Vanguard CPW 125-4-S2-s-s2 Welding System Manuals

Manuals and User Guides for Vanguard CPW 125-4-S2-s-s2 Welding System. We have 1 Vanguard CPW 125-4-S2-s-s2 Welding System manual available for free PDF download: Operation And Maintenance Manual

Vanguard CPW 125-4-S2-s-s2 Operation And Maintenance Manual (545 pages)

Weld-deck welding package

Brand: Vanguard | Category: Welding System | Size: 9 MB

Table of Contents
3
Foreword
6
Literature Information
6
Machine Description
6
Safety
6
Operation
6
Maintenance
7
Maintenance Intervals
7
California Proposition 65
7
Certified Engine Maintenance
7
Safety Section
7
Safety Signs and Labels
7
Do Not Operate (1)
11
Electrical Shock (2)
11
Do Not Weld on the Machine (3)
13
Hot Surface (4)
14
Hot Fluid under Pressure (5)
15
Electrical Shock (6)
16
Volt DC System (7)
17
Drain Air Receiver Daily (11)
21
Do Not Step (12)
22
Maximum Surface Load Capacity (13)
23
Ethyl Ether Cylinder
24
Batteries
25
General Hazard Information
26
Pressure Air and Water
27
Trapped Pressure
27
Fluid Penetration
27
Containing Fluid Spillage
27
Inhalation
28
Exhaust
28
Asbestos Information
28
Dispose of Waste Properly
28
Crushing Prevention and Cutting Prevention
28
Burn Prevention
29
Coolant
29
Oils
29
Batteries
29
Fire Prevention and Explosion Prevention
29
General
29
Battery and Battery Cables
31
Wiring
32
Lines, Tubes and Hoses
32
Ether
33
Fire Extinguisher
33
Fire Safety
33
Fire Extinguisher Location
34
Electrical Cables and Wire-Harnesses
34
Electrical Storm Injury Prevention
34
Before Starting Genset-Engine
34
Genset-Engine Starting
34
Before Operating Equipment
35
Visibility Information
35
Operation
35
Machine Operating Temperature Range
35
Machine Operation
35
Machine Parking
36
Genset Engine Stopping
36
Sound Level Information
36
Sound Level Information for Machines in European Union Countries and in Countries that Adopt the "EU Directives
36
Vibration
36
Guards (Operator Protection)
36
Product Information Section (Cpw-124-4-S2)
37
General Information
37
Equipment Information Section
37
Restrictions to Application and Configuration
40
Identification Information
40
Plate Locations and Film Locations
40
Ce Mark
40
ISO Symbols (Model Usage)
41
Declaration of Conformity
42
Emissions Certification Film
43
Operation Section
44
Mounting and Dismounting
44
Battery Disconnect Switch
45
Operator Controls
46
Emergency Stop
46
Control Panel Illumination Button
47
Genset Stop/Run/Start Switch
47
Rated/Idle Switch
48
Ether Starting Aid
48
Genset Engine Gauges and Indicators
49
Main Supply AC Circuit Breaker
51
Main Supply AC Meters
52
Three Phase Equipment Circuit Breakers and Receptacles
54
60Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Interrupters (GFCI) - Standard Receptacles
55
50Hz Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Feeder Circuit Ground Fault Circuit Interrupters (GFCI) - Optional Receptacles
57
Single Phase Equipment Ground Fault Circuit Interrupters (GFCI)-Connecting to
58
Air Compressor
59
Air Compressor Start/Stop Switch
59
Compressed Air Pressure Gauge
60
Compressed Air Receiver Drain Valve
61
Compressed Air Supply Line Tee
61
Air Receiver Relief Valve
62
Air Compressor and Tank
62
Welder Doghouse Enclosure
63
Before Starting Genset-Engine
64
Welding Deck
64
Welder Doghouse
64
Genset
64
Control/Distribution Center
65
Genset Cold Weather Operation
66
Winter-Fronts
67
