4.3Fitting units onto the transport vehicle ............................................................................. 3/4
4.4Fitting wire feed units ....................................................................................................... 3/5
4.4.1 Fitting WELDON DRIVE 4L or PHOENIX DRIVE 4L............................................. 3/5
4.4.2 Fitting WELDON DRIVE 4 or PHOENIX DRIVE 4................................................. 3/5
4.5Fixing and securing gas cylinders.................................................................................... 3/6
4.5.1 Transport vehicle with one gas bottle .................................................................... 3/6
4.5.2 Transport vehicle with two gas bottles................................................................... 3/6
5Spare parts list.......................................................................................................................... 4/1
Contents/1
Safety instructions
For Your Safety:
Ignoring the following safety precautions can be fatal.
Observe accident prevention regulations.
These operating instructions are valid only in conjunction with the relevant safety
regulations, especially with accident prevention regulations VBG 9 and operating
instructions of one of the welding machines from our product range!
Proper usage
This machine has been manufactured according to the latest developments in technology and
current regulations and standards. It is to be operated only for the use for which it was designed
(see chapter Commiss ioning/ Ar ea of applic at io n) .
Improper usage
This machine may be a hazard to persons, animals and property, however, if it is
• not used as designed
• used by unskilled persons who have not been trained,
• modified or converted improperly
Our operating instructions will provide you with an introduction into the safe use of the
machine.
Therefore please read them carefully and only start work when you are familiar with them.
Any person involved in operation, maintenance and repair of this machine must read and follow
these operating instructions, especially the safety precautions. Where appropriate, this must be
confirmed by signature.
Furthermore, the
• relevant accident prevention regulations,
• generally recognised safety regulations,
• local regulations, etc. must be observed.
Secure gas cylinder
• Place shielding gas cylinders in the holders provided for them and secure with safety
chains or belts.
• Take care when handling cylinders; do not throw or heat, guard against them toppling
over.
• For transport vehicles which can be moved by crane, the gas bottle must be removed
before crane transport.
When moving and setting up the transport vehicle, it is only secure against falling to an
angle of 10
additional danger results from obstacles on the floor as these can cause additional tilting
moments.
Comprehensive and additional welding safety precautions can be found in the operating
instructions for our welding machines. A list of the standards and specifications currently
in force can also be found in these instructions.
Repair and modifications may only carried out by authorised, trained, specialist staff.
The warranty becomes null and void in the event of unauthorised interference.
°°°°. Special attention should be paid to the fact that, when the machine is moved,
S / 1
Safety instructions
Notes on the use of these operating instructions
Our operating instructions will provide you with an introduction into the safe use of the
machine.
Therefore please read them carefully and only start work when you are familiar with them.
These operating instructions are arranged into chapters.
To help you find your way around more quickly, in the margins you will occasionally see symbols
along with the sub-headings. These symbols refer to particularly important passages of text which
are graded as follows depending on their importance:
(Note):Applies to technical peculiarities which must be observed by the user.
(Warning):Applies to working and operating procedures which must be carefully
followed to avoid damaging or destroying the machine.
(Caution):Applies to working and operating procedures which must be carefully
followed to avoid endangering people and includes the "Warning" symbol.
Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet
points, e.g.:
• Insert plug of welding current lead into socket
Meaning of the diagram descriptions:
e.g.
(C1) means:Item C / figure 1 in the relevant chapter
• Steady and stable design due to the welded construction
• Building site, assembly and workshop use
• Brackets for all the necessary components
Fig. 2/1 e.g. Trolly 70-2
complete with equipment
Fig. 2/2 e.g. Trolly 70-3 DF
complete with equipment
2/1
2Description
2.2Overview
TROLLY70-170-2
1)
70-2 DF
Brackets for the following welding machines, components, incl. torches, tube packages, accessories and filler metals
Welding machine/s
Module/s
Wire feed unit
Gas cylinder/s
Option required
Opt. PHOENIX 300 holding
plate
Opt. TRITON 260 holding plate
Fully fitted; item no.
For fitting; item no.
