Miller DEL-200 Owner Manual

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MILLER ELECTRIC MEG, CO.
718 S. BOUNDS ST. Р.О. Box 1079
APPLETON, Wi 54912 LISA
NWSA CODE NO. 4579
PRINTED iN U.S.A.
August1984 FORM: OM-412J
Effective With Serial No. JE772330
MODEL
DEL-200 {60 Hz)
DEL-200 {50 Hz)
LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ех-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY -Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miiler is free from defect in workmanship and
material as of the time and place of delivery by Miller. No war-
ranty is made by Miller with respect to engines, trade ac-
cessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any . All
engines are warranted by their manufacturer for one year from
date of original purchase.
Except as specified below, Miller's warranty does not apply
to components having normal useful hfe cf less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
Miller shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip-
ment to the original user:
1. Arc welders, power sources and components .. 1 year
2. Original main power rectifiers ................ 3 years
(labor - 1 year only)
3. Allwelding guns and feeder/guns ............ 90 days
4. All other Millermatic Feeders. ................. 1 year
5. Replacement or repair parts, exclusive of labor . 60 days
B. Batteries. . ..... ae 6 months
provided that Miller is notified in writing within thirty {30) days
of the date of such failure.
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As a matter of general policy only, Miller may honor clams Ne
submitted by the original user within the foregoing periods. O
In the case of Millers breach of warranty or any other duty / й
with respect to the quality of any goods, the exclusive remedies e
therefore shall be, at Miller's option {1) repair or (2) replacement q
or, where authorized in writing by Miller in appropriate cases, (3) Y
the reasonable cost of repair or replacement at an authorized f,
Miller service station or (4) payment of or credit for the purchase €
price {less reasonable depreciation based upon actual use) upon x
return of the goods at Customer's risk and expense. Upon receipt q
of notice of apparent defect or failure, Miller shail instruct the clai- Jr
mant on the warranty claim procedures to be followed. №
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND É)
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA- —
TION AS TO PERFORMANCE, AND ANY REMEDY FOR :
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, NA
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, 3
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING M
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO VE
ANY AND ALL EQUIPMENT FURNISHED BY MILLER 15 EX- *
CLUDED AND DISCLAIMED BY MILLER. u
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN Y
WRITING, MILLER PRODUCTS ARE INTENDED FOR fF
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL v
USERS AND FOR OPERATION BY PERSONS TRAINED AND N
EXPERIENCED IN THE USE AND MAINTENANCE OF j
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR №
CONSUMER USE. MILLER" WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND jf
MILLER'S WARRANTIES TO, ANY CONSUMER. :
y
7 SNE RF NCSA NT NER
ERRATA SHEET
August 23, 1985
FORM: OM-412J
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data
appearing later in this manual. |
Dia. Part Replaced
** Mkgs. No. With Description Quantity
2-29 - 603 124 095970 STRIP, rubber 18 inches. .............Ñ...... e... 0 íredcsiare, 2
2-45 070210 099268 BASE[(Effw/JF916666) .................... nunerarererecas. 1
3-61 070 010 097 829 BOLT, J1/4-20 x2-3/4................. . eerooorerdereredeo 2
4-16 SR1 045032 099190 RECTIFIER, silicon diode .................. 2... errada, 1
6- C6 049961 106 494 CAPACITOR, ceramic 0.1 uf 500 volts de ..................eeo.., 1
7-8 049 281 Deleted
099 267 UPRIGHT, base LH (Effw/JF916666)......................... 1
099 264 UPRIGHT, base RH (Eff w/JF916666)............—.....—...0.0.0.... 1
**First digit represents page no - digits following dash represents item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Es TABLE OF CONTENTS ea sa
Section No. Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. Introduction.........1122222 00441100 0 a a a a a 0 aa a ee eee eee. 1
1-2. General Précautions ..........0-2020 555 usa ee eee ee a ana 000000 1
1-3. ArcWelding. .. cco. i i rire eae 4
1-4. Standards Booklet Index ...........—————errserereereceresvere. 6
SECTION 2 - INTRODUCTION
2 - 1. General Information And Safety............0244 40011110 u 00 6 7
2-2. Receiving-Handling ........... ccc. 8
2-3. DesCrpliOn oie eee ie 8
SECTION 3 - INSTALLATION
3-1. I Yo) {To 2 R RR RER ns 0 8
3-2. Preparing New Battery For Service. ..........ee__eceeererevvveoes 9
3-3. =F nconmac e, 10
3-4. Lubrication...........ocomoe.ereceeomarosnerarr irene ono 10
3-5. Equipment Grounding Terminal .................. cei... 10
3-6. Weid Output Connections ...........—.—e_._e.errerrcereaereeneeo. 10
SECTION 4 - AUXILIARY POWER
4-1. Auxiliary Power Operation ..........—e.corrcrrec0aaaaa dore rarra, 12
4-2. Field Installation instructions For 240 Volts AC Duplex Receptacie
And Reconnection .......... eee earoernorororeereredaronn eo 14
SECTION 5 - OPERATOR CONTROLS
5-1. Range Switch ............eeeeeeeeenvrcociareeonereco nana. 15
5 - 2. Fine Amperage Controi ..........2202020000 40e a ee sea eee are 0 15
5-3. Volt-Ampere Curves...........2241 4444400 a a 1 eee a 1 eee 1200 0 15
5-4. Duty Cycle.............2...eeeeererrrrirrreseome vease cerarez. 15
5-5. Weld/Power Switch..........oec_e=-..e.e.eeeeorenesrreeór en. 15
5-6. Run/Stop Control...............0e. e... srerororrereerorecaro, 15
5-7, Start Switch .........e_eee.eeesemererarerrecammorrone canceme 16
5-8. Automatic idle Control Switch ........... Ca eae 16
5-9. OilPressure Switch.......1220 0 0e ee ea 0 4 a ee a a 4 4 a 0 0 8 0 a a ee ua 100 6 16
5-10. HourMeter ......1220200 000404444444 4e a a a a a a da a eee ee» 16
SECTION 6 - SEQUENCE OF OPERATION
6-1. Shieided Metal-Arc Welding ........20400 00800400 4 se era a sac 00 0 16
6-2. Power Plant Operation ...........ceoee..eeeeeeemenconeeee vena 17
6 - 3. Starting The Engine ........ PS 17
6-4. Stopping TheEngine ............20222000 0004 4e sa ea ae eau 0 0 17
SECTION 7 - MAINTENANCE
7-1. General................. 0... a. uaa0arararara nu a a a ann 17
7 - 2. PeriodicCleaning AndlInspection. ......... .................. 17
7-3. AirVentingTheFuelSystem. ......... co. iii... 17
7-4. AirCleaner Service .............c iii A 18
7 - 5. ‘EHectrical System. ............ 0 aa nue 18
7 - 6: -Idle'Control Circuit Protection ...............ee..eerecerrereca 18
7-7. Spark Arrestor.............e._..esrre carece near eveaenenaveven. 18
7-8. Brushes And Slip Rings ..........—r.eeeeeeesrenereosreoreraaD 18
7-9. Engine Speed Adjustments .............. RAA 19
Section No. Page No.
SECTION 8 - TROUBLESHOOTING
8 - 1. General. RER da a 19
8 - 2. TroubleshootingChart .............. ccc... 19
8-3. BoosterBatteryJump Starting .............. ci iii. 21
mSECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCEm
1-1. INTRODUCTION - We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un-
wise. Let the experience of others teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment,
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
These safe practices are divided into two Sections:
1 - General Precautions, common to arc welding and
cutting; and 2 - Arc Welding {and Cutting) (only).
Reference standards: Published Standards on safety are
also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards index in this manual. ANSI 249.1 is
the most complete,
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fiuxes can produce differant fumes, gases,
and radiation levels. In addition to the information
in this manual, be sure to consult flux and elec-
trode manufacturers for specific technical data
and precautionary measures concerning their
material.
A. Burn Prevention
Wear protective clothing - gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt coliar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im-
mediate treatment of fiash burns of the eyes and skin
burns.
Ear piugs shouid be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, iilness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan-
dard 249.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryilium -
bearing and similar materials, when welded {or cut} may
produce harmful concentrations of toxic fumes. Ade-
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be us-
ed,
Metals coated with or containing materials that emit
toxic fumes shouid not be heated unless coating is
removed from the work surface, the area is weli ven-
tilated, or the operator wears an air-suppiied respirator.
Work in a confined space only while it is being ven-
tilated and, if necessary, while wearing an air-supplied
raspirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into
a confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
OM-412 Page 1
highly toxic gas, and other lung and eye irritating pro-
ducts. The uitraviolet (radiant) energy of the arc can
also decompose trichioroethylene and per-
chloroethylene vapors to form phosgene. DO NOT
WELD or cut where solvent vapors can be drawn into
the welding or cutting atmosphere or where the radiant
energy can penetrate to atmospheres containing even
minute amounts of trichloroethylene or per-
chloroethylene. -
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
if combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ven-
tilators. If the work cannot be moved, move com-
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
snug-fitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on {or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire ex-
tinguishing equipment during and for some time after
welding or cutting if:
a. appreciable combustibles {including building
construction) are within 35 feet
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
c. openings {concealed or visible) in floors or
walls within 35 feet may expose com-
bustibles to sparks
d. combustibies adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions
have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
OM-412 Page 2
never be weided on or cut, uniess container has first
been cleaned as described in AWS Standard A6.0,
listed 3 in Standards index.
This includes: a thorough steam or caustic cieaning (or
a solvent or water washing, depending on the com-
bustible’s solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.0. Waterfilling just
below working level may substitute for inerting.
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
smell or sight to determine ¡f it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in
this manual, and those detailed in CGA Standard
P-1, PRECAUTIONS FOR SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS, listed 6 in
Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure: it is not intended to
protect any downstream equipment. Provide such
protection with one or more relief devices.
Never connect a regulator to a cylinder containing
gas other than that for which the regulator was
designed.
Remove fauity regulator from service immediately
for repair (first close cylinder valve). The following
symptoms indicate a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure continues to
rise with downstream valve closed.
Faulty Gauge - if gauge pointer does not move off
stop pin when pressurized, nor returns to stop pin
after pressure release,
Repair. Do NOT attempt repair. Send faulty
regulators for repair to manufacturer's designated
repair center, where special techniques and tools
are used by trained personnel.
2. Cylinders |
Cylinders must be handled carefully to prevent
leaks and damage to their walls, valves, or safety
devices:
Avoid electrical circuit contact with cylinders in-
cluding third rails, electrical wires, or welding cir-
cuits. They can produce short circuit arcs that may
lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is
an assurance cf safety when the cylinder is properly
handled.
Identifying gas content. Use only cylinders with
name of gas marked on them; do not rely on color to
identify gas content. Notify supplier if unmarked.
NEVER DEFACE or alter name, number, or other
markings on a cylinder. It is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT: keep them separate from FULLS and
return promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate or secure cylinders so they cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradie. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, fails,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. De NOT use a hammer or wrench to open
a cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchang-
ed.
3. Hose
Prohibited use. Never use hose other than that designed
for the specified gas. A general hose identification rule
Is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferruies or clamps designed for the hose (not or-
dinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangies.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate leaks.
Repair leaky or worn hose by cutting area out and splic-
ing (1-203). Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintiess cloth.
Match regulator to cylinder. Before connecting, check
that the regulator labei and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. i connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter {available from your sup-
piier} between cylinder and regulator, if ane is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet (or hose} connections may be iden-
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent
before opening cylinder {or manifold valve} by turning
adjusting screw in (clockwise). Draining prevents ex-
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized {gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open-to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of ivory
OM-412 Page 3
Liquid* or equivalent per galion of water). Bubbles in-
dicate leak. Clean off soapy water after test: dried soap
Is combustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
1-3. ARC WELDING - Comply with precautions in
1-1, 1-2, and this section. Arc Welding, properly done,
Is a safe process, but a careless operator invites trouble.
The equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us-
ed. The wise operator avoids unnecessary risks and pro-
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radia-
tion can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
DON'T GET BURNED; COMPLY WITH PRECAU-
TIONS.
1. Protective Clothing
Wear long-sleeve clothing {particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-
resistant leggings. Avoid outergarments of untreated
cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place
over face before striking arc.
*Trademark of Proctor & Gamble.
OM-412 Page 4
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when
broken, pitted, or spattered.
Flash goggles with side shields MUST be worn under
the helmet tc give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Locking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shielded arc} can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a
separate room or enclosed bay is best. In open areas,
surround the operation with low-reflective, non-
combustibie screens or panels. Allow for free air circula-
tion, particularly at floor level.
Viewing the weld. Provide face shields for all persons
who will be locking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Compiy with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc
welding squipment. It may overheat cables and cause a
fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
handling. ;
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SIT, LIE,
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp-
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
part - or grounded metal - reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
1. Grounding the Equipment
When arc welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 ‘Safety In Welding And Cut-
ing,” a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
When installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas ora flammable |-
quid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip-
ment ground lead to the third {live} wire, or the equip-
ment will become electrically HOT - a dangerous condi-
tion that can shock, possibly fatally.
Before weiding, check ground for continuity. Be sure
conductors are touching bare metai of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-
prong piug is added for connection to a grounded
mating receptacle, the ground iead must be connected
to the ground prong only. if the line cord comes with a
three-prong plug, connect to a grounded mating recep-
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to
join weiding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly - lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6. Electrode
a. Equipment with output on/off contro! (con-
tactor)
Welding power sources for use with the gas
metal arc weíding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per-
mit on-off control of the welding power out-
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b. Equipment without output on/off control
{no contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar pro-
cesses may not be equipped with welding
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never touch the electrode unless the
welding power source is off.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equip-
ment, shut OFF all power and remove line fuses {or lock
ОМ-412 Раде 5
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull ali 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
Leaving equipment unattended. Aiways shut OFF and
disconnect ail power to equipment.
Power disconnect switch must be available near the
welding power source.
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards
or their latest revisions and comply as applicable:
1. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O, Box
351040 |
Miami, FL 33135.
2. NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern-
ment Printing Office, Washington, D.C. 20402,
4. ANSI} Standard 287.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
5. ANSIStandardZ41.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
6. ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards institute, 1430 Broadway, New York,
NY 10018.
OM-412 Page 5
10.
11.
12.
13.
14.
15.
AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE HELD COM-
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd.
P.O. Box 351040, Miami FL 33135.
NFPA Standard 51, OXYGEN - FUEL GAS
SYSTEMS FOR WELDING AND CUTTING ob-
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
NFPA Standard 70-1978, NATIONAL ELEC-
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Bouievard, Rexdale, Ontario,
Canada M9W 1R3.
NWSA booklet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
American Welding Society Standard AWSF4.1
“Recommended Safe Practices for the Prepara-
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances”,
obtainable from the American Welding Society,
950 Le Jeune Rd. P.O. Box 351040, Miami, FL 33135.
ANSI Standard 288.2 ‘Practice for Respiratory
Protection’ obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
FEST SECTION 2 - INTRODUCTION m
Output Rating Welding Current Ranges Open- approx]
At 100% Welding in Amperes Circuit Weight
Duty Cycle Range Coarse Ranges | Fine Range| Voitage Power Net Ship
225 Amperes 45-225 Min.-40 1 kva, 115 volts, 8.7
At 25 Voits Amperes 40-55 From Min. 80 Volts amperes ac while
AC AC 55-75 To Max. A С welding 670 ibs. | 708 ‘bs
70-105 Of Each 72 Volts 4.5 kva, 120/240 volts — (204 kg) (321 ka)
200 Amperes | 35-200 90-135 Coarse DE 38/19 amperes 60 Hz. ac!
At 25 Volts | Amperes 115-165 Range (single-phase) as
DC DC 140-Max. power plant.
Figure 2-1. Specifications
7/16 in.
(11.1 mm) * |
Dia. {8 Holes) A
| N
AO > e |
` NN
| (mr q Q » |
| \ WT +! > |+ :
| > |
Л |
28-3/4 in. - с
(730 mm) Os | | |
| y | I I
| Y A +
Sg i | HY) F e
| Nl Equipment Г N
| | Grounding Е |
Terminal A |
|| В.
uf 49-1/4 in. Base Mounting Hole Dimensions | |
15 in. > — 11251 mm) Inches | Millimeters | |
+
B 38-3/8 974.7 Е |
< с 3 228.6 |
D 20-1/2 520.7 F
*23-1/2 in. (597 mm) Overall Width Е 37/8 A тс-070 939
Figure 2 - 2. Dimensional Drawing And Base Mounting Hole Layout
2-1. GENERAL INFORMATION AND SAFETY
A. General
information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip-
ment design, installation, operation, maintenance, and
troubleshooting which shouid be read, understood, gad
то
followed for safe and effective use of this equipmént
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment Is to
be installed, operated, and maintained only by qualifiec
persons in accordance with this manual and all ap-
plicable codes such as, but not limited to, those listed at
the end of Section 1 - Safety Rules For Operation Of
Arc Welding Power Source.
Safety instructions specifically pertaining to this unit ap-
pear throughout this manual highlighted by the signal
words gC ICH and Jes :RERgTeINE which identify
different leveis of hazard.
Ru el statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
AOL statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
OM-412 Page 7
A third signal word, EDO, highlights instruc-
tions which need special emphasis to obtain the most
efficient operation of this equipment.
=
2-2. RECEIVING-HANDLING - Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bili
of lading will be furnished by the manufacturer on re-
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
(or Style) Numbers of the equipment be supplied.
3-1. LOCATION (Figure 2-2)
Ae Vie ENGINE EXHAUST GASES can kill.
© Operate in open well ventilated areas or if
operated indoors vent engine exhaust outside the
building.
0 Keep engine exhaust vent outlet away from
building air intakes.
ENGINE EXHAUST SPARKS can cause fire.
e Exhaust spark arrestor must be installed in accor-
dance with local, state, and federal regulations.
The engine exhaust system on this welding generator
has not been equipped with a spark arrestor unless it
. was ordered as an optional accessory. A spark arrestor,
maintained in effective working order, is mandatory if
this welding generator is to be operated in a National
Forest or on California Grasslands, brush, or forest
covered land (see Section 4442 of California Public
Resources Code). For other areas, check your state and
local laws.
IMPROPER LIFTING OF EQUIPMENT can result in
personal injury and equipment damage.
® Use equipment of adequate capacity to lift the
unit,
® [fusing lift forks to handle this unit, be sure the lift
forks are long enough to extend out of the op-
posite side of the base.
Using lift forks too short will expose internal com-
ponents to damage should the tips of the lift forks
penetrate the bottom of the unit.
OPERATION ON UNLEVEL SURFACE can cause
improper lubrication and result in severe engine
damage.
® Operate unit in an approximately level position.
© See Figure 3-1 for maximum allowable tilt for pro-
per operation,
e Check crankcase oil level with unit on a level sur-
face.
RESTRICTED AIR FLOW causes overheating and
possible damage to internal parts.
® Maintain at least 18 inches (457 mm) of
unrestricted space on all sides of the unit and keep
underside free of obstructions.
e Do not place any filtering device over the intake air
passages of this welding generator.
Warranty is void if any type of filtering device is used.
OM-412 Page 8
2-3. DESCRIPTION - This unit is a constant current
ac/dc arc welding generator, driven by a one-cylinder
Deutz diesel engine. it is designed to be used for the
Shielded Metal-Arc Welding process.
Rated weld output is 225 amperes at 25 volts ac or 200
amperes at 25 volts dc. 1 kva of 115 volts (8.7 amperes)
100 Hertz ac auxiliary power is available while welding.
4.5 kva of 120/240 volts {38/19 amperes) 60 Hertz ac
auxiliary power is available when the engine is running
at power rpm.
SECTION 3 - INSTALLATION = sy a Ss
UNCONTROLLED TILTING OF TRAILER can result
in personal injury or equipment damage.
© Distribute weight so that trailer tongue weight is
approximately 10% of the gross trailer weight.
e Follow trailer manufacturer's instructions when
mounting welding generator onto trailer.
It is recommended that a properly fitting canvas cover
(optional) be placed over the welding generator when
not in operation to protect the unit from the environ-
ment. Be sure unit is cool before installing any cover.
This welding generator is provided with a lifting eye for
moving the unit and mounting holes in the base for
securing the unit in a permanent location, or to a runn-
ing gear, trailer, or transport vehicle. Figure 2-2 gives
overall dimensions and base mounting hole layout.
The mounting location should allow sufficient room to
remove the cover and side panels for maintenance and
repair functions.
The service life and operating efficiency of this unit are
reduced when the unit is subjected to high levels of
dust, dirt, moisture, corrosive vapors, and extreme
heat.
— AT
Side View
30
{
1
0] End View —
Figure 3 - 1. Allowable Tilt Angles
A-046 152
3-2. PREPARING NEW BATTERY FOR SER-
VICE - This unit may be equipped with a maintenance-
free battery, a conventional wet charged battery, or a
dry charged battery. Maintenance-free batteries do not
have conventional vent caps since they do not require
the addition of water during normal service. Once the
battery type is determined, read the following WARN-
ING and proceed to the appropriate section: A.
Maintenance-Free Battery; B. Wet Charged Battery; C.
Dry Charged Battery.
LG BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
® Wear correct eye and body protection when work-
ing with batteries.
ABNORMAL VOLTAGE can cause damage to
engine electrical components,
e Do not operate engine without the battery con-
nected.
8 Do not disconnect the battery while the engine is
running.
A. Maintenance-Free Battery
To place this battery in service connect the negative (-)
battery cable to the negative battery terminal. No other
preparation should be required.
B. Wet Charged Battery
Connect the negative (-) battery cable to the negative
terminal on the battery. If the battery has enough power
to start the engine, it will charge up while the engine is
running. However, if the battery fails to supply enough
power to crank the engine, the battery will require
recharging. |
PECLIDICS CHARGING A FROZEN BATTERY
can cause the battery to explode and result in
serious personal injury or damage to equipment.
e Check the state of the electrolyte solution and
allow battery to warm to 60°F (16°C) before
charging if electrolyte is frozen or slushy.
Remove the vent caps and refer to Section 3-2C, Steps
7-9 for charging instructions.
C. Dry Charged Battery
1. Obtain battery grade (1.265 specific gravity)
electrolyte solution.
2. Remove battery from unit and place on a level
work table or other suitable surface.
3. Remove vent caps.
RUZGINDISS BATTERY ACID can burn eyes and
skin and destroy clothing and other materials;
BATTERY GASES can explode and shatter the bat-
tery.
e Wear correct eye and body protection.
® Do not spill or splash battery fluid,
® Do not apply pressure to walls of filled bat-
tery— use battery carrier or place hands on op-
posite corners when lifting battery.
e Do not lean over battery when testing.
® Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
e Use enough ventilation to keep battery gases from
building up during activation.
4. Fill battery cells to top of separators with elec-
trolyte.
5. Allow battery to stand for 20 minutes.
6. Recheck electrolyte level and add if necessary to
fill to top of separators.
7. Check electrolyte temperature in one of the
center cells with a battery thermometer. For
each 10°F {6°C) increment above 83°F (27°C),
a correction factor of 0.004 specific gravity must
be added to the specific gravity reading taken in
Step 8. For each 10°F (6°) increment below
80°F (27°C), 0.004 must be subtracted from the
reading taken in Step 8.
