Miller BIG 40 DIESEL User manual

Miller BIG 40 DIESEL User manual
September 1984 FORM: OM-466C
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MODEL
BIG 25 DIESEL
BIG 40 DIESEL
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DED
MILLER ELECTRIC MFG. CO.
718 $. BOUNDS ST. P.O. Box 1079
APPLETON WI 54912 USA
ADDITIONAL COPY PRICE $1.00
NWSA CODE NO. 4579
FRINTED IN U.S.A.
LIMITED WARRANTY
. EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is €x-
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 Miller 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 companents having normal useful life of 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. Allother Millermatic Feeders...............—... 1 year
5. Replacement or repair parts, exclusive of labor . 50 days
6. BatterieS As 6 months
provided that Miller is notified in writing within thirty (30) days
of the date of such failure.
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
In the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Miller's option {1} repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use) upon
return of the goods at Customer's risk and expense. Upon receipt
of notice of apparent defect or failure, Miller shall instruct the clai-
mant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX-
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND МОТ FOR CONSUMERS OR
CONSUMER USE. MILLER" WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLER'S WARRANTIES TO, ANY CONSUMER,
ERRATA SHEET
Sept. 15, 1986
FORM: OM-466C
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
3-30 071 389 071 389 CAP, weather No. 4 .............e_ec_erervevecoreraremerare, 1
4-61 083 730 111508 HOSE, radiator-lower ..............._e—e:ererrirearre ere 0 1
4-75 089 259 095 624 PUMP, fuel 12 volts de ..............eoee..eereareea reo. A 1
5-117 049 082 111311 UPRIGHT, base-front (Eff w/JG098154) ...................... 1
5-118 171 084 814 090735 REACTOR (environmental protection) ............ KG 1
6-7 085 274 110371 GUARD, starter (Eff w/JG098154) .................eo-.eeecixo. 1
6-8 085 548 (090 736 STATOR {environmental protection) ............. cocci... 1
6-14 044 374 089 115 STATOR, excitor-aux power 120/240 (environmental protection) . 1
6-16 049 652 106 424 BARREL (Effw/JG035627) ..........._re=revrerereenveanea. 1
6-17 SR3 072182 106 430 DIODE ASSEMBLY, SP (Eff w/JG035627} .............. oot. 1
6-18 025 305 106 425 .INSULATOR ...........—.—...—er.0e.sdeaonrecrere rene coa. 2
6-20 000 901 048 420 .CAPACITOR, ceramic 0.01 uf 500 volts de ..............—.....> | 2
6- 046 455 106641 .CAPACITOR, ceramic 0.01 uf 500 volts de. .............—.—...... 1
6-21 025 306 1106 426 INSULATOR (Effw/JG035627)..........-—e—ee.eewerrecsrereare, 4
6-22 049 653 106 440 BUS BAR (Effw/JGO35627) ............_.=m—eesrervoerrerorer. 2
6-23 SR3 072950 106 427 DIODE ASSEMBLY, RP (ЕН му/ 26035627) .................... 1
6-25 025 305 106425 INSULATOR .... iii i ert ean a 2
6- 000 901 048 420 . CAPACITOR, ceramic0.01 ufb00voltsdc..................... 2
6- 046 455 106 641 .CAPACITOR, ceramic 0.01 uf 500 volts de..................e.e 1
108 081 TERMINAL PROTECTOR, battery post ..............—.—.—_—_—.reee.. 2
**Cirst digit represents раде no - digits following dash represents item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Section No.
RCN T A B LE O Е CO NTE NTS AP EEE EE EME PE TE QE ЧТОТО CT
Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
Introduction
General Precauticns
Arc Welding
Standards Bookiet Index
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2 - INTRODUCTION
General information And Safety
Receiving-Handling
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3 - INSTALLATION
NOOR WN
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Spark Arrestor/ Muffler Installation
Preparing New Battery For Service
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Engine Pre-Start Checks
Equipment Grounding Terminal
Weld Output Connections
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SECTION 4 - AUXILIARY POWER
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120 Volts AC Receptacle
240 Volts AC Receptacle
7.5 KVA AC Power Plant
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5 - OPERATOR CONTROLS
Ampere Range Switch
Amperage And Voltage Adjustment Control
Voit-Ampere Curves
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Start Push Button And Fuel Switch
Engine Shutdown Switch
Glow Plug Push Button
Auto Idle Control Switch
Battery Charge Indicator Lamp
Engine Temperature And Oil Pressure Lamp
Time Meter
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Qil Pressure Gauge
Temperature Gauge
Polarity Switch
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Remote Current Control Switch
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SECTION 6 - SEQUENCE OF OPERATION
Shielded Metai-Arc Welding (SMAW)
6 - 2. Optional 7.56 KVA Power Plant Operation
6 - 3. Starting The Engine
Engine Shut Down
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10
11
11
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12
12
12
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Section No. Page No
SECTION 7 - MAINTENANCE
7-1. General. ..... ccc iia tr tee ica a na 0 0 ea 00 00 17
7-2. Periodic Cleaning AndlInspection........... ccc iii, 17
7-3, Fuel/Water Separator And Sludge Drain Plug . .. .. aa sn ae 18
7-4. AirCleaner Service...........244112010 00 0 a aa au 0e na aa aa 10000 19
7-5. Electrical System................ reer 19
7-6. Servicing The Spark Arrestor ........... fe eae 19
7-7. BrushesAndSlipRings ........... cc. iii. 19
7 -8. EngineSpeedAdjustments .............. cial. 19
SECTION 8 - TROUBLESHOOTING
8-1. General............_eeeecrecocanioearacenroarendzoonraarv nao 20
8-2. TroubleshootingChart.............. iii. 20
8-3. BoosterBattery Jumper Starting ............ iia. 20
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) {ontly).
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. ANS! 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 fluxes can produce different 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 collar 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
shouid 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 flash burns of the eyes and skin
burns.
Ear plugs should 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, illness 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 ANS! Stan-
dard 249.1 listed 1 In Standards index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium -
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 should not be heated unless coating is
removed from the work surface, the area is well ven-
tilated, or the operator wears an air-supplied respirator.
Work in a confined space only while it is being ven-
tilated and, if necessary, while wearing an air-supplied
- respirator.
Gas leaks in a confined space shouid 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-466 Page 1
highly toxic gas, and other lung and eye irritating pro-
ducts. The ultraviolet (radiant} energy of the arc can
also decompose trichloroethyiene 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, fiying 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 ail, 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. combustibles 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-466 Page 2
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.0,
listed 3 in Standards index.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the com-
bustibie’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 levei may substitute for inerting.
A container with unknown contents shouid be cleaned
(see paragraph above). Do NOT depend on sense of
smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode. |
Explosive atmospheres. Never weid or cut where the air
may contain flammabie 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 faulty 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 manufacturers 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.)
(СС or DOT marking must be on each cylinder. it is
an assurance of 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 cradle. 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,
siag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130°F. Cool with water spray
whare such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve, Do NOT use a hammer or wrench to open
a cylinder valve that can not be opened by hana. 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 ferrules 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 tangles.
Protect hose from damage by sharp edges, and by
sparks, siag, 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 spiic-
ing (1-2D3). Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of Impurities that may cios
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Yipe
with a clean lintiess cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outiet 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. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your sup-
plier) between cylinder and regulator, if one 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 reguiator of residual gas through suitable vent
before opening cylinder {or manifold valve) by turning
adjusting screw in (ciockwise}. 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 siowly So that regulator pressure n-
creases siowly. 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 teak. tor 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 reguiarly
there-after. Brush with soap solution {capful of ivory
ОМ-466 Page 3
Liquid® or equivalent per gallon of water). Bubbles in-
dicate ieak. 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 shouid not be used for weiding 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-466 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 to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking 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 enciosed bay is best. In open areas,
surround the operation with low-reflective, non-
combustible 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 looking 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 1-28.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc
welding equipment. 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 weiding,
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 749.1 “Safety In Weiding And Cut-
ting,” 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 or a flammable li-
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 iead to the third (live) wire, or the equip-
ment will become electrically HOT - a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal 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 plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep-
tacie. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2. Electrode Hoiders
Fully insulated electrode holders shouid be used. Do
NOT use holders with protruding screws,
3. Connectors
Fully insulated lock-type connectors should be used to
join welding 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 cabie 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 control (con-
tactor)
Welding power sources for use with the gas
metal arc welding (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 eiectrode 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 uniess 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 iock
OM-466 Page 5
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 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. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available near the
welding power source.
F. Protection For Wearers Of Electronic Life
Support Devices
Magnetic fields from high currents can affect
pacemaker operation. Persons wearing a pacemaker or
other electronic life support equipment should consult
with their doctor before going near arc welding, goug-
ing, or spot weiding operations.
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards
or their latest revisions and comply as applicable:
1. ANSI Standard 249.1, 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. ANSI Standard 241.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-466 Page 6
10.
11.
12.
13.
14.
15.
ANSI Standard 749.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards institute, 1430 Broadway, New York,
NY 10018.
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 Boulevard, Rexdale, Ontario,
Canada MSW 1R3. |
NWSA booklet, WELDING SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103. В
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,
550 Le Jeune Rd. P.O. Box 351040, Miami, FL 33135.
ANS! Standard Z88.2 "Practice for Respiratory
Protection” obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
TTM as SECTION 2 - INTRODUCTION
*Overall case dimensions.
