Miller Electric 600 X Owner`s manual

OM-4428
215 932P
2008−06
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
Big Blue 500D
Big Blue 600 X
(Deutz-Powered)
File: Engine Drive
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
9
9
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
3-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
4-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
16
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
4-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
5-4. Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
5-5. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
5-6. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Installing Optional Ether Cylinder (Deutz D912L03 Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
5-8. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
5-9. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
26
5-11. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5-12. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
5-13. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . .
5-14. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
29
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
6-1. Front Panel Controls For CC Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
32
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
TABLE OF CONTENTS
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Front Panel Controls For CC/CV Models (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . .
7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Fuel/Hour Gauge Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Domestic Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Export Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − MAINTENANCE (DEUTZ D2011L04i−POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Maintenance Label (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Routine Maintenance (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Servicing Air Cleaner (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . .
9-6. Adjusting Engine Speed (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7. Servicing Fuel And Lubrication Systems (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . .
9-8. Overload Protection (Deutz D2011L04i-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − MAINTENANCE (DEUTZ D912L03−POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Maintenance Label (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Routine Maintenance (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Servicing Air Cleaner (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . .
10-6. Adjusting Engine Speed (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Servicing Optional Ether Starting Aid (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Servicing Fuel And Lubrication Systems (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . .
10-9. Overload Protection (Deutz D912L03-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
34
34
35
36
37
38
39
39
40
41
42
42
43
44
45
46
47
48
49
50
50
51
52
53
54
55
55
56
57
58
58
62
74
74
75
76
77
84
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2007−04
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live when power is
on. In semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring —
replace cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FLYING METAL or DIRT can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side shields even under your
welding helmet.
OM-4428 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
BUILDUP OF GAS can injure or kill.
Noise from some processes or equipment can damage hearing.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Wear approved ear protection if noise level is
high.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-4428 Page 2
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
COMPRESSED AIR can cause injury.
Wear approved safety goggles.
Do not direct air stream toward self or others.
OM-4428 Page 3
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
Use only genuine replacement parts from the
manufacturer.
Do not touch hot compressor or air system
parts.
Let system cool down before touching or servicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Lift and support unit only with proper equipment
and correct procedures.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
OM-4428 Page 4
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
Read Owner’s Manual before using or servicing unit.
Use only genuine replacement parts from the
manufacturer.
Perform engine and air compressor maintenance and service according to this manual
and the engine/air compressor (if applicable)
manuals.
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-6. California Proposition 65 Warnings
Welding or cutting equipment 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 Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-7. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-4428 Page 5
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2007−04fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce moment-là.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en
contact avec le fil de soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
OM-4428 Page 6
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
pas endommagé ou dénudé − remplacer le cordon immédiatement
s’il est endommagé − un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
OM-4428 Page 7
LES CHAMPS MAGNETIQUES peuvent
affecter des implants médicaux.
Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font
normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants
en caoutchouc et vêtements de protection lors
d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles
de batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou
des véhicules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas approcher les mains des ventilateurs,
courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
OM-4428 Page 8
Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Remettre en place les panneaux ou les dispositifs de protection et
fermer les portes à la fin des travaux d’entretien et avant de faire
démarrer le moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le générateur.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du
moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
2-4. Dangers liés à l’air comprimé
RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer
la mort.
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un incendie ou une explosion.
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques.
Ne pas couper ou gouger à proximité de produits inflammables.
Surveillez et garder un extincteur à proximité.
L’AIR COMPRIMÉ peut provoquer
des blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou
soi-même.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provoquer des blessures.
Relâcher la pression d’air de l’outillage ou du
système avant d’effectuer la maintenance,
avant de changer ou de rajouter des éléments
ou avant d’ouvrir la purge ou le bouchon de
remplissage d’huile.
DES PIECES CHAUDES peuvent provoquer des brûlures et blessures.
Ne pas toucher le compresseur ou d’autres
éléments du circuit air comprimé chauds.
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la
maintenance.
LIRE LES INSTRUCTIONS.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’APPAREIL peut blesser.
Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Ne lever et ne soutenir l’appareil qu’avec de
l’équipement approprié et en suivant les
procédures adéquates.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
OM-4428 Page 9
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LIRE LES INSTRUCTIONS.
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
N’utiliser que les pièces de rechange recommandées par le constructeur.
Effectuer la maintenance et le service du moteur et du compresseur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
OM-4428 Page 10
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-6. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
2-8. Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-4428 Page 11
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions (For Wordless Labels)
S-177 571
1
+
2
2
3
+
3
1
4
DIESEL
5
4
6
5
7
0 − 50 h Std.
200A
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
Check oil level. Add oil if
necessary.
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
After the first 50 hours of
operation, change the oil and
oil filter.
0 − 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
OM-4428 Page 12
3-2. Symbols And Definitions
Some symbols are found only on CE products.
A
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Starting Aid
Battery (Engine)
Engine Oil
Pressure
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Protective Earth
(Ground)
Positive
Negative
Certified/Trained
Mechanic
Welding Arc
Volts
Panel/Local
Remote
Engine
Air Temperature Or
Engine
Temperature
Output
Alternating
Current
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Amperes
Time
3
V
h
Hours
Three Phase
Read Operator’s
Manual
Electrode
Connection
Work Connection
s
Seconds
1
Single Phase
Do Not Switch
While Welding
Circuit Protector
G
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
X
Duty Cycle
U0
Rated No Load
Voltage (Average)
U2
Conventional
Load Voltage
n1
Rated Idle
Speed
n0
Rated No Load
Speed
I
Current
Hz
n
I2
Hertz
Rated Load
Speed
Rated Welding
Current
Contactor On
OM-4428 Page 13
SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld
Output
Range
Maximum
Open-Circuit
Voltage
Rated Welding
Output
65 − 600 A
(CC Models)
CC/DC
20 − 600 A
(CC/CV
Models)
CV/DC
(CC/CV
Models
Only)
14 − 40 V
IFC Rating
500 A, 40 Volts DC,
100% Duty Cycle
550 A, 40 volts DC,
60% Duty Cycle
Engine
Standard:
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC, 50/60 Hz
95
600 A, 30 Volts DC,
40% Duty Cycle
Generator Power
Rating
Three-Phase Generator
Option:*
Single-Phase/Three-Phase,
12/20 kVA/kW, 50/48A,
120/240 VAC, 60 Hz
56
*In Addition To Standard
4 kVA/kW Generator Power
DEUTZ
Deutz D2011L04i
Air/Oil-Cooled, Four
Cylinder, 46.3 HP
Diesel Engine
Fuel
Capacity
25 gal
(95 L)
or
Deutz D912L03,
Air-Cooled, Three
Cylinder, 41.5 HP
Diesel Engine
4-2. Dimensions, Weights, And Operating Angles
Dimensions
50 in (1270 mm)
(to top of muffler)
Height
Width
G
28-1/2 in (724 mm)
(mtg. brackets turned in)
!
Do not exceed tilt angles or engine could
be damaged or unit could tip.
30-3/4 in (781 mm)
(mtg. brackets turned out)
!
Do not move or operate unit where it could
tip.
Depth
65-1/8 in (1654 mm)
A
65-1/8 in (1654 mm)
B*
56 in (1422 mm)
C*
46-1/2 in (1181)
D*
9-5/8 in (244 mm)
A
B
C
*With mounting brackets in center position. Dimensions vary with location of
mounting bracket.
Weight
D2011L04i
D912L03
H
D
30°
Front Panel End
No Fuel: 1690 lb (767 kg)
w/Fuel:1880 lb (853 kg)
No Fuel: 1785 lb (810 kg)
w/Fuel:1975 lb (896 kg)
Lifting Eye Weight Rating:
2500 lb (1134 kg) Maximum
OM-4428 Page 14
20°
30°
20°
F
E
802 161-A
803 602
4-3. Volt-Ampere Curves For CC Models
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
Ranges
300−Max
185−425
125−320
85−190
55−90
DC VOLTS
80
60
40
20
0
0
100
200
300
400
500
600
700
800
900
DC AMPERES
203 412
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 15
4-4. Volt-Ampere Curves For CC/CV Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
100
Ranges
275−Max
150−525
110−390
80−240
50−125
DC VOLTS
80
60
40
20
0
0
100
200 300 400
500 600 700 800 900 1000
DC AMPERES
B. MIG Mode
100
DC VOLTS
80
60
MAX
40
20
0
MIN
0
100
200
300
400
500 600
700
800
900 1000
DC AMPERES
C. TIG Mode
100
Ranges
50−440
35−320
25−215
15−115
DC VOLTS
80
60
40
20
0
0
100
200
300
DC AMPERES
OM-4428 Page 16
400
500
217 811 / 203 415 / 217 810
4-5. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
1800 RPM
IDLE
0
0
50
100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE
193 093
Notes
OM-4428 Page 17
4-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
100% Duty Cycle At 500 Amperes
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Continuous Welding
202 356
4-7. AC Generator Power Curve
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
150 300
AC VOLTS
125 250
100 200
75
150
50
100
25
50
0
0
0
5
10
15
20
AC AMPERES IN 240V MODE
25
30
0
10
20
30
40
AC AMPERES IN 120V MODE
50
60
193 018
OM-4428 Page 18
4-8. Optional Three-Phase Generator Curves
The ac power curves show the generator power available in amperes
at the single-phase 120/240 volt receptacle or three-phase 240 volt
terminals.