8. Check the specific gravity of each cell with a
hydrometer. (Draw in and expel the electrolyte
two or three times from the first сей to be tested
to adjust the temperature of the hydrometer to
that of the electrolyte).
Follow the precautionary steps
below in addition to those given in the previous
WARNING statements.
e Use enough ventilation to keep battery gases from
building up during and for several hours after bat-
tery charging.
e Turn battery charger off before making connec-
tion to battery.
® Do not touch or move connections on battery
whife battery charger is on.
e Do not jean over battery when charging.
e Be sure battery charger connections to battery are
clean and tight,
O Be sure that vent caps are tight and level and
cover battery with a damp cloth.
e Be sure battery charger output matches battery
voltage.
9. If a corrected specific gravity reading of 1.260 at
80°F (27°C) is not obtained, replace the vent
caps and recharge the battery following the bat-
tery charger manufacturer's instructions.
BATTERY GASES can explode and
shatter the battery.
e Turn the battery charger off before disconnecting
the charger from the battery.
10. Recheck electrolyte level and add if necessary.
Le STE BATTERY ACID is corrosive to
metals.
e Do not pour electrolyte into a metal sink or drain.
OM-412 Page 9
11. Thoroughly rinse with water and mutilate empty
electrolyte containers before discarding.
12. Reinstall battery in welding generator.
13. Replace battery holddown and tighten securely.
Do not overtighten.
14, Connect positive (+) battery cable to positive
(+) battery terminal.
15. Connect negative (-) battery cable to negative (-)
battery terminal.
3-3. FUEL (Figure 3-2)
BULL ENGINE FUEL can cause fire or ex-
piosión. |
Do not spill fuel; if spilled, wipe up.
Do not fill fuel tank if engine is hot or running.
Do not refuel near sparks or open flame.
Do not smoke while refueling.
Do not fill fuel tank to top; allow 3/4 in. (19 mm)
from fuel to tank top for expansion.
USE OF GASOLINE will damage engine.
© Do not use gasoline to fuel a diesel engine.
Lack of lubrication in the fuel will damage the injector
pump and the injectors.
9868868
This welding generator is shipped with a smail amount
of fuel in the fuel tank, and the fuel shut-off vaive,
located under the fuel tank, in the open position. See
the Engine Manufacturer's Manual for fuel recommen-
dations. The capacity of the fuel tank is 3.5 gallons
{13.2 liters}.
ENGINE Fill fuel tank up to 3/4 in. (19 mm)
from top with fresh fuel before starting engine the first
time. Rust and corrosion preventative was added to in-
side of fuel tank and engine at the factory and could
cause rough engine running if not properly diluted with
a full tank of fresh fuel. If rough engine running Is en-
countered, contact the nearest Deutz service represen-
lative.
à LITERS/HR.
= IMP.GALJHR.
U.S. GAL/HR
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EL
3.78 0.83
—
=
2.84 0.62 —
al
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o
A
ом
o om
ka
in
35 0.71
25 50 75 190 125 150 175 200 225 250
WELD AMPERES AT 100% DUTY CYCLE
0.5 1.0 15 2.0 25 3.0 3.5 4.0 45
POWER KVA AT 100% DUTY CYCLE
B-088 605
Figure 3 - 2. Fuel Consumption Chart
Keep the fuel tank filled to ensure that the injector
system receives an adequate supply of fuel. If the fuel
tank is allowed to empty, air will enter the system caus-
ing starting problems (see Section 7-3 for procedures
on air venting the fuel system).
OM-412 Page 10
Figure 3-2 illustrates typical fuel consumption under
specific load conditions. Fuel consumption will vary
from one engine to another. Different brands of fuel,
operating conditions, condition of the engine, etc., will
affect the fuel consumption of this engine.
3-4. LUBRICATION (Figure 3-3) - The engine is
shipped with its crankcase filled with SAE-20 break-in
oil. if the oil level is not up to the full mark on the
dipstick, add oil according to the recommendations in
the Engine Manufacturers Manual before starting the
engine.
E
KEEP OIL mn
AT THIS LEVEL LL. de FULL
NEVER OPERATE
ENGINE WITH OIL
BELOW THIS LEVEL ——--- = СОМ
TA-900 435-8
Figure 3 - 3. Oil Level Indicator
3-5. EQUIPMENT GROUNDING TERMINAL
(Figure 2-2) - Normally engine-driven welding
generators do not require grounding. However, this
machine has auxiliary power plant capability; therefore,
grounding of the frame and case is recommended.
Also, unusual circumstances may require machine
grounding. For these reasons a convenient grounding
terminal is provided on all weld/power units.
For detailed grounding instructions consult your local
and state codes and the latest issue of the National Elec-
trical Code. if additional information regarding your par-
ticular operating circumstances and/or grounding re-
quirements is needed, consult a qualified electrician or
your dealer. After determining the extent to which any
grounding requirements apply to your particular situa-
tion, follow them explicitly.
3-6. WELD OUTPUT CONNECTIONS (Figure 5-1)
Le
To obtain the full rated output from this unit, it is
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance.
A. Welding Cables
If welding cables were not ordered with this unit, the
steps listed should be followed to ensure the best
welding performance:
1. Keep cables as short as possible and place cables
close together. Excessive cable length adds
resistance which may reduce output or cause
overloading of the unit.
Select adequate size welding cable for the an-
ticipated maximum weld current. Use. total
length of welding cable in the circuit to deter-
mine cable size. For example: If the electrode
holder cable is 75 feet (23 m) long and the work
cable is 25 feet (8 m) long, select the size cable
recommended in Table 3-1 for 100 ft {31 mj.
Do not use damaged or frayed cables.
install electrode holder to cable following
manufacturer's instructions, An insulated elec-
trode holder must be used to ensure operator
safety.
Install a correct size lug onto one end of work
cable, and install work clamp to cable.
Install jack plugs onto cables as instructed in
Subsection B.
Table 3-1. Welding Cable Size
WELDING
AMPERES} *50 1 100 150 200 250 300 350 400
100 4 4 2 2 2 1 1/0 1/0
150 2 2 2 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4/0
250 1/0 1/0 1/0 2/0 3/0 4/0 4/0 2-2/0
"TOTAL LENGTH OF CABLE (COPPER) IN WELD CIRCUIT
NOTE: "A.
A-002 702-A
50 FEET OR LESS.
*B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP,
“Cc. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT-
AGE (OCV) OF THE WELDING GENERATOR MUST BE
USED. WHILE MOST WELDING GENERATORS HAVE
AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100
VOLTS, SOME WELDING GENERATORS OF SPECIAL
DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE. |
Jack Plug Installation (Figure 3-4)
The red jack plugs are supplied to provide correct con-
nections to the weld output receptacles. Connect the
red jack piugs to the weld cables as follows:
1.
Remove 3/4 inch {19 mm) of insulation from one
end of each welding cable,
Clamp the welding cable in a vice with the unin-
sulated end protruding upward out of the vise
approximately 1-3/4 inches (44 mm}.
Place the steel tie wire (see item A, Figure 3-4)
approximately 1/4 inch (6 mm) from the end of
the insulation.
Make a half turn around the cable bringing the
looped ends of the tie wire together.
Insert a rod of approximately 3/8 inch (10 mm)
diameter through the two locped ends of the
WIre.
Twist the tie wire (B) until the entire tie wire Is
twisted and is tight around the insulation of the
welding cable.
Clip off the looped ends of the tie wire.
10.
11.
12.
13.
Bend the twisted tie wire over and along the side
{С} © the uninsulated portion of the welding
cable.
Wrap the strip of copper foil tightly around the
uninsulated end of the welding cable and twisted
tie wire (D).
Place the jack plug on the end of the welding
cable and push it onto the welding cable over the
copper foil (D).
Insert the 1/4-20 setscrews into the center and
bottom holes in the jack plug and tighten (E).
Remove the welding cable from the vise and in-
sert the jack plug into the insulating sleeve. Slide
the insulating sieeve over the jack plug and
welding cable until the hole in the insulating
sieeve lines up with the remaining hole in the jack .
plug.
Insert the 8-32 self-tapping screw (F) through
the hole in the insulating sleeve into the jack
piug. Tighten the screw with a screwdriver,
F E
TA-501 024-4 -
Figure 3 - 4. Jack Plug installation
Weld Output Receptacles (Figure 5-1)
Two AC WELD output receptacies and two DC
WELD output receptacles are provided for mak-
ing ac or dc weld output connections. Give the
jack plugs a quarter turn when inserting into the
receptacle. To remove the jack plugs, give a
quarter turn in the opposite direction while
withdrawing.
To obtain dc straight polarity weld output, con-
nect the Work cable jack plug to the POSITIVE
receptacle, and the Electrode cable jack plug to
the NEGATIVE receptacle.
To obtain dc reverse potarity weld output, the
above connections should be reversed.
OM-412 Page 11
For ac weld output, connect the Work cable jack
plug to the WORK receptacle and the Electrode
cable jack plug to the ELECTRODE receptacle.
ENTER ELECTRIC SHOCK can kill; ARCING
can burn skin or damage electrical connections.
® Do not touch five electrical parts.
® Ensure that the unit is completely shut down
before making any weld output connections.
WORK ELECTRODE
7 AC
WELD
4-1. AUXILIARY POWER OPERATION
POWER OUTPUT
ID (>
RANIA ELECTRIC SHOCK can kill.
e [Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-}
battery cable from battery before making internal
connections.
@ Do not connect to any electrical distribution
system normally supplied by utility power unless a
proper transfer switch and grounding procedure
are employed.
ELECTRIC SPARKS can cause fire.
® Disconnect welding cables when using auxiliary
power.
® Watch for fire.
e Keep appropriate fire extinguisher at work site and
be familiar with its use.
The weld output terminals are electrically energized
whenever the engine is running.
LOW VOLTAGE AND FREQUENCY can damage
electrical equipment.
© Turn off all electrical equipment connected to the
120V 30A AC (optional 240V 15A AC) or T15V
AC WHILE WELDING receptacle before starting
or stopping the engine.
® Place the Idle Control Switch in the AUTO IDLE
OFF position when using the 115V AC WHILE
WELDING receptacle.
e Rotate the FINE AMPERAGE control to 100 when
using the 120V 30A AC (or 240V 15A AC) recep-
tacie.
When starting or stopping, the engine has low speed
which causes low voltage and frequency.
A. 115 Volts AC While Welding {Figure 4-1}
115V7 AC
WHILE WELDING
OM-412 Page 12
; SECTION 4 - AUXILIARY POWER
® Do not change position of the welding cable jack
plugs while welding.
© Be sure that jack plugs are secure in correct recep-
tacles before welding.
1. Connect the weld cables to the appropriate weid
output receptacles.
2. Ensure that all connections are clean and tight.
NEGATIVE POSITIVE
EEE
DC
WELD
— . EEE !
This receptacle is provided to supply power for ac-
cessory equipment used with the welding process.
Power available at this receptacle is rated at 1000
watts/8.7 amperes of 115 volts ac, 100 Hz. while
welding. The engine must be operating at weld rpm to
obtain the power output. Be sure that the Automatic
Idle Control switch is in the AUTO IDLE OFF position
when using power from this receptacie.
ELUUEYE IMPROPER FREQUENCY can
damage equipment.
e Do not operated equipment rated only for 50 or 60
Hertz from this receptacle.
® Use receptacle power only for operating
resistance heaters without fans, incandescent
lights, and universal power tools.