Basa Mounting Hole Dimensions
Inches Millimeters
A 2-7/8 73
B 9-1/2 241.3
с 26-15/16 684.2
D 34-3/4 382.7
E 46-1/4 1174.8
F 59-1/8 1501.8
G 62 1574.8
H 7/8 22.2
i 23-1/4 590.5
J 24-3/4 628.6
Figure 2-2. Overall Dimensions And Base Mounting Hole Layout
Welding | Rated Single-Phase , Weight
Rated Three-Phase | Ampere Power While Open-Circuit } Max RPM Engine
Model Welding Amperes | Ranges Welding Voltage No Load Speeds Net Ship
250 at 40 volts 1510 lbs. | 1550 lbs.
3-cylinder| de, 100% duty Min.-65 (605 kg.) | (703 kg.)
engine cycle 55-110 3 kva
9 у 35.210 120/240 volts 55-95 1850 | Weld: 1 800
; die: 120
4-cylinder| 300 at 40 volts | 110-270 | 25713 amperes | volts de \die: 1200 | 1650 ibs, | 1690 Ibs.
engine de, 100% duty | 190-Max. ne (748 kg.) | (767 kg.}
cycle
Figure 2-1. Specifications
A
— _*
° TF B |
x ; °
\—21/32 in. Dia. с |
(16.7 mm) D
All Hol
53-1/4 in. oles |
(1352 mm) E
E = 2 F
| ©
A |
a. и Engine End
24-3/4 in.” gine=nd 1
(629 mm) |, .
р
| J и
TB-086 534
OM-466 Page 7
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 should be read, understood, and
followed for the safe and effective use of this equip-
ment.
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 qualified
persons in accordance with this manual and alf 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 and which identify
different levels of hazard.
ENGINE statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
Tes SECTION 3 -
3-1. LOCATION (Figure 2-1)
RUZLLNDIEE ENGINE EXHAUST GASES can kill.
e Operate in open well ventilated areas or if
operated indoors vent engine exhaust outside the
building.
® Keep engine exhaust vent outlet away from
building air intakes.
ENGINE EXHAUST SPARKS can cause fire.
e Watch for fire.
® Keep appropriate fire extinguisher at work site and
be familiar with its use.
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 spark arrestor unless it was
specifically ordered as an optional accessory. À spark
arrestor, maintained in effective working order, is man-
datory 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.
OM-466 Page 8
INSTALLATION =
LEL* statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could resuit in minor personal injury
or damage to this equipment.
A third signal word, ALLE, 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 bill
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.
2-3. DESCRIPTION - This diesel engine driven
welding generator is designed to produce a three-phase
constant current dc output for Shielded Metal-Arc
Welding. A duplex receptacle, located on the front
panel, provides up to 3 kva of 120 volts or 240 volts,
50/60 Hertz single-phase ac power, to operate lights,
power tools, etc., while welding.
Optional equipment includes weld meters, remote
amperage control and 7.5 kva power plant. This unit
can provide 240 volts ac at the front panel when the
240 volts ac duplex option is installed.
3-cylinder models are driven by a Teledyne-Continental
TMD-20 engine. 4-cylinder models are driven by a
Teledyne-Continental TMD-27 engine.
IMPROPER LIFTING OF EQUIPMENT can result in
personal injury and equipment damage.
® Use equipment of adequate capacity to [lift the
unit,
e [fusing lift forks to hand/e 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.
e Operate unit in an approximately level position.
e See Figure 3-1 for maximum allowable tilt for pro-
per operation.
e Check crankcase off level with unit on a level sur-
face.
Exceeding these limits can cause severe engine
damage.
RESTRICTED AIR FLOW causes overheating and
possible damage to internal parts.
e Maintain at least 18 inches (457 mm) of
unrestricted space on all sides of 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.
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 instailing any cover.
This welding generator is provided with a lifting eye for
moving the unit and mounting holes in the base rails for
securing the unit in a permanent location, or to a trailer,
or transport vehicle. Figure 2-2 gives overall dimensions
and base mounting hole layout.
The mounting location should allow sufficient room to
open the side doors and remove the cover and paneis
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
ee
A] L—
T_ ~~
À
20°
. TA-046 152
End View
Figure 3-1 Allowable Tilt Angle
3-2. SPARK ARRESTOR/MUFFLER INSTALLA-
TION
1. Install spark arrestor/muffler over exhaust pip
and secure with muffler clamp. |
2. Install weather cap on spark arrestor/ muffler so
that exhaust air is discharged to the near side of
the unit.
3-3. 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 normai 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.
Акт BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
® Wear correct eye and body protection when work-
ing with battertes.
ABNORMAL VOLTAGE can cause damags to
engine electrical components.
® Do not operate engine without the battery con-
nected.
e [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.
TCI UE CHARGING A FROZEN BATTERY
can cause the battery to explode and result in
serious persona! injury or damage to equipment.
e Check the state of the electrolvte solution and
allow battery to warm to 60°F (76°C) before
charging if electrolyte is frozen or slushy.
Remove the vent caps and refer to Section 3-3C, Steps
7-9 for charging instructions.
С. Dry Charged Battery
1. Obtain battery grade (1.265 specific gravity)
electrolyte solution.
2. Remove battery from unit and place on a ievel
work table or other suitable surface.
3. Remove vent caps.
Li
DANNA BATTERY ACID can burn eyes and
skin and destroy clothing and other materials;
BATTERY GASES can expiode and shatter the bat-
tery.
® Wear correct eye and body protection.
® Do not spill or splash battery fluid.
® Do not apply pressure to walls of filled battery-use
battery carrier or place hands on opposite corners
when lifting battery.
OM-465 Page 9
e Do not lean over battery when testing.
® Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
® 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 80°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°C) 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 cell to be tested
to adjust the temperature of the hydrometer to
that of the electrolyte).
КИЙ Foliow the precautionary steps
below in addition to those given in the previous
WARNING statements.
® Use enough ventilation to keep battery gases from
building up during and for several hours after bat-
tery charging.
® Turn battery charger off before making connec-
tion to battery.
® Do not touch or move connections on battery
while battery charger is on.
® Do not lean over battery when charging.
e Be sure battery charger connections to battery are
clean and tight.
® Keep vent caps in place and cover top of battery
with damp cloth.
® Be sure battery charger output matches battery
voitage.
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.
E ic BATTERY GASES can explode and
shatter the battery.
© Turn the battery charger off before disconnecting
the charger from the battery.
10. Recheck electrolyte level and add if necessary.
AZ ALICE BATTERY ACID
metals.
© Do not pour electrolyte into a metal sink or drain.
is corrosive to
11. Thoroughly rinse with water and mutilate empty
electrolyte containers before discarding.
OM-466 Page 10
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,
3-4. FUEL (Figure 3-3)
AAA II ENGINE FUEL can cause fire or ex-
plosion.
Do not spill fuel; if spilled, wipe up.
Do not refuel 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.
LUNES Fill fuel tank up to 3/4 in. (79 тт)
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
Examine inside of fuel tank cap. If the cap is equipped
with a valve, be sure that the valve is in the OPEN posi-
tion to provide proper venting.
See the engine manufacturer's manual for fuel recom-
mendations. The capacity of the fuel tank is 16 gallons
(60.6 liters). a
es Wo
e Ns
7.57 1,7 №
6.62 146 1.75
567 125 1.5
4,73 1.04 1.25
3.78 0.83 1.0
284 0.62 75
1.98 0.4 50
45 0.21 25 1200
50 100 150 200 250 300 350 400
WELD AMPERES AT 100% DUTY CYCLE
3-Cylinder Engine Models B-090 120
\
y À
A М. ok
e We 5. ap"
7.57 17 20
6.62 1.46 175
9.67 1,725 1.5
473 1.04 125
3.78 0.83 1.0
2.84 0.62 0.75
198 04 05
35 0.21 0.25
ILE
1200 RPM,
50 100 150 200 250 300 350 400
DC WELO AMPERES AT 100% DUTY CYCLE
4-Cylinder Engine Models 8-086 185
Figure 3-2. Fuel Consumption Chart
3 - 5. ENGINE PRE-START CHECKS
A. Oil Level
The engine is shipped with its crankcase filled with SAE
20W break-in oil. If the oil level is not up to the full mark
on the dipstick, add oil according to the recommenda-
tions in the Engine Manufacturer's Manual before star-
ting the engine.
B. Cooling System
The coolant capacity of the unit is 9 quarts (8.5 liters).
Check coolant level before operation. If unit is operated
in temperatures below 0°F {-18°C}, additional ethylene
giycoi-base anti-freeze must be added to protect unit.
3-6. EQUIPMENT GROUNDING TERMINAL
(Figure 3-3) - 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 or
state codes or the latest issue of the National Electrical
Code. If additional information regarding your particular
operating circumstances and/or grounding re-
quirements is needed, consult a qualified eiectrician or
your dealer. After determining the extent to which any
grounding requirements apply to your particular situa-
tion, follow them explicitly.
The connection shown
is for dc reverse
polarity
Equipment
Grounding
Terminal
Positive Weld
Output Terminal
Nagative Weld
Output Terminal 18-086 535
Figure 3-3. Weld Output Connections
3-7. WELD OUTPUT CONNECTIONS (Figure
3-4) - 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
overioading of the unit.