AC VOLTS
A. 12 kVA/kW Single-Phase AC Output (No Weld Load)
280
270
260
250
240
230
220
210
200
190
90 180
140
135
130
125
120
115
110
105
100
95
20
0
40
60
80
100
AC AMPERES
B. 20 kVA/kW Three-Phase AC Output (No Weld Load)
280
260
240
220
200
180
0
10
20
30
40
AC AMPERES
50
60
70
197 472 / 197 473
OM-4428 Page 19
SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Movement
!
Do not move or operate unit
where it could tip.
!
Always securely fasten welding generator onto transport
vehicle or trailer and comply
with all DOT and other applicable codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
OR
OR
See Section 4-2 for lifting eye rating.
See Section 5-2 for mounting information.
Location/Airflow Clearance
OR
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
OR
18 in
(460 mm)
18 in
(460 mm)
install3 2008-01 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
OM-4428 Page 20
5-2. Mounting Welding Generator
!
Supporting The Unit
Do not weld on base. Welding on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use crosssupports to adequately support unit
and prevent damage to base.
2
Mounting Surface:
1
2
OR
Cross-Supports
Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brackets.
3
1
4
1/2 in Bolt And Washer
(Minimum − Not Supplied)
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Using Mounting Brackets
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place
Bolting Unit In Place
3
2
4
Tools Needed:
9/16 in
install3 2008--01 803 274 / 200 864-A / 803 231
OM-4428 Page 21
5-3. Grounding Generator To Truck Or Trailer Frame
1
!
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
!
Bed liners, shipping skids,
and some running gear insulate the welding generator
from the vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to
bare metal on the vehicle
frame as shown.
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
GND/PE
2
3
3
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
rot_grnd 2008-01 − 800 652-D
5-4. Rating Label Location
4
1
Rating Label − Typical
Locate rating label on unit. Label provides information such as weld output
ratings, generator ratings, and engine
information.
Evidence of label tampering voids
warranty.
rot_label 2008-01 − 804 712
OM-4428 Page 22
5-5. Using Lifting Eye
1
2
3
1
Lifting Eye
Nut
Carriage Bolt
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
2
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).
Tools Needed:
3
Lift1 2008−01 804 712
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 23
5-6. Installing Exhaust Pipe
!
Stop engine and let cool.
Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
Exhaust1 2008−01 Ref. 803 604 / Ref. 236 972
5-7. Installing Optional Ether Cylinder (Deutz D912L03 Engine Only)
1
!
Stop engine.
!
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
!
Do not use Ether Starting Aid
while engine is running.
Remove rubber access plug from
cover.
2
3
4
5
1
Ether Cylinder
2
Nozzle
Remove cover and clean cylinder
nozzle.
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove cap and clean fitting.
Install cylinder on fitting. Tighten
clamp.
After installing cylinder, wait at
6
least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
Put cap on fitting when cylinder is
removed.
Reinstall plug in cover.
ether1 7/96 − 153 382-A / Ref. 236 972
OM-4428 Page 24
5-8. Activating The Dry Charge Battery (If Applicable)
!
3
Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
Remove battery from unit.
1
2
2
1
3
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
Well
Fill each cell with electrolyte to
bottom of well (maximum).
!
Do not overfill battery cells.
Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps.
4
Battery Charger
!
Read and follow all instructions supplied with battery
charger.
5
5 Amperes For 30 Minutes
Charge Time
30 Amperes For 12 Minutes
Charge Time
6
5
4
Charge battery. Disconnect charging cables and install battery.
When electrolyte
is low, add
only distilled water to cells to
maintain proper level.
5A
+
6
−
Tools Needed:
30 A
drybatt 12008−01 − S-0886
5-9. Connecting The Battery
!
Connect negative (−) battery
cable last.
Reinstall cover after connecting battery.
+
−
Tools Needed:
1/2 in
Ref. 236 972 / 803 605 / S-0756-C
OM-4428 Page 25
5-10. Engine Prestart Checks
Full
Diesel
Deutz D2011L04i Engine
Full
Full
Diesel
Deutz D912L03 Engine
Full
Ref. 803 657 / 803 658
Check all engine fluids daily.
Fuel
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil. The
Automatic shutdown system stops engine if
oil pressure is too low or coolant temperature is too high.
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Use optional Starting Aid switch (see
Section 6-1 or 7-1).
Add fresh diesel fuel before starting to prevent air from entering the fuel system (see
engine maintenance label for fuel specifications). Leave filler neck empty to allow room
for expansion.
Keep battery in good condition. Store
battery in warm area.
This unit has a low oil pressure shut-
down switch. However, some conditions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
pipe during run-in, see Section 13.
OM-4428 Page 26
Engine stops if fuel level is low.
Oil
After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
To improve cold weather starting:
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel information.
Use correct grade oil for cold weather
(see Section 9-1 or 10-1).
5-11. Connecting To Weld Output Terminals
Stick and TIG Welding
For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or optional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.
!
Stop engine.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
!
Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or optional Polarity/AC switch, connect wire feeder
cable to Electrode (+) terminal on left and
work cable to Work (−) terminal on right.
1
Tools Needed:
2
3/4 in
3
MIG and FCAW Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP) on CC/CV models,
connect wire feeder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right. Use Process/Contactor switch
to select type of weld output (see Section 7-3).
6
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Correct Installation
Incorrect Installation
803 602 / 803 778-A
OM-4428 Page 27
5-12. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
!
!
Stop engine before
connecting to weld
output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
10 − 100% Duty Cycle
Do not use worn, damaged, undersized, or
poorly spliced cables.
*Chart
is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
5-13. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 6-3).
Ref. 154 862-A / 048 720-K / 803 602
OM-4428 Page 28
5-14. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket*
Socket Information
A
24 volts ac. Protected by supplementary protector CB5.
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
D
Remote control circuit common.
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
24 VOLTS AC
New! LDR-14 long
distance remote
(includes 120 V
receptacle)
REMOTE
OUTPUT
CONTROL
OR
I
115 volts, 10 amperes, 60 Hz
ac. Protected by supplementary
protector CB6.
J
Contact closure to I completes
115 volt ac contactor control
circuit.
GND
K
Chassis common.
NEUTRAL
G
Circuit common for 24 and 115
volt ac circuit.
115 VOLTS AC
Ref. 803 602
*The remaining sockets are not used.
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
OM-4428 Page 29
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS
6-1. Front Panel Controls For CC Models (See Section 6-2)
7
8
12
13
5
6
3
4
9
10
1
2
11
238 627-A / 803 602
OM-4428 Page 30
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1)
Engine Starting Controls
1
Starting Aid Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
2
Engine Control Switch
Use switch to start and stop engine.
To Start:
NOTICE − Do not use ether. Using ether
voids warranty.
If engine does not start, let engine come
to a complete stop before attempting restart.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
tor the engine charging system. The meter
should read about 14 volts dc when the engine is running, and about 12 volts dc when
the engine is stopped.
5
6
Weld Controls
Max OCV Control Circuit: This unit has
a max OCV control circuit that resets Amperage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust opencircuit voltage.
To Stop: turn Engine Control switch to Off
position.
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
Scratch Start TIG position (see item 9).
Engine Gauges And Meters
Engine Fuel/Hour Gauge
Use gauge to monitor engine running time for
scheduling maintenance and to determine
cause of engine shutdowns.
Use gauge to check fuel level. Engine stops
if fuel level is low.
To check fuel level when engine is not running, turn Engine Control switch to Run or
Run/Idle position.
See Section 7-5 for complete fuel/hour gauge
information.
4
Battery Voltmeter (Optional)
Use gauge to check battery voltage and moni-
Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
3
Engine Coolant Temperature Gauge
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
7
Ampere Range Switch
NOTICE − Do not switch under load.
Use switch to select weld amperage range.
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
8
Amperage Adjust Control
Control adjusts amperage within range selected by Ampere Range switch. Weld output
would be about 180 A DC with controls set as
shown (50% of 150 to 330 A).
The numbers around the control are for
reference only and do not represent an
actual percentage value.
9 Stick/TIG Selection Switch
Use switch to disable the max OCV circuit
and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).
When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.
Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.
10 Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Connect optional remote control to RC13
(See Section 5-13). Use switch to select front
panel or remote amperage control. For remote control, place switch in Remote position
and connect remote control to Remote Amperage Adjust receptacle RC13 (see Sections 5-13 and 6-3).
11 Polarity Switch (Optional)
NOTICE − Do not switch under load.
Use switch to change weld output. Select either DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
Weld Meters
12 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
13 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
OM-4428 Page 31
6-3. Remote Amperage Control On CC Models (Optional)
1
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
RC13 (see Section 5-13).
In Example:
Range = 115 to 330 A DC
Percentage Of Range = 50%
Max = About 240 A DC (50% of 150 to 330)
Example: Combination Remote Amperage Control (Stick)
Max (240 A DC)
Min (84 A DC)
Set Switches
Set Range
Set Control
Adjust Optional Remote Control
Ref. 154 862-A / Ref. 236 973 / 803 602
6-4. Weld Control/Arc Condition Information Label
Set weld controls as shown to
achieve softer or stiffer arc conditions for different applications.
212 944-A
OM-4428 Page 32
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 33
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS
7-1. Front Panel Controls For CC/CV Models (See Section 7-2)
8
9
13
14
5
6
3
4
2
7
10
1
11
12
OR
238 623-A / 802 602
OM-4428 Page 34
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1)
Engine Starting Controls
4
1
Use gauge to check battery voltage and monitor the engine charging system. The meter
should read about 14 volts dc when the engine is running, and about 12 volts dc when
the engine is stopped.
Starting Aid Switch
Use switch to energize starting aid for cold
weather starting (see starting instructions following).