B. 120 Volts AC Power Plant (Figures 4-1 And
5-1)
120V 30A "Ny AC
Up to 4.5 kva of 120 volts ac, 38 amperes, 60 Hz. (3
kva if the unit is a 50 Hz. model) power is available at
this duplex receptacle; however, the power supplied is
dependent on the amount of power being used from the
120/240 Volts AC terminal strip. In all cases, total ac
auxiliary power output cannot exceed unit rating 4.5
kva. Whenever this receptacle is used, the engine must
be operating at power rpm and the Weld Power switch
must be in the POWER position.
o
- 260 130
S
er 240 120 ,
60 Hz.
> 220 110 50 Hz. °
© 200 100 A | | Ä |
I 0 10 20 30 40 50
AC POWER AMPERES AT 120V.
0 5 10 15 20 25
AC POWER AMPERES AT 240Y.
8-088 082
Figure 4 - 1. AC Power Curves
C. 120/240 Volts AC Terminal Strip (Figures 4-2
And 4-3)
This welding generator is equipped with a four-pole ter-
minal strip 1T located behind the right side panel. The
terminal strip serves as a connection point when aux-
iliary power is needed. Because this unit has power
plant capability, grounding of the generator frame and
case may be required. See Section 3-5 for specific infor-
mation on grounding this unit.
If there are any questions regarding proper connection
to terminal strip 1T and/or correct circuit grounding
procedures, consult a qualified electrician.
To make connection from an externa! load to terminal
strip 1T, proceed as follows:
1. Remove the right side panel.
2. Insert ieads through the strain relief provided on
the generator rear panel. Route the leads over to
terminal strip 17. See Figure 4-2.
De: This unit is shipped with the jumper
links on terminal strip 1T positioned for 120 volts (see
Figure 4-3). (If the unit is equipped with an optional 240
volts ac receptacle, the jumper links wiil be positioned
for 240 volts).
Welding Generator :
Right Side Panel
120/240 Volts AC
Termina! Strip
120/240 Volts AC Cable
Input Hole And
Strain Relief y
B-049 944-A
Figure 4 - 2. Location of 120/240 Volts
Terminal Strip
Lead No, 58 To ol]
Lead No. 58
240 Volts AC (Optional)
TA-049 945
:
120 Volts AC (Standard)
Figure 4 - 3. Jumper Link Arrangement 120/240
Volts AC Terminal Strip
A total of 4.5 kva of 120 volts, 38 amperes, 60 Hz. ac
auxiliary power (3.0 kva if the unit is a 50 Hz. model) is
available from this unit. When the unit is linked for 120
volts, full kva is available at either half of the 120V 30A
AC receptacle or from terminal strip 1T.
If the unit is linked for 240 volts, 1/2 of the total kva of
the unit is available at either half of the 120 volts duplex
receptacie or full kva can be obtained at the terminal
strip. In ali cases, when power is supplied to the duplex
receptacle and/or the terminal strip, total ac auxiliary
power cannot exceed unit rating. |
When making lead connections to terminal strip 1T use
ring terminals to ensure that proper connections are
made.
3. For 120 volts ac auxiliary power:
a. Connect one lead to terminal A or B on ter-
minal strip 1T.
b. Connect remaining lead to terminal C or D
on terminal strip 1T.
с. Ensure that the jumper links on terminal strip
1T are positioned for 120 volts ac (see
Figure 4-3).
d. If the circuit must be grounded, connect a
ground lead to the ground terminal below
terminal strip 1T.
e. Tighten strain relief on generator rear panel.
f. Install right side panel and resume operation.
For 240 volts ac auxiliary power:
a. Remove and retain the jumper links from ter-
mina! strip 1T.
b. Move lead No. 58 from terminal B to ter-
minal D on the same side of termina! strip
1T.
c. Position the jumper links on 1T for 240 volts
ac (see Figure 4-3).
d. Connect line leads to terminals A and D on
terminal strip 1T.
e. If the circuit must be grounded, connect a
ground lead to the ground terminal below
terminal strip 1T.
f. Tighten strain relief on generator rear panel.
g. Install right side panel and resume operation.
For 120/240 volts ac auxiliary power:
a. Remove and retain the jumper links from ter-
minal strip 1T.
OM-412 Page 13
b. Move lead No. 58 from terminal B to ter-
minal D on the same side of terminal strip
1T.
c. Position the jumper links on 1T for 240 volts
ac (see Figure 4-3).
d. Connect line leads to terminals A and D on
terminal strip 1T.
e. Connect neutral lead to terminal B on ter-
minal strip 1T.
f. If the power supply neutral must be ground-
ed, connect a ground lead from terminal C
on terminal strip 1T to the ground terminal
below terminal strip 1T.
g. [If the circuit must be grounded, connect a
ground lead to the ground terminal below
terminal strip 1T.
h. Tighten strain relief on generator rear panel.
i. Install right side panel and resume operation.
D. 240 Volts AC Receptacle (Optional) (Figure
3-6)
Up to 4.5 kva of 240 volts, 19 amperes, 60 Hz. ac
power is available at this duplex receptacle; however,
the power supplied is dependent on the amount of
power being used at the 120/240 Volts AC terminal
strip. In all cases, total ac auxiliary power output cannot
exceed unit rating {4.5 kva). Whenever this receptacle
is used, the engine must be operating at power rom and
the Weld/Power switch must be in the POWER posi-
tion,
4-2. FIELD INSTALLATION INSTRUCTIONS FOR
240 VOLTS AC DUPLEX RECEPTACLE AND
RECONNECTION
The 120/240 Volts AC terminal strip (see Figure 4-2)
provides reconnection capability for 240 volts ac.
Although the capability for 240 voits ac is present, an
optional kit must be purchased if 240 volts is desired at
the front panel. For the 240 volts ac auxiliary power out-
put of the unit, see Section 4-1D.
DAUER ELECTRIC SHOCK can kill,
e Do not touch live electrical parts.
® $Shutdown the engine and disconnect negative (-)
battery cable from battery before making internal
inspection or reconnection.
1. Remove right side panel.
2. Remove 120 VOLTS AC duplex receptacle RC2
located on the front panel. Remove leads and
allow them to hang free.
3. Connect leads No. 56 and 58 removed from RC2
to the 240 volts ac duplex receptacie (one on
each side of receptacle). Connect lead No. 33 to
the ground terminal on the receptacie.
4. Install the 240 volts ac duplex receptacie in the
front panel.
5. Affix supplied 240 VOLTS AC label over existing
120 VOLTS AC designation for duplex recep-
tacle on nameplate.
6. Locate terminal strip 1T on the right side of the
welding generator (see Figure 4-2). Disconnect
two leads No. 57 from terminal strip 1T. Tape up
terminals on both leads No, 57 and tie leads into
wiring harness.
7. Remove and retain the jumper links from ter-
mina! strip 1T.
8. Move lead No, 58 from terminal B to terminal D
on the same side of terminal strip 1T,
9. Position the jumper links on 1T for 240 volts ac
(see Figure 4-3).
10. Install right side panel and resume operation.
HK SECTION 5 - OPERATOR CONTROLS ema E
Range Switch —
——ÑRun/ Stop
Control
Fine Amperage Control
Start
Switch
Idle Control
— Switch
Г — Weld/Power Switch
7 C6 fo Ag > О
X) Y ->- =D lou 115V AC While
/ 3 N Welding
- 120V 30A AC TA.
1 Work м Electrode ; \ Negative + Positive Receptacle Ref: TA-048 782
AC Weld Output DC Weld Output
Figure 5 - 1. Front Pane! Controls
OM-412 Page 14
5-1. RANGE SWITCH (Figure 5-1)
A
AMPERE RANGE”
The Range switch provides seven coarse amperage
ranges. The range of each switch position is displayed
on the scale surrounding the Range switch handle.
DANN ARCING can damage switch con-
tacts.
Vo ‘о
o° / 40
® Do not change the position of the Range switch
while welding or under load.
Arcing causes the contacts to become pitted and even-
tually inoperative.
5-2. FINE AMPERAGE CONTROL (Figure 5-1)
A
FINE
AMPERAGE
The FINE AMPERAGE control permits the operator to
select a welding current between the minimum and
maximum values of the coarse range selected by the
Range switch. The scale surrounding the control is
calibrated in percent and does not indicate an actual
amperage valve,
Ze: NIE The FINE AMPERAGE contro! can be
adjusted while welding. However the FINE AMPERAGE
control must be set at 100 to obtain the full rated output
from the 120V 30A AC receptacle when the welding
generator 15 used to supply ac auxiliary power,
5-3. VOLT-AMPERE CURVES (Figure 5-2)
80
AC VOLTS
5 100 155 200 750 300 350 B-047 085
AC AMPERES
DC VOLTS
Je
o
159 700 250 300 350 400 450 500
DC AMPERES
B-047 038
Figure 5 - 2. Volt-Ampere Curves
at the proper speed for welding.
The volt-ampere curves show the voltage and amperage
output capabilities of the welding generator at min. and
max. of each coarse range. Voltage and amperage ad-
justment within each range is provided by the FINE
AMPERAGE control.
With the use of the volt-ampere curves it is possible to
determine the load voltage at any particular weld cur-
rent.
5-4. DUTY CYCLE {Figure 5-3} - The duty cycle of
the welding generator is the percentage of a ten minute
period that a welding generator can be operated at a
given output without causing overheating and damage
to the unit. This welding generator is rated at 100 per-
cent duty cycle. This means that this unit can be
operated at rated load continuously. This unit,
however, does not offer output in excess of its rating if
the duty cycle is decreased.
RATED OUTPUT —
300
no
can
a
N
N
tn
sm
=
=
—
n
=
WELDING AMPERES
2
100 | i | ] J ! |
25 30 40 50 60 70 80 90 100
% DUTY CYCLE
68-057 360-B
Figure 5 - 3. Duty Cycle Chart
(ATT EE EXCEEDING DUTY CYCLE RATINGS
will damage the welding generator.
e Do not exceed indicated duty cycles.
5-5. WELD/POWER SWITCH {Figure 5-1)
WELD POWER
The Weld/Power switch provides selection of weld
curent or power plant output. Placing the Weld/ Power
switch in the WELD position enables the engine to run
Placing the
Weld/Power switch in the POWER position enables the
engine to run at the proper speed for auxiliary power.
5-6. RUN/STOP CONTROL (Figure 5-1)
RUN ta) STOP
IN = ov
>
The RUN/STOP control controls the flow of fuel to the
injector pump. The RUN/STOP contro! must be pushed
fully in to the RUN position when starting the engine.
OM-412 Page 15
Putiing the RUN/STOP control fully out shuts off fuel to
the injector pump, thereby stopping the engine.
5-7. START SWITCH (Figure 5-1)
the START switch is a spring-loaded toggle switch.
Placing the switch in the START position will engage
the starter. The switch must be released as soon as the
engine has started to prevent damage to the starter.
gerrvrdlel E: REENGAGING STARTER MOTOR
while fiywheel is rotating can damage starting
components.
® Do not reengage starter motor until starter pinion
and flywheel have stopped rotating.
5-8. AUTOMATIC IDLE CONTROL SWITCH
(Figure 5-1) - The automatic idling device reduces fuel
consumption during welding operation by aliowing the
engine io idle when the generator is not loaded. The
Automatic idle Control switch controls the operation of
the device.
A. Auto idie On
Na AUTO
IDLE ON
When the Automatic Idle contro! switch is in the AUTO
IDLE ON position, the engine will remain at idle rpm,
1860 + 100 for 60 Hz. Models {1660 + 100 for 50 Hz.
Models), until an arc is struck. When an arc is struck,
the engine speed will increase to weld rpm (3000). Ap-
proximately 15 seconds after the arc is broken, the
engine will return to idle rpm. This time delay is nonad-
justable.
The Automatic Idle control AUTO IDLE ON position can
be used for Shielded Metal-Arc Welding.