Table 3-1. Weld Cable Size
weLDING L TOTAL LENGTH OF CABLE (COPPER! IN WELD CIRCUIT
AMPERES] *50 | 100 150 | 200 | 250 | 300 | 350 | 400
100 4 4 2 2 2 1 1/0 11/0
150 2 2 2 1 1/0 120 13/0 | 3/0
200 1 1 1 1/0 2/0 [13/0 14/0 | 4/0
250 11/0 11/0 1/0 | 2/0 3/0 14/0 | 4/0 |2-2/0
200 |2/0 lo 12/0 | 3/0 4/0 law | 2-2/0 | 2-3/0
350 [3/0 |3/0 |3/0 | 4/0 am | 2-2/0 | 2-3/0 | 2-3/0
400 [3/0 13/0 3/0 | 40 2.2/0 | 2-3/0 | 3-2/0 | 2-4/0
A-002 702-A
NOTE: “A. 50 FEET OR LESS.
"B. CABLE SIZE 15 BASED ON DIRECT CURRENT (DCH,
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
"С. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPENCIRCUIT 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 CPEN-CIRCUIT
VOLTAGE.
2. 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
(torch) cabie is 20 feet (6.1 m) long and the work
cable is 30 feet (9.1 m) long, select the size cable
recommended in Table 3-1 for 50 ft (15.2 m).
3. Do not use damaged or frayed cables.
4. |f necessary, install electrode hoider to cabie
following manufacturers instructions. An in-
sulated electrode holder must be used to ensure
operator safety.
5. Install correct size lugs to remaining end of elec-
trode holder cable (if applicable} and to both
ends of work cable.
6. Instail work clamp to cable.
B. Installation (Figure 3-3)
STANS ELECTRIC SHOCK can Kill.
® Do not touch live electrical parts.
e Ensure that the unit is completely shut down
before making any weld output connections.
1. Open the left side access panel and route the
cables through the bracket on the lower left side
of the front upright.
2. Connect work lead to WORK output terminal.
3. Connect electrode cable to ELECTRODE output
terminal.
4. Close left side access panei.
OM-466 Page 11
EZ SECTION 4 - AUXILIARY POWER =
ENTES ELECTRIC SHOCK can kill,
Do not touch live electrical parts while the engine
is running.
e 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.
e Jsolate the electrode and work cables from each
other and from any conductive surface when not
welding.
The weld output terminals are electrically energized
when using auxiliary power.
LOW VOLTAGE AND FREQUENCY can damage
electrical equipment.
e Turn off or disconnect all electrical equipment
connected to the 120 (or 240) VOLTS AC recep-
tacle and the 7.5 kva ac power plant before star-
ting or stopping the engine or while the engine is
idling.
When starting, stopping, or idling the engine has low
speed which causes low voltage and frequency.
4 - 1. 120 VOLTS AC RECEPTACLE (Figures 4-1 &
5-1)
120V 26A Ny AC
Up to 3 kva of 120 volts ac 50/60 Hertz power is
available at the 120 VOLTS AC duplex receptacie for
operating power tools, lights, etc., when the welding
generator is operated at weld rpm. 15 amperes can be
drawn from either half of the receptacle; however totai
load on the receptacle cannot exceed 26 amperes. The
voltage at the receptacle will vary according to the ap-
plied power and weld load. The voitage at various loads
can be determined from Figure 4-1.
130
—
2
un
1
2.35KVA
—
ka
=
1
3.10KVA
J.BIKVA
AC POWER VOLTS
305
I I
=
=
Le
1
100 | L ol le Ll q Л
0 5 10 15 20 25 30 35 40
AC POWER AMPERES
B-085 330
Figure 4-1. AC Power Curve For 120 And 240 Volts
AC Receptacle {No Weld Load
Condition)
4-2. 240 VOLTS AC RECEPTACLE (Optional)
¡Figure 4-1) - Up to 3 kva of 240 volts ac 13 amperes,
50/60 Hertz power is available at the 240 VOLTS AC
duplex receptacle for operating power tools, lights,
etc., when the welding geneator is operated at weld
rpm. The voltage at the receptacle will vary according to
the applied power and weid load. The voltage at various
loads can be determined from Figure 4-1.
OM-466 Page 12
4-3.75 KVA AC POWER PLANT (Optional)
(Figures 4-2 & 4-3)
A. General
The terminals, located behind the left side door, provide
7.5 kva of 120/240 volts ac 62/31 amperes, 50/60
Hertz single-phase power for operating power tools or
providing standby service to rural, residential, or other
buildings requiring 120/240 volts ac 3 wire connection.
The voltage at the 120/240 volts ac terminals will vary
according to the applied load. The voltage at various
loads can be determined from Figure 4-2.
260
250
240
230
AC POWER VOLTS
220
12 KVA
210
200 ln [ | | |
Q 10 20 30 40 50 60 70 80
“AC POWER AMPERES 8.070 735
Figure 4-2. AC Power Curve For 120/240 Volts AC
~ Terminals (No Welding Load
Condition)
B. Connection Procedure
A: CIUDTOR ELECTRIC SHOCK can Kill.
Keep junction box cover in place while engine is
running.
e Shut down the engine and disconnect the
negative (-) battery cable before making connec-
tions or changing fuses.
® Ground in accordance with NEC, state, or local
codes; install circuit grounding lead finside junc-
tion box) to box mounting hardware and ensure
that a proper ground is connected to the Equip-
ment Grounding Terminal provided on the equip-
ment frame.
IMPROPER FUSE SIZE can damage equipment.
6 Use fuses no larger than 45 ampere rating.
IMPROPER VOLTAGE OR FREQUENCY can
damage equipment.
e ead all equipment instruction manuals before
making connections,
e Use only equipment suitable for operation on
50/60 Hz power.
® Turn off or disconnect electrical equipment from
120/240 volts fuse block before starting or stopp-
ing engine.
1. Open ieft side panel.
2. Remove cover from junction box.
3. Install circuit grounding lead if required.
4. Select desired lead entry location, and remove
knockout blank from junction box.
5. Install proper connector (not supplied) into open-
ing and route load leads through connector into
iunction box.
6. Strip approximately 3/4 inch (19 mm) of insula-
tion from ends of leads, and connect to proper
load terminals (see Figure 4-3); tighten connec-
tors securely. |
Circuit Grounding
Jumper Lead
{Shipped Ungrounded}
TC-000 680-8
Figure 4-3. Power Plant Connections
7. Reinstall cover onto junction box.
8. Close left side panei, and begin operation,
4 - 4. FIELD INSTALLATION INSTRUCTIONS FOR
240 VOLTS DUPLEX RECEPTACLE (Figures 4-4 &
4-5) - A voltage changeover terminal block, located
behind the right side door, provides reconnection
capability for 240 volts ac. Although the capability for
240 volts ac is present, an optional kit must be purchas-
ed if 240 volts is desired at the front panel. For the 240
voits auxiliary power output of the unit, see Section
4-2.
RAEE ELECTRIC SHOCK can kilt.
Do not touch live electrical parts.
. Shut down and disable engine before proceeding
with this installation.
e Disconnect negative (-) battery cable from bat-
tery.
This installation must be performed by qualified person-
nel familiar with standard safety practices. Familiarize
yourself with the circuit diagram provided in the
Troubleshooting Section of this manual.
IEEE Al directions, such as left or right, are
with respect to the operator facing the welding
genera tor front panel. Retain all hardware removed dur-
ing this procedure for reinstallation.
Terminal Strip TE1
Duplex Receptacle
N
BS
Center Bolt
~~. insulation Board
TA-059 485
Figure 4-4. Location Of Reconnectabie Com-
ponents
1. Raise the right side door and secure open.
2. Remove center bolt from insulation board {see
Figure 4-4), remove and retain insulation board.
3. Remove the 120 VOLTS AC duplex receptacle
from the front panel and disconnect leads No.
111, 3, and 42 from the receptacle.
4. Reconnect leads No. 111 and 3 to the 240 volts
ac duplex receptacle {one on each side of recep-
tacle). Reconnect lead No. 42 to the ground
(green) terminal on the receptacle.
5. Install the 240 volts ac receptacie in the front
panel.
6. Affix the 240 VOLTS AC label over existing 120
VOLTS AC designation on the nameplate.
7. Move lead No. 3 (see Figure 4-5) from terminal B
on the changeover terminal biock to terminai A.
8. Position the jumper links on the changeover ter-
— minal block for 240 volts (see Figure 4-5;.
9. Reinstall insulation board.
10. Close right side door and resume operation.
120 VOLTS AC (STANDARD) 240 VOLTS AC (OPTIONAL)
TA-059 243
Figure 4-5. Jumper Link Arrangement On
Terminal Block TE1 For 120 And 240
Volts AC
OM-466 Page 13
—— SECTION 5 - OPERATOR CONTROLS emmener
>
Ampere Range
Battery Indicator Lamp ‘Ajust ont Contra
k
Oil 6 Temp indicator Lamp
Engine Hour Meter —
Auto Idle Switch
Pme
Fuel Switch
Power Output
120 Volts AC
Glow Plug Push Button
Start Pushbutton
Engine Shutdown Switch Circuit Breakers
, TB-086 536
Figure 5-1. Front Panel Controls
5-1. AMPERE RANGE SWITCH (Figure 5-1) 100
A A
80 4 \
AMPERAGE RANGES RB)
The AMPERE RANGE switch provides five course
amperage ranges. The range of each switch position is
displayed on the nameplate. |
D.C. VOLTS
an
е 6 a
#
5
A
7
LX ARCING can damage switch con- NA $
tacts. 30 FU \
LI AN \
®- | “uba \
— 10 y 4 la
DO NOT SWITCH UNDER LOAD Mr
0 100 200 300 400 500 600
® Do not change the position of the AMPERE DC AMPERES
RANGE switch while welding or under load. B-030 135
Arcing causes the contacts to become pitted and even-
tually inoperative.