2
Engine Control Switch
Use switch to start engine, select engine
speed ( if unit has auto idle option), and stop
engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
To Start:
NOTICE − Do not use ether. Using ether
voids warranty.
If engine does not start, let engine come
to a complete stop before attempting restart.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
To Stop: turn Engine Control switch to Off
position.
Battery Voltmeter (Optional)
6
11 Polarity Switch (Optional)
Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
Weld Controls
7 Process/Contactor Switch
See Section 7-3 for Process/Contactor
switch information.
8
Ampere Range Switch
NOTICE − Do not switch under load.
Use Polarity switch to change weld output.
Select either DC Electrode Positive (DCEP)
or DC Electrode Negative (DCEN).
12 Polarity/AC Switch (Optional)
!
Electric shock can kill.
!
Do not use AC output in damp areas,
if movement is confined, or if there is
a danger of falling.
!
Use AC output ONLY if required for the
welding process. If AC output is required, use remote output control if
present on unit.
NOTICE − Do not switch under load.
Use switch to select weld amperage range.
Use the lowest four ranges for Stick and TIG
welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
3
9
Voltage/Amperage Adjust Control
To check fuel level when engine is not running, turn Engine Control switch to Run or
Run/Idle position.
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in TIG mode, but has no effect in Stick
and MIG modes.
See Section 7-5 for complete fuel/hour gauge
information.
Weld output would be about 250 A DC with
controls set as shown (50% of 110 to 390 A).
Use gauge to check fuel level. Engine stops
if fuel level is low.
10 Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
Engine Coolant Temperature Gauge
Engine Gauges And Meters
Engine Fuel/Hour Gauge
reference only and do not represent an
actual percentage value.
Use switch to select front panel or remote
voltage/amperage control. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle
RC14 (see Sections 5-14 and 7-4).
5
For most welding applications, use lowest
amperage range possible to help prevent arc
outages.
Use gauge to monitor engine running time for
scheduling maintenance and to determine
cause of engine shutdowns.
The numbers around the control are for
NOTICE − Do not switch under load.
Use Polarity/AC switch to select AC or DC
weld output and DC weld output polarity. For
Direct Current Electrode Negative (DCEN),
turn switch to − (Negative) position. For Direct
Current Electrode Positive (DCEP), turn
switch to + (Positive) position. For weld processes that require alternating current (AC),
use AC position.
Weld Meters
13 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
14 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the
unit.
OM-4428 Page 35
7-3. Process/Contactor Switch On CC/CV Models
1
Process/Contactor Switch
!
Weld output terminals are energized when Process/Contactor
switch is in an Weld Terminals
Always On position and the engine is running.
!
DC voltage is still present at the
weld terminals when Process/
Contactor switch is in the Remote On/Off Switch Required −
Stick position and the engine is
running.
1
Use switch to select weld process and
weld output on/off control (see table below and Section 7-4).
Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides additional amperage during low voltage (short
arc length conditions) to prevent “sticking” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.
Place switch in Weld Terminals Al-
ways On - Stick position when using optional three-phase generator
(see Section 8-2).
The engine auto idle option does
not work in the Remote On/Off
Switch Required-TIG mode.
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Engine Auto Idle (Optional)
Remote On/Off Switch Required − TIG, HF Required
Or Scratch Start TIG
GTAW With HF Unit, Pulsing
Device, Or Remote Control
At Remote 14 Receptacle
Not Active
Remote On/Off Switch
Required − Stick
Stick (SMAW) With Remote On/Off
At Remote 14 Receptacle
Active
Remote On/Off Switch
Required − CV Feeder
Using Remote
MIG (GMAW)
At Remote 14 Receptacle
Active
Weld Terminals Always On −
Wire
MIG (GMAW)
Electrode Hot
Active
Weld Terminals Always On −
Stick
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Electrode Hot
Active
Weld Terminals Always On −
TIG, Scratch Start
TIG Scratch Start (GTAW)
Electrode Hot
Active
OM-4428 Page 36
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1
Remote 14 Receptacle RC14
Connect optional remote control to
RC14 (see Section 5-14).
1
In Example:
Process = Stick (Using Remote On/Off)
Range = 110 to 390 A DC
Min = 110 A DC
Max = 390 A DC
Example: Combination Remote Amperage Control (Stick)
Max (390 A DC)
Min (110 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Control Not
Used In Remote
Stick Mode
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 35 to 320 A DC
Percentage Of Range = 50%
Min = 35 A DC
Max = About 178 A DC (50% of 35 to 320)
Example: Combination Remote Amperage Control (TIG)
Max (178 A DC)
Min (35 A DC)
Set V/A
Adjust Switch
Set Remote
Process
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 236 972 / Ref. 803 602
OM-4428 Page 37
7-5. Fuel/Hour Gauge Descriptions
OM-4428 Page 38
SECTION 8 − OPERATING AUXILIARY EQUIPMENT
8-1. Domestic Auxiliary Power Receptacles
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz singlephase power at weld/power speed.
1
3
2
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
4
3
Supplementary Protector CB1
4
Supplementary Protector CB2
CB1 protects RC1 and the generator winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset.
If
a supplementary protector
continues to open, contact
Factory Authorized Service
Agent.
Generator
power is not affected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all receptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624-A
OM-4428 Page 39
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
Place Process/Contactor switch
1
Single-Phase Power Connection
in Electrode Hot - Stick position
when using three-phase generator (see Section 7-3).
2
Single-Phase Generator Power
1
120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
three-phase generator and supplies
60 Hz single-phase power at weld/
power speed. Maximum output from
RC5 is 12 kVA/kW. Power available
at RC5 is reduced when welding.
2
Supplementary Protector CB7
CB7 protects single-phase receptacle RC5 and the load wires from
overload. If CB7 opens, all threephase generator output stops and the
receptacle does not work.
Three-Phase Power Connection
!
Volts
Single
Phase
1
120/240
Three
Phase
3
240
Amps
50
48
KVA/KW
12
20
AC
Output
Close panel opening
if no connections are
made to generator.
Frequency
Engine Speed
60 Hz
1850 RPM
93
91
90
92
4
Rear Of Panel
5
91
92
93
3
6
Stop engine.
!
Power and weld outputs are
live at the same time. Disconnect or insulate unused
cables.
cording to circuit diagram and
Generator Power Guidelines
(see Section 14).
Remove generator power panel
mounting screws. Tilt panel forward.
3
Lead 93
4
Lead 92
5
Lead 91
6
Lead 42 (Circuit Grounding
Lead)
7
Lead 90 (Neutral)
8
Isolated Neutral Terminal
9
Jumper Lead 42
10 Grounding Terminal
2
7
!
Have qualified person install ac-
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
Remove plug
before inserting
leads. Reinstall
bushing.
Three-Phase Generator Power
12
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes.
10
Lead 42 connects to front panel
Ground stud.
11 User-Supplied Leads
12 Supplementary Protector CB7
User Terminals
11
!
9
8
Close panel
opening if no
connections
are made to
generator.
240V
1-Phase
120V
120V
Tools Needed:
240V
3-Phase
240V
Connect user-supplied leads to terminals on CB7 and to the isolated
neutral terminal and grounding terminal as necessary.
CB7
protects single-phase receptacle RC5 and the load wires
from overload. If CB7 opens, all
three-phase generator output
stops and the receptacle does
not work.
Reinstall generator power panel.
240V
Ref. 197 399 / 802 332-B / 803 655
OM-4428 Page 40
8-3. Export Auxiliary Power Receptacles
4
3
European Receptacle
Australian Receptacle
1
2
5
South African Receptacle
6
238 127-A / 805 259-A
1
120V 15/20A AC Receptacle GFCI1
tacles is 4 kVA/kW.
Receptacles supply 60 Hz single-phase
power at weld/power speed.
EXAMPLE: If 13 A is drawn from RC1, only
7 A is available at GFCI1:
If a ground fault is detected, GFCI1 Reset
button pops out and receptacle does not
work. Check for faulty tools plugged into receptacle. Press button to reset GFCI1.
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
At least once a month, run engine at
CB2 protects GFCI1 from overload. If a circuit breaker opens, the receptacle does not
work. Press CB2 to reset breaker.
weld/power speed and press test button to verify GFCI is working properly.
Maximum output is 2.4 kVA/kW from GFCI1
and 4 kVa/kW from RC1.
Maximum combined output of all recep-
2
3
Circuit Breaker CB2
Earth Leakage Circuit Breaker
ELCB1
ELCB1 protects RC1 from Earth leakage
fault. If circuit breaker opens the receptacle
does not work. Place circuit breaker switch
in the On position to reset breaker.
At least once a month, press test but4
5
6
ton. If ELCB is working properly, power
will be disconnected. Reset breaker.
220V 16A AC European
Receptacle RC1
240 V 15 A AC Australian
Receptacle RC1
240 V 15 A AC South African
Receptacle RC1
If a circuit breaker continues to open,
contact Factory Authorized Service
Agent.
OM-4428 Page 41
SECTION 9 − MAINTENANCE (DEUTZ D2011L04i−POWERED
UNITS)
9-1. Maintenance Label (Deutz D2011L04i-Powered Units)
OM-4428 Page 42
9-2. Routine Maintenance (Deutz D2011L04i-Powered Units)
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
8
Hours
Stop engine before maintaining.
See
Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Section
5-10
FUEL
WATER
Fuel/Water Separator
Fuel Level
Oil Level
Oil, Fuel Spills
Every
50
Hours
Weld Terminals
Every
100
Hours
Section 9-4
Battery Terminals
Every
250
Hours
Air Cleaner Hoses
Air Cleaner Element
Engine
Manual,
Section 9-5
1/2 in.