B. Auto [dle Off
AUTO
о IDLE OFF
When the Automatic Idle control switch is in the AUTO
IDLE OFF position, engine speed remains at weld rpm
when the generator is not loaded.
5 - 9. OIL PRESSURE SWITCH - This unit is equip-
ped with an oil pressure switch S2 which automatically
disconnects the battery from the excitation and idle
control circuitry when the engine shuts down. |
5-10. HOUR METER (Optional) - This unit can be
equipped with an hour meter. The meter, labeled
TOTAL HOURS, registers the total hours of engine
operation. This information is useful for routine
maintenance on the engine.
Buel MOVING PARTS can cause serious
injury: IMPROPER AIR FLOW can result in damage
to internal parts; EXPOSURE TO WEATHER can
shorten the life of internal components.
® Keep all covers and panels in place while
operating.
S Protect yourself with dry insulating gloves and
clothing.
@ Stop and disable engine before inspecting or ser-
vICINg.
® Keep clear of moving parts, i.e., fans, belts,
rotors, etc.
Warranty is void if the welding generator is operated
with any portion of the outer enclosure open or remov-
ed.
ARC RAYS, HOT SLAG, AND SPARKS can burn
eves and skin; NOISE can damage hearing.
8 Wear correct eye, ear, and body protection.
HOT METAL, SPATTER, SLAG, AND EXHAUST
OR ARC SPARKS can cause fire.
® Watch for fire.
® Keep appropriate fire extinguisher at work site and
be familiar with its use.
® (se exhaust spark arrestor in accordance with
focal, state, and federal regulations.
® Disconnect welding cables when using auxiliary
power.
See Section 1 - Safety Rules For Operation Of Arc
Welding Power Source for protective information.
OM-412 Page 16
6-1. SHIELDED METAL-ARC WELDING
1. Ensure that the unit has been installed and
prepared as Instructed in Section 3.
2. Rotate the Range switch to the desired position
(see Section 5-1).
3. Rotate the FINE AMPERAGE control to the
desired setting (see Section 5-3).
4. Place the Weld/Power switch in the WELD posi-
tion.
5. Connect the work clamp to the object to be
welded. Place the desired electrode into the elec-
trode holder.
O. Start the engine as instructed in Section 6-3.
7. Connect desired accessory equipment to the
115V AC receptacle (see Section 4-1A), Ensure
that all ac auxiliary equipment is turned off or
disconnected.
8. Place the Automatic idle Control switch in the
desired position.
9. Begin welding.
6-2. POWER PLANT OPERATION
1. Ensure that the unit has been installed and
prepared as instructed in Section 3.
Follow the precautionary steps given in
the WARNING at the beginning of Section 4-1.
2. Make connections to the 120V 30A AC recep-
tacle (see Section 4-1B) and/or the 120/240
Volts AC terminal strip (see Section 4-1C).
3. Place the Weld/Power switch in the POWER
position.
4. Rotate the FINE AMPERAGE contro! to 100.
5. Start the engine as instructed in Section 6-3.
6. Turn on auxiliary equipment when the engine
has come up to proper speed.
6-3. STARTING THE ENGINE
1. Push the RUN/STOP control fully in to the RUN
position.
m= SECTION 7 -
RZ ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable from battery, if applicable, before in-
ternally inspecting or servicing.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, ie., fans, belts,
rotors, etc.
HOT SURFACES can cause burns.
® Allow equipment and work to cool before
touching.
Maintenance to be performed only by qualified persons.
7-1. GENERAL - The service life of this welding
generator can be prolonged and operating efficiency
maintained under normal conditions by following the
routine service and workshop maintenance procedures
outlined in this section and in the Engine
Manufacturers Manual (F1L 210D Engine). Where
operating conditions are severe, more frequent atten-
tion must be given to all routine service categories:
however a special effort must be made to maintain
clean internal and external engine surfaces.
7-2. PERIODIC CLEANING AND INSPECTION - A
schedule for cleaning and inspection should be set up,
based on the type and conditions of service, to include
the following:
Keep the inside of the unit clean by blowing out the unit
with clean, dry compressed air.
Wipe oil and fuel spills from engine immediately to avoid
accumulation of dust.
2. Place the Automatic Idle Control switch in the
AUTO IDLE ON position.
3. Place the Starter switch in the START position
(see Section 5-7).
4. As soon as the engine starts, release the START
switch and allow the engine to run for a few
minutes before applying a load. This is necessary
to enable the engine tc properly warm up and en-
sure proper lubrication.
6-4. STOPPING THE ENGINE
1. Remove all weld and power icads from the unit.
2. Place the Automatic Idle Control switch in the
AUTO IDLE ON position.
3. Operate the engine at idle speed for 2 minutes to
allow internal engine temperature to equalize.
4. Puil the RUN/STOP control fully out to the
STOP position. After the engine has stopped,
return the RUN/STOP control to the RUN posi-
tion,
M A | N ] E N A Ni C E TA NR AR INERTES ne
Check for fluid leaks indicating loose oil or fuel connec-
tions. Tighten loose connections and clean oi! or fuel
spills or leaks off engine surfaces.
iV RENE BE Periodically inspect the labels on this
unit for legibility. All precautionary labels must be main-
tained in a clearly readable state and replaced when
necessary. See the Parts List for part number of precau-
tionary labels,
7-3. AIR VENTING THE FUEL SYSTEM
1. Loosen thumb screw and slide retaining spring
off hand primer on fuel pump mounted to base
on left side of engine.
2. Loosen bleed screw in banjo connector at injec-
tion pump {see Engine Owner's Manual for pump
location).
3. Hand prime the injection pump until fuel free of
bubbles emerges.
4. Lock primer pump and tighten bleed screw.
9. “Start the engine. If the engine does not run pro-
репу, loosen the bleed screw until air is com-
pletely vented from fuel line. Tighten bleed
screw.
BARES /f the engine still does not run proper-
y, loosen injection line at injector (see Engine Owner's
Manual for injector location}: crank engine until fuel free
of bubbles emerges at injector; tighten injection fine.
OM-412 Page 17
7-4. AIR CLEANER SERVICE - The air cleaner is
one of the most important parts of the engine from the
standpoint of engine life. An engine consumes several
thousand cubic feet of air per hour when operating. If
dirty air gets into the engine, it can wear out a set of
piston rings within a few operating hours. See the
Engine Manufacturer's Manual for oil bath air cleaner
maintenance intervals and service procedures.
oy {Nile DIRTY AIR can damage engine.
@ Do not operate engine with dirty air cleaner.
e Do not operate engine without air cleaner in place.
7-5. ELECTRICAL SYSTEM
A. Cables And Wiring
Check “interconnecting wiring and connections for
tightness and flaws. Ensure that the weld output cable
connections are clean and tight. Check the insulation
for breaks or other signs of damage. Repair or replace
cables or wiring as necessary.
B. Battery
ENDE BATTERY ACID can burn eyes and
skin and destroy clothing and other materials.
e Wear correct eye and body protection.
Periodically inspect the battery for loose connections,
defective cables, corrosion, cracked case or cover,
loose holddowns, and loose or deformed terminal
posts.
On units equipped with conventional wet or dry charged
batteries with removable vent caps, check the elec-
trolyte level frequently. Add clean, mineral-free or
distilled water to bring the electrolyte in each cell up to
the level indicator.
7-6. IDLE CONTROL CIRCUIT PROTECTION - The
idle control printed circuit board and the throttle
solenoid are protected by an automatic reset circuit
breaker CB1 located behind the right side panel.
Normally, this circuit breaker should not trip. However,
if an arc is struck or the AUTO IDLE switch is placed in
the OFF position after the throttle solenoid has
deenergized and the engine is slowing down, CB1 may
trip. if this occurs, wait approximately one minute
before resuming operation.
7-7. SPARK ARRESTOR (Optional) - Internal com-
bustion engines operating in a highly combustible en-
vironment are a common fire hazard. Glowing carbon
particles blown out with the exhaust can retain suffi-
cient heat to ignite materials. While no practical spark
arresting device will stop all sparks, this device will
minimize fire hazards by removing and trapping most
solid particles provided that it is properly maintained.
The carbon trap should be serviced weekly or every 50
operating hours, whichever occurs first. The entire
spark arrestor should be inspected every 1000 operating
hours or three times per season.
OM-412 Page 18
A. Inspection
1. Visually examine the outside of the device for
holes, cracks, or metal corrosion.
2. With the engine stopped, !ook inside the spark
arrestor outlet tube with a flashlight or other light
source. Visually examine the vanes and the
outlet tube for metal or weid failure. The vanes
must be firmly attached to the inlet tube and the
outlet tube must be completely intact (this is an
important factor in maintaining spark arresting
efficiency).
3. Check the mounting clamp to ensure that the
spark arrestor is securely mounted. Replace the
spark arrestor if inspection reveals any signs of
failure.
-———
B. Servicing The Carbon Trap
“CAUTION-: Service the device in an area where there
is no danger from flying sparks or hot carbon particles.
1. Stop the engine and allow the exhaust system 16
cool.
2. Remove the cleanout plug from the bottom of
the spark arrestor with a wrench. if a crust has
formed over the hole, break it loose with a
screwdriver or similar tool.
3. Start the engine and run it at idle rpm to blow
collected particles out the cleanout hole. If par-
ticles are slow to discharge, momentarily cover
the end of the exhaust stack.
4. Stop the engine. Replace and secure the
cleanout plug.
7-8. BRUSHES AND SLIP RINGS (Figure
7-1) - Brush life is very good under normal operating
conditions. The brushes and slip rings should be in-
spected every six months or whenever excitation
voltage is lost. Check for cleantiness of the slip rings and
freedom of motion of the brushes. If the welding
generator has been operating under extremely dusty or
dirty conditions, increase the frequence of inspection.
1/4 in. {6.4 mm)
Minimum
Figure 7 - 1. Brush Replacement
TA-083 205
Under norma! use the slip rings will discolor to a dark
brown. if a buildup of brush material is noted, it may be
necessary to clean the slip rings. Use a 3/0 or finer
sandpaper followed by a crocus cloth. Never use emery
cloth as part of the emery will embed itself into the rings
and in turn destroy the carbon brushes.
Replace the brushes if they become chipped or broken
or if less than 1/4 in. (6.4 mm) of brush material is left.
7-9. ENGINE SPEED ADJUSTMENTS (Figure 7-2)
Dude AVR Engine speed adjustments should be
made by an authorized diesel machanic.
The engine speeds have been factory adjusted and will
not require frequent readjustment. After tuning the
engine, check the speeds with a tachometer. With no
load applied, the power speed should be 1860 rpm for
60 Hz. Models (1650 for 50 Hz. Models} and the weld
speed 3000 rpm. If necessary adjust the speeds as
follows:
Speed Control
Lever Speed Control
Plunger
Knurled Nut
7
e
i)
CC)
с)
C=
EF
Throttie Spring
Weld Speed
ы Locking Nuts
Locking Nut
Plunger
— Throttie Solenoid
А-070 474
Figure 7 - 2. Engine Speed Adiustments
A. Idle Speed Adjustment
1. Start the engine as outlined in Section 6-3.
2. Place the Weid/Power switch in the POWER
position. | |
3. Rotate the FINE AMPERAGE control to 100.
A Weld Speed Adjustment Nut
4. Ensure that the speed control lever does not con-
tact the speed control plunger during the follow-
Ing adjustment:
Loosen the idle speed locking nut. Rotate the
knurled adjustment nut until 1860 rpm is obtain-
ed. Tighten the locking nut.
В. Weld Speed Adjustment
1. Shut down the engine.
2. Remove the lead seal from the weld speed ad-
justment nut.