3-Cylindar Engine Modeis
100
5-2. AMPERAGE AND VOLTAGE ADJUST- ;
MENT CONTROL (Figure 5-1) ”
30 | X
A / V |
AMPERAGE € VOLTAGE ADJUSTMENT |
The AMPERAGE & VOLTAGE ADJUSTMENT control
permits the operator to select a welding amperage and
voltage between the minimum and maximum values of
the course range selected by the AMPERE RANGE 30
switch. The scale surrounding the AMPERAGE & 20
VOLTAGE ADJUSTMENT control is calibrated in per-
cent and does not indicate an actual amperage value. 10 | |
| | 1
5 - 3. VOLT-AMPERE CURVES (Figure 5-2) - The 0 300 400 500 600
volt-ampere curves show the voltage and amperage DC AMPERES |
output capabilities of the weiding generator at min. and B-086 122
max. of each coarse range. Adjustment within each 4-Cylinder Engine Models
range is provided by the AMPERAGE E VOLTAGE AD-
JUSTMENT control. | Figure 5-2. Volt-Ampere Curves
OM-466 Page 14
DC VOLTS
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
a welding generator is the percentage of a ten minute
period that a welding generator can safely be operated
at a given output. This welding generator is rated at 100
percent duty cycle. This means that the welding
generator can be safely operated at rated load con-
tinuously. If the welding amperes are increased beyond
rated output, the duty cycle will decrease. Figure 5-3
enables the operator to determine the safe output of the
welding generator at various duty cycles.
Fiji EXCEEDING DUTY CYCLE RATINGS
will damage the welding generator.
e [Do not exceed duty cycles indicated on duty cycle
chart.
RATED QUTPUT
1200
1000
800
Tn
=
=
WELD AMPERES
8
300 4-Cylinder Engine Models
3-Cylinder Engine Models
200
B-090 342
40 50 60 70 80 90100
% DUTY CYCLE
Figure 5-3. Duty Cycle Chart
5 - 5. START PUSH BUTTON AND FUEL SWITCH
(Figure 5-1}
| on
O OFF
Placing the FUEL switch in the ON position will energize
the welding generator engine circuitry. When the FUEL
switch is in the ON position, holding the Engine Shut-
down switch closed and depressing the START push
button will engage the starter motor and start the
engine. Once the engine has started, release the
START push button. Placing the FUEL switch in the
OFF position will shut the welding generator down. The
FUEL switch must be left in the CFF position when the
engine is not running to prevent the battery from
discharging.
FUEL START
EF VISE REENGAGING STARTER MOTOR
while fiywheel is rotating can damage starting
components.
® Do not reengage starter motor until starter pinion
and flywheel have stopped rotating.
5-6. ENGINE SHUTDOWN SWITCH (Figure
5-1} - The Engine Shutdown switch will automatically
shut down the engine if oil pressure drops to an unsafe
level or water temperature becomes too high. Depress
this switch and hold in until the engine starts and the
OIL & TEMP light goes off.
NIVEL. YR ® This switch is protected by a fuse
located on the bottom of the switch assembly directly
behind the front panel. Should this fuse open, the
engine would not start.
5-7. GLOW PLUG PUSH BUTTON
д J =
. A : у ы
x 1 A:
; | a
К :
Ша
д
il Li
GLOW
PLUG
The GLOW PLUG push button is provided to aid initial
engine start up. When the GLOW PLUG push button is
depressed, glow plugs in the cylinder head heat up pro-
viding à warm air-fuei mixture for combustion. At 70°F
(21°C) ambient temperature, the GLOW PLUG push
button should be depressed and held ciosed approx-
imately 10 seconds; at 32°F (0°C) approximately 20
seconds: at -4°F (-20°C) approximately 25 seconds.
I GELEAT- RR A Fuse wire protects the engine cir-
cuitry from damage caused by glow plug failure. If the
fuse wire opens, the glow plugs are disconnected from
the engine circuitry. See Figure 7-2 for fuse wire loca-
tion
5-8. AUTO IDLE CONTROL SWITCH (Figure 5-1)
AUTO IDLE
E
«уч» ом
- OFF
The automatic idling device saves fuel by allowing the
engine to idle when the welding generator is net loaded.
The AUTO IDLE control switch controls the operation
of this device. |
A. ON Position
When the AUTO IDLE control switch is in the ON posi-
tion, the engine will remain at idle rpm until an arc is
struck or load is applied to the 120 volt receptacies.
When an arc is struck, the engine speed will increase to
weid rpm. Approximately 15 seconds after the arc is
broken, the engine will return to idle rpm. The ON posi-
tion may be used for Shielded Metai-Arc Welding pro-
vided accessory power equipment is not being operated
from the 120 VOLTS AC receptacle or 120/240 volts ac
terminals.
OM-468 Page 15
B. OFF Position
When the AUTO IDLE control switch is in the OFF posi-
tion, the engine will run at governed weld rpm {1800}.
(TXT LOW VOLTAGE AND FREQUENCY
can damage electrical equipment.
e Turn off or disconnect all electrical equipment
connected to auxiliary power before starting or
stopping the engine or while engine idles.
When starting, stopping, or idling the engine has low
speed which causes low voltage and frequency.
5-9. BATTERY CHARGE INDICATOR LAMP
(Figure 5-1)
BATTERY
The BATTERY indicator lamp is illuminated when the
engine battery charge current is not flowing. It is normal
for this lamp to be illuminated when the FUEL switch is
in the ON position and the engine is NOT operating.
5-10. ENGINE TEMPERATURE AND OIL
PRESSURE LAMP (Figure 5-1)
OIL & TEMP
EE
The OIL & TEMP warning lamp is illuminated if the oil
pressure decreases below 8 psi or if the coolant
temperature increases above 240° F. It is normal for this
lamp to be illuminated when the FUEL switch is in the
ON position and the engine is NOT operating.
5-11. TIME METER
ENGINE
t
This unit is equipped with an hour meter. The meter,
labeled ENGINE HOURS, registers the total hours of
engine operation. This information is useful for routine
maintenance on the engine.
5-12. CIRCUIT BREAKERS
CIRCUIT BREAKERS
—
©
©
[| cLosep
| | OPEN
The auxiliary power windings on the welding generator
are protected from overload by CIRCUIT BREAKERS
CB1 and CB2. If a 120 volts overioad occurs, both CB1
and CB2 open interrupting output. if a 240 voits
overload occurs, either CB1 or CB2 opens interrupting
output. Remove the load, determine the cause of the
overload, and manually reset the CIRCUIT
BREAKER(S).
OM-466 Page 16
5-13. METERS (Optional) - The meters are provided
to monitor the welding operation. They are not intended
for exact current or voltage measurements. These
meters are internally connected to the output terminals,
The voltmeter indicates the voltage at the output ter-
minals, but not necessarily the actual voltage at the
welding arc (due to cable resistance, poor connections,
etc.). The ammeter indicates the current output of the
unit.
5-14. OIL PRESSURE GAUGE (Optional) - This
unit can be equipped with an optional OIL PRESSURE
gauge which registers the lubricating system pressure In
pounds per square inch. The pressure registered by the
gauge should remain constant for a given engine speed.
Should the pressure fluctuate or drop, stop the engine
and do not operate again until the trouble has been cor-
rected.
5-15. TEMPERATURE GAUGE (Optional) - This
unit can be equipped with an optional TEMPERATURE
gauge which will register the coolant temperature and
indicate when an overheated condition occurs.
5-16. POLARITY SWITCH (Optional) - The
POLARITY SWITCH provides a means of selecting
either de STRAIGHT or de REVERSE polarity without
changing cable connections.
To ensure that the weld current output will be in accor-
dance with the labeling of the position on the POLARI-
TY SWITCH, connect the electrode holder cable to the
ELECTRODE terminal and the work cable to the WORK
terminal.
DALE ARCING can damage switch con-
tacts.
® Do not change the position of the POLARITY
SWITCH while welding or under load.
Arcing causes the contacts to become pitted and even-
tually inoperative.
5-17. REMOTE CURRENT CONTROL SWITCH
(Optional) - When Remote Amperage Control is
desired, the CURRENT CONTROL switch, located on
the welding generator front panel, must be placed in the
REMOTE position. If the Remote Amperage Control is
not utilized, the CURRENT CONTROL switch must be
placed in the STANDARD position, giving the welding
generator AMPERAGE & VOLTAGE ADJUSTMENT
control full control of weld output.
When a Remote Amperage Control is used, the Remote
Amperage Control functions as a fine amperage adjust-
ment of the AMPERAGE & VOLTAGE ADJUSTMENT
control setting. For example: if the AMPERAGE &
VOLTAGE ADJUSTMENT control is set at the 50%
position, the Remote Amperage Control provides {from
its min. to max. positions) fine amperage adjustment of
one half of the welding generator output for the current
range selected. Fine adjustment of the current range
selected is obtained by setting the AMPERAGE &
VOLTAGE ADJUSTMENT control at 100%.
was SECTION 6 - SEQUENCE OF OPERATION mmm
RIGE 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.
e Keep all covers and panels in place while
operating.
® 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
eyes and skin; NOISE can damage hearing.
6 Wear correct eye, ear, and body protection.
e Allow equipment and work to cool before
touching. |
HOT METAL, SPATTER, SLAG, AND ARC
SPARKS can cause fire.
e Watch for fire.
e Keep appropriate fire extinguisher at work site and
be familiar with its use.