(13 mm)
Unreadable Labels
Fan Belt Tension
Cooling System
Spark Arrestor
Every
500
Hours
Weld Cables
Every
1000
Hours
Oil
Oil Filter
Section
5-10, 9-3,
9-7 and
Engine
Manual
Fuel Filter
FUEL
OR
SLUDGE
Slip Rings*
Brushes*
Inside Unit
Valve Clearance*
Drain Sludge
Every
3000
Hours
Injectors*
Every
6000
Hours
or 5
Years
Engine Timing Belt
OM-4428 Page 43
9-3. Checking Generator Brushes
!
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush holder cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.
Minimum Length:
5/8 in (16 mm)
New Length: 1-1/4 in (32 mm)
Replace
Damaged Brushes
1
Ref 215 158
Notes
OM-4428 Page 44
9-4. Servicing Air Cleaner (Deutz D2011L04i-Powered Units)
!
1
2
3
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
1
Keep nozzle
2 in (51 mm)
from element.
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-4428 Page 45
9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz D2011L04i-Powered Units)
!
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
2
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
!
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
803 656 / Ref. 236 972
OM-4428 Page 46
9-6. Adjusting Engine Speed (Deutz D2011L04i-Powered Units)
!
Stop engine and let cool.
Engine speed is factory set and
should not require adjustment. After tuning engine, check engine no
load speed with a tachometer or frequency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
On CC Models, place Stick/TIG
switch in Stick position.
On CC/CV models, turn Process/
Contactor switch to Stick − Electrode Hot position.
Standard Models:
1850 rpm Max.
(61.6 Hz)
1250 rpm
(41.5 Hz)
1
Engine Speed Adjustment
Screw
2
Locking Nut
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
Do not set engine speed higher
than specified.
Models With Automatic Idle
(Optional)
3
Throttle Rod
4
Locknut
Loosen locknuts. Place engine
control switch in Run/Idle position.
Standard Models
Turn throttle rod until engine runs at
idle speed. Tighten locknuts.
5
Engine Speed Adjustment
Screw
2
6
Locknut
1
Place engine control switch in Run
position.
Loosen locknut. Turn screw until
engine runs at weld/power speed.
Tighten locknut.
Do not set engine speed higher
than specified.
!
Models With Automatic Idle (Optional)
4
Stop engine.
Close door.
3
5
6
Tools Needed:
3/8, 7/16 in
803 657
OM-4428 Page 47
9-7. Servicing Fuel And Lubrication Systems (Deutz D2011L04i-Powered Units)
Tools Needed:
3
4
5
6
2
1
7
803 657
!
!
1
2
3
4
Stop engine and let cool.
After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
Primary Fuel Filter (Fuel/Water Separator)
5
Petcock
6
Secondary Fuel Filter
7
Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve through hole
in base. See engine manual and engine
OM-4428 Page 48
maintenance label for oil/filter change information.
To drain water from fuel system:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
To replace secondary fuel filter:
See engine manual.
Close doors.
To drain sludge from fuel tank:
!
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clockwise. Bleed air from fuel system according
to engine manual.
Inspect fuel line, and replace if cracked or
worn.
!
Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while draining fuel tank.
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
9-8. Overload Protection (Deutz D2011L04i-Powered Units)
!
Stop engine.
When
a supplementary protector,
circuit breaker or fuse opens, it usually indicates a more serious problem
exists. Contact Factory Authorized
Service Agent.
1
2
2
F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.
3
4
1
5
9
Fuse F1
Fuse F2
8
7
Circuit Breaker CB4 (Not Shown)
Supplementary Protector CB5
(CC/CV Models Only)
Supplementary Protector CB6
(CC/CV Models Only)
6
Circuit Breaker CB10 (Not Shown)
7
Supplementary Protector CB11
8
Supplementary Protector CB12
9
Supplementary Protector CB13
10 Circuit Breaker CB14 (Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault
is corrected.
4
CB5 protects the 24 volt ac output to remote receptacle RC14, and 24 volt output
to field current regulator board PC1 (CC/
CV models only). If CB5 opens, weld output and 24 volt output to RC14 stops. On
units with optional three-phase generator, generator power output at receptacle
RC5 also stops if CB5 opens.
5
CB6 protects the 115 volt ac output to remote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.
CB10 protects the engine battery circuit.
If CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the weld control circuit. On
CC models, if CB11 opens the max OCV
circuit does not work and open circuit
voltage is variable at all times (see max
OCV note under Weld Controls in Section
6-2). If CB11 opens on CV models, weld
output stops (generator power is still
available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite at start-up and weld and generator
power output may not be available.
CB13 protects the engine control circuit.
If CB13 opens, the engine does not
crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14 opens,
the engine does not run at idle speed.
CB14 automatically resets when the fault
is corrected.
Ref. 803 657
Press button to reset supplementary protector.
OM-4428 Page 49
SECTION 10 − MAINTENANCE (DEUTZ D912L03−POWERED
UNITS)
10-1. Maintenance Label (Deutz D912L03-Powered Units)
OM-4428 Page 50
10-2. Routine Maintenance (Deutz D912L03-Powered Units)
!
Recycle engine
fluids.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
8
Hours
Stop engine before maintaining.
See
Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
= Replace
Reference
Section
5-10,
FUEL
WATER
Fuel/Water Separator
Fuel Level
Oil Level
Oil, Fuel Spills
Every
50
Hours
Weld Terminals
Every
100
Hours
Section
10-4
Battery Terminals
Air Cleaner Hoses
Every
250
Hours
Air Cleaner Element
Engine
Manual,
Section
10-5
1/2 in.
(13 mm)
Unreadable Labels
Fan Belt Tension
Cooling System
Weld Cables
Oil
Oil Filter
Spark Arrestor
Every
500
Hours
Every
1000
Hours
FUEL
OR
SLUDGE
Slip Rings*
Brushes*
Inside Unit
Fuel Filter
Section
5-10, 10-3
and Engine
Manual
Drain Sludge
Valve Clearance*
Every
3000
Hours
Injectors*
Every
6000
Hours
or 5
Years
Engine Timing Belt
OM-4428 Page 51
10-3. Checking Generator Brushes
!
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush holder cap. Remove brushes.
Replace brushes if damaged or if brush
material is at or near minimum length.
Minimum Length:
5/8 in (16 mm)
New Length: 1-1/4 in (32 mm)
Replace
Damaged Brushes
1
Ref 215 158
Notes
OM-4428 Page 52
10-4. Servicing Air Cleaner (Deutz D912L03-Powered Units)
!
1
2
3
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
1
Keep nozzle
2 in (51 mm)
from element.
Housing
2
Safety Element (Optional)
3
Primary Element
4
Dust Cap
5
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-4428 Page 53
10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz D912L03-Powered Units)
!
Stop engine and let cool.
1
Spark Arrestor Muffler
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
2
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
!
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
803 656 / Ref. 236 972
OM-4428 Page 54
10-6. Adjusting Engine Speed (Deutz D912L03-Powered Units)
!
Engine Speed
(No Load)
Weld/Power
RPM (Hz)
1850
(61.6 Hz)
Stop engine.
Engine speeds have been factory
set and should not require adjustment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load speed.
If necessary, adjust speed as follows:
1
Speed Adjustment Screw
2
Locknut
Loosen nut. Start engine.
Turn screw until engine runs at
weld/power speed. Tighten locknut.
Do not set engine speed higher
than specified.
!
Stop engine.
Close side door.
1
2
Tools Needed:
9/16, 7/8 in
803 658 / 134 730-C
10-7. Servicing Optional Ether Starting Aid (Deutz D912L03-Powered Units)
!
Stop engine.
!
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.
1
1
Ether Cylinder
2
Valve
3
Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and
valve fitting is clean.
Replace cylinder according to
Section 5-7.
3
33 oz
(935 g)
15 oz
(425 g)
Full
Empty
2
ether2 7/96 − ST-153 382-A / Ref. 202 705 / S-0692
OM-4428 Page 55
10-8. Servicing Fuel And Lubrication Systems (Deutz D912L03-Powered Units)
Tools Needed:
6
3
4
5
2
1
7
803 658
!
!
1
2
3
4
Stop engine and let cool.
After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
Primary Fuel Filter (Fuel/Water Separator)
5
Petcock
6
Secondary Fuel Filter
7
Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve through hole
in base. See engine manual and engine
OM-4428 Page 56
maintenance label for oil/filter change information.
To drain water from fuel system:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
To replace secondary fuel filter:
See engine manual.
Close doors.
To drain sludge from fuel tank:
!
To replace primary fuel filter:
Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clockwise. Bleed air from fuel system according
to engine manual.
Inspect fuel line, and replace if cracked or
worn.
!
Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while draining fuel tank.
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
10-9. Overload Protection (Deutz D912L03-Powered Units)
!
Stop engine.
When a supplementary protector, cir-
cuit breaker or fuse opens, it usually indicates a more serious problem exists.
Contact Factory Authorized Service
Agent.
1
2
Fuse F1
Fuse F2
F1 and F2 protect the stator exciter winding
from overload. If F1 opens, weld and generator power is low or stops entirely. If F2
opens, weld output is low or stops entirely.
4 kVA/kW generator power is still available.
