Thermal Arc 000 Pro K Owner'S Manual Download

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Raider 10,000 Pro K

DC CC/CV Welding Generator

STICK

MIG

AUXILIARY POWER

Owners Manual

MI420-06-00-00

Date 06/03/04 KLA

Manual

Summary of Contents for 000 Pro K

Page 1: ...1 Raider 10 000 Pro K DC CC CV Welding Generator STICK MIG AUXILIARY POWER Owners Manual MI420 06 00 00 Date 06 03 04 KLA Manual ...

Page 2: ...2 Date 06 03 04 KLA Manual ...

Page 3: ...7 2 11 Wiring Optional 230 Volt Plug 18 2 12 Grounding The Generator 18 2 13 When Connecting To Home Shop or Farm Wiring 19 2 14 Auxiliary Power Requirements 19 2 15 Simultaneous Welding and Power 21 2 16 Selecting and Preparing Weld Output Cables 21 SECTION 3 TROUBLE SHOOTING GUIDE 23 3 01 There is No Auxiliary Voltage and or Welding Current 24 3 02 The Generator Is De Energized when Load is conn...

Page 4: ...t when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Sec 25249 5 et seq Date 06 03 04 KLA Manual ...

Page 5: ...ther warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that th...

Page 6: ...l being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These...

Page 7: ...our eyes and burn your skin The arc welding cutting process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to prot...

Page 8: ...SI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilisés pour mettre en relief des informations à caractère important Ces mises en relief sont classifiées comme suit NOTE Toute opération procédure ou renseignem...

Page 9: ...du circuit de soudage Réparez ou remplacez toute pièce usée ou endommagée Prenez des soins particuliers lorsque la zone de travail est humide ou moite Montez et maintenez le matériel conformément au Code électrique national des Etats Unis Voir la page 5 article 9 Débranchez l alimentation électrique avant tout travail d entretien ou de réparation Lisez et respectez toutes les consignes du Manuel d...

Page 10: ...TÉ 29CFR 1910 disponible auprès du Superintendent of Documents U S Government Printing Office Washington D C 20402 2 Norme ANSI Z49 1 LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE disponible auprès de la Société Américaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L ARC ET AU GAZ disponible...

Page 11: ...OGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE disponible auprès de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSF4 1 de l Association Américaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX disponible auprès de...

Page 12: ...es Specifications DC Amperage Range 15 270 Duty Cycle 270 60 AC DC welding current 250 100 Volt Range CV Mode 16 30 OCV CC Mode 70 VDC Auxiliary Power Single Phase 115 2ea GFCI Duplex Receptacles 3 5Kva Single Phase 115 240 8 5Kva Three Phase 460 10Kva Engine Make Type KOHLER Model series COMMAND CH20 Number of cylinders 2 Displacement 624 cc Power 20 HP Engine Speed 3750 rpm no load Engine speed ...

Page 13: ...3 Ans Warranty 95 23 185 18 55 28 16 30 21 25 140 14 24V 10A 14 14 SMAW CV 0 CONTACTEUR CONTACTOR A V CC 2 1 3 4 5 10 9 8 7 6 Front Panel 1 230 115V Single Phase Receptacle Supplies 60 Hz single phase power at weld power speed 2 Earth connection used to earth ground the generator for auxiliary power 3 230 115V 50A Circuit breakers Push to reset Controls 230 115V power source for the 230 115V recep...

Page 14: ...AC 10A Circuit breaker Push to reset Controls 24V power source for wire feeders Controlled through the 14 pin receptacle 20 Hour meter Monitors Time in hours when the engine is on 21 Fuel Gauge Monitors fuel level 22 START button Used to start the engine Set the ON OFF switch to ON push START button to the start the engine When engine starts release button 23 Engine ON OFF switch Place in the ON p...

Page 15: ...earance Maintain at least 19 7 inch 500mm of unrestricted space on all sides of the unit and keep underside free of obstructions Do not place any filtering device over the intake air passages of this welding generator Warranty is void if any type of filtering device is used The service life and operating efficiency of this unit is reduced when the unit is subjected to high levels of dust dirt mois...

Page 16: ...W 3 Circuit breakers to protect 4 240 V receptacle from overload 4 240 V 50 A AC receptacle Supplies 60 Hz single phase power at maximum speed 3600 rpm Maximum output is 8 5 kVA kW 5 Earth ground connection 460 Three Phase connection 1 460 V 13 A AC three phase Circuit Breaker connection Supplies 60 Hz three phase power at maximum speed 3600 rpm Maximum output is 10 kVA kW To connect load remove t...

Page 17: ... Auxiliary power receptacles are Neutral bonded to frame 2 3 Prong plug for case Grounded equipment 3 2 Prong plug for double insulated equipment 2 12 Grounding The Generator TO A TRUCK OR TRAILER FRAME 1 Generator base 2 Metal vehicle frame 3 Equipment grounding terminal 4 Grounding cable Use 10 AGW or larger insulated copper wire NOTE FOR THE GFCI RECEPTACLES TO PERFORM PROPER PROTECTION THE WEL...

Page 18: ...is the installer s responsibility to follow the applicable rules from the National Electrical Code NEC state local and OSHA codes for the installation and use of auxiliary power generators Customer supplied equipment is required if generator is to supply standby power during emergencies or power outages 2 14 Auxiliary Power Requirements The following section provides some general guidelines for th...