Genset-Engine Starting
67
Starting above 0°C (32°F)
67
Cold Weather Starting below 0°C (32°F) with Ether Starting
68
Genset Engine Starting with Jump Start Cables
69
Use of Jump Start Cables
69
Starting Procedure after Extended Shutdown or Oil Change
70
After Starting the Engine
70
AC Power-UP
71
Ground Fault Circuit Interrupters (GFCI) 60 Hz-Test Daily
72
Ground Fault Circuit Interrupters (GFCI) 50 Hz-Test Daily
73
Genset Shutdown
74
Machine Parking
75
Transportation Information
75
Shipping the Carrier-Mounted Weld-Deck
75
Towing the Carrier
75
Maintenance Section
77
Torque Specifications
77
Torques for Standard Fasteners
78
Torques for Metric Fasteners
78
Torques for Vibration Isolator Mounts
79
Maintenance Welding to the Weld-Deck
80
Recommended Service Intervals-Minimum Service
81
Break-In Periods
81
10 Hours or Daily
81
250 Hours or 3 Months
82
500 Hours or 6 Months
82
1000 Hours or Yearly
83
All Other Service Intervals
83
Genset Frequency Configuration-60Hz and 50Hz Modes
83
60Hz Mode
84
50Hz Mode
86
Single Phase Front-Mounted Equipment Receptacles-Installation
89
Engine Lubricating Oil and Filter Change
91
Cooling System: Core - Clean
93
Cooling System: Service
94
Air Cleaner Service
94
Air Compressor
95
Air Compressor Motor Bearings
95
Bottle Rack - Gas Bottle Change
95
Troubleshooting
97
General Information
97
Engine Faults
97
Engine Won't Crank
98
Engine Won't Start
99
Engine will Not Idle
100
Engine will Not Go to Full Speed (Run)
100
Batteries Fail to Charge (Low DC Voltage)
101
24VDC Alternator Overcharging (High DC Voltage)
102
Vac Three Phase Supply Voltage
103
Main Breaker will Not Set
103
Vac Ground Fault Interrupter (Gfci) Circuit Breakers will Not Set
104
Electrical Schematics
105
480VAC, 60 Hz Supply Schematic
105
24VDC Controls Schematic
106
Compressor Faults
107
Appendices: Equipment Modules' Operation and Maintenance Manuals
108
Appendixa - Air Cleaner Service
109
Appendixb - Air Compressor
114
Safety and Operation Precautions
119
Explanation of Safety Instruction Symbols and Decals
120
Introduction
123
Warranty
123
Installation
125
Operation
128
Maintenance
129
Compressor Pilot Valve Differential Pressure Adjustment
132
Compressor Oil Specifications
133
Lubricant
133
Torque Valves
133
Troubleshooting Chart
134
Decal Group
143
Record of Maintenance Service
144
Appendixc - Ac Generator and Voltage Regulator
146
S Afet S y
150
S Tor Age
150
F Igu Re
151
F Ig F U Re
151
O L T a G E R E G U L a T I O N
152
N O Nli O N E a R Load a I Ng
152
O P E Ra E T T Ion
152
S T a R T - up
157
S Hut down Pro C U R E
158
M a I N T E N Ance
158
P Ace H E at E Rs
159
F or
159
T Est Ing
159
S U a L I N S P E C T I O N
159
D I O D E T E S T I Ng
160
S E R V I Ce
160
B E a R I N G R E M O V a L
161
D I Ve End
161
T W O Bear G Units
161
Appendixd - Engine Diagnostic Trouble Codes
175
Appendixe - Engine Digital Display
193
Canopy
234
Foreword
235
Literature Information
235
Machine Description
235
Safety
235
Operation
236
Maintenance
236
Maintenance Intervals
236
Safety Section
236
Safety Signs and Labels
236
Do Not Operate (1)
240
Not a Lifting Device (2)
241
No Clearance (3)
242
Electrical Power Lines (4)
242
General Hazard Information
243
Pressure Air and Water
243
Trapped Pressure
243
Fluid Penetration
244
Containing Fluid Spillage
244
Inhalation
244
Asbestos Information
244
Dispose of Waste Properly
244
Crushing Prevention and Cutting Prevention