2
1
3
4
5
9
8
7
Circuit Breaker CB4 (Not Shown)
Supplementary Protector CB5
(CC/CV Models Only)
Supplementary Protector CB6
(CC/CV Models Only)
6
Circuit Breaker CB10 (Not Shown)
7
Supplementary Protector CB11
8
Supplementary Protector CB12
9
Supplementary Protector CB13
10 Circuit Breaker CB14
(Not Shown)
CB4 protects the welding arc drive (dig) circuit. If CB4 opens, electrode may stick to
the workpiece more frequently during low
voltage (short arc length) conditions. CB4
automatically resets when the fault is corrected.
4
5
CB5 protects the 24 volt ac output to remote
receptacle RC14, and 24 volt output to field
current regulator board PC1 (CC/CV models only). If CB5 opens, weld output and 24
volt output to RC14 stops. On units with optional three-phase generator, power output
at receptacle RC5 also stops if CB5 opens.
CB6 protects the 115 volt ac output to remote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to RC14
stops.
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault is
corrected.
CB11 protects the weld control circuit. On
CC models, if CB11 opens the max OCV
circuit does not work and open circuit voltage is variable at all times (see max OCV
note under Weld Controls in Section 6-2). If
CB11 opens on CC/CV models, weld output
stops (generator power is still available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite
at start-up and weld and generator power
output may not be available.
CB13 protects the engine control circuit. If
CB13 opens, the engine does not crank.
CB14 protects fuel solenoid FS1. If CB14
opens, the engine does not start. CB14 automatically resets when the fault is corrected.
Press button to reset supplementary protector.
Ref. 803 658
OM-4428 Page 57
SECTION 11 − TROUBLESHOOTING
11-1. Troubleshooting
A. Welding − CC Models
Trouble
Remedy
No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.
Check position of optional Polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
control to Remote Amperage Adjust receptacle RC13 (see Sections 5-13 and 6-1).
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-13).
Check fuse F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check integrated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and weld excitation circuit.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Section 9-8 or 10-9).
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check OCV control circuit.
Low weld output.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8
frequently during low voltage (short arc or 10-9). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions.
SR5.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
Place Amperage Adjust switch in Remote position.
Check and secure connections to Remote Amperage Adjust receptacle RC13 (see Section 5-13).
Reset supplementary protector CB11 (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check control relay CR7.
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.
OM-4428 Page 58
B. Welding − CC/CV Models
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles.
On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
(see Sections 5-14 and 7-1).
Check position of Ampere Range switch.
Check position of optional Polarity switch or Polarity/AC switch.
Reset supplementary protector CB11 (see Section 9-8 or 10-9).
Reset supplementary protector CB5 (see Section 9-8 or 10-9). Check for faulty remote device connected to RC14.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-14).
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check brushes and slip rings, weld excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Erratic weld output.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage feedback circuit.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode.
Range switch in highest range.
Low weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8
frequently during low voltage (short arc or 10-9). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions.
SR5.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Check position of Process/Contactor switch.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-14).
Repair or replace remote control device.
Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections.
Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 9-8 or 10-9).
work.
Check and secure connections to Remote 14 receptacle RC14 (see Section 5-14).
Repair or replace wire feeder.
OM-4428 Page 59
Trouble
Low CV weld output.
Remedy
Set Ampere Range switch to highest range.
Increase Voltage/Amperage Adjust Control setting.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control R1, and field current
regulator board PC1.
C. Standard Generator Power
Trouble
Remedy
No generator power output at ac recep- Reset receptacle supplementary protectors.
tacles; weld output okay.
Reset GFCI receptacle.
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, and the rotor.
Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 .
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Check engine speed, and adjust if necessary.
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power ac recep- Check engine speed, and adjust if necessary.
tacles.
Check fuse F1, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service Agent
check integrated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Three-Phase Generator Power (CC/CV Models Only)
Trouble
No or low output at optional threephase generator/receptacle RC5.
Remedy
Place Process/Contactor switch in Weld Terminals Always On - Stick position (see Section 7-3).
Reset supplementary protector CB7(see Section 8-2).
Reset supplementary protector CB5 (see Section 9-8 or 10-9).
Check engine weld/power speed, and adjust if necessary (see Section 9-6 or 10-6).
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional three-phase
generator/receptacle RC5.
Check engine weld/power speed, and adjust if necessary (see Section 9-6 or 10-6).
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage
feedback circuit.
Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacle RC5.
PC1.
OM-4428 Page 60
E. Engine
Trouble
Engine will not crank.
Remedy
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8
or 10-9). Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check control relay CR1, control relay CR5, fuel/hour gauge,
and Engine Control switch S1.
Engine cranks but does not start.
Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel/hour gauge, control relay CR5, fuel pump, and fuel
solenoid FS1.
Air in fuel system. See engine manual.
Engine starts, but stops after 30 sec- Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
onds.
temperature is too high (see Section 5-10). Automatic shutdown system is inhibited for 30 seconds after
start-up.
Have Factory Authorized Service Agent check fuel/hour gauge, and control relay CR5.
Engine hard to start in cold weather.
Use starting aid switch (see Section 6-1 or 7-1).
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Use correct grade oil for cold weather (see Section 9-1 or 10-1).
Engine suddenly stops.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperature is too high (see Section 5-10). Automatic shutdown system is inhibited for 30 seconds after
start-up.
See engine manual.
Engine slowly stopped and cannot be
restarted.
Check fuel level.
Check engine air and fuel filters (see Sections 9-4 and 10-4, or Sections 9-7 and 10-8).
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Engine idles, but does not come up to
weld speed (models with idle option
only).
Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.
Check for obstructed throttle solenoid.
Engine does not run at idle speed
(models with idle option only).
CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch RequiredTIG.
Check for obstructed throttle solenoid.
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.
Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 13).
wetstacking occurs.
OM-4428 Page 61
SECTION 12 − ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For CC Welding Generator (Deutz D2011L04i-Powered Units)
OM-4428 Page 62
238 628-A
OM-4428 Page 63
Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz D2011L04i-Powered Units)
(Export Models)
OM-4428 Page 64
238 928-A
OM-4428 Page 65
Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz D2011L04i-Powered Units)
OM-4428 Page 66
238 630-A
OM-4428 Page 67
Figure 12-4. Circuit Diagram For CC/CV Welding Generator
(Deutz D2011L04i-Powered Units) (Export Models)
OM-4428 Page 68
238 944-A
OM-4428 Page 69
Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz D912L03-Powered Units)
OM-4428 Page 70
238 930-A
OM-4428 Page 71
Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz D912L03-Powered Units)
OM-4428 Page 72
238 929-A
OM-4428 Page 73
SECTION 13 − RUN-IN PROCEDURE
run_in1 2007−04
13-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1
2
1
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
OM-4428 Page 74
13-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.
4
2
1
NOTICE − Do not perform runin procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
3
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see nameplate, rating label, or the specifications section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
NOTICE − Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welding generator for two hours minimum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking
is present.
S-0683
OM-4428 Page 75
13-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.
6
NOTICE − Do not perform runin procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
3
5
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
Start engine and run for several
minutes.
Set grid switches and then adjust generator A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
NOTICE − Check oil level frequently during run-in; add oil if needed.
It is recommended to run the welding generator for two hours minimum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-4428 Page 76
SECTION 14 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
14-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
Be sure equipment has double
insulated symbol and/or wording on it.
1
!
2
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 2008−01 − ST-800 577
14-2. Grounding Generator To Truck Or Trailer Frame
!
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
3
1
2
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
GND/PE
!
Bed liners, shipping skids,
and some running gear insulate the welding generator
from the vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to
bare metal on the vehicle
frame as shown.
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
3
800 652-D
OM-4428 Page 77
14-3. Grounding When Supplying Building Systems
1
2
1
2
Use #10 AWG or larger insulated
copper wire.
3
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
ST-800 576-B
14-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 14-8).
VOLTS 115
AMPS 4.5
Hz
60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts.
3
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-4428 Page 78
14-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
14-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-4428 Page 79
14-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
OM-4428 Page 80
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
14-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
14-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-4428 Page 81
14-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
4
3
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install and ground
this equipment according to
its Owner’s Manual and national, state, and local codes.
Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
1 Utility Electrical Service
5
2 Transfer Switch (Double-Throw)
Essential
Loads
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 14-4).
OM-4428 Page 82
14-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-4428 Page 83
SECTION 15 − PARTS LIST
Hardware is common and not
available unless listed.
A
Deutz D2011L04i enginepowered unit is shown below.
See insert for parts specific to a
Deutz D912L03-powered unit.
Parts not related to the engines
are the same in both units.
15
14
3
2
16
17
13
1
12
4
18
11
5 6
19
9
10
8
7
107
106
12
100 (Fig. 15−8)
92
101
105
21
20
99
125
22
90
98 (FIG. 15−2 OR 15−3)
95 (CC ONLY)
91
96
97 (CC ONLY)
93
103
102
94 (CC ONLY)
104 (FIG. 15−4 OR 15−5)
CC CC Models Only
CV CC/CV Models Only
Figure 15-1. Main Assembly
OM-4428 Page 84
A Deutz D2011L04i en-
Deutz D912L03 Engine
gine-powered unit is
shown below. See insert for parts specific to
a Deutz D912L03-powered unit. Parts not related to the engines are
the same in both units.
