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Red-D-Arc ZR-8 Operator's Manual

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IM928
RED-D-ARC
January, 2007
ZR-8
11399
For use with machines having Code Numbers:
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder is designed and built with safety in mind.
However, your overall safety can be increased by proper installation
... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America's Largest Fleet of Welding Equipment

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Summary of Contents for Red-D-Arc ZR-8

  • Page 1 For use with machines having Code Numbers: OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind.

  • Page 2: California Proposition 65 Warnings

    SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY CYLINDER may explode WELDING and CUTTING SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 6 for selecting a QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment.

  • Page 7: Table Of Contents

    Connection of Tig Module .....................A-5 Additional Safety Precautions,Welding Operation Output..........A-5 Auxiliary Power Receptacles, and Plugs ................A-6 Motor Starting and Extension Cord Length Table ..............A-6 Electrical Device Used with the ZR-8 ...................A-7 Auxiliary Power While Welding, Standby Power Connections ..........A-8 Premises Wiring ........................A-9 ________________________________________________________________________________ Operation.........................Section B...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS ZR-8 (K2392-2) INPUT - GASOLINE ENGINE Description Operating Displacement Capacities Make/Model Starting Horsepower Speed (RPM) cu. in. System (cu.cm.) 2 cylinder High Idle 3700 12VDC 4 Cycle Battery Air-Cooled Fuel: Electric Start Gasoline 23 HP @ 9 Gal (34 L)

  • Page 9: Safety Precautions

    Do not ground the machine to a pipe that carries equipment and likely additional attachments. explosive or combustible material. ------------------------------------------------------------------------ 2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework. ZR-8...

  • Page 10: Vehicle Mounting

    ZR-8 base. VEHICLE MOUNTING WARNING The ZR-8 is shipped with the engine crankcase filled Improperly mounted concentrated loads may with SAE 10W-30 oil. Check the oil level before start- cause unstable vehicle handling and tires or other ing the engine.

  • Page 11: Angle Of Operation

    ------------------------------------------------------------------------------- full tank of gasoline. A lift bail is mounted to the The ZR-8 is shipped with the exhaust coming out on the left machine and should always be used when lifting the side. The exhaust can be changed to the opposite side by machine.

  • Page 12: Location And Ventilation

    60% duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period. Duty CONNECTION OF THE LN-25 TO THE ZR-8 Cycle for the ZR-8 is 100%. • Shut the welder off. • Connect the electrode cable from the LN-25 to ZR-8 the“ELECTRODE”...
  • Page 13 INSTALLATION AUXILIARY POWER The ZR-8 can provide up to 9,000 watts of 120/240 volts AC, single phase 60Hz power for continuous use, and up to 10,500 watts of 120/240 volts AC, sin- gle phase 60Hz power peak use. The front of the machine includes three receptacles for connecting the AC power plugs;...

  • Page 14: Electrical Device Used With The

    INSTALLATION TABLE lll ELECTRICAL DEVICE USE WITH THE ZR-8. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electrical control.
  • Page 15 Also, the “Output Control” is set at “10” for maximum auxiliary power. 2. Take necessary steps to assure load is limited to the capacity of the ZR-8 by installing a 38 amp 240V double pole circuit breaker. Maximum rated TABLE I load for the 240V auxiliary is 38 amperes.

  • Page 16: Premises Wiring

    NOTE: No. 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. WARNING Connection of ZR-8 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. ZR-8...

  • Page 17: Operation

    When the electrode touches the work, the welding GENERAL DESCRIPTION arc is initiated and the engine accelerates to full The ZR-8 is a twin-cylinder, gasoline driven, multi- speed. process arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job After welding ceases (and no auxiliary power is site.

  • Page 18: Zr-8 Approximate Fuel Consumption

    Provides three selectable welding polarities: AC, DC+ & DC- CAUTION Never change the Polarity switch setting while welding. This will damage the switch. ------------------------------------------------------------------------ ZR-8 APPROXIMATE FUEL CONSUMPTION KOHLER 23 H.P. COMMAND Low Idle - No Load .4 Gallons/Hour 2200 RPM (1.5 Liters/Hour)

  • Page 19: Starting/Shutdown Instructions

    “OFF” position. clothing. A fuel shut off valve is not required on the ZR-8 because the fuel tank is mounted below the engine. • Keep flammable material away. BREAK-IN PERIOD • Insulate yourself from work and ground.

  • Page 20: Welding Process

    .030” and .035” L-50 and L-56. They must be used with a blended shielding gas such as The ZR-8 can be used with a broad range of AC and C25 (75% Argon - 25% CO ). The welding ranges that DC stick electrodes.

  • Page 21: Summary Of Welding Processes

    START SWITCH WIRE FEED, LN-15 Auto Cold Press gun trigger. ACROSS the ARC LN-15 contactor closes, (has internal contactor) Welding starts immediately and engine goes to High Idle. Note: Output Control must be set above “3”. ZR-8...

  • Page 22: Accessories

    K1788-1 ROLL CAGE - Gives added damage protection. Start Switch) is pressed. Attaches to K1737-1, K1770-1, and K957-1. K936-4 CONTROL CABLE - Connects TIG Module to ZR-8. K886-1 CANVAS COVER -To protect the ZR-8 when not in use. Made from attractive red canvas material...

  • Page 23: Recommended Equipment

    PRO TORCH ® TIG Torch K1783-9 PTA Torch Magnum Parts Kit and Argon Gas K930-2 TIG Module Requires K938-1 Contactor Kit, K936-4 Control Cable, and K814 Arc Start Switch Optional TIG Equipment: K939-1 Docking Kit K937-45 Control Cable Extensions ZR-8...
  • Page 24 At the end of each day’s use, refill the fuel tank to minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated. ZR-8...
  • Page 25 Reinstall the oil filler cap. 6. Start the engine and check for oil filter leaks. 7. Stop the engine, and check the oil level. If neces- sary, add oil to the upper limit mark on the dipstick. ZR-8...

  • Page 26: Maintenance

    Element FRAM CA79 Air Filter KOHLER 24 083 02 Pre-Cleaner Fuel Filter KOHLER 24 050 10 Spark Plugs CHAMPION RC12YC (Resistor (.030” GAP) Type) (.76mm) * Oil capacity increases from 2.0 - 2.1Qts.(1.9 - 2.0Ltrs.) when using this filter. ZR-8...

  • Page 27: Troubleshooting

    CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. ZR-8...
  • Page 28 Faulty P.C. Board. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. ZR-8...
  • Page 29 Spark plugs are fouled. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. ZR-8...
  • Page 30 WIRING DIAGRAM ZR-8...
  • Page 31 DIAGRAMS ZR-8...

  • Page 32: Dimension Print

    DIMENSION PRINT ZR-8...
  • Page 33 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 34 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • Page 35 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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