EWM Trolly 55-6 DF User manual

Operating instructions
EN
Transport systems
Trolly 55-6
Trolly 55-6 DF
099-008825-EW501
Observe additional system documents!
12.02.2019

General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No
other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed
accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods
are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this
reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect
installation, improper operation or incorrect usage and maintenance or any actions connected to this in
any way.
© EWM AG
Dr. Günter-Henle-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [email protected]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 Part of the complete documentation..............................................................................................6
3Intended use...........................................................................................................................................7
3.1 Applications....................................................................................................................................7
3.2 Use and operation solely with the following machines..................................................................7
4Machine description –quick overview ................................................................................................8
4.1 Front view / side view from the right..............................................................................................8
5Design and function...............................................................................................................................9
5.1 System overview............................................................................................................................9
5.2 Installing power source or cooling module ..................................................................................11
5.3 Transport and installation ............................................................................................................13
5.3.1 Craning principle...........................................................................................................14
5.3.2 Intermediate hose package strain relief.......................................................................14
5.3.2.1 Locking the strain relief.................................................................................14
5.4 Functional characteristics............................................................................................................15
5.4.1 Securing the shielding gas cylinder..............................................................................15
5.4.2 Using the transport system...........................................................................................16
6Maintenance, care and disposal.........................................................................................................17
6.1 General........................................................................................................................................17
6.1.1 Cleaning .......................................................................................................................17
6.1.2 Dirt filter........................................................................................................................17
6.2 Maintenance work, intervals........................................................................................................18
6.2.1 Daily maintenance tasks ..............................................................................................18
6.2.2 Monthly maintenance tasks..........................................................................................18
6.2.3 Annual test (inspection and testing during operation)..................................................18
6.3 Disposing of equipment ...............................................................................................................19
7Technical data ......................................................................................................................................20
7.1 Trolly 55-6 / Trolly 55-6 DF..........................................................................................................20
8Accessories..........................................................................................................................................21
8.1 General accessories....................................................................................................................21
9Appendix...............................................................................................................................................22
9.1 Searching for a dealer .................................................................................................................22

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value –adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green
Output
Signal light lights up in red
Time representation (e.g.: wait 4 s /
actuate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Wire feeder
A.2
Conversion instructions
A.3
Power source
A.4
Cooling unit, voltage converter, tool box etc.
A.5
Trolley
A.6
Welding torch
A.7
Remote control
A.8
Control
A
Complete documentation

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
•Do not improperly modify or convert the equipment!
3.1 Applications
To transport arc welding systems and process-dependent components such as shielding gas cylinders.
3.2 Use and operation solely with the following machines
•ON Case
•Cool 40, 50
•Microplasma 25, 55, 105
•Picomig 185, 355
•Tetrix 230 DC
•Tetrix 230 AC/DC
•Tetrix 300 DC Comfort 2.0 / Smart 2.0
•Tetrix 300 AC/DC Comfort 2.0 / Smart 2.0
•Phoenix 355 TKM, TKW
•Phoenix 355, 405, 505 TDM
•Taurus 355 TKW, TKM
•Taurus 355, 405, 505 TDM, TDW
For systems equipped with a wire feeder, additional options have to be retro-fitted. See the
system overview for the relevant options and combinations > see 5.1 chapter.

Machine description –quick overview
Front view / side view from the right
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4 Machine description – quick overview
4.1 Front view / side view from the right
Figure 4-1
Item
Symbol
Description 0
1
Hose package holder
2
Hold-down fitting for welding machine
3
Machine mounting attachment
4
Transport wheel
5
Wheels, guide castors
6
Lifting lug > see 5.3.1 chapter
7
Intermediate hose package strain relief > see 5.3.2 chapter
8
Clamping belt
9
Retainer panel for gas cylinder

Design and function
System overview
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5 Design and function
5.1 System overview
Figure 5-1
Item
Symbol
Description 0
1
Transport vehicle - Trolly 55-6 DF