29
119
122
2
33
118
110
117
124
120
108
53
54
114
123
121
113
115
65
116
111
109
112
16
63
67
28
26
59
68
17
35 (Fig. 15−7)
24
56
57
58
61
62
69
29
25
60
47
70
44 46
31
27
45
48
23
43
50
33
42
126
30
32
51
2
49
34
41
38
37
39
40
52
61
65
84
82
83
64
63
69
54
60
55
56
57
62
58
2
68
53
35 (Fig. 15-7)
81
67
2
36
2
70
74
72
71
73
59
85
75
86
80
66
76
87
88
79
89
78
90
77
803 659 / 803 665
OM-4428 Page 85
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 189 824
. . . 1 . . . . . . . . . . . . ♦199 294
. . . 2 . . . . . . . . . . . . . 225 120
. . . 3 . . . . . . . . . . . . +189 828
. . . 3 . . . . . . . . . . . ♦+199 301
. . . . . . . . . . . . . . . . . . ♦212 570
. . . 4 . . . . . Z1 . . . . 189 395
. . . 4 . . . . . Z1 . . . ♦201 520
. . . 5 . . . . . 1T . . . . 038 621
. . . . . . . . . . . . . . . . . . . 038 620
. . . 6 . . . . . . . . . . . . . 081 499
. . . 7 . . . . . . . . . . . . . 206 352
. . . . . . . . . . . . . . . . . . . 203 260
. . . 8 . . SR4, SR5 . 215 909
. . . 9 . . . . CB4 . . . 045 061
. . . 10 . . . . . . . . . . . . . 201 697
. . . 11 . . . . . T1 . . . . 201 613
. . . 11 . . . . . T1 . . . ♦205 636
. . . 12 . . . . . . . . . . . . . 173 352
. . . 13 . . . . . . . . . . . . . 189 708
. . . 14 . . . . . . . . . . . . . 191 307
. . . 15 . . . . . . . . . . . . . 191 829
. . . 16 . . . . . . . . . . . . . 189 763
. . . 17 . . . . . . . . . . . . . 189 764
. . . . . . . . . . . . . . . . . . . *192 938
. . . . . . . . . . . . . . . . . *♦192 939
. . . 18 . . . . . . . . . . . . . 189 464
. . . . . . . . . . . . . . . . . . . 173 909
. . . 19 . . . . . . . . . . . . . 201 658
. . . 20 . . . . . . . . . . . . +200 999
. . . 20 . . . . . . . . . . . ♦+203 382
. . . 21 . . . . . . . . . . . . . 196 220
. . . 22 . . . . . . . . . . . . . 192 362
. . . 23 . . . . . . . . . . . . +201 934
. . . 23 . . . . . . . . . . . ♦+202 640
. . . 24 . . . . . . . . . . . . . 189 052
. . . 25 . . . . . . . . . . . . . 190 198
. . . 26 . . . . . . . . . . . . . 192 041
. . . 27 . . . . . . . . . . . . . 222 513
. . . 28 . . . . . . . . . . . . . 224 265
. . . 29 . . . . . . . . . . . . . 105 734
. . . 30 . . . . . . . . . . . . . 201 592
. . . 31 . . . . . . . . . . . . . 201 851
. . . 32 . . . . . . . . . . . . . 191 354
. . . 32 . . . . . . . . . . . . . 202 633
. . . 33 . . . . . . . . . . . . . 010 875
. . . 34 . . . . . . . . . . . . . 200 730
. . . 35 . . . . . . . . . . Figure 15-7
. . . 36 . . . . . . . . . . . . . 191 577
. . . 37 . . . . . . . . . . . . . 191 809
. . . 38 . . . . . . . . . . . . . 190 951
. . . 39 . . . . . . . . . . . . . 191 817
. . . 40 . . . . . . . . . . . . . 237 003
. . . . . . . . . . . . . . . . . . . *067 265
. . . . . . . . . . . . . . . . . . . *192 744
. . . . . . . . . . . . . . . . . . . *066 217
. . . . . . . . . . . . . . . . . . . *195 745
. . . . . . . . . . . . . . . . . . . *195 746
OM-4428 Page 86
. . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, engine side (export models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, ac environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . .
. . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . .
. . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . .
. . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, use diesel fuel only (Wordless Label) . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment can cause serious . . . . . . . . . . . . . . . . .
. . LABEL, warning hot exhaust parts do not touch . . . . . . . . . . . . . . . . . . . . .
. . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, cover e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, muffler 2.000 dia u pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUARD, starter (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg engine LH (Deutz D2011L04i engine) . . . . . . . . . . . . . . . .
. . EDGE TRIM, styel tl750-b2 x 1/16 black w/clips 1.625 . . . . . . . . . . . . . . .
. . BAFFLE, air (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENGINE, Deutz dsl elec D2011L04i (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . FILTER, oil (engine) (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . .
. . . . FILTER, fuel spin-on (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . .
. . . . FILTER, fuel secondary (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . .
. . . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SENDER, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
8
1
1
1
1
1
1
2
1
2
1
2
1
1
1
1
3ft
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . ♦174 064 . . IDLE, solenoid assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . ♦175 937 . . BRACKET, support solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . . *067 266 . . BELT, blower (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . 201 714 . . BOX, air intake (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . . 201 748 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . ♦202 638 . . UPRIGHT, rear ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . . 202 639 . . COVER, battery access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . +215 252 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 53 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . . 191 812 . . BRACKET, mtg engine RH (Deutz D2011L04i engine) . . . . . . . . . . . . . . . .
. . . 56 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . .
. . . 59 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 199 507 . . HOSE, oil drain assy 20 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . . 176 528 . . FITTING, hose brs barbed elbow fem 1/2 tbg x 1/2 NPT . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . . 173 336 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . . 219 229 . . BRACKET, mtg solenoid (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . .
. . . 67 . . . . . . . . . . . . . 206 297 . . BASE, fuel filter assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 68 . . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . .
. . . 69 . . . . . . . . . . . . . 196 465 . . HOSE, SAE .312 ID X .560 OD X 23.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 200 032 . . HOSE, SAE .312 ID X .560 OD X 38.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 70 . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 71 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 72 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e-coat . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 73 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 74 . . . . . . . . . . . . . 237 352 . . LABEL, maintenance big blue deutz series ce . . . . . . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 75 . . . . . . . . . . . . +210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 76 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 77 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 78 . . . . . . . . . . . . . 199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 79 . . . . . . . . . . . . . 199 300 . . PANEL, gen RH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 80 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 81 . . . . . . . . . . . . . 218 087 . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 82 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 83 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . .
. . . 84 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . .
. . . 85 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 86 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 87 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
4
4
1
4
4
4
4
1
1
1
2ft
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
1
4
2
1
1
1
1
1
OM-4428 Page 87
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly (Continued)
. . . 88 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft
. . . 91 . . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 92 . . . . . . . . . . . . . 218 086 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . 224 266 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 94 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . R4 . . . CC191 292 . . RESISTOR, WW fxd 375W 50 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . R2 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . R3 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . Figure 15-2, Figure 15-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . Figure 15-8 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . ♦199 305 . . TOP, cover front upright ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . ♦+202 637 . . UPRIGHT, front ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 233 953 . . LABEL, warning general precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . Figure 15-4, Figure 15-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . ♦202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . CV193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . PC1 . . CV207 397 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 215 631 . . KIT, label (includes safety & informational labels) (CC models) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 632 . . KIT, label (includes safety & informational labels) (CC/CV models) . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 995 . . KIT, label (includes safety & informational labels) (CC export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 994 . . KIT, label (includes safety & informational labels) (CC/CV export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz D2011L04i engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 991 . . KIT, label (includes safety & informational labels) (CC export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 990 . . KIT, label (includes safety & informational labels) (CC/CV export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . 237 002 . . ENGINE, Deutz dsl elec D912L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . . *064 677 . . FILTER, oil (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . *066 271 . . BELT, blower (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . *195 745 . . SWITCH, pressure oil 1.5 bar nc cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . *195 746 . . SENDER, coolant temp & 130 degee C switch . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . . . . . . . . . . . 194 135 . . BACKPLATE, Deutz D912L03 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . 194 572 . . SUPPORT, front engine (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . FS1 . . . 141 346 . . SHUTDOWN KIT, engine (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . . . . . 118 452 . . FTG, adapter oil drain (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . 193 313 . . MANIFOLD, exhaust muffler (Deutz D912L03 engine) . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . 194 496 . . BAFFLE, lower air outlet (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . 194 497 . . BAFFLE, upper air outlet (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . 194 500 . . BAFFLE, air intake (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . 194 485 . . HOSE, air cleaner (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . +201 714 . . BOX, air intake (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . . . 195 560 . . GUARD, starter hole (Deutz D912L03 engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . . 194 467 . . WASHER, flat 6.25idx11.50odx.062t buna n . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . . . . . . . . . . 212 944 . . LABEL, stick overlap weld ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 126 . . . . . . . . . . . . 233 088 . . LABEL, danger using a generator indoors can kill you in minutes (unit) . 1
. . . . . . . . . . . . . . . . . . . 237 013 . . LABEL, hour/fuel meter usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
C CC models only.
C
* Recommended Spare Parts.
♦optional
C
V C/CV models only.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 88
4
14
18
24
23
6
21
3
17
8
7
25
2
22
1
15
20
10
9
11
19
13
16
12
5
803 660-D
Item
No.
Dia.
Mkgs.
Part
No.
Figure 15-2. Control Box Assembly − CC Models
Description
Quantity
Figure 15-2. Control Box Assembly − CC Models (Figure 15-1 Item 98)
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . C12 . . . 191 944 . . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 238 763 . . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . .
. . . 7 . . . . CR7 . . . 188 636 . . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . D8/C8, D12 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . SR1, SR2 . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . CR5 . . . 223 710 . . . . RELAY, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on−none−on spd term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 092 670 . . . . CONN, rect univ 084 3p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
. . . 11 CB11, 12, 13 139 266 . . . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . .
. . . . . . . . . . . . . . . . . . . 214 932 . . . . CONN, rect univ 039 8p/s 2row plug cable . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
5
1
3
1
OM-4428 Page 89
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-2. Control Box Assembly − CC Models (Continued)
. . . . . . . . . . . . . . . . . . . 215 013
. . . . . . . . . . PLG3 . . . 158 465
. . . . . . . . . . . . . . . . . . . 187 654
. . . . . . . . . . PLG6 . . . . 114 063
. . . . . . . . . . . . . . . . . . . 192 309
. . . 12 . . . . . . . . . . . . . 177 136
. . . 13 . . . . . C9 . . . . . 087 110
. . . 14 . . . . . R6 . . . . 141 424
. . . 15 . . . . PC7 . . ♦195 706
. . . 16 . . . . CR4 . . ♦113 247
. . . 17 . . . . CR6 . . ♦090 104
. . . 18 . . . . CR3 . . . 090 104
. . . . . . . . . . . . . . . . . . . 215 660
. . . 19 . . . D1/C1 . . 189 701
. . . 20 . . . . CB10 . . . 190 374
. . . . . . . . . . . . . . . . . . . 148 850
. . . . . . . . . . PLG4 . . . . 114 062
. . . . . . . . . . . . . . . . . . . 173 916
. . . 21 . . . . CR1 . . . 214 876
. . . 22 . . . . CB14 . . ♦205 927
. . . . . . . . . . . . . . . . . . . 205 931
. . . 19 . . . D8/C8 . . 189 701
. . . 20 . . . . CB10 . . . 190 374
. . . . . . . . . . . . . . . . . . . 148 850
. . . . . . . . . . PLG4 . . . . 114 062
. . . 21 . . . . CR1 . . . 214 876
. . . 22 . . . . CB14 . . . 205 927
. . . 23 . . . . CR8 . . ♦197 325
. . . 24 . . . . CR9 . . . 090 104
. . . . . . . . . . . . . . . . . . . 235 251
. . . 25 . . . . . R7 . . . . 235 250
. . . . . . . . . . . . . . . . . . . 148 850
. . HARNESS, unit weld control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONN, rect univ 084 12p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONN, rect univ 084 4p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . .
. . . . CLIP, snap in .630 bundle .250 hole .248 thk . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . .
. . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . .
. . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . .
. . HARNESS, engine control (Deutz D2011L04i engine) (consisting of) . .
. . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . .
. . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . .
. . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . .
. . HARNESS, engine control (Deutz D912L03 engine) (consisting of) . . . .
. . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . .
. . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . .
. . . . RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
. . HARNESS, fuel shutdown solenoid (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . RESISTOR, hsc 30 w 3 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 90
4
5
23
6
7
3
8
9
2
24
10
1
12
11
13
22
14
21
19
20
18
16
17
15
803 661-D
Figure 15-3. Control Box Assembly − CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-3. Control Box Assembly − CC/CV Models (Figure 15-1 Item 98)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
. . . F1, F2 . . *085 874
. . . . . . . . . . . . . 046 432
. . . . . . . . . . . . . 201 077
. . . . . . . . . . . . . 201 078
. . . . CR3 . . . 090 104
. . . . CR8 . . ♦197 325
. . . . CR1 . . . 214 876
. . . . CR6 . . ♦090104
. D8/C8, D12 189 701
. . . . CB14 . . . 205 927
. . . . CB10 . . . 190 374
. . . . CR5 . . . 223 710
. . . . PC7 . . ♦195 706
. . . . SR1 . . . 035 704
. . . . . . . . . . . . . 201 079
. . . . CR4 . . ♦113 247
. . . . PC9 . . . 192 224
. . . . . . . . . . . . . 134 201
. . . . . C9 . . . . . 087 110
. . . . . . . . . . . . . 177 136
. . . D1/C1 . . 189 701
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . .
RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc dpst−no 25a 6pin flange . . . . . . . . . . . . . . . . . . . . . . .
MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIODE CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
3
1
1
1
OM-4428 Page 91
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-3. Control Box Assembly − CC/CV Models (Continued)
. . . 22 . CB11, 12, 13 139 266 . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . .
. . . 23 . . . . CR9 . . . 090 104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 238 683 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . .
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . .
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-5) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-5) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 214 932 . . . . CONN, rect univ 039 8p/s 2row plug cable . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 193 183 . . . . CONN, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 196 602 . . . . PLUG, cavity 18,30 position cinch connector . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 196 603 . . . . SEAL, switch 6 position rotary .250 shaft . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 141 450 . . . . CONN, rect metrmate 10skt 1row plug cable lkg . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 206 024 . . HARNESS, engine control (Deutz D2011L04i engine) (consisting of) . . .
. . . . . . . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 173 916 . . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 205 931 . . HARNESS, engine control (Deutz D912L03 engine) (consisting of) . . . .
. . . . . . . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 185 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 235 251 . . HARNESS, fuel shutdown solenoid (consisting of) . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . R7 . . . . 235 250 . . . . RESISTOR, hsc 30 w 3 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
1
1
1
1
1
1
1
1
5
1
1
4
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 92
Hardware is common and
4
not available unless listed.
3
5
2
6
1
7
8
9
10
11
41
40
39
12
13
14
37
15
38
36
35
34
33
21
31
16
17
32
20
18
30
19
22
23
24
29
28
27
26
25
803 662-C
Figure 15-4. Panel, Front w/Components − CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
Description
Figure 15-4. Panel, Front w/Components − CC Models (Figure 15-1 Item 104)
. . . 1 . . . . . . . . . . . . . 238 627 . .
..............................
... 2 ........................
. . . 3 . . . . . . . . . . . . . 238 616 . .
. . . 4 . . . . . S3 . . . . 208 278 . .
PLATE SCREENED, ident control rating; when ordering this item,
the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
OM-4428 Page 93
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-4. Panel, Front w/Components − CC Models (Continued)
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . S2 . . . ♦021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . S1 . . . . 217 680 . . SWITCH, ignition 4 position w/out handle . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 207 073 . . LEVER, ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . CB1 . . . 201 083 . . SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac
(European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . CB1 . . ♦202 683 . . SUPPLEMENTARY PROTECTOR, man reset 2p 40a 240vac
(export models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . Figure 15-6 . . AUXILIARY POWER GROUP , Export
. . . . . . . . . . . . . . . . . . . 215 437 . . AUXILIARY POWER GROUP, Domestic (Includes)
. . . . . . . . . . . . . . . . . . ♦197 527 . . . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . CB2, CB3 ♦201 083 . . . . SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac . . . . . .
. . . . . . . . . . . . . . . . . . . 201 109 . . . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . .
. . . 14 . . . GFCI1 . . 151 981 . . . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . .
. . . 15 . . . . RC1 . . . 147 632 . . . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦213 577 . . . . HARNESS, generator power (export models) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦189 549 . . . . BLOCK, term assy standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . ♦038 620 . . . . LINK, jumper term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . RC1 . . ♦173 556 . . . . RECEPTACLE, str 2p3w 32a 130v flange mtg (export models) . . . . . . .
. . . . . . . . . . RC2 . . ♦176 355 . . . . RECEPTACLE, str 2p3w 16a 220v flange mtg (export models) . . . . . . .
. . . . . . . . . . RC3 . . ♦173 555 . . . . RECEPTACLE, str 2p3w 16a 130v flange mtg (export models) . . . . . . .
. . . 16 . . . . . . . . . . . . . 190 861 . . . . LABEL, warning, electric shock and moving parts etc . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . +215 347 . . . . PANEL, gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . ♦+215 045 . . . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . ♦+204 258 . . . . PANEL, gen pwr (110/220 volt receptacles) (export models) . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 083 030 . . . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 601 836 . . . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . 209 056 . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . 206 795 . . . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . S12 . . ♦220491 . . SWITCH, ac/polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . ♦199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . 201 045 . . COVER, receptacle twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . .
OM-4428 Page 94
1
1
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3
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
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1
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1
1
2
2
2
1
1
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1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-4. Panel, Front w/Components − CC Models (Continued)
. . . 34 . . FUEL/HM . . 232 113
. . . 35 . . . . TEMP . . 217 084
. . . . . . . . . . . . . . . . . . . 197 798
. . . 36 . . . . . OIL . . . . 217 083
. . . . . . . . . . . . . . . . . . . 193 230
. . . . . . . . . . . . . . . . . . ♦194 403
. . . 37 . . . . . V1 . . . ♦164 874
. . . 38 . . . . . A1 . . . ♦164 873
. . . 39 . . . . . . . . . . . . . 189 161
. . . 40 . . . . . . . . . . . . . 010 647
. . . 41 . . . . . . . . . . . . . 019 602
. . . . . . . . . . . . . . . . . . . 024 103
..
..
..
..
..
..
..
..
..
..
..
..
GAUGE, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAUGE, coolant temp 0− 300 deg f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . .
GAUGE, pressure oil 0−100 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADAPTER, oil pressure sender (Deutz D2011L04i) . . . . . . . . . . . . . . . . . . .
VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLANK, snap−in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
♦Optional
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 95
Hardware is common and
not available unless listed.