See Section 1 - Safety Rules For Operation Of Arc
Welding Power Source for protective information.
6 - 1. SHIELDED METAL-ARC WELDING
1. Ensure that the engine has been prepared as in-
structed in Section 3.
2. Make connections to the weld output terminals
as required.
3. Rotate the AMPERE RANGE switch and
AMPERAGE AND VOLTAGE ADJUSTMENT
CONTROL to the desired position.
4. Start the engine as instructed in Section 6-3.
5. Place the AUTO IDLE contro! switch in the
desired position and commence welding.
5 - 2. OPTIONAL 7.5 KVA POWER PLANT
OPERATION
1. Ensure that the engine has been prepared for
operation as instructed in Section 3.
EGU HOT ENGINE PARTS can cause
severe burns.
8 Wear protective gloves and clothing when work-
ing on a hot engine.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts.
® Shut down the engine and disconnect negative (-)
battery cable from battery before internally in-
specting or servicing.
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
2. Make connections to the 120/240 volts ac ter-
minals as instructed in Section 4-3.
3. Rotate the AMPERE AND VOLTAGE ADJUST-
MENT CONTROL to 100 (full counterciockwise).
4, Start the engine as instructed in Section 6-3.
5. Place AUTO IDLE control switch in OFF posi-
tion.
6. Once the engine is operating properly at
weld/ power rpm, power may be obtained from
the welding generator.
6 - 3. STARTING THE ENGINE
1. Make all welding and electrical connections to
the welding generator.
2. Place the AUTO IDLE control switch in the ON
position.
3. Place the FUEL switch in the ON position.
4. Depress and hold the GLOW PLUG push button
(see Section 5-7).
5. Press the START push button and START
Engine Shutdown push button.
6. When the engine starts, release the START push
bution. When the OIL & TEMP light goes off,
release the Engine Shutdown push button.
6 - 4. ENGINE SHUT DOWN
1. Remove all weld and power loads from the unit.
2. Allow the engine to idle for a few minutes to per-
mit the internal engine temperature to equalize.
increase the idling time if the engine has been
operating for an extended period or at full load.
3. Place the FUEL switch in the OFF position.
Manufacturer's Manual. Where operating conditions
are severe, more frequent attention 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 INSPEC-
TION - 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 low pressure compressed air.
Check for fluid leaks indicating loose water, oil, or fuel
connections. Tighten loose connections and clean oil or
fuel spills or leaks off of engine surfaces.
OM-466 Page 17
Foliow 1. Stop engine.
5. Wipe out element chamber
7. Reinstall element.
immediately because a washed
element must be dried before
re-use. However, washing does
Compressed Air Washing
Direct air through element in
the direction opposite to normal
air flow through the element.
Move nozzle up and down while
rotating element. Keep nozzle
at least one inch from pleated
paper. Maximum air pressure
- 100 P.5.1, 40 P.S.1.)
with clean, damp cloth.
These 2. Wipe off cover before opening 8. Replace cover.
Easy air cleaner. 6. Inspect new element and
Steps: ай gaskets for shipping damage
3. Remove cover. before use.
4. Remove element.
important | 1. Don’t attempt to service air 3. Don't leave open air cleaner 5. For Donaclone air cleaners -
cleaner with engine running. exposed to blowing dust while don't blow out Donaclone tube
you clean element. Replace section without element, cover
2. Don't blow out the inside of the cover. and inner cover (if any) correctly
air cleaner with compressed air. installed or you will blow dust
&, If air cleaner is horizontally into the engine.
mounted, be sure that dust cup
is positioned so arrows point up.
How To Clean element by one of the a better job and must be used (When cleaning Cyclopac
Clean following methods: when exhaust soot has lodged in elements, do not remove plastic
fine pores of the fiiter media. fin assembly - back-flowing with
Elements Compressed Air or Washing. Use Donaldson D-1400 detergent compressed air or washing will
For which contains a special additive remove dust-from beneath the
Compressed air is recommended for removing scot and carbon. fin assembiy.)
Re-Use when element will be re-used
Replace element after 6 cleanings
or annually, whichever
occurs first.
1. Soak element 15 minutes or
more in Donaldson D-1400 and
water solution. See carton for full
instructions.
2. Rinse until water is clear
{Maximum water pressure
3. Air-dry or use warm flowing
air, max. 160°F. Do not use
compressed air or light bulbs.
inspection
Place bright light inside element
and rotate element slowly. If
any rupture, holes or damaged
gaskets are discovered - replace.
Figure 7-1. Air Cleaner Service
Ze]: ENE 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. FUEL/WATER SEPARATOR AND SLUDGE
DRAIN PLUG
AITOR ENGINE FUEL can cause fire or ex-
plosion.
® Do not drain fuel tank while engine is running.
8 Do not smoke while handling fuel.
e Do not allow fuel to drain onto the engine or other
components.
o
Do not spill fuel; if spilled, wipe up.
ОМ-466 Раде 18
TA-072 606
The fuel/water separator, located below the fuel tank
on the right rear portion of the engine, is provided to
drain off water from the fuel tank. Before starting the
engine for the first time each day, open the petcock on
the bottom of the separator and drain the water into a
metal container. Close the petcock at the first signs of
fuel.
The fuel/water separator should be changed every 125
hours of operation or 4 months, whichever occurs first.
A sludge drain plug is provided on the bottom of the
fuel tank to drain off sediment from the fuel tank. Once
a week, drain the sludge into a metal container. If ex-
tremely dirty fuel is encountered, a more frequent drain-
ing will be necessary.
7 - 4. AIR CLEANER SERVICE (Figure 7-1} - 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. Every 50 hours or less depending on conditions,
empty the dust cup and inspect the element.
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
CINE BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
0 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.
Frequently check the electrolyte level. Add ciean
minerai-free or distilled water to bring the electrolyte in
each cell up to the level indicator.
7-6. SERVICING THE SPARK AR-
RESTOR - Internal combustion engines operating in a
highiy combustible environment are a common fire
hazard. Glowing carbon particles blown out with the ex-
haust can retain sufficient heat te ignite materials.
While no practical spark arresting device will stop all
sparks, this device will minimize fire hazards by remov-
ing 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.
A. inspection
1. Visually examine the outside of the device for
holes, cracks, or metal corrosion.
2. With the engine stopped, look inside the spark
arrestor outlet tube with a flashlight or other light
source. Visually examine the vanes and the
outiet tube for metal or weld 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
ENTES EXHAUST SPARKS can cause fire.
© Clean spark arrestor/ muffler in a non-combustible
environment.
1. Stop the engine and allow the exhaust system to
cool.
2. Remove the cleanout plug from the side of the
spark arrestor with a wrench. If a crust has form-
ed over the hole, break it loose with a
screwdriver or similar tool.
3. Start the engine to blow collected particles out
the cleanout hole. If particles are slow to
discharge, momentarily cover the end of the ex-
haust stack.
4. Stop the engine. Replace and secure the
cleanout plug.
7-7. BRUSHES AND SLIP RINGS - Brush life is
very good under normal operating conditions. The
brushes and slip rings should be inspected every six
months or whenever excitation voltage is lost. Check
for cleanliness of the slip rings and freedom of motion of
the brushes. If the welding generator has been
operating under extremely dusty or dirty conditions, in-
crease the frequency of inspection.
If the welding generator has not been used for an ex-
tended period of time, oxidation may form on the slip
rings causing excitation voltage to be lost. This can
usually be remedied by simply spraying the slip rings
with an antioxidant type contact cleaner and running
the engine.
Under normal use the slip rings will discolor to a dark
brown. If a build up of brush materiai is noted, it may be
necessary to ciean 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 1/2 inch of brush material is left.
7 - 8. ENGINE SPEED ADJUSTMENTS (Figure
7-2)
1. Start engine and check weld and idle rpm (no
load applied).
2. Place AUTO IDLE control switch in OFF posi-
tion.
3. Loosen locking nut and adjust high speed adjust-
ment screw for 1800 rpm. Tighten locking nut.
4. Shut engine down.
OM-466 Page 19
5. Push throttle arm in direction of solenoid until
solenoid plunger is fully bottomed in solenoid
body. Be sure that the plunger is bottomed
BEFORE the low speed adjustment screw hits
the stop. If the low speed adjustment screw hits
the stop before the plunger is fully bottomed,
back out low speed adjustment screw.
oJ Seg le] V8 INCORRECT SPEED ADJUS-
MENT can damage idle device.
e Be sure that solenoid plunger is fully bottomed in
solenoid body at idle (1200) rpm.
‚6. Start engine and place AUTO IDLE control
switch in ON position.
“..
Loosen locking nut on throttle arm and rotate
throttle arm until 1200 rpm is obtained. Tighten
locking nut.
— Fuse Wire
y
Low Speed
Adjustment
Screw
Throttie Arm
*4-Cylinder Engine Illustrated
High Speed Adjustment
Screw
Throttle . E
Solenoid
Solencid k
Plunger
ТА-091 065
Figure 7-2. Engine Speed Adjustments*
жа SECTION 8 - TROUBLESHOOTING suman
8 - 1. GENERAL - It is assumed that proper installa-
tion has been made, according to Section 3 of this
manual, and that the welding generator has been func-
tioning properly until this troubie developed.
8 - 2. TROUBLESHOOTING CHART
BUY CLICHE ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Protect yourself with dry insulating gloves and
clothing.
e Shut down engine and disconnect negative (-)
battery cable from battery before internally in-
specting or servicing.
MOVING PARTS can cause severe injury.
® Keep clear of moving parts.