Design and function
Installing power source or cooling module
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Item
Symbol
Description 0
2
Transport vehicle - Trolly 55-6
3
Shielding gas cylinder
4
Shielding gas cylinder
5
Extension of the Trolly's cross arm to accommodate added modules -
ON Extender 092-003507-00000
6
Transport cart - Trolly 55-6 + power source Microplasma + cooling module
7
Transport cart –Trolly 55-6 + power source + ON TC 092-002899-00000
8
Transport vehicles - Trolly 55-6 + Power source + cool
9
Transport vehicles - Trolly 55-6 + Power source
10
transport cart - Trolly 55-6 + power source + cooling module + ON TC 092-
002899-00000
11
ON TR Trolly 55-5
Cross arm and holder for wire feeder - 092-002700-00000
12
ON PS Trolly 55-5 drive 4L/4X
Pivot support –092-002712-00000
13
ON PS Trolly 55-5 drive 200/300C
Pivot support –092-002634-00000
14
Wire feeders - drive 200/300C (pivotable)
15
Wire feeders –drive 4L/4X (rotatable)
16
All wire feeders - drive

Design and function
Installing power source or cooling module
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5.2 Installing power source or cooling module
CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
•Disconnect all supply lines before transport!
The welding machines can be mounted on the transport vehicle with or without cooling unit.
When mounting a machine without cooling unit, the machine hold-down device has to be
mounted in a lower position, however.
Figure 5-2
Item
Symbol
Description 0
1
Holding plate BK210X73X10,5
2
Holding plate BK260X84X9,5
•Unscrew the holding plates from the trolly.
Depending on the power source or cooling module to be installed, different holding plates are
required at the shown positions.
Product
Holding plate
Microplasma 25, 55, 105
2
Picomig 185, 355
2
Tetrix 230, 300
1
Phoenix 355
2
Taurus 355
2
Set Taurus 505 Basic Duo Gouging
2
cool40
1
cool50
2
ON TC 55
2

Design and function
Installing power source or cooling module
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Figure 5-3
Item
Symbol
Description 0
1
Machine feet
2
Machine support
•Place the machine with its feet in the recesses provided.
Figure 5-4
Item
Symbol
Description 0
1
Machine mounting attachment
2
Hexagonal screw M8 x 20
3
Machine support
•Mount the machine mounting attachment with hexagonal screws on the machine support.

Design and function
Transport and installation
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Figure 5-5
Item
Symbol
Description 0
1
Transport bar
2
Allen screw
3
Plain washer
4
Hexagon nut
•Mount transport bar with fastening material and wire feeder machine support.
5.3 Transport and installation
WARNING
Risk of injury when lifting by crane!
When lifting the machine by crane, persons may be severely injured by falling machines
or mount-on components!
•Remove any supply lines and accessories before lifting by crane (e.g. hose package, wire
spool, shielding gas cylinder, toolbox, wire feeder, remote control, etc.)!
•Avoid jerky movements!
•Properly close and lock all casing covers and protective caps before lifting by crane!
•Ensure that the load is distributed evenly! • Use chain hoists and chain slings of the same
length only!
•Stay outside the danger zone underneath the machine!
•Use the correct number of hoisting equipment of the right size in the correct position!
Observe the crane principle > see 5.3.1 chapter!
•Follow the regulations for occupational safety and accident prevention of the respective
country!
CAUTION
Improperly secured equipment!
Equipment, equipment combinations and accessories incorrectly fastened onto
transport systems can tip over during transport and cause injuries!
•Only used the original parts supplied to fasten the equipment.
•Use the systems only for transporting the machines > see 3.2 chapter.
•Check the fixing points before each transport and at regular intervals.

Design and function
Transport and installation
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5.3.1 Craning principle
Figure 5-6
5.3.2 Intermediate hose package strain relief
Missing or incorrectly fitted strain relief!
Connection sockets or connection plugs on the machine, or the intermediate tube package, may
be damaged if the strain relief is missing or incorrectly fitted. The strain relief takes the strain
from cables, plugs and sockets.
5.3.2.1 Locking the strain relief
Figure 5-7
•Insert the end of the hose package through the strain relief of the hose package and lock by turning to
the right.