245
Oils
245
Fire Prevention and Explosion Prevention
246
General
246
Wiring
246
Lines, Tubes and Hoses
247
Fire Extinguisher
247
Fire Safety
247
Fire Extinguisher Location
248
Electrical Cables and Wire-Harnesses
248
Before Operating Equipment
249
Visibility Information
249
Operation
249
Machine Operating Temperature Range
249
Machine Operation
249
Load Capacities
249
Electrical Power Lines
250
Machine Parking
250
Sound Level Information
250
Sound Level Information for Machines in European Union Countries and in Countries that Adopt the "EU Directives
250
Vibration
250
Guards (Operator Protection)
251
Product Information Section (Slewing Canopy)
252
General Information
252
Equipment Information Section (SLEWING CANOPY)
252
Intended Use
253
Load Capacity
254
Identification Information
255
Plate Locations and Film Locations - Ce Mark
255
Declaration of Conformity
256
Operation Section
257
Before Operation
257
Mounting and Dismounting
257
Daily Inspection
257
Operator Controls
258
Slewing Canopy Controls
259
Machine Parking
260
Ransportation Nformation
260
T8 Slewing Canopy Configure for Transport
260
D6N Slewing Canopy Configure for Transport
262
Towing the Carrier
264
Maintenance and Lubrication Section
264
Lubricant Viscosities
264
General
264
Selecting the Viscosity
264
Lubricant Viscosities for Ambient Temperatures
264
Capacities (Refill)
265
Maintenance Interval Schedule (Mis)
265
Service Intervals
265
Break-In Period
265
When Required
265
Every 10 Service Hours or Daily
265
Every 2000 Service Hours or 1 Year
266
Slewing Drive Maintenance
266
Slewing Drive Bearing - Lubricate
266
Slewing Drive Roller Bearings and Worm Gear - Lubricate
267
Canopy Support Cylinder Pivot Pins - Lubricate
268
Slewing Canopy Pivot Pin - Lubricate
269
Slewing Drive Mounting Bolts Retighten to the Prescribed Torque - Check
270
Appendices: Equipment Modules' Operation and Maintenance Manuals
271
Appendix 1) - Slewing Drive Manual
272
Preface
274
Transport, Handling & Storage
276
Installation
277
Preparation
277
Cleaning
277
Permissible Flatness Deviation
278
Mounting Bolts
279
Install the Slewing Drive
280
Determine Tilting Clearance
282
Maintenance & Safety Checks
283
Mounting Bolts
283
Torsional Clearance
286
Lubrication Instruction
287
Weather Protection
288
Paint Spec
288
Fastener And/Or Coating
289
Grease Spec
290
Rubber Spec
291
Liquid Sealant
292
Thread Lock Liquid
300
Temperature Rating of Overall Drive
300
Limited Warranty
301
Foreword
309
Literature Information
309
Machine Description
309
Safety
309
Operation
311
Maintenance
311
Maintenance Intervals
311
Safety Section
311
Safety Signs and Labels
311
Do Not Operate (1)
313
Pinch Point (2)
314
Electrical Power Lines (3)
315
Load May Rotate (4)
316
Overhead Load (5)
317
Overload (6)
318
General Hazard Information
319
Pressure Air and Water
319
Trapped Pressure
319
Fluid Penetration
320
Containing Fluid Spillage
320
Inhalation
320
Asbestos Information
320
Dispose of Waste Properly
321
Crushing Prevention and Cutting Prevention
321
Oils
321
Fire Prevention and Explosion Prevention
322
General
322
Wiring
322
Lines, Tubes and Hoses
323
Fire Extinguisher
323
Fire Safety
323
Fire Extinguisher Location
324
Electrical Cables and Wire-Harnesses
324
Before Operating Equipment
325
Visibility Information
325
Operation
325
Machine Operating Temperature Range
325
Machine Operation
325