HOT SURFACES can cause burns.
e Affow equipment to cool before touching.
® Wear protective gloves and clothing when work-
ing on a hot engine.
Troubleshooting of internal parts to be performed only
by qualified persons.
The following chart and the chart provided in the Engine
Manufacturer's Manual are designed to diagnose and
provide remedies for some of the troubles that may
develop in this welding generator.
Use these charts in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro-
OM-466 Page 20
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. In al! cases of equipment
malfunction, the manufacturers recommendations
should be strictly followed.
8 - 3. BOOSTER BATTERY JUMPER STAR-
TING - If jump starting is attempted, employ the safety
precautions below and the following step by step pro-
cedures in order of appearance.
ERE 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 personne! injury and damage equipment.
e Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
e Ensure that all personnel are a safe distance from
batteries and clear of moving parts while starting.
e Do notjump 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.
e Be sure that vent caps are tight and level on both
batteries and cover batteries with a damp cloth.
® Wear correct eye and body protection and remove
all metal jewelry.
e Keep jumper cables clear of moving parts.
e Ensure that both batteries are the same voltage.
Do not jump start a trailer mounted welding 4.
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 5.
allow vehicle to make contact with welding
generator case or frame.
Connect remaining end of cable to welding
generator engine block at least 18 inches {457
mm) from battery {do not connect ic welding
generator case, frame, or equipment grounding
terminal as damage to equipment can result).
Wait at least cne minute afer connecting cables
before starting engine.
Do not jump start by applying power to weld out- 6. Start engine following procedures outlined In
put receptacles or terminals. | Section 6 {Sequence Of Operation; of this
Do not allow jumper cables to contact any other manual.
metal while attaching or removing cables.
7. Remove jumper cable from engine block.
1. Use properly insulated jumper cables of ade-
quate size. 8. Remove other end of same cable {rom booster
battery negative (-) terminal.
2. Connect ends of one cable to positive (+) ter-
minals of each battery. | 9, Remove other jumper cabie from welding
generator battery positive { +! terminal.
3. Connect one end of other cable to negative (-}
terminal of booster battery. | 10. Remove remaining end of cable from booster
battery positive { +; terminal.
11. Discard damp cloths.
TROUBLE PROBABLE CAUSE REMEDY |
Engine fails to starts. Fuse on Safety Shutdown | *Replace fuse on MS1 (see Section 5-6).
switch MS1 open.
-
Battery. Units With Conventional Batteries: inspect the
electrical system (see Section 7-5). 1 the battery |
requires recharging (see Section 3-30, Steps |
7-10) follow ail applicable safety procedures and
the battery charger manufacturers 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-
bie is isolated to the battery, reolace the battery,
Jump start the engine emploving approved safety
practices and booster jump sterting instructions
provided in Section 6-5.
Engine suddenly shuts | Low oil or coolant level | Add oil or coolant.
down: OIL & TEMP. warn- | (other probable causes can
tng light on. be found in the engine
manual).
BATTERY warning light on. | Loose or faulty electrical | Inspect ignition system. Clean ang tighten con-
connection. nection.
Defective alternator. Replace aiternator {see Engine Manufacturers
Manual),
Defetive regulator. Repiace regualtor (see Engine Manufaciursrs |
Manual.
OM-465 Page 21
TROUBLE
PROBABLE CAUSE
REMEDY
No weld output.
Poor contact between slip
rings and brushes.
Clean slip rings (see Section 7-6).
Replace the brushes.
AMPERE RANGE switch
S3 is between positions.
Place AMPERE RANGE switch S3 in proper posi-
tion.
Erratic weld current.
Loose or dirty connections.
Check connections both inside and outside of
welding generator.
No output at 120 VOLTS
AC receptacle RC1, no
weid output.
Circuit breaker CB1 and/or
CB2 open.
Reset CB1 and or CB2.
Poor contact between slip
rings and brushes.
Clean the slip rings {see Section 7-7).
High or low voltage at 120
volts receptacie RC1 and
weld output terminals.
Improper engine speed.
Check the engine speed. The engine must run at
1800 rpm when AUTO IDLE control switch is OFF
and no load is applied (see Section 7-8).
Battery discharges between
uses.
FUEL switch S1 left in ON
position.
Ensure the FUEL switch S1 is left in the OFF posi-
tion when the unit is shutdown.
Build up of acid on top of
battery (white-grayish
substance).
Clean battery with soda solution; rinse with clear
water.
Infrequent use.
Periodically recharge battery.
Defective battery.
Replace battery.
Engine ran fine but slowly
stopped; unable to restart
engine.
If fuel tank cap is equipped
with an inside valve, it may
be in the CLOSED position
(other probable causes can
be found in the engine
manual).
Examine the inside of the fuel tank cap. If the cap
is equipped with an adjustable valve, rotate the
valve to the OPEN position.
OM-466 Page 22
MMT
AEMOTE CONTROL
(OPTIONALLY
REMOTE CONTROL FACI „те
CAPT
WINALL
LINE Jar 18 CONNECTED
TO 55 RATHER THAN Ay
GROUND STRAP BETWEEN ENGINE
BLOCH AND WELDER FRAME
42
EQUIPMENT
& но
NEUTARL GROUND AS REQUIRED
RUNNING
CAY
FUSE
WIRE
STARTER
£7
TO GLOW CAUTION
PLUGS Tm.
REFER TO IMSTAUCTIONS BEFORE
ATTEMPTING TZ INSTALL OPERATE
DR MAINTAIN EQUIPMENT
Figure 8-1, Circuit Diagram For 3-Cylinder Engine Models
56
WATER
TEMP FS
144, РЫМР
LOCATED IN T
HOUR METER
FUSE
HELE IN
TG START
ELECTRIC
FUEL
PUMP
E
AC POWER
REMOTE CONTROL
[OPTIONAL]
REMOTE CONTROL pans)
[OPTIONAL]
LINE 703 15 CONNECTED
TO 5% AATHER THAN Ay
GAQUND STRAF BETWEEN ENGINE
BLOCK AND WELDER FRAME
Iga
EQUIPMENT
GROUND
|
La
1
т
СОР ТОМАС)
—
M
NEGATIVE POSITIVE
ELECTRODE* WORK*
AC POWER By MATIONALELOCAL ELECTRIC CODES
TLONALS
(OP TIONAL 22 23 161636 22 23 2025 2632 3330 15 38
Listas! Bl be 38] [21] [za
sag)
BUUUVEE | |
. 1134/87) 3 +112] 14 15| 17 [19202223
24
HI. 32
7 27 37
53
X X [37
< e = 1 6
m ILS
с r
> ATE >
1
e “i 8
2 w 7 |
a 1204, Jeon | L
co) Lo
ACY mu
a £a
I
De
всё | 1
ТЕ 3
| | Cat
в + E \
3 = | 1 pla
с SAG, | 1
— ПОНИ o CS
es een I re +
1 NT
OPTIONAL KIT 3 ¡Er 7 ;
INCLUDING 280 v0LT AUTOMATIC STATS"
RECEP TALLE -
CONTROL “о WELD MÉTERSIQETIONAL)
SHUNT IS SERIES
DEF + — CONNECTED IN LINE 75
= POLARITY SW.IOPTIONAL?
FWITH FOLARITY Sy. OPTION,
LÉADS 792 30 GOTO FOLARITY
Sw RATHER THAN JQUTPUT
STUCS, QUTPUT STUDS ARE
LABELED ELECTRODE & WORK,
Circuit Diagram No. B-089 500
NEUTRAL GROUND AS REQUIRED
Ay NATIONALS LOCAL ELECTRIC CODES
12 13 M1816 22 232425 26032 333 XE JE
!
E ls e >| [6 (18 24
ээо | |
PRUU VE GrXVENVECUOEE
1] 34167 | 31172 1415| 17 529 (272 234
Zn
41314 ASH
G131d A3Y
OPTIONAL KIT
INCLUDING 2300 T
AECEPTALLE
AUTOMATIC
gere
CONTROL
{
cn /er
= ©
+ FUNNING Sa
on
i
у
® 3
wn
Ya _
> 8
a 7
@
a
in к
=
“x
À
в
1
! 40
FUSE >,
WIRE =
то GLOW CAUTION
PLUGS
REFER TO INSTRUCTIONS BEFORE
ATTEMPTING TO INSTALL, OPERATE
GA MAINTAIN ÉGQUIPMENT.
56
WATER
TERME
A =
LOCATED TN
INJ, PUMP
HOUR METER
te y
FUSE
HOLD IN
TO STAËT
ELECTRIC
FUEL
PUMP
3 PHASE
WELD GEN.
JF
MEGATIVE
ELECTRODE®
POSITIVE
WORK
4 WELD METE RSCOPTIÓNAL
SHUNT IS SERIES
CONNECTED IN LINE 78
= POLARITY SWIOPTIQ MAL)
"WITH POLARITY Sw. OPTION,
LEADS 9 LIO GOTO POLARITY
Sw, RATHER THAN SUTPUT
STUDS. OUTPUT STUDS ARE
WABELED ELECTRODE = WORK,
Circuit Diagram No. B-089 440
Figure 8-2. Circuit Diagram For 4-Cylinder Engine Models
OM-466 Page 23
TERMINAL REFERENCE
АВ СВЕ 6 HO
DIODE D52 j{ {11111
ISOLATED p <— pol.