Page 19: ...eres at 115 volts calculate its running power requirements in watts VOLTS x AMPERES WATTS 115V x 5A 575W Therefor the individual load applied by the drill is 575 watts Example 2 If a light bulb is rated at 200 watts the individual load applied the light bulb is 200 watts If three 200 watt light bulbs are used with the drill from example 1 add the individual loads to calculate total load 200W 200W ...

Page 20: ...en set screw with supplied hex wrench to secure connector body onto cable 7 Push insulator onto connector body to cover set screw WELD CABLE CONNECTIONS 1 Do not touch live electrical parts 2 Shut down unit before making any weld output connections 3 Do not change position of the welding cable connectors while welding 4 Be sure that the connectors are secure in receptacle before welding TYPICAL PR...

Page 21: ...control is not used place the Amperage Voltage switch in panel position 7 Rotate Amperage Voltage control to desired position 8 Turn on shielding gas supply and set desired flow rate 9 Begin welding SELECTING WELD CABLE SIZES Weld cable size AWG is based on either a 4 volts or less drop or a current density of more than 300 circular mils per ampere 100ft 30 m 150ft 45 m 200ft 60 m 250ft 70 m Weldi...

Page 22: ...ted in series and directly connected to both ends of the exciter windings This produces a charge discharge situation that augments to the point at which it stabilizes itself in proportion to the magnetic force of the rotor winding wire s size and length capacity of the capacitors and engine speed 3600 rpm at about 60 times per second The Charge discharge effect produces a collapsing of magnetic fi...

Page 23: ...f necessary disconnect the plugs from the current sockets If generator still does not generate welding current refer to test section for exciter capacitors Stator The and welding cables are in short circuit through electric contact between them The electrode Work lead are connected in short circuit condition Disconnect electrode Work leads If generator still does not generate welding current refer...

Page 24: ... capacitors See capacitor testing in the the Troubleshooting Guide Repair the faulty capacitor connections Replace any capacitor that may be found to be defective 3 05 Insufficient Welding Current PROBABLE CAUSE CONTROLS REMEDIES The engine does not obtain maximum speed Check the Fine Current Control function Repair or replace the Fine Current Control Check engine throttle linkage Fuel and electri...

Page 25: ...26 Section 5 Parts List 5 01 Stator Parts ...

Page 26: ... Engine bulkhead 13 11 3793 Silencer 14 11 4185 5A fuse 15 11 4179 Fuse holder 16 11 3499 Flap 17 11 3721 Oil drain cap 18 11 3722 Hose clamp 19 11 4180 Clamp 20 11 4183 Oil drain pipe 21 11 4184 Nipples 22 11 3017 Engine shock absorber 30x30 mm 23 11 4191 Engine holder 24 11 3871 Flange nut M5x16 mm 25 11 3659 Engine connection flange 26 11 3872 Washer M10 mm 27 11 3870 Screw M3 8 x1 mm 28 11 366...

Page 27: ...28 5 02 Front Panel Parts ...

Page 28: ...r 15 11 3048 Ring 16 11 3148 20A circuit breaker 17 11 3149 50A circuit breaker 18 11 3232 Male Texas plug 19 11 3231 Welding outlet 20 11 3146 3A circuit breaker 21 11 4160 Potentiometer knob assembly 22 11 4156 1K potentiometer 23 11 3876 Oil pressure signal lamp 24 11 4182 1N4007 diode 25 11 3723 Switch cover 26 11 3809 Switch 3 poles 27 11 4189 Aluminium front plate 28 11 4166 Front plate shee...

Page 29: ...30 5 03 Sheet Metal Parts ...

Page 30: ...7 Battery cover 19 11 3895 Battery clamp 20 11 3544 Battery tie rod 21 11 3543 12V 44Ah battery 22 11 3616 Frame 23 11 3878 Rubber wire holder 24 11 3790 Support 25 11 3677 Fuel tank 26 11 3087 Rubber wire holder 27 11 3619 Lower conveyor 28 11 3618 Bridge for capacitor 29 11 3942 3x50µF capacitor 30 11 3662 Spacer 31 11 3329 Tie rod 32 11 3674 Reactor 33 11 4026 200 VA Transformer 34 11 4027 Tran...

Page 31: ...ttle assembly Fuel Pump Kit 24 559 05 S Red blower housing Solenoid Kit 25 435 05 S Solenoid Idle 24 435 06 S Spark Plug 12 132 02 S Starter Solenoid Shift 25 098 09 S Model number Identification Miscellaneous Parts C Command Engine Catalog Number Description H Horizontal Crankshaft 11 3543 Battery 12V 340A Style DT50 20 20HP 11 4033 Engine Fuel Warning label S Version Code Electric start 11 4194 ...

Page 32: ...33 5 06 Schematic ...

Page 33: ...tion to 5k ohm remote control potentiometer D Zero ohm minimum connection to 5k ohm remote control potentiometer E Wiper arm connection to 5k ohm remote control potentiometer F Not Used G 24 115 VAC circuit common also connected to chassis H Not Used I 115 VAC auxiliary high side J 115 VAC input to energize solid state contactor Contact closure between pin I and pin J K Chassis ground ...

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