1) Transport only permitted with one power source and one module; 2) Transport only permitted with one power source and two modules; 3) TRITON 260 without cooling
moduel, no holding plate option required
-1 module, e.g. COOL 70 U40 /412 modules, e.g. COOL 70 U40 /41 und MULTIVOLT 70-
WELDON/ PHOENIX
DRIVE 4/ DRIVE 4L
11212
3)
----
1 power source: E.g. TRITON 400, 500
1)
SIRION 400, 500
PHOENIX 300, 400, 500
70-3
2)
500
WELDON/ PHOENIX
DRIVE 4/ DRIVE 4L
70-3 DF
2)
2/2
2Description
2.3Equipment
A1
A1
B1
C1
A1
D1
E1
F1
G1
H1
N1
M1
A1
L1
K1
K1
H1
E1
I1
Fig. 2/3 e.g. Trolly 70-2
Item Description
A1 Fixing points for crane transportation
B1 Brackets for wire feed units WELDON DRIVE 4 and PHOENIX DRIVE 4
C1 Hook for holding accessories, such as welding torches
D1 Intermediate tube package strain relief
E1 Exterior bores for housing the rubber feet, e.g. on the following units:
COOL 71U40/41; MULTIVOLT 70-50 0; TRITO N 400/50 0; SIRION 400 /50 0; PHO ENI X
300/400/500 (chap. 4.3)
F1 Interior bores for housing the rubber feet, e.g. on the following units:
COOL 30U20; TRITON 260 (chap. 4.3)
G1 Guide castors
H1 Holding plate with brackets for fixing the units
I1 Fixed castors
J1 Carrier plate for gas cylinder
K1 Securing chain fixing point for gas cylinder
L1 Clamping plate for housing the welding machine handle
M1 Press arbor retainer
N1
Press arbor for housing the wire feed units WELDON DRIVE 4L or
PHOENIX DRIVE 4L
I1
J1
2/3
3Assembly / fitting
3.1Indivi dual parts
17
15
16
15
14
234
11
5
67
1
8
9
10
11
12
Fig. 3/1 Trolly 70-2, disassembled
13
14
Fig.3/2 Trolly 70-2, fully fitted
3/1
3Assembly / fitting
Please check that the parts are complete after unpacking the transport vehicle.
Tube B medium (TROLLY 70-2 / 70-2 DF)
Tube B high (TROLLY 70-3 / 70-3 DF)
1Cylinder holder
M8X15 self-locking hexagongal screw
6
Base assembly, fully fitted with wheels, holding plate, cylinder base
1
Tube A high (TROLLY 70-1)
2
Tube A medium (TROLLY 70-2 / 70-2 DF)
Tube A high (TROLLY 70-3 / 70-3 DF)
Rubber blank
1
Gas cylinder securing chain
1-2
Tube guide (TROLLY 70-2 DF / 70-3 DF only)
2
Cylinder guide (TROLLY 70-2 DF / 70-3 DF only)
1
3.2Fitting TROLLY 70-1; 70-2; 70-3
• Loosely screw cylinder holder (11) to the base assembly (16) [(12) thread] using the M8X15
self-locking hexagonal screws (13).
• Insert one tube A (17) and B (8) through the tube guides (10) on the cylinder holder (11) into the
holes (15) on the base assembly (16) and screw on loosely using the M8X15 self-locking
hexagonal screws (14).
• Screw the wire feed carrier plate (2) using the M8X10 hexagonal screws (6) and the DV302
holder plates (5) onto the tubes already fitted. The position of the holder plates (5) (angle
section up or down) depends on the wire feed case to be transported (chap. 4.4).
• Connect the second tube A (17) to the tube B (8) already fitted and the second tube B (8) to the
tube A (17) already fitted and screwn on loosely to the base assembly (16). (Fig. 3/1).
• Tighten all loosely fastened screws.
• Screw the fitted tubes to the tube guides (10) using the M8X10 hexagonal screws (9) and
tighten.
• Affix the rubber blank (not illustrated) onto the wire feed carrier plate (2).
• Insert the press arbor socket (3) into the relevant hole in the wire feed carrier plate (2).
• Insert the press arbor (4) into the fitted socket (3).
• Screw the clamping plates (7) onto the wire feed carrier plate (2) using the star handles (1).
After assembly, check that all the screws and connections are tightly secured.
Ensure that the correct clamping plates (7) for the equipment being fitted have been used
(chap. 2.2 and chap. 4.3).