Design and function
Functional characteristics
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5.4 Functional characteristics
5.4.1 Securing the shielding gas cylinder
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders
can cause serious injuries!
•Observe the instructions from the gas manufacturer and any relevant
regulations concerning the use of compressed air!
•Lift the shielding gas cylinder onto the receptacle of the shielding gas
cylinder and secure with both safety belts provided on the device as
standard! Belts must be tight.
•Do not attach any element to the shielding gas cylinder valve!
•Prevent the shielding gas cylinder from heating up.
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a
fundamental requirement for optimum welding results. In addition, a blocked shielding gas
supply may result in the welding torch being destroyed.
•All shielding gas connections must be gas tight.
Figure 5-8
Item
Symbol
Description 0
1
Clamping belt

Design and function
Functional characteristics
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Item
Symbol
Description 0
2
Tension closure
3
Shielding gas cylinder holder > see 5.4.1 chapter
Carrier plate for the shielding gas cylinder
4
Shielding gas cylinder
•Open the closure of the straps.
•Place shielding gas cylinder on the retainer.
•Secure shielding gas cylinder using straps.
•Fasten straps using the closure.
•Make sure the straps on the cylinder are securely fastened!
5.4.2 Using the transport system
CAUTION
Improperly secured equipment!
Equipment, equipment combinations and accessories incorrectly fastened onto
transport systems can tip over during transport and cause injuries!
•Only used the original parts supplied to fasten the equipment.
•Use the systems only for transporting the machines > see 3.2 chapter.
•Check the fixing points before each transport and at regular intervals.
Figure 5-9

Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1. Switch off machine.
2. Remove the mains plug.
3. Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel. A qualified person is one who, because of his or her training,
knowledge and experience, is able to recognise the dangers that can occur while testing
welding power sources as well as possible subsequent damage, and who is able to
implement the required safety procedures.
Observe the maintenance instructions > see 6.2 chapter.
•In the event that the provisions of one of the below-stated tests are not met, the machine
must not be operated again until it has been repaired and a new test has been carried out!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.1.1 Cleaning
•Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
•Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
•Check the coolant for contaminants and replace, if necessary.
6.1.2 Dirt filter
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume. The dirt
filter must be remove at regular intervals and cleaned by blowing out with compressed air (depending on
the level of soiling).

Maintenance, care and disposal
Maintenance work, intervals
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6.2 Maintenance work, intervals
6.2.1 Daily maintenance tasks
Visual inspection
•Mains supply lead and its strain relief
•Gas cylinder securing elements
•Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
•Gas tubes and their switching equipment (solenoid valve)
•Check that all connections and wearing parts are hand-tight and tighten if necessary.
•Check correct mounting of the wire spool.
•Wheels and their securing elements
•Transport elements (strap, lifting lugs, handle)
•Other, general condition
Functional test
•Operating, message, safety and adjustment devices (Functional test)
•Welding current cables (check that they are fitted correctly and secured)
•Gas tubes and their switching equipment (solenoid valve)
•Gas cylinder securing elements
•Check correct mounting of the wire spool.
•Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
•Remove any spatter.
•Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.2.2 Monthly maintenance tasks
Visual inspection
•Casing damage (front, rear and side walls)
•Wheels and their securing elements
•Transport elements (strap, lifting lugs, handle)
•Check coolant tubes and their connections for impurities
Functional test
•Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
•Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
•Check coolant tubes and their connections for impurities
•Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
6.2.3 Annual test (inspection and testing during operation)
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!

Maintenance, care and disposal
Disposing of equipment
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6.3 Disposing of equipment
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
•Do not dispose of in household waste!
•Observe the local regulations regarding disposal!
•According to European provisions (Directive 2012/19/EU on Waste of Electrical and Electronic
Equipment), used electric and electronic equipment may no longer be placed in unsorted municipal
waste. It must be collected separately. The symbol depicting a waste container on wheels indicates
that the equipment must be collected separately.
This machine has to be disposed of, or recycled, in accordance with the waste separation systems in
use.
•According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG)), used machines are to be placed in a
collection system separate from unsorted municipal waste. The public waste management utilities
(communities) have created collection points at which used equipment from private households can be
disposed of free of charge.
•Information about returning used equipment or about collections can be obtained from the respective
municipal administration office.
•In addition to this, returns are also possible throughout Europe via EWM sales partners.

Technical data
Trolly 55-6 / Trolly 55-6 DF
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7 Technical data
7.1 Trolly 55-6 / Trolly 55-6 DF
Trolly 55-6
Trolly 55-6 DF
Shielding gas cylinder support
(10 l/20 l/50 l)
max. pressure: 300 bar
max. height: 1640 mm (+/-20)
max. diameter: 229 mm (+/-1%)
Dimensions (L x W x H)
1114 x 678 x 1486 mm
43.9 x 26.7 x 58.5 inch
Weight without accessories
approx. 50.4 kg
approx. 50.8 kg
approx. 111.1 lb
approx. 112 lb