3. Press the plunger to the bottom of the throttle
solenoid and check for 1/8 + 1/16 inch (3.2 +
1.6 mm) stretch in throttle spring. If adjustment
is necessary, loosen the appropriate locking nut
on the plunger and rotate the remaining locking
nut to obtain the proper distance.
4. Start the engine as outlined in Section 6-3.
5. Place the Weid/ Power switch in the WELD posi-
tion.
6. Place the Automatic idle Control switch in the -
AUTO IDLE OFF position.
7. Loosen the weld speed locking nut and rotate
the weld speed adjustment nut until 3000 rpm is
obtained. Check for proper throttle spring
stretch. Readjust spring stretch if necessary and
recheck weld speed. Tighten locking nut.
MAC E: NERE /f the throttle spring works loose or is
disconnected, reattach the spring as shown in Figure
7-2.
8. Shut down the engine.
9. Reseal the weld speed adjustment nut.
8-1. GENERAL - !tis assumed that proper installation
has been made, according to Section 3 of this manual,
and that the welding generator has been functioning
properly until this trouble developed.
8-2. TROUBLESHOOTING CHART
AZ Ne ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Shut down the engine and disconnect negative (-)
battery cable from battery before internally in-
specting or servicing.
MOVING PARTS can cause severs injury.
® Keep clear of moving parts, ie., fans, belts,
rotors, etc.
HOT ENGINE PARTS can cause severe burns.
® Wear protective gloves and clothing when work-
ing on a hot engine.
Troubleshooting of internal parts to be performed only
by qualified persons.
Use the chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro-
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. in ail cases of equipment
malfunction, the manufacturer's recommendations
should be strictly followed.
OM-412 Page 19
TROUBLE
PROBABLE CAUSE
REMEDY
Engine fails to start.
Battery.
Units With Conventional Batteries: Inspect the
electrica! system (see Section 7-5). If the battery
requires recharging (see Section 3-2C, Steps
7-10) follow al! applicable safety procedures and
the battery charger manufacturer's instructions.
Never use a battery charger without these instruc-
tions. If the battery does not recharge, replace the
battery.
Units With Maintenance-Free Batteries: Inspect
the electrical system (see Section 7-5). If the trou-
ble is isolated to the battery, replace the battery.
Jump start the engine employing approved safety
practices and booster jump starting instructions
provided in Section 8-3.
Battery discharges between
uses.
Build-up of acid on top of
battery (white-grayish
substance).
Clean battery with soda solution; rinse with clear
water.
infrequent use (units with
conventional batteries
only).
Periodically recharge battery (approximately every
3 months).
Defective battery.
Replace battery.
Defective oii
switch $2.
pressure
Replace S2.
No power output at power
receptacies.
Weld/ Power switch $1 in
WELD position.
Расе $1 in POWER position.
Low power output at power
receptacles.
Low setting on FINE
AMPERAGE control R1.
Rotate R1 to 100.
Engine running below re-
quired speed (1860 rpm).
Check air filter; clean if necessary.
Adjust engine speed (see Section 7-9).
Voitage Regulator board | Replace PC2.
PC2 defective.
Transformer T1 defective. Replace T1.
Low weld output.
Engine running below re-
quired speed (3000 rpm).
Check air filter; clean if necessary.
Fill fuel tank.
Adjust engine speed (see Section 7-91.
Erratic weld output.
Damp, defective, or wrong
type electrodes.
Try different electrodes.
Improper connection 10
workpiece.
Check and tighten loose connections.
Erratic weld and power out-
put.
Dirty slip rings and/or worn
brushes.
Clean slip rings and/or replace worn brushes (see
Section 7-8).
High power voltage.
Voitage Regulator board
PC2 defective.
Replace PC2.
OM-412 Page 20
TROUBLE
PROBABLE CAUSE
REMEDY
High weld voltage.
Voltage Regulator board
PC2 defective.
Disconnect lead No. 48 from Voltage Regulator
board PC2. If voltage drops to 80 volts ac, replace
Voltage Regulator board PC2.
8-3. BOOSTER BATTERY JUMP STARTING - If
jump starting is attempted, employ the safety precau-
tions below and the following step by step procedures
in order of appearance.
BATTERY GASES OR A DAMAGED
BATTERY can explode thereby shattering the bat-
tery; BATTERY ACID can burn eyes, skin, destroy
clothing, and damage other material; MOVING
PARTS and IMPROPER CONNECTIONS can cause
serious personal injury and damage equipment.
Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
Ensure that all personnel are a safe distance from
batteries and clear of moving parts while starting.
Do not jump start a frozen or completely discharg-
ed battery.
Do not jump start a battery which has loose ter-
minals or one having evidence of damage such as
a cracked case or cover.
Be sure that vent caps are tight and level on both
batteries and cover both batteries with a damp
cloth.
Wear correct eye and body protection and remove
all metal jewelry.
Keep jumper cables clear of moving parts.
Ensure that both batteries are the same voltage.
Do not jump start a trailer mounted welding
generator with the towing vehicle battery unless
the trailer is completely disconnected from the
towing vehicle.
Do not jump start a vehicle mounted welding
generator from the vehicle battery.
If booster battery is installed in a vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
Do not jump start by applying power to weld out-
put receptacles or terminals.
Do not allow jumper cable clamps to contact any
other metal while attaching or removing cables.
1.
10.
11.
Use properly insulated jumper cables of ade-
quate size.
Connect ends of one cable to positive (+) ter-
minals of each battery.
Connect one end of other cable to negative (-)
terminal of booster battery.
Connect remaining end of cable to welding
generator engine block at least 18 inches (457
mm) from battery (do not connect to welding
generator case, frame, or equipment grounding
terminal as damage to equipment can result).
Walt at least one minute after connecting cables
before starting engine.
Start engine following procedures outlined in
Section 6 {Sequence Of Operation} of this
manual and allow engine to return to idie speed.
If the unit does not start after cranking for thirty
seconds, stop the jump starting procedure. More
than thirty seconds seldom starts the engine
unless some mechanical adjustment is made.
Remove jumper cable from engine biock.
Remove other end of same cable from booster
battery negative (-) terminal.
Remove other jumper cable from welding
generator battery positive { +) terminal.
Remove remaining end of cable from booster
battery positive (+) terminal.
Discard damp cloths.
OM-412 Page 21
RUNNING
HOUR METER
{OPTIONAL}
RC
TEV AL - i»
fn
TA 8 © PP agas) |
26 | =
75 E ут 55 54
ar O VOLTAGE
RO 24l с — ро о— = — = 1 REGULATOR
© wELDO PPOWER |, F PC
E G
EXCITER a 1
000 0000
EXCITER REV. FIELD
30000 ONO
AUTOMATIC
IBLE CONTROL
DIODE Ds2
ISOLATED np € >» —
RESET
POSITIVE B< 9 +—— (e
Cay Cs2 rl Ir B
D50 F 5| 16 P54 OUTPUT @50
OUTPUT Dse| Der | Y | (DELAY ON) — PINVIEW
(DELAY OFF) C<- + y $ >A,
G
RESET& E<€ ? я
BURDEN RESISTOR B Q51
8
D53 K
AlsCR Al/G A 0
F Sa 51 51 с
ст Se | к 541" 255 5СЯ 50 & 51
T le 3 ß
H | JE | Ü
STARTER‘
ALT
REG
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pe
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+
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REGULATOR
POWER WDG.
AC A
ELECTRODE WORK
IT 120 VOLTS
à
5
с и APTICMAL
STANDARD CONNECTION
CONNECTION
1207 240 VOLTS
J HE cs
58] SPECIAL
17 CONNECTION
240 VOLTS
Circuit Diagram No. B-086 953
Figure 8 - 1. Circuit Diagram For Welding Generator
NEGATIVE J<-
TERMINAL REFERENCE
1161111
B C D E
J
Circuit Diagram No. A-071 600
Figure 8 - 2. Circuit Diagram For Automatic Idle Control Circuit Board PC1
OM-412 Page 22
DEZ2 Ds3
B 0—
R70
AO
с D54
C50
Circuit Diagram No. A-049 506-A
Figure 8 - 3. Circuit Diagram For Voltage Regulator Circuit Board PC2
OM-412 Page 23
August 1984 FORM: OM-412
Effective With Serial No. JE772330
g-Gr6 0L0°AL
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OM-412 Page 1
item Dia. Part
No. Mkas. No. Description Quantity
Figure À Main Assembly
1 082 316 CABLE, battery - positive ..............e..e.dccerccori ceder en ene 1
2 604 318 NUT, self-lockinghex1/4-20 ........................ eee 3
3 070 213 HOLDDOWN, battery ...............— e eecdenverio.eremenaceneeanecar 1
4 082 317 CABLE, battery - negative ..........r...eeeececada ra Aa a ae a a a aa eee un» 1
5 032 878 CLAMP, 9/16 dia x 13/32 hole ..............—..eee_eeeeecresrinvrorevenraco 2
6 046 392 LABEL, generalprecautionary................... AAA AS 1
7 +035 141 COVER, top ...........eeereerrecroaaaaoaonaraaaacrroreoaarrenreremD.. 1
8 +071 944 TANK, fuel (consisting of) ..........._.eem_rersrrreoacces a a sa a a a aan» 1
9 015 603 .CAP, tank-fuel..............eeoeoececerzcerenaroorraooracarcanaaaa nao 1
10 020 185 FITTING, pipe - elbow street 1/8 NPT ............erem00eeoaaaaanovaanece 1
11 073 432 FITTING, Багрей та! 3/16 ТВС х 1/8 МРТ. ............................. 1
12 014 951 STRAP, mounting-fueltank............. oii ie eee inna 2
13 603 120 STRIP, felt .............. eee eee ann 2
14 071 823 LABEL, engine maintenance ............eeereeevorcdocorerea ooo aaeeero, 1
15 082 968 PUMP, fuel - hand primer ..................oeemccecdaderaaerecoaaaroa 1
062 234 CONNECTION, banjo ............... esesddsdrroerranenenaaeanooacareoa 1
16 010 678 FITTING, pipe-brasselbowst1/4NPTL ...... cco... 2
17 070 917 HOSE, No. 1x 1/4 1D X 12-172 00ER RR a a aa a ea ea Lan 1
18 010 865 CLAMP, hose .406 - 7/16 di& 2.0.0000 RR RK RR 4
19 604 308 FITTING, brass-barbedM 1/4 TBGX1/4NPT ............ RAS 1
20 039 559 FITTING, barbed M5/16 TBGX1/4NPT ............. PU ee een 1
21 084 173 CLAMP, hose .460 - 545 dia.........1222112 0e aa ea a aa La aa La Lea ea aan à 2
22 084 210 HOSE, No. 1 x5/161Dx19...........—..—.—........rerooaaaoaeeararevcores 1
23 070 819 FILTER, fuel-inline iii sa A a a ee a ee a ea ea La a ane n 1
24 047 420 FILTER, fuei-inline1/4w/hoses&clamps .................. co... 1
25 604 313 FITTING, barbed -M 1/4 TBGXT/8NPT .... iii iia. 1
26 010 868 FITTING, pipe-brassdraincock F1/8NPT ........... iin... ees 1
27 602 898 FITTING, pipe-nippleclose 1/8 NPT... cite 1
28 035 471 BAFFLE, air ... ER a a 4 Aa aa 1
29 603 124 STRIP, rubber{order by ft)... Re 3 ft
30 015 712 GROMMET, rubber 5/8 1D x 7/8 mtg hole. .................... "e ..... 1
31 010 610 CONNECTOR, clamp-cable1/2inch ............. 0 LL LL 1 1
32 604 550 HOSE, No. T(orderby ft). ...... oo ee e enacoco 1 ft
33 070 961 ENGINE, diesel-electric (FIgEPG 10} .... coin, 1
34 010 954 WASHER, flat 13/32 ID x1-1/40DX 1/8 rer 2. aareredo, 9
35 013 367 LABEL, caution-compressionrelease ............... iim aan 1
36 Figure B GENERATOR ASSEMBLY (PO 4)... oie i 1
37 017 836 SPACER, 2sq x7/16x 1/4... eee eee ee 1
38 070 218 RETAINER, engine - mount ..............._.oe_..ereeeesvedodeoacacíaenoo 2
39 070 717 MOUNT, engine ............. e... e... ereriaroeoceaaaaoarororeceo 2
40 AC-Z 049 466 REACTOR oii ee ee oro. 1
D4 049 943 DIODE, 3amp 1000 volts SP Lo... oot ee eee aa a aa 1
41 047 491 LABEL, 120/240 volts . ... iit ee ee ei 1
42 605 181 NUT, self-locking -hex3/8-16 .......... cine, ... 5
43 Figure D BRACKET, mounting - w/components{Pg7)...................... aa 1
44 010 955 VWASHER, flat 13/32 ID x2 OD x 1/8 vorrei 1
45 070 210 BASE i RER a a ea aa AA a a ana aa 1
46 009 235 MOUNT -.............eeseorara0oaorareroeeaaeaaacee da da ana 1
47 T1 049 712 TRANSFORMER, control. .................. ee eee eee. 1
48 CT1 095 041 TRANSFORMER, control-idie isa неее 1
49 —. 027 698 LABEL, equipment ground. ..............—. ... LL La LL LE 1
50 Figure C PANEL, front - w/components (Pg 6) .................... errerooo.. 1
083 030 STUD, brass 1/4-20 x 1-3/4 ......... uu 2 некий инок иене 1
6017 836 NUT, brass-hex jam 1/4-20 ................. LL Le an 2
51 039 608 PLUG, jack - red (consisting of) ................._.. LL LL 2
52 010 521 . WIRE, tie ............ e anaereaen a een aororeredóccena 1
53 019 833 . STRIP, copper 0.01 x 2-1/2 X3/4 .......... LR 1
54 602 178 .SCREW, socket hd 1/4-20 x 3/8 ......... ee ee eee eee 2
1
55 U nana anna annee ARP ee
| OM-412 Page 2
ltem Dia. Part
No. Mkgs. No. Description Quantity
Figure À Main Assembly (Cont'd)
56 602 814 INSULATION, jack plug-red ........ cia iene 1
57 602 160 . SCREW, self-tapping fillisterhd 8-32 x 1/4... ..... oi icin. 1
58 DC-Z 035 429 STABILIZER... oo eee eee 1
59 035 135 PANEL, side-righthand .......... ci iii eee ea ee es ne sa ae eee 0 1
60 035 136 PANEL, side -lefthand..........22242000 00 ae a ea a ea eee a ae eee aa a eee ee 6 1
60 070 211 SHELF, battery ...........e.-e-rcerenecedarrerere aer erre Ace. 1
61 070 010 BOLT, J 1/4-20 x2-5/16..........—..—.—e-resveraverireearrecnecm. aaa 2
62 071 678 BATTERY, 12 volt 74 amp............—eemerecseorrerredvecnerervróre. 1
Parts For Optional Equipment
HM 032 936 METER, hour 4-40 volts dC 200000200000 0e ee ee ee eee see aa a a See 1006
RC2 604 103 RECEPTACLE, straight -duplex grounded 2P3W 15 amp 260 volts . ..........