RESET J
POSITIVE B< + ++ e
C51 Casa a R B
#050 Е = 5 16 $054 OUTPUT Qs0
OUTPUT Oss | Ds7 (DELAY ON) PINVIEW
(DELAY OFF) C€ , >| |< >A 4
‚ G
RESET 8 EL =D
BURDEN RESISTOR Qs
a
к |
ле 0
F ===
CT SCRSOA 51
Hé
NEGATIVE J<
Circuit Diagram No. A-071 600
Figure 8-3. Circuit Diagram For Automatic Idle Control Printed Circuit Board PC1
ОМ-466 Раде 24
ÿ September 1984 FORM: OM-466C
Effective With Serial No. JE753567
Figure A - Main Assembiy (3 Cylinder Model illustrated)
OM-466 Page 1
FAA
A EA
EEN
DL и = TX “NA TD
; PT
' _ _ A ; _ Mu AI Bea HAL
4 PA
Ч
—
71 70 4142 89
Y
“Includes Items 70-080 081
69 thru 88
OM-466 Page 2
Quantity
Model
item Dia. Part Cylinders
No. Mkgs. No. Description 3 | 4
Figure A Main Assembly
1 089 517 STRAP, fueltank .......... iii iii anne 2 2
2 016 434 STRIP, rubber 1/2x2x2 .......... 5.2.5.5 не квн вина нк нк a een aa ace 6 2 2
3 085 384 TANK FUEL (consisting of).........e....-—e-—-—e2exxevrerrerr een A 1 1
4 049 192 .CAP, fueltank ..........e.-ee_eeerncecoonererocrarereneorerereonaven. 1 1
605 288 FITTING, pipe-plug sq hd 1/4 NPT ............r.—em—.eeesasucrroreracaao 1 2
5 020 185 FITTING, pipe-brass elbow st 1/8 NPT ..................mexecoreronene. 1 1
6 073 432 FITTING, pipe-brass M 3/16 TBGx 1/8 NPT.............ee.n0recore... 1 1
7 604 550 HOSE, No. 1 x3/16 lorder by ft) .............._—.w-em2eeseaaenoneraaoa.. 3it ЗН
8 071 388 STRIP, rubberadhesiveback 1/8 x1x28 ........... iii... 2 2
9 010 314 VALVE, shut-offfuel ......... coi iii is 1 1
10 604 308 FITTING, brass-barbed M 1/4 TBG x 1/4 NPT .... iio... 3 3
11 010 678 FITTING, pipe-brass eibow st 1/4 NPTL ........ co iii, 1 1
12 017 473 SEAL, weather .......... e_wec_ceéereoaxrsvocrrerecuvenoveneotrermavano, 1 1
13 053 606 УРНСНТ, Базе-сеп#ег ...................... Ch teehee, 1 1
14 062 342 SEPARATOR, fuel-filter Et water ........... REKEN 1 1
15 089 519 BRACKET, mtg-solenoid............_é__eeeesrecraroeiorrrrtaconreeene, 1 1
16 089 513 BASE, filter-fuel w/adapter ............_—eeee=-exrdaaoricareoreonearon e. 1 1
17 CRI 070 109 CONTACTOR, solenoid 12 volts de 400 amp..............—eee._reevocenrs 1 1
++ 089 830 FUSE LINK ..............0000smmecraacoreaaceraaatecorronieanannonmeda 1 1
18 604 314 HOSE, No. 1 x 1/4 ID [order by Ft) .................e..e0mere0vereedeca. ЗН 3ft
19 601 945 SCREW, cap-hex hd 5/8-18 X4.............er—s.ee0orredareracentec... 4 4
20 071 731 WASHER, flat21/32IDx2-1/4Xx3/16 ... citi ieee ieee iin 4 4
21 071 890 RETAINER, mount........_._..zeeerrecorearerear rece dr arena ree ac 4 4
22 071 730 TUBING, steel 7/8 OD x 12 ga x2-3/8 ............ee.reenoosavarreresma. 4 4
23 072 848 TUBING, neoprene 2-1/2 OD x7/81Dx2 .........._.....0....... urea. 4
23 083 475 TUBING, neoprene 2-1/2 OD x 7/8 1Dx2 ...........—rr—eevrevrrerarec cares 4
24 030 342 TRAY, siide-battery ............—_—remesrreorvrorertecrarrecarvecroreren. 1 1
25 EAT 012 724 BATTERY, 12 volts 160 amp ......._....._eorercearerasnorernoreao e ren. 1 1
26 032 452 CABLE, battery-positive .............eñe._eeerisrerorere recorren ma. 1 1
27 082 583 DOOR, access-battery ...........—————eecrerecsreororrecnrrevacionere, 1 1
28 010 875 CLAMP, muffier 2 inch ............_.ee_e_erecrrcasaocravarertenoran=eres 1 1
293 071 596 MUFFLER, exhaust .........e_reeee-eceorvecnaridarrerecer vera rea 1 1
30 071 389 CAP, weather No. 4 .......2020 2004221000 a aa ee 0 ea aa ue ee a a en na ea 00006 1 1
31 012 378 LABEL, use no petrol etC. ..........._.-eeeroreoertarrerteaorreamear me 1 1
32 035 968 WASHER, neoprene 5-7/8 OD x 3-5/8 ID x 1/16 ............———=reareco> 1 1
33 028 089 DOOR, access-radiator .........o._e.eeece0ecrereenvecorrorremereenoren 1 1
34 089 509 COVER, top.........eerreeorncaroacorrennoorrnaroeaarreamarvaro rea 1 1
35 045 657 AIR CLEANER, intake (consisting of) ........ eae 1 1
36 021 116 .CAP, dUSt 2er ieee testi teat aceasta aan can saan raennes 1 1
37 021 117 .NUT, wing............o mee =erreorrcaavare—. eae La ae 1 1
38 *020 319 . ELEMENT Lo titi et tetas aa aaa 1 1
‚ 39 021 115 . BAND, mounting ........._eeereevaoxcorereavoereanoereroreacece, 1 1
40 021 114 .CLAMP ASSEMBLY ..........ece—.eeeoeorenanoecacoricanrreroecame. 1 1
004 115 .BAFELE, dustcap ..........e..rennscosorresanorererrecanme ten eame, 1 1
41 010 863 CLAMP, hose 2-1/16 x 3 clampdia............—.eeerrcesoccrerecccorer. 2 2
42 089 514 HOSE, eibow-air cleaner .........c_.e.e.erecmorreayeorena. RS 1 1
43 089 510 DOOR, side .............eeeerecareriorerecararecaaorenaartne venden 2 2
44 086 402 RIVET, 3/16 X 1-1/4 ,............eoredenrrrcaranrrcarorrenrar tocan n 0 2 2
45 085 160 BRACKET, mtg-latch..............—eeecrenronscerorerer reriacor terca о 2 2
46 604 393 NUT, speed 3/16 ..............-e—e-e.onme0daorerarvarveroreconverioredao 2 2
47 085 158 TUBING, steel 1/4 0D x 13/16 ............e-eremorerevareraresvenreen. 2 2
48 085 157 TUBING, steel 0.275 1D x 7/16 ..........vremreorvecanraccan recrea = 0 2 2
49 085 159 LATCH, door .............—.e20ee_edsavrrracerrecadetranrorverevorarne 2 2
50 A a aa a a a a a aa ea ae ea ee a eee ee a 0 ea a a es AS ses 00 2 2
51 071 881 PIPE, exhaust ............oo.ec_eerescarveresororrec voor teavresvEnte. 1 1
CM-466 Page 3
Quantity
Model
item Dia. Part | Cylinders
No. Mkgs. No. | Description 3 | 4
Figure A Main Assembiy (Cont'd)
52 084 979 HOSE, radiator ...... oe RE da aa aa 1 1
53 010 861 CLAMP, hose 1-1/16 x2 clampdia...... counties 4 4
54 011 198 LABEL, danger-fan ......11202 0101440 aa ea 4 a Lea ea ea ea ea aa 2 2
55 +053 966 GUARD, fan .......211111 12e Lada aa La AAA a Aa a aa ea aa 2 2
57 08S 946 RADIATOR, w/shroud {consisting of) .............. uuu... 1
57 089 947 RADIATOR, w/shroud (consisting of) ................. rane. 1
58 605 982 .CAP, radiator 7 ¡bs pressure ..................ec0. 0.0000 rien aaao.. 1 1
59 081 500 ENCLOSURE, radiator............ ee ee eee aa, 1 1
60 006 015 FITTING, pipe-brass drain cock 1/4 NPT ........ ere... ae 1 1
61 083 730 HOSE, radiator-lower................... e e. rececarraarareaaeooo 1 1
62 090 610 ENGINE, diesel (consisting of) ,................. .. LL LL a aa 1
62 091 030 ENGINE, diese! (consisting of) .................. a Lan LL LL 1
073 432 . FITTING, brass-barbed M3/16 TBGX1/8NPT .... coon 1 1
63 088 781 FAN Le Re 1 1
64 084 740 .STRIP, adjusting-alternator ................. ee eee 1 1
65 605 430 . PULLEY, single-belt.............. 2... ee ee 1 1
66 083 713 BELT, Voit ee ee ee ee ee a aa 1 1
67 ALT 605 429 . ALTERNATOR, 35.amp 12 Vols +. otitis ee eee eee 1 1
68 084 496 . BRACKET, mtg-alternator ......L.L22 0104 La aa aa aa aa a da ana sa aan 1 1
69 . GASKET (see engine parts list)... 1.221120 0 204 ae aa a a nee a ea A 1 1
70 602 887 . FITTING, pipe-brassplughex hd 1/4NPT ... .......... iui... 1 1
71 S7 025 473 . SWITCH, pressure-oil ....... e... ee eee 1 1
72 073 432 .FITTING, brass-barbed M 3/16 TBGx1/8.NPT Le. ene 1 1
