Lincoln-electric IM858 RED-D-ARC ZR-8 User Manual

RED-D-ARCZR-8IM858July, 2004Red-D-Arc Spec-Built Welding EquipmentThis RED-D-ARC welder is built to RED-D-ARC Extreme Dutydesign specifications by Lin

3. Proper placement of the equipment on the trailer toinsure stability side to side and front to back whenbeing moved and when standing by itself whil

A-4INSTALLATION ZR-8A-4WELDING OUTPUT CABLESWith the engine off, connect the electrode and workcables to the studs provided. These connectionsshould

• Position the welder “Polarity” switch to thedesired polarity, either DC (-) or DC (+).• Position the “RANGE” switch to the “WIREFEED” position.• Att

120 V DUPLEX RECEPTACLESThe 120V auxiliary power receptacles should only beused with three wire grounded type plugs or approveddouble insulated tools

A-7INSTALLATION ZR-8A-7TABLE lllELECTRICAL DEVICE USE WITH THE ZR-8.Type Common Electrical Devices Possible ConcernsResistive Heaters, toasters, inc

A-8INSTALLATION ZR-8A-8STANDBY POWER CONNECTIONSThe ZR-8 is suitable for temporary, standby, or emer-gency power using the engine manufacturer’s rec

240 Volt60 Hz.3-WireServicePOWERCOMPANYMETER240 VOLT120 VOLT120 VOLTLOADNNEUTRALBUSGROUNDPREMISESDISCONNECT ANDSERVICEOVERCURRENTPROTECTIONGNDNNOTE:

WELDER CONTROLS - FUNCTION ANDOPERATIONENGINE SWITCHThe engine switch is used to Start the Engine, SelectHigh Idle or Auto Idle while the engine is r

“ RANGE” SWITCHThe “Range” switch is used to select one of threeamperage ranges with generous overlap for Stick/TIGwelding, or one Wire Feed welding r

B-3OPERATIONB-3STARTING/SHUTDOWN INSTRUCTIONSSTARTING THE ENGINEBe sure all Pre-Operation Maintenance has been per-formed. Also, read the Engine Owner

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-4OPERATIONB-4WELDING PROCESSFor any electrodes the procedures should be keptwithin the rating of the machine. For electrode infor-mation see the app

B-5OPERATIONB-5ZR-8SUMMARY OF WELDING PROCESSESCONTROL ELECTRODECABLE IDLE WHEN NOT

C-1ACCESSORIESC-1ZR-8OPTIONAL EQUIPMENT (Field Installed)K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS - For road, off-road and in-plantand y

C-2ACCESSORIESC-2ZR-8K844-1 Water Valve Kit - For use with water cooled TIG torch,Installs inside of TIG Module.K939-1 Docking Kit - For Mounting the

Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be necessaryto remove saf

D-2MAINTENANCED-2Use 4-stroke motor oil that meets or exceeds therequirements for API service classification SG or SH.Always check the API SERVICE lab

D-3MAINTENANCED-3ENGINE ADJUSTMENTSOVERSPEED IS HAZARDOUSThe maximum allowable high idle speed for thismachine is 3750 RPM, no load. Do NOT tamperwit

E-1TROUBLESHOOTINGE-1ZR-8If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLo

E-2TROUBLESHOOTINGE-2ZR-8Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or a

E-3TROUBLESHOOTINGE-3ZR-8Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures or a

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

STARTERCR1STARTERSOLENOID12 VOLTIDLERSOLENOIDBATTERYAC ACB+SWITCHREGULATORFLYWHEEL ALTERNATORB-HOUR METER5E5D224ENGINE COMPONENTS224A123CONNECTOR PIN

F-2DIAGRAMSF-2ZR-8ZR-8 / / L LN-15 AND LN-25 ACROSS T AND LN-25 ACROSS THE ARC CONNECTE ARC CONNECTION DIN DIAGRAMELECTRIC SHOCK can killDo not oper

F-3DIMENSION PRINTF-3ZR-8M20267 A26.5930.279.09 9.0917.0021.228.80 30.0042.0022.1510.33CENTER OF GRAVITY WITH OIL INENGINE AND FULL FUEL TANK9.31CENTE

NOTESZR-8

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

Mar. ‘93ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques q

vvThank Youfor selecting a QUALITY product. We want you to take pride inoperating this product ••• as much pride as we have in bringingthis product to

viviTABLE OF CONTENTSPageInstallation...

A-1INSTALLATION ZR-8A-1TECHNICAL SPECIFICATIONS ZR-8 (K2392-1)INPUT - GASOLINE ENGINERATED OUTPUT @ 104°F (40°C)- WELDERHEIGHT WIDTH DEPTH WEIGHT3

A-2INSTALLATION ZR-8A-2SAFETY PRECAUTIONSMACHINE GROUNDINGBecause this portable engine driven welder or genera-tor creates its own power, it is not