025 234 CAP, straight grounded 2P3W 15 amp2b0volts ............... cen.
048 901 SPARK ARRESTOR, exhaust .......reeeororenveosvervesnveacoríere e.
061 864 GASKET, exhaust ........._—e—.re.ecorvecacoreerecacerrrtarecerterr 0000
041 057 FA-2 Flame Arrestor Fuel Cap ........20000 00080 a 0e eee a a se ane ae sa 00000
— al ard | === == ==
+ When ordering a component originally displaying a precautionary label, the label shouid also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
TD-082 187-A
15 14 13 12 11 10 9 8
Figure B - Generator Assembly
OM-412 Page 3
Item Dia. Part
No. Mkags. No. Description Quantity
Figure B Generator Assembly (Fig A Pg 2 Item 36)
1 072 859 GUARD, fan .............eeeererorererere, etree. 1
2 070 212 ROTOR, generator {consistingof) ........................ ca. 1
3 024 617 . RING, retaining..............—.._ee_eccconccorereerera rar Erone e 1
4 053 390 .BEARING ...............e0srecas0cerrareraceavamenec cernvorerverver. 1
5 006 307 . FAN ............oeeorerarececenenemananmenaanmanaraaaoecrarerererne». 1
026 206 . KEY, 1/4 x 1/4x 1-3/4 LL 1114024444 41e a a ee a a ee a a a ea a a a a ene 1
6 006 298 ADAPTER, engine ...........222100 10000000 aa a 800 0 8 0 0 a KK 1
7 SR2 035 704 RECTIFIER, integrated 30 amp 600 МОЙ $ ee 1
8 047 878 BAR, retaining-brushholder .......................... eae 1
9 047 885 CAP, hoider - brush ..........e_eerreororenoorrnrarorevecorasecnarda aaa 3
10 *049 125 BRUSH, w/spring .........—._..eeeeesonoeererroracoan.oncereneaaannzonea 3
11 005 614 HOLDER, brush w/tabs.........__—_e_ecwerenecorecoomaar0reavercecdercenao 3
12 007 250 BRACKET, mounting - brush holder ................—eeee.ees.esrerecucona 1
13 +086 961 STATOR (60 Hz) or ........_.re..eeeeeeeorrvecorereraovacacernananene na 1
13 +086 960 STATOR (50 Hz) .............—..—..eme00aaeveerecananaaaaonoaaroeoooo 1
14 020 908 ENDBELL.............r—xevosccccorecorrerecorerreeeearenaamenaaeenaa 1
15 010 222 CONNECTOR, rectifier - cell .................eoe.cc.crer0aeenocoooeco.. 3
16 SR1 045 032 RECTIFIER, silicon diode (consisting of) .............................. .. 1
17 035 410 . ANGLE, mounting - rectifier ............... 2... ieee 0 2
18 037 305 . DIODE, rectifier 150 amp 300 volts straightpolarity ..................... 2
19 C14 031 689 . CAPACITOR, ceramic 0.01 uf500voltsdc ................... cv... 4
20 037 306 . DIODE, rectifier 150 amp 300 volts reverse polarity. ..................... 2
21 R3,VR1 046 819 . SUPPRESSOR, rectifier ............._—.eeomccearacecarrecanr naa ercer. 1
*Recommended Spare Parts.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered,
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-412 Page 4
16— Fig C1
Ref: TD-048 814-А
Figure C - Panel, Front - W/ Components
OM-412 Page 5
tem Dia. Part
No. Mkgs. No. Description Quantity
Figure C Panel, Front W/Components (Fig A Pg 2 Item 50)
1 057 608 RECEPTACLE, jack plug - yellow (consisting of)..............o_ee.exerrevcao. 2
2 072 334 .RECEPTACLE& NUT, yellow... ii i a a ne see en» 1
3 010 291 . WASHER, flat - nylafil 5/8 1D x 1-1/4 OD x1/8............—..—.—...—.—.—.—.-—.ero.. 1
4 604 668 . NUT, self-locking hex 1/2-20 ...............--ermeerreeeererenarrre 1
5 601 881 . NUT, hex-jam1/2-20..... ee ee eee eee eee ner. 1
C6 049961 CAPACITOR, ceramic0.1ufb00voltsdc ....... iii it, 1
6 039 826 RECEPTACLE, jack plug - black (consistingof).. .................. PAIE 1
7 091 542 .RECEPTACLE € NUT, black ............oe.esroonecaronenenenrecernareeae 1
8 010291 .WASHER, flat - nylafil 5/8 1D x 1-1/4 OD x1/8....... La a 1 a ea a 4 a Va aa aan 1
9 604 668 . NUT, self-locking hex 1/2-20 .......21240212 000044 eee a a ee da aa ea a eee a a ee 000 1
10 601 881 .NUT, hex-jam 1/2-20............xerereceorreoevesorecoanecacaracacaraaera 1
11 039 800 RECEPTACLE, jack plug - red ..............eoeñecceuaevevarrtesarenarorenrea 1
12 091 541 .RECEPTACLE € NUT, red.................0000adreaxaraacania de aren near 1
13 010 291 . WASHER, flat - nylafi! 5/8 IDx1-1/40Dx1/8 .... ... ii... 1
14 604 668 .NUT, self-locking hex 1/2-20 ............vressddac0d0r0 vara er rene 1
15 601 881 .NUT, hex jam 1/2-20 ...........—..—r—eredxceeavevmanenevemecercorceararoran. 1
16 S5 005563 SWITCH, selector (Fig C1 Pg 7) coi ieee 1
17 R1 081712 RHEOSTAT, WW 100 watt 30 Ohm. a a aa 2» 1
18 S1 6011622 SWITCH, toggle 3PDT 15 amp 125 volts ..........eeeeeíeaoracerrerin are. 1
19 $3 021467 SWITCH, toggle SPST MD 3 amp 125 volts ac ...........—e_eecreeeaacioreceoo 1
20 S4 053359 SWITCH, toggle SPST 20 amp 125 volts ...............eeee.n.eac0aronmenenen., 1
21 RC2 039864 RECEPTACLE, straight : duplex grounded 2P3W 15 amp 125 volts ............. 1
22 R2,4 052 782 RESISTOR ASSEMBLY, dual adjustable 180 watt 12 ohm.............——.—.—e—.e.. 1
23 049 213 PANEL, front.............eeceeceemaaeraeaaverecarverrereneovaranaoeero, 1
24 NAMEPLATE (order by model and serial numbers) ...........eeeeorooreo0ea. 1
25 RC1 034952 RECEPTACLE, straight - 3P3W 15 amp 125 volts ,............—e—e—eereeereerev 1
26 019 790 CONTROL, push/pull................. 2... 0... ..ererciaaarereaa. a 1
27 019 609 KNOB, pointer. .......... ee _eecrverrrrive dar recaaarrandavarar eeranoecneo 1
28 010 647 PIN, spring - compression 5/32 Xx 1-1/4.............eeoreceoceredrere decada à 1
29 006 927 HANDLE, switch -range .............eeee.000dzaaavvaaeazeroarioaacerandaao 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-412 Page 6
Item Part
- No. No. Description © Quantity
Figure C1 005 563 Switch, Selector (Fig C Pg 6 Item 16}
005 562 BRACKET, mounting - switch
005 561 SHAFT, rotor ..........._eeeeceaaarrnrdaraaaenarerecarevererecmorvrereo.
005 564 INSULATOR, screw - switch ..........o_eeeeexeroeernvnvoo0nmervvervreresaa.
605 276 SCREW, cap - steel hex hd 1/4-20 x 1-1/4..........—.—.—-—-—e.rree=sevcerearece.
005 559 CONTACT BOARD, movable - switch. ..........._c_eoocorvrrrecareeneane..
005 560 CONTACT, switch - movable ........ñ..._._eeocecrrerrenerreróreoreeeeees
008 485 SPACER, contact - switch. ...........e.eeerrereneorordiarirererabareer e.
049 281 STOP, switch-selector.............oeeerrecororerocareerecroaver rr rev»
005 566 CONTACT BOARD, stationary - switon ............. i iii...