The procedure for fitting the holder plates (5) depends on the wire feed case being
transported (chap. 4.4)
3/2
4Commissioning
4.1Area of application
4.1.1TROLLY 70-1
•Transport of TRITON 260 + COOL 30 U20 + WELDON DRIVE 4/4L or TRITON 400/500,
SIRION 400/500 and PHOENIX 300/400/500 + PHOENIX DRIVE 4/4L only
This produces the following possible combinations:
TRITON 260XXXX
COOL 30 U20X X
Opt. TRITON 260 holding plateX X
WELDON DRIVE 4 / 4LXX
This produces the following possible combinations:
TRITON 400/500; SIRION 400/500; PHOENIX 400/500X X
COOL 71 U40 / 41X X X
MULTIVOLT 70-500X X X
WELDON or PHOENIX DRIVE 4 / 4LX
PHOENIX 300X
Opt. PHOENIX 300 holding plateX
•Bracket for one gas cylinder (TROLLY 70-3) (chap.2, J1 and chap. 4.5) or
for two gas cylinders (TROLLY 70-3 DF)
•Brackets for all the necessary additional components:
Welding torches, hose assemblies, accessories and filler metals
4/1
4Commissioning
4.2Transport/set-up
The points listed in chapters 4.2.1, 4.2.2, 4.2.3 und 4.2.4 are examples only.
More detailed information can be found in the general and specific safety and accident
prevention regulations.
4.2.1Crane transport
•The transport vehicles can be transported by crane by attaching the lifting lugs to the fixing
points (fig. 4/1).
Use only these fixing points for lifting by crane.
• Before crane transport remove the gas cylinder
from the transport vehicle.
• Before crane transport, remove wire feed unit
from transport vehicle.
• If the transport vehicle has to be moved with
the wire feed unit, ensure that the unit is
sufficiently well attached and secured.
• The wire coil must always be removed when
moving the machine with a crane, with the wire
feed unit attached.
• When moving the machine with a crane with
the wire feed units WELDON DRIVE 4L or
PHOENIX DRIVE 4L attached, ensure that the
press arbor (chap.2, N1) is removed from the
bracket (chap.2, M1) before attaching and
securing the unit.
Fig. 4/1
• During crane transport no-one should be standing under the suspended load.
• Before lifting it must be ensured that all the fixing points are securely assembled.
• Before and after lifting, check that the snap closures between the cooling unit and
welding machine are sitting properly.
• Before and after lifting, check that the holding plates for fixing the units to the transport
vehicle are correctly positioned.
• The clamping plates for housing the welding machine handle must be securely
attached.
• All loose parts such as accessories and welding torches are to be removed from the
transport vehicle before lifting.
•
Only use undamaged cables for lifting.
• Do not raise or lower the load suddenly.
4.2.2Assembly
Risk of injury when assembling the machines on the transport vehicles.
• Avoid the risk of injury by careful, prudent and foresighted actions during assembly
onto the transport vehicle.
• First fit the cooling module, then the welding machine and lastly the wire feed case.
• For WELDON and PHOENIX DRIVE 4L wire feed units, the angle section of the A2 rail
should be fitted so that it points downwards (fig. 4/7). Otherwise there is a risk of
injuries from crushing when the wire feed units are rotating.
• For housing WELDON and PHOENIX DRIVE 4 wire feed units, the angle section of the
A2 rail should be fitted so that it points upwards (fig. 4/9).
•Always use original accessories and spare parts.
4/2
4Commissioning
4.2.3Installation
The transport vehicle must be installed on a firm base.
4.2.4Procedure
• Do not position on uneven surfaces.
• The floor must not be at an angle and must be level.
• When moving and setting up the transport vehicle, it is only secure against falling to an
angle of 10
• Caution is required on a sandy, loamy, soft, wet or slippery base.
• Avoid projecting parts such as accessories and torches. There is the risk of becoming
caught on the machine, e.g. people passing by.
• Do not place on glowing slag or caustic liquids, or the wheels could be damaged.
The following points must be noted when using the transport vehicle:
• When moving and setting up the transport vehicle, it is only secure against falling to an
angle of 10
• Prudent behavior is a necessity when using the transport vehicle.
• Before using the transport vehicle, ensure that all fixing points are securely attached.
• Before and after lifting, check that the snap closures between the cooling unit and
welding machine, and the holding plates for fixing the units to the transport vehicle, are
correctly positioned.
• The clamping plates for housing the welding machine handle must be securely
attached.
• Caution: The centre of gravity of the loaded transport vehicle changes according to the
load, e.g. with different sizes of gas cylinders.
• Do not use sloping routes when pushing the transport vehicle.
• The base on which the transport vehicle is moved must be level, firm and dry. If the
base is uneven (e.g. ground beams) an additional securing device specific to the wire
feed unit must be fitted.
Caution is required on a sandy, loamy, soft, wet or slippery base.
• The route to be travelled by the transport vehicle should be checked for obstacles
beforehand. Sufficient space must be ensured, particularly in narrow passages, such as
doors. When using the transport vehicle there is a risk from objects on the ground,
because additional tilting moments may arise.