Stability
326
Equipment Lowering with Engine Stopped
327
Electrical Power Lines
327
Sound Level Information
327
Vibration
327
Guards (Operator Protection)
328
Product Information Section (Auto Tie-In Crane)
329
General Information
329
Equipment Information Section (Auto Tie-In Crane)
329
Intended Use
332
Load Capacity
332
Identification Information
335
Plate Locations and Film Locations
335
Operation Section
336
Before Operation
336
Mounting and Dismounting
336
Daily Inspection
336
Operator Controls
338
Auto Tie-In Crane Controls
338
T12 Auto Tie-In Crane Configure for Transport
341
T12 Shack Deck Configure for Transport
342
Towing the Carrier
343
Maintenance and Lubrication Section
343
Viscosities
343
General
343
Maintenance Interval Schedule (Mis)
344
Service Intervals
344
Break-In Period
344
Every 10 Service Hours or Daily
345
Every 500 Service Hours or 6 Months Service
346
Every 1000 Service Hours or Yearly Service
346
Bleeding Air from the Crane Hydraulic System
346
Appendices: Equipment Modules' Operation and Maintenance Manuals
348
Appendix 1) - Crane Owner's Manual
349
1.1 Warnings
355
2.1 Introduction
356
3.1 General Specifications
357
Dimensions
357
Capacity
357
Reach
357
Cable
357
Chassis and Mounting Requirements
357
Hydraulic Requirements
357
Electrical System Requirements
357
Rotation
357
3.2 Hc-12 Nexstar III, General Dimensions
358
3.3 Load Chart
359
Nexstar III Decal Layout, P/N 475000202
360
Qualifications and Operating Practices
361
4.2 Operators
361
4.3 Qualifications for Operators
361
4.4 Conduct of Operators
361
Operating Practices/Handling the Load
362
Operating Near Electrical Power Lines
363
4.7 Preparing the Crane for Operation
364
During Operation
364
After Operation
365
5.1 Nexstar III Operation
366
5.2 General
366
5.2.1 Remote Control Unit
366
5.2.2 Remote Control Initialization
366
5.2.3 Pre-Operation Test
366
5.3 Remote Control Layout
367
5.4 Display Screen Layout
368
5.5 Speed and Mode Selection
369
5.5.1 Speed Selection
369
5.5.2 Mode Selection
369
5.5.3 Mode Description
369
5.6 Operation - Valve Override
370
6.1 Nexstar III Troubleshooting
371
6.1.1 Troubleshooting Flow Chart
371
Nexstar III Remote Control Troubleshooting Table
372
6.1.3 Nexstar III Error Code Table
373
Nexstar III Mechanical Troubleshooting Table
374
Nexstar III Electrical Troubleshooting Table
375
7.1 Maintenance
377
7.1.1 Inspection Requirements
377
7.1.3 Frequent Inspection
377
7.1.4 Periodic Inspection
378
7.1.5 Cranes Not in Regular Use
379
7.1.6 Inspection Records
379
7.2 Testing Requirements
379
7.3 General Repairs and Maintenance
379
7.3.1 Maintenance Precautions
379
7.3.2 Adjustments and Repairs
380
7.3.3 Lubrication
380
7.3.4 Rope Replacement
380
7.3.5 Rope Installation and Maintenance
380
7.3.6 Paint Finish Maintenance
381
Lubrication and Maintenance Schedule
382
7.5 Lubrication Points
383
7.6 Rotation Bearing Replacement
384
7.6.1 Replace the Bearing if
384
7.6.2 Axial Play Allowance Check Procedure
384
Hc-12Nexstar III, Cartridge Maintenance
385
Crane Mounting and Installation
386
Nexstar III, Counterbalance Valve Adjustment
388
8.2 Emergency Crane Operation
388
Introduction
405
Engine and System Identification
447
Operating Instructions
457
Maintenance Guidelines
475
Service Literature
485
Service Assistance
496
Maintenance Specifications
499
Warranty
519

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