4
3
5
6
7
8
9
2
1
10
11
12
57
13
56
14
55
15
54
16
17
18
33
53
19
20
52
51
21
48
50
49 47
46
22
31
30
23
24
45
26
32
43
25
44
29
28
27
34
35
42
41
36
40
39
38
37
803 663-D
Figure 15-5. Panel, Front w/Components − CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-5. Panel, Front w/Components − CC/CV Models (Figure 15-1 Item 104)
. . . 1 . . . . . . . . . . . . . 238 623 . . PLATE SCREENED, ident control; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 238 616 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . S3 . . . . 208 278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-4428 Page 96
1
1
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1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . GUARD, circuit breaker (for S6 − not included w/harness) . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . 139 266 . . SUPPLEMENTARY PROTECTOR, Man Reset 1p 15a 250vac . . . . . . . . 1
. . . 11 . . . . CB6 . . . 083 432 . . SUPPLEMENTARY PRO, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S1 . . . . 217 680 . . SWITCH, ignition 4 position w/out handle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 207 073 . . LEVER, ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . Figure 15-6 . . AUXILIARY POWER GROUP , Export
. . . . . . . . . . . . . . . . . . . 215 437 . . AUXILIARY POWER GROUP, Domestic (Includes)
. . . . . . . . . . . . . . . . . . . 201 553 . . . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . 201 083 . .
SUPPLEMENTARY PROTECTOR, Man Reset 2p 20a 250vac . . . . . 1
. . . 14 . . . . CB1 . . ♦202 683 . . . . SUPPLEMENTARY PROTECTOR, Man Reset 2p 40a 240vac . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197 527 . . . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201 083 . . . . SUPPLEMENTARY PROTECTOR, Man Reset 2p 20a 250vac . . . . . 2
. . . . . . . . . . . . . . . . . . . 201 109 . . . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, Man Reset 1p 20a 250vac Frict . . . . . . . . 1
. . . 16 . . . GFCI1 . . 151 981 . . . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 147 632 . . . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213 577 . . . . HARNESS, generator power (export models) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189 549 . . . . BLOCK, term assy standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038 620 . . . . LINK, jumper term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . ♦173 556 . . . . RECEPTACLE, str 2p3w 32a 130v flange mtg (export models) . . . . . . . 1
. . . . . . . . . . RC2 . . ♦176 355 . . . . RECEPTACLE, str 2p3w 16a 220v flange mtg (export models) . . . . . . . 1
. . . . . . . . . . RC3 . . ♦173 555 . . . . RECEPTACLE, str 2p3w 16a 130v flange mtg (export models) . . . . . . . 1
. . . 18 . . . . RC5 . . ♦182 954 . . . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025 248 . . . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604 102 . . . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197 527 . . . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197 363 . . . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦214 926 . . . . SUPPLEMENTARY PROTECTOR, Man Reset 3p 50a 250vac . . . . . 1
. . . 24 . . . . . . . . . . . . +215 347 . . . . PANEL, generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+215 406 . . . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+204 258 . . . . PANEL, gen pwr (110/220 volt receptacles) (export models) . . . . . . . . . 1
. . . 24 . . . . . . . . . . . +♦215 363 . . . . PANEL, generator power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦214 927 . . . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197 508 . . . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077 440 . . . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 601 836 . . . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 29 . . . . . . . . . . . . . 209 056 . . . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 083 030 . . . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197 433 . . . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 190 861 . . . . LABEL, warning, electric shock and moving parts etc . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 209 056 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦220 491 . . SWITCH, ac/polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4428 Page 97
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-5. Panel, Front w/Components − CC/CV Models (Continued)
. . . 36 . . PC4, PC5 . 189 744
. . . 37 . . . . . . . . . . . . . 039 046
. . . . . . . . . . . . . . . . . . . 180 735
. . . 38 . . . . . . . . . . . . . 134 201
. . . 39 . . . . . . . . . . . . . 181 169
. . . 40 . . . . . . . . . . . . . 186 621
. . . 41 . . . . . . . . . . . . ♦059 773
. . . 42 . . . . . . . . . . . . ♦010 647
. . . 43 . . . . . . . . . . . . . 039 047
. . . 44 . . . . . . . . . . . . ♦196 073
. . . 45 . . . . . . . . . . . . . 021 385
. . . 46 . . . . . . . . . . . . . 190 323
. . . 47 . . . . . . . . . . . . . 170 391
. . . 48 . . FUEL/HM . . 232 113
. . . 49 . . . . . . . . . . . . ♦193 228
. . . 50 . . . . TEMP . . 217 084
. . . . . . . . . . . . . . . . . . . 197 798
. . . 51 . . . . . OIL . . . . 217 083
. . . . . . . . . . . . . . . . . . . 193 230
. . . . . . . . . . . . . . . . . . . 194 403
. . . 52 . . . . . A1 . . . ♦164 873
. . . 53 . . . . . V1 . . . ♦164 874
. . . 54 . . . . . . . . . . . . . 097 922
. . . 55 . . . . . . . . . . . . . 189 161
. . . 56 . . . . . . . . . . . . . 010 647
. . . 57 . . . . . . . . . . . . . 097 924
. . . . . . . . . . . . . . . . . . . 215 207
. . . . . . . . . . PLG6 . . . . 114 063
. . . . . . . . . . PLG8 . . . 193 184
. . . . . . . . . PLG13 . . 147 992
. . . . . . . . . . PLG3 . . . 158 465
. . . . . . . . . . . . . . . . . . . 088 731
. . . . . . . . . . . . . . . . . . . 135 873
. . . . . . . . . . . . . . . . . . . 187 654
. . . . . . . . . . . . . . . . . . . 024 103
. . . . . . . . . . . . . . . . . . . 120 304
. . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GAUGE, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . .
. . GAUGE, coolant temp 0− 300 deg f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . .
. . GAUGE, pressure oil 0−100 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, oil pressure sender (Deutz D2011L04i) . . . . . . . . . . . . . . . . . . .
. . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . .
. . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . .
. . HARNESS, unit weld control − CV (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . . . . . .
. . . . CONNECTOR, rect cinch 30 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 039 10p/s 2 row plug cable . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect univ 084 12p/s 3 row plug cable . . . . . . . . . . . . . . . .
. . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . .
. . . . CLIP, conduit convoluted 1/2 in mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SEAL, wire univ 12p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLANK, snap−in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
2
12
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 98
3
1
2
4
5
6
10
9
8
7
805 259-A
Figure 15-6. Auxiliary Power Group, Export
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-6. Auxiliary Power Group, Export
. . . 1 . . . . . . . . . . . . +223121 . . Panel, Aux Power (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 144844 . . Stand−off, No 6−32 X .875 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . ELCB1 . . 222991 . . Circuit Breaker, Elcb 20a 220v 0.030a Trip . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts Ce . . . . . . . . . . . . . . . . . 1
. . . 5 . . . GFCI1 . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . CB2 . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . RC1 . . . 176355 . . Rcpt, Str 2p3w 16a 220v Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 99
Hardware is common and
not available unless listed.
16
11
15
18
17
12
10
9
13
14
19
8
21
7
20
6
5
3
22
4
1
2
27
28
31
34
33
26
25
24
23
29
30
32
802 404-C
Figure 15-7. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-7. Generator (Figure 15-1 Item 35)
. . . 1 . . . . . . . . . . . . . 132 053 . . SCREW, 375-16 x 1.50hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 2 . . . . . . . . . . . . . 183 387 . . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195 911 . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 099 . . STATOR, exciter/gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . ♦213 448 . . STATOR, exciter/gen pwr (export models) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . +208 287 . . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦209 220 . . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . 190 197 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 172 674 . . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 039 207 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . ROTOR, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 210 446 . . . . ROTOR, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 024 617 . . . . . . RING, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 053 390 . . . . . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 210 447 . . . . FAN, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 210 332 . . . . . . PLATE, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 206 242 . . . . . . FAN, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . 049 026 . . . . . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . 083 883 . . . . . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . 080 389 . . . . . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 4
OM-4428 Page 100
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-7. Generator (Continued)
. . . 21 . . . . . . . . . . . . . 049 026
. . . 22 . . . . . . . . . . . . . 191 579
. . . 23 . . . . . . . . . . . . . 083 883
. . . 24 . . . . . . . . . . . . . 172 555
. . . 25 . . . . . . . . . . . . . 602 159
. . . 26 . . . . . . . . . . . . . 601 961
. . . 27 . . . . . . . . . . . . . . 602 211
. . . 28 . . . . . . . . . . . . . 139 341
. . . 29 . . . . . . . . . . . . . *190 823
. . . 30 . . . . . . . . . . . . . 208 469
. . . 31 . . . . . . . . . . . . . 189 142
. . . 32 . . . . . . . . . . . . . 602 242
. . . 33 . . . . . . . . . . . . . . 602 211
. . . 34 . . . . . . . . . . . . . 604 534
. . . . . . . . . . . . . . . . . . . 190 259
. . . . . . . . . . PLG1 . . . 168 071
. . . . . . . . . . . . . . . . . . . 187 651
. . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, starter hole Perkins/Continental . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . .
. . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw . . . . . . . . . . . . .
. . SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . .
. . SCREW, .312−18x1.25 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . .
. . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1
6
6
6
4
6
4
3
3
1
2
2
2
1
1
1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-4428 Page 101
4
Hardware is common and
not available unless listed.
3
2
1
5
6
7
8
9
802 279-A
Figure 15-8. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-8. Main Rectifier Assembly (Figure 15-1 Item 100)
. . . . . . . . . . SR3 . . . 215 910 . . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 188 137 . . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 188 517 . . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . 188 135 . . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 134 201 . . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . 215 755 . . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 188 136 . . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . 188 493 . . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 208 334 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 208 335 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 102
Effective January 1, 2008
(Equipment with a serial number preface of LJ or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend
models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
3.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2008-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2008 Miller Electric Mfg. Co. 2008−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com