011 644 CONTACT, stationary -switch 022002000004 0 40e es a aa 0 ie itera
052 405 SPRING, pressure - contactswitch ........0000200 0000000 ea es a a ae ne se eue 0e
052 404 CONTACT, movable - switch ........202022020 0000 0e ea sea a ea a sea sea ae eee 0
005 557 BUS BAR, switch - range
005 558 SPRING, selector - switch
eue 1 B ® E 1 нити мне но ® ¥F 4 § ® om om mom om mom kb A & = = om =
e —o—o— —
т о юн © © © 5 © сл А © № —
== ее очей == с] ей ld od dt ld old o ==
TC-052 524-A
Figure C1 - Switch, Selector >
8
T8-082 288
- _ , . =‘ _ WwW
item Dia. Part | Figure D - Bracket, Mounting /Components
No. Mkgs. No. Description Quantity
Figure D Bracket, Mounting - W/ Components (Fig A Pg 2 Item 43}
1 080 509 GROMMET, screwNo. 8/10 panelhole ................ iii 4
2 049 377 BRACKET, mounting - components ...........0400000 0000 eee ace ee eee nec ee 1
3 CBi 045061 CIRCUIT BREAKER, auto reset 24 volts de 7 amp. .........._—e.—enrreevresreres 1
4 PC2 049 404 CIRCUIT CARD, regulator 115 volts (Fig D1 Pg8) ........-210000 01100 ee eee 200 1
5 PC1 0718609 CIRCUIT CARD, weld/idlecontrol{FigD2Pg8}........... coon 1
6 038 620 LINK, jumper -terminal block30 amp... ane eee 0 2
7 1T 038621 BLOCK, terminal 30 amp 4 pole..........2.-400000 00 aa eee ea eee ee ee eee eee = = 1
8 C5 070949 CAPACITOR, ignition Buf...........00000000 00 eee nes aa eee rennes ae eee 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-412 Page 7
Dia.
Mkgs. Part No. Description Quantity
Figure D1 049 404 Circuit Card, Regulator (Fig D Pg 7 Item 4)
A50 009 159 IC, linear 358.............—._—e—cee-eeeacooerrsrereo.. enoooooorrorananacradaa 1
C50 028 294 CAPACITOR, mylarT uf200voltsdc ............ 0 iin... RE 1
C51 053 992 CAPACITOR, ceramic 0.001 uf1000 volts. ........... co ii i ieee 1
C52 000 348 CAPACITOR, tantalum 0.47 uf3bvolts ................ iin. FR 1
Ch3 005 023 CAPACITOR, tantalum 2.2 uf 20 volts .. 1.111044 4 44048 4 4 4 eee 4 4 4 a ee ea 1 aa 1
C54,56 000 861 CAPACITOR, electrolytic33 uf35 volts ........ co iii iii eens 2
C55 038 585 CAPACITOR, mylar 0.22 uf 50 volts .........20002 04 4e a a 4 ee a a ae ea ae a a een + 1
C57 028 292 CAPACITOR, ceramic 0.005 uf 1000 voltsdc .......... ii iii, 1
D50 028 351 DIODE, signal 8.020 amp 7b volts S ................... PA 1
D51 049 641 DIODE, zener 27 volts 1 watt RR 1
D52,53,54 026 202 DIODE, 1ampd400voitsSP ....... i ne» RAA AAA 3
D55,56 073555 DIODE, 1 amp 600 voits SP .......11212 22000 ee a a a a a a a 4 a A aa a a a a a ee ea aan 0 000 2
D57,58 070 250 DIODE, 3 amp 600 volts ee eee ee eee 2
D59 030 529 DIODE, 12 amp 600 voltsRP ........02221110 2022 a a 4 aa a a a ea a a a a a a a aa aa eee se 1
Q50 039 355 TRANSISTOR, unijunction 15MA 40 volts ee кк к квн кк кк кк ввкккке 1
051,52 037 200 TRANSISTOR, 200MA 40 voits NPN ........22014 14 4 a a a a a a a a a ea ea a au a ea ae 0 2
053,54 — 049 642 THYRISTOR, SCR8 amp 600 volts..........222200 0224 aa aa a ee ee ea a a a aan 0 2
R50 005 640 RESISTOR, carbon 0.5 watt 680K ohm ..................0..es. e meeerara a. 1
R51 035 884 RESISTOR, carbon film 0.25 watt 100K ohm ............ i... 1
Rb2 039 328 RESISTOR, carbon fim 0.2bwatt1500ohm......... iL. 1
R53,54,65 035 886 RESISTOR, carbon film 0.28 watt 22K ohm 102222210110 a a a aa a aa ann 0 3
R55 039 329 RESISTOR, carbon film 0.25 watt 2700 oRm.............._ee0ee_esscanadaroooo 1
R56,84 035 827 RESISTOR, carbon film 0.25 watt 10Kohm ................1111111010111 2040 2
R57,62 028 285 RESISTOR, carbonfiimO.bwatt100ohm ......... iii... 2
R58,53 035823 RESISTOR, carbon film 0.25 watt 100 ohm .............. anne. 1
R59 035 888 RESISTOR, carbon film 0.25 watt 2200 ohm........1202001 0011144 a aa a aa aa a a à 1
R60 074 026 RESISTOR, carbon 0.25 watt 150 ohm .................... aa 1
R61 006 424 POTENTIOMETER, cermet 1 turn 0.5 watt 2K ohm ......... .... . ... . ......... 1
R66 039 332 RESISTOR, carbon film 0.25 watt 15K ohm ©... iia. 1
R67 039 334 RESISTOR, carbon film 0.25 watt 27K ohm... e semeaooreconoa 1
R68 039 331 RESISTOR, carbon film 0.25 watt 4700 ohm... . iii. 1
R69 049 439 RESISTOR, carbon 2 watt 47K ohm... oe eee eee eee 1
R71 030 707 RESISTOR, carbon Twatt47 ohm... LL Le LL La aa aa a a a aa à 1
R70 074 099 RESISTOR, carbon 1 watt 150 ohm ...........1111111 1111 a aa a LL Lane 1
VR50 081 832 REGULATOR, voltage 0.5 amp 15 volts .............. ......... eee 1
080 506 HEAT SINK, dual . RR RR ee 1
ol I [ee | О
| jo O 053)
= o MON
O psa) pss) ® VRS0
— FF X 979 D55( | Res ME В -
| А . w= В COMPONENTS TO BE
: Ca : a REPLACED BY
= Dep I E В ns QUALIFIED PERSONNEL ONLY
< | В ;
U o
o SEBCH cs О
ТА-048 815
Figure D1 - Circuit Card, Regulator
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-412 Page 8
Dia. Part |
Mkgs. No. Description Quantity
Figure D2 071609 Circuit Card, Weid/idie Control {Fig D Pg 7 !tem 5)
C50,54 035 522 CAPACITOR, mylar 0.047 uf 100 volts ........................ .eecieaa. 2
C51,52 045 868 CAPACITOR, electrolytic 100 uf 25 volts de ................e. 22.000.002. 2
C53 080 507 CAPACITOR, tantalum 22 uf 15 volts «Lori ii eee eee rene 1
D50,54 070 260 DIODE, 3amp B00 volts... .. ie eae 2
D51-53,
56,57 026 202 DIODE, 1 amp 400 volts SP ............e cer mrevrecaco.ecoc rre oeaa ena. 5
D55 037 243 DIODE, zener 18 volts 1 watt. .............e_ _—.—.rrrecic,reeaae demi nane.. 1
050 000 088 TRANSISTOR, 800 MA 400 volts NPN .............. 7... .00e0eda.eeeeea. 1
051 039 355 TRANSISTOR, unijunction 15 MA 40 volts.. RR 1
R50,63 000 039 RESISTOR, carbon2watt880 ohm ......... ci iin, «2
R51,56 605 919 RESISTOR, carbon 0.25 watt47 ohm ......................m000síecrwredó_. 2
R52 605 916 RESISTOR, carbon 0 2bwatt1Kohm . ii. 1
R54 035 824 RESISTOR, carbon film 0.25 watt 270 ohm .............. iii... 1
R57 052 146 RESISTOR, carbon film 0.25 watt E20K ohm ............._...e0.ererecaren. 1
R58 053 572 RESISTOR, carbon fim 0.26watt 12Kohm ............. iii. 1
R59 052 138 RESISTOR, carbon film 0.25 watt 20K ohm ............................... 1
R60 035 822 RESISTOR, carbon film 0.25 watt 10 ohm ....... oii кко о 1
R61,62 030 026 RESISTOR, carbon 0.5 watt 560 ohm .............eeeeeceseroreaeeo er. 2
RG3 003 272 RESISTOR, carbon film 0.25 watt 1 meg ohm ............................ 1
R64 071 595 RESISTOR, carbon fim 0.25 watt22ohm ............ iii... 1
SCR50,51 080 508 THYRISTOR, SCR8.5amp200Voits ........... iii. 2
SR50 035 841 RECTIFIER, integrated 1.6 amp 200 volts ........... iii. 1
080 506 HEAT SINK, dual ............... ee RER RR KR 1
COM PONENTS TO BE TA-048 B16-A
REPLACED BY
QUALIFIED PERSONNEL ONLY
Figure D2 - Circuit Card, Weid/ldle Control
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-412 Page 9 '
item Dia. Part
No. Mkgs. No. Description Quantity
Figure E 070 961 Engine, Diesel - Electric (Fig A Pg 2 Item 33)
1 070 214 GUARD, alternator ......0.00.000000000000R eee ea ea ea ae eee aa es eee eee ee» 1
2 070 220 TUBING, steel 1/20D x17 gawallx2-1/8....... iii, 2
3 070 217 STRIP, adjusting -alternator ......... ccc iinet a 1
4 088 567 BELT,V .........2.2 2200000 ea ae ea aa ae eee da eee see a de ne sa eee 01011006 1
5 605 430 PULLEY, single - belt ..........._eeoeeeeeorrrrrecoaoaetriecracer rre 1
6 605 429 ALTERNATOR, 35amp12Vvols.... cocina ieee 1
7 070 020 SPACER, alternator ............. eee eee a a a a a da a eee 0000 1
8 009 043 SCREW, cap - hex hd 3/8-16 x3 ..... iii ieee 1
9 070 434 BRACKET, mounting - alternator ..........._.e.-.emereenertrenorren ETA. 1
19 070 216 BRACKET, mounting - cable stop .........—.—..e_eeseeeeeveorrerecoorrneneAD. 1
010517 CLIP, conduit............eemereemrrisecrre vent rennenen A. Las sa na nue 000 1
11 070 456 RETAINER, spring......1..222000 00000 40e ea a ee ee ea ea eee seen ee see eau 2000 1
12 070 255 SPRING, compression ...........20000000000 ee ee 1
13 070 441 НОЗЕ, 1/2 10 х 11/16 ОБ х 19............-e=re--eerecrrterrereerare tene. 1
14 064 646 SPRING, highspeed . . ................ PS ES 1
15. 070 442 CHAIN, throttile .........2242124 4500 a ea eee a ea ee ea de ae ee se ee a ea eee ee ee « 1
16 605 277 PIN, cotter 3/32 x 3/4 .........._— remove. a eee eee 1
17 049 839 BRACKET, adjustment-solenoid ............... coin, eee eee 1
18 070 215 BRACKET, mounting-solenoid ...........e___eieererervervrrrcesrrerencen. 1
19 034 116 CLAMP,5/8diax15/32hole ...... cima 1
20 TSi 032 933 SOLENOID, 12 volts de 20 amp ...........eeeeeresrererecorecrreacarenAD. 1
21 070 900 GUARD, solenoid ...........e_-eeee-sroceraconiareecorécaosnecrcenmerA 1
22 010 516 -SWIVEL, wire-inner.............000000000 0400 eee ee aa sa a ae ea ae ee | 1
23 $2 011917 SWITCH, pressure 2P normaily open ..........—r.eoe—_—e—reseereverereeneree— 1
TD-070 946-А
Figure E - Engine, Diesel-Electric
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-412 Page 10

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