control can be achieved by using a remote control device.
^ When operating with remote control switch the remote switch control to position I
(ON) and connect the cable of the remote control unit to the 14 pin remote control
socket.
^ Connected the Electrode Lead to the positive terminal and the work lead to the
negative terminal.
Note: Stick electrodes are generally connected to the positive terminal but if in doubt
consult the electrode manufactures literature.
^ In standby mode, ie not welding or supplying power to auxiliary outlets, the engine idles
at approximately 2000 rpm.
^ When an arc is struck or the unit is supplying power to auxiliary outlets then the engines
speed increases to approximately 3000 rpm. The returns to idle speed approximately 25
seconds after welding has ceased.
9

6.1 CONSTANT CURRENT (CC) MODE
^ Set the CC/CV mode switch to the mode CC position.
^ If using a remote control pendant, plug remote pendant into the 14 pin remote control
socket and set the REMOTE CONTROL switch to the REMOTE position. Set the
REMOTE CONTROL switch to the PANEL position if a remote pendant is not used.
Note: When a remote control pendant is fitted (see 'Q' on page 7), the Welding
current/voltage control is switched out of the circuit and remote control pendant
has full control over the welding current.
^ For MMAW (stick) welding connected the Electrode Lead to the positive terminal (see
'W' on page 7) and the work lead to the negative terminal (see 'Y' on page 7).
Note: Stick electrodes are generally connected to the positive terminal but if in doubt
consult the electrode manufactures literature.
^ For GTAW (TIG) welding connected the Electrode Lead to the negative terminal (see
'Y' on page 7) and the work lead to the positive terminal (see 'W' on page 7).
7.1 CONSTANT VOLTAGE (CV) MODE
^ Set the CC/CV mode switch to the mode CV position.
^ Connect wire feeder cable to 14 pin remote control socket.
^ If a remote control pendant is plugged into the remote control socket of the wirefeeder
then set the REMOTE CONTROL switch to the REMOTE position. Set the REMOTE
CONTROL switch to the PANEL position if a remote pendant is not used.
Note: When a remote control pendant is fitted (see 'Q' on page 7), the Welding
current/voltage control is switched out of the circuit and remote control pendant
has full control over the welding voltage.
^ For GMAW (MIG) welding connected the Electrode Lead to the positive terminal (see
'W' on page 7) and the work lead to the negative terminal (see 'X' on page 7).
10

8.1 USE OF ENGINE DRIVEN WELDER AS A GENERATING SET
^ Start the engine ass described in section 4.1
^ Switch the ELCB lever up to setting I (ON). Switch the single phase 16A CB lever up
to setting I (ON).
^ The single phase voltmeter (see 'I' on page 7) reads approximately 170V when the
engine is at idle speed.
^ In standby mode, ie not welding or supplying power to auxiliary outlets, the engine idles
at approximately 2000 rpm.
^ When an arc is struck or the unit is supplying power to auxiliary outlets then the engines
speed increases to approximately 3000 rpm. The returns to idle speed approximately 25
seconds after the auxiliary equipment is disconnected from the auxiliary outlets.
9.1 STOPPING ENGINE
^ Disconnect any load from the auxiliary outlets and the welding terminals of the Engine
Driven Welder.
^ Wait approximately 1 minute then turn the ignition key to the 0position and the motor
will stop.
11

10.1 ENGINE PROTECTION
^ The DAS Engine Protection Device checks for low oil pressure, no battery charge, high
water temperature and low fuel level conditions when the Engine Driven Welder is in
operation.
^ When a low oil pressure, no battery charge, high water temperature or low fuel level
condition occurs the DAS stops the engine and illuminates the corresponding lamp on
the control (expect for the low fuel level condition). When the faulty condition has been
removed the engine can be re-started.
^ Note that if the low oil pressure, no battery charge, high water temperature or low fuel
level condition is still present when after the engine is re-started then the DAS Engine
Protection Device will stop the engine after approximately one minute has elapsed.
11.1 WARNING
^ In order to preserve the engine performance CIGWELD strongly recommends that the
maintenance schedule is adhered to as specified in the engine manufacturer "Use and
maintenance" user manual. Poor maintenance could result in a shorter operating life,
decreased performance and loss of engine warranty.
^ DO NOT disconnect the battery from the Engine Driven Welder when the engine is
running as this action will cause the alternator regulator to fail.
12