• Ensure that projecting parts such as accessories or welding torches do not become
caught when pushing past obstacles.
• If large gas cylinders in particular are assembled on the transport vehicle, the forces to
be applied when using should be estimated correctly.
• When pushing the transport vehicle keep both hands on the handles.
• Do not move over glowing slag or caustic liquids, or the wheels could be damaged.
• The chains for fixing the gas cylinders must always be hung correctly on the hooks
provided for them and must by lying firmly against the gas cylinders.
°°°°.
°°°°.
4/3
4Commissioning
4.3Fitting units onto the transport vehicle
For the combination options for assembling machines and modules (e.g. COOL 30 U20 or
MULTIVOLT 70-500) in relation to the different transport vehicles, please see the tables in
chap. 4.1
A1
B1
A1
Fig. 4/2
D1
A1
A1
C1
E1
C1
Fig. 4/3
Assembling the welding machine or module
•Place the welding machine or module (e.g. COOL 30 U20 or COOL 71 U40/41) in the
corresponding holes using the rubber feet:
Place the TRITON 260 or COOL 30 U20 into the inner holes B1.
Place TRITON 400/500, SIRION 400/500 and PHOENIX 300/400/500 or COOL 71 U40/41 and
MULTIVOLT 70-500 in the outer holes A1.
•Hook holding plate C1 into the relevant recesses on the machine
(fig. 4/3) and screw tight using the rotary handles D1.
•Fit the clamping plates (fig. 4/4; E1) using the relevant recesses on the welding machine
handle and tighten using the rotary handles (see fig. 4/4 and fig. 4/5)
Assemble the welding machine with module/s
•Place the module with the rubber feet into the corresponding holes (fig. 4/2)
Place COOL 30 U20 into the inner holes B1.
Place COOL 71 U40/41 or MULTIVOLT 70-500 into the outer holes A1.
• Fit the welding machine onto the module using the snap closures located on the module.
• Fit the clamping plates (fig. 4/4; E1) using the relevant recesses on the welding machine
handle and tighten using the rotary handles (see fig. 4/4 and fig. 4/7; B2)
Before and after assembly work check the snap closures are properly located.
For transport with the TROLLY 70-2 / 70-2 DF, one module and for the TROLLY 70-3 / 70-3
DF two modules must be assembled in addition to the welding machine.
When transporting the TRITON 260 + COOL 30 U20 with the transport vehicle TROLLY 70-1
or PHOENIX 300 with the transport vehicles TROLLY 70-1; 70-2 / 70-2 DF (+1 module) or
TROLLY 70-3 / 70-3 DF (+2 modules) special optional holding plates (clamping plates) are
required. (chap. 2.2 and chap. 4.1)
Fig. 4/4
4/4
4Commissioning
4.4Fitting wire feed uni ts
For WELDON and PHOENIX DRIVE 4L wire feed units, the angle section of the A2 holder
plate should be fitted so that it points downwards (fig. 4/7). Otherwise there is a risk of
injuries from crushing when the wire feed units are rotating.
For housing WELDON and PHOENIX DRIVE 4 wire feed units, the angle section of the A2
holder plate should be fitted so that it points upwards (fig. 4/9).
•Insert the end of the tube package on the wire feed unit through the strain-relief (fig. 4/7) and
lock by turning to the right (fig. 4/8).
Fig. 4/5
4.4.1Fitting WELDON DRIVE 4L or PHOENIX DRIVE 4L
C2
A2
Fig. 4/7
•The wire feed unit should be fitted with the retainer located on the base plate on the pin plug
C2 (fig. 4/7 and fig. 4/8).
4.4.2Fitting WELDON DRIVE 4 or PHOENIX DRIVE 4
E1
Fig. 4/6
C2
Fig. 4/8
A2
Fig. 4/9
•Position the wire feed unit on the relevant rails A2 (fig. 4/9 and fig. 4/10)
4/5
Fig. 4/10
4Commissioning
4.5Fixing and securing gas cylinders
• Position the gas cylinders on the carrier plate (chap.2; J1)
• Secure the gas cylinders with the chains (chap.2; K1)
• Ensure that the chains are positioned securely against the gas cylinders.
Large cylinders with 50 l and 300 bar are generally not permissible.
TROLLY 70-1
20L gas cylinder, max. 200bar
20L gas cylinder, max. 300bar
50L gas cylinder, max. 200bar
50L gas cylinder, max. 300barNot normally permissible!