73 090 468 . ANGLE, holddown-clamp ..............—....s... esiacaraoro o, 1 1
74 089 256 .CLAMP, 1-3/4 dia ........... eee 1 1
75 087 912 . FITTING, Бгаз5-Нагес ейбому М 1/4 ТВС х 3/8 ТВб..................... 1 1
76 095 624 . PUMP, fue! 12 voltsdc ....L..11 12104111 LL La 4 A1 4 ee a a a a ea a dan ne 1 1
77 089 341 . LINE, fuel .......... ee 1 1
090 413 .FITTING, brass-flareless nut 5/16 TRG x0.562-24 hd. .................. 1 1
090 414 . FITTING, brass-flareless sleeve 5/16 TBG ......... ovine, 1 1
78 089 512 . BRACKET, mtg-solenoid Re 1 1
79 1TS1 080 517 .SOLENOCID, 12 volts de.............. eee ee eee eee 1 1
80 605 277 PIN, cotter3/32 x 3/4... nano ananecandaeda ae 1 1
81 049 839 . BRACKET, adjustment-solenoid .......... oun LL LL 1 1
82 083 521 .ROD, throttle ............ ee ee eee ee eee eee 1 1
83 024 799 .BALL, joint 1/4-28 thread. ................... riecaaaoaorareconaro, 1 1
84 089 518 ARM, throttle . .... .ereceraaaananaaadencenar or, 1 1
85 085 963 .SPRING..........—.. La da aa a ea aa AAA aa aa Aa ana 1 1
86 56 025 474 . SWITCH, thermo-temp.................0000) 0. e reuerederonódo, 1 1
87 089 520 .STRIP, mtg-spring ............. eee ee a A ALL 1 1
88 089 515 . ANGLE, mtg-engine iit ee ei 2 2
89 047 812 CABLE, battery-negative...... ee eee eee aa 0 1 1
90 Figure BL GENERATOR ASSEMBLY (Pg6) ...... e aaa enano, 1 1
91 087 341 BUMPER, door...... 11111 aa ae aa La La ALL LL 4 4
92 004 130 BRACKET, sUpPOrt-g00r. «oor eee ee eee ee ii AL 2 2
93 082 582 HOLDDOWN, battery RR aa a LL 1 1
94 017 477 ROD, holddown-battery LL LR LL 2 2
OM-466 Page 4
Quantity
Model
item Dia, Part | Cylinders
Ne. Migs. No. Description 3 | 4
Figure A Main Assembly (Cont'd)
95 CT EEE 1
95 089 535 BASE RR RR RER KR RR 1
96 6501 851 NUT, hex5/8-18 ................emei00xreriore rie ere. 4 4
97 010 146 CLAMP, 5/8 dia.........112100 0444111 da eee eee see a ae eee ae a ea en 0 1 1
38 503 107 HOSE, neoprene-siit5/321D{orderby ft). ......... oii, 1ft 1
ss TES 038 621 BLOCK, terminal 30 amp 4 pole .......2.2220080 4000 sa a aan se ae ea een 00 1 1
038 620 LINK, jumper-terminal block 30 amp ........00010001 01e ea ane eee ea ee 0 2 2
100 053 967 INSULATION, rectifier ........1221102 044040 REKEN RK 1 1
101 981 499 BRACKET, mtg-terminal block.........0222000280 00 Lea a aa 0e ee aa ee sean 0 1 1
102 (35 860 RECTIFIER ASSEMBLY (consisting of) ..........e..e.e.....errrecarreoo 1 1
103 581,2 035 704 . RECTIFIER, integrated 30 amp 800 volts ............ cit 2 2
104 031 926 BEAT SINK Lo ee 4 V4 Aa a ee eee 1 1
105 PCI 371 609 CIRCUIT CARD, weld/idle control {Fig EPg 9) ....... ois. 1 1
108 Rb 072 634 RESISTOR, WW iixed2bwattb0ohm............ orien 1 1
107 C1 046 655 CAPACITOR, ignttion 0.5 Uf...........e sere rrcererrarer e rceren eee 1 1
108 085 730 BRACKET, mtg-circuit card .............__e=rereeririio area en e, 1 1
109 086 411 LABEL, starting instructions..........20242 00100002 a 0e ieee 1 1
110 046 392 LABEL, general precautionary .......... citi aia 1 1
111 +093 559 PANEL, front-lower ......1122220 040444 44444 aera a a nana 0e 0 1 1
112 027 657 LABEL, caution-equipment ground .. ........ KR aa ren 0 1 1
113 Figure C PANEL, front-w/components{(Pg7) ............. iii tn, 1 1
114 Oi] 081 359 TRANSFORMER, idlecontrol. ...... coin ii eee as 1 1
115 081 983 STRIP, mig-transformer .........22220 404000 ea ete aa ne sa ea a sa es ae» 1 1
118 Figure D TERMINAL ASSEMBLY, power-output(Pg8) .......... cco, 1 1
117 049 082 UPRIGHT, base-front ..........._——.—eceererecrrecarer recrean. ae. 1 1
118 1 084 814 REACTOR ......111 1111110114 4 4 a da a a a 44 a ee 4 ea a a ee a ee a eee een aan 1 1
119 085 551 FRAME, mtg-reactor & fuel tank .......002000 00e en ea sea ee eee sea nee ne 1 1
120 R2,3 030 060 RESISTOR, WW adj375watt20chm ........... iii. 2 2
121 085 B58 STRIP, MUG-TeSISION . .. tritici EEN 1 1
122 070 010 SOLT, J1/4-20 x2-5/16 ...........0.-—rreererecanoorecacenreroneerem e. 2 2
123 089 343 RIVET, truss hd 1 inch .............—eeeecereerrrac eee aora. 6 6
*Recommended Spare Parts
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
+ + Fuse Wire
E£ SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-465 Page 5
Item Dia. Part
No. Mkgs. No. | Description Quantity
Figure B Generator Assembiy (Fig A Pg 4 item 90)
1 049 650 BRACKET, mtg-brush holder .........12020000 00404 s Lea a aa ea ae a ea ane» 1
2 018 614 BRUSH SET (consistingof) ........... RR RE RK 3
3 *044 755 BRUSH ... oi ee eee aaa 1
4 600 270 HOLDER, brush ...... oe eee ee eae ee cies 1
5 018 665 . CAP, brush holder ...... ee ee eee aa 0 0 1
6 013 367 LABEL, caution-compression release .........._.—._c_weeoeorcavermoreevaro 1
7 085 274 GUARD, generator ..........._e_e_.-_.ees0rreconrneayerrranevreaorerca. 1
8 +085 548 STATOR, generator Or. ...........em-—.e0eceeacorrevrade dere eraróreco. 1
8 +090 941 STATOR (used w/7.5 kva option) ...............emWe.—.......s0eareeaan.. 1
9 039 207 BAFFLE, alr-generator ..........._.__e.eereeneoorraronazoneereo tarta 1
10 089 736 ROTOR, generator (consisting of? ............. i iii. 1
11 024 617 . RING, retaining-external ............—.—_eererresvoorereorrren eee. 1
12 053 390 . BEARING, bat ......1112 0104404 a ea a eee a a a ea a a a aa ra aa ee a aa» 1
13 089 737 . РАМ, го!0г............. 2.5... к кл а 4 4 4 a 4 4 a 4 a 4 4e AA a a a a a 4 aa a ee ee nee 1
035 776 . KEY, 3/8x3/8x2..11111 114 2e LL LL aa a ae a eee ae aa 1
14 044 374 STATOR, exciter-aux power 120/240... iin 1
15 049 235 ENDBELL, generator .............em_._eeererirociorareoror arena ena 1
16 049 652 BARREL, rectifier ...............eeÑeceaaurrrrrra cea veccaonaeeeearóaonm. 1
17 SR3 072 182 DIODE ASSEMBLY, straight polarity {(consistingof ...................... 1
18 025 305 .INSULATOR..............eoserecnawooenrerarcaaoraanonrearrecormenoo 2
19 037 956 . DIODE, rectifier 275 amp 300 volts straight polarity .............—.—re..e... 3
20 0009 901 .CAPACITOR, ceramic 0.01 uf 500 volts de .............e_.e5ervereroo. 2
046 455 .CAPACITOR, ceramic 0.01 uf 500 volts de ............._eseerree cena. 1
R4,VR1 046 819 . SUPPRESSOR iti i ee te teeter tere a e 1
21 025 306 INSULATOR .................0eseer0corereceoereerercerecrerer en npenaa 4
22 049 653 BUS BAR, rectifier. ..................... PE 2
23 SR3 072 950 DIODE ASSEMBLY, reverse polarity {consistingof) ...................... 1
24 037 957 . DIODE, rectifier 275 amp 300 volts reverse polarity... ........... LL. 3
25 025 305 .INSULATOR..... fh ee ee eee ee ieee teas 2
000 901 . CAPÂCITOR, ceramic 0.01 uf 500 voits dc iin... 2
046 455 .CAPACITOR, ceramic 0.01 uf 500 volts de .............eeerencciaaona. 1
Figure B - Generator Assembly nef: TD-089 758
*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-466 Page 6
tem Dia. Part
No. Mkgs. No. Description — Quantity
Figure C Panel, Front-W/Components (Fig A Pg 5 Item 113}
1 010 836 PIN, spring-compression 3