13
MPM 12/400 I-KA
(Part Number 636804)

14
MPM 12/400 I-KA
(Part Number 636804)

SPARE PARTS LIST MPM 12/400 I-KA (Part Number 636804)
Front and coverOGS1870831
Right plate rectifierOGS1887330
Left plate rectifierOGS1887229
Rectifier assemblyOGS1876028
20x20 shock absorberOGS1724527
Resistor tie rodOGS84626
ShuntOGS1872325
100 Ohm - 75 W resistorOGS1277624
Resistor supportOGS1872423
Bowden supportOGS1831022
8A fuseOGS1228421
Fuse holderOGS58820
Wire for solenoidOGS1267419
Shaft for solenoidOGS1267318
60x60x150 solenoidOGS99117
Solenoid supportOGS1625916
Diode / heatsink assyOGSOO7915
Amperometric relayOGS99314
Electronic panel GS9603/AOGS1857613
PanelOGS1836912
Flex plateOGS1433911
Shaft with rotorOGS1836810
Bearing 100/45/25 2RSOGS9039
CirclipOGSO9058
Fan coverOGS187647
FanOGS101756
Flange with bearing seatOGS186995
Stator tie rodOGS114464
Engine connection flangeOGS184863
Stator protectionOGS185122
StatorOGS194931
DescriptionOrdering
no
Item
no
15

SPARE PARTS LIST MPM 12/400 I-KA (Part Number 636804)
Left hand coverOGS1626562
CoverOGS1626761
Amperometric transformerOGS1340760
12V relayOGSO33659
DAS: automatic stop for engine protectionOGS1650558
Terminal board assemblyOGS1276357
24V ac relayOGS1419756
115V ac relayOGS1437055
1K potentiometerOGS90954
PlateOGS1872853
Potentiometer knobOGS1884452
Grub screwOGS1752151
PinOGS1751950
Oil pressure lampOGS1945849
Glow plug lampOGS1538048
Battery charge lampOGS1026447
Water temperature lampOGS1695946
HourmeterOGS91245
CC/CV switch assemblyOGS91044
Socket for remote control and wire feeder 14 polesOGS1822543
Switch assemblyOGS1216342
Fuel meterOGS1168841
300V F.S. voltmeterOGS32240
230V 15A single phase socketOGS1948239
400V 20A three phase socketOGS1948338
ProtectionOGS1319137
16A circuit breakerOGS63236
ProtectionOGS1393335
25A earth fault protectionOGS83934
Plate for earth fault protectionOGS1005733
Front plateOGS1949832
DenominationOrdering
no
Item
no
16

SPARE PARTS LIST MPM 12/400 I-KA (Part Number 636804)
Tie rodOGS94893
Battery clampOGS1172692
Negative battery charging clipOGS1424891
Positive battery charging clipOGS1424790
43Ah 12V BatteryOGS42589
Fuel level gaugeOGS1561388
Fuel drain capOGSO92387
Fuel prefilterOGS1627286
Fuel filter capOGS1627185
Fuel tankOGS1524684
Air filter supportOGS1949983
Fuel prefilterOGS1646882
50x50 shock absorberOGS92781
Stator bracketOGS1842780
PanelOGS1837079
InsulatorOGS1170778
1" ¼ gas rubber wire holderOGS1026777
Plate for canopyOGS1552676
60kg gas spring filterOGS1162175
WasherOGS1253274
Tie rodOGS1253173
PinOGS1141072
Plate for capacitorsOGS1693471
Plate for capacitorOGS1689670
3x60µF capacitorOGS1694069
Plug for welding outletOGS88668
Welding outletOGS83667
PlateOGS1886966
ReactorOGS1278665
FrameOGS1725564
Right hand coverOGS1626663
DenominationOrdering
no
Item
no
17

SPARE PARTS LIST MPM 12/400 I-KA (Part Number 636804)
Locking hook (opened front cover)OGS12528124
PlateOGS12527123
SpringOGS12526122
Locking hook (closed front cover)OGS12529121
Instrument front coverOGS16279120
Pivot shaftOGSO881119
CanopyOGS16278118
Steel cableOGS16119117
HookOGS19494116
Panel support hookOGS19495115
Right plate for hookOGS19497114
Left plate for hookOGS19496113
Engine stator protectionOGS18425112
PanelOGS18870111
PlateOGS18871110
Filter supportOGS18618109
Clip for pipeOGS12728108
M14 screwOGSO872107
WasherOGSO873106
ScrewOGS18309105
Oil drain pipeOGS14775104
3/8" capOGS11817103
Right engine support bracketOGS18303102
Left engine support bracketOGS18302101
Engine supportOGS17749100
50x35 shock absorberOGS1349399
Dia. 16 rubber wire holderOGS1131298
Rubber pufferOGS1430097
Silencer extensionOGS1830896
SilencerOGS1619195
Battery coverOGS1619094
DenominationOrdering
no
Item
no
18

SPARE PARTS LIST MPM 12/400 I-KA (Part Number 636804)
WheelOGS10538132
AxleOGS15247131
BraceOGSO924130
Adjustable clampOGSO548129
Jog wheelOGS949128
RubberOGSOO90127
Frame locking hookOGS10530126
Air grateOGS16280125
DenominationOrdering
no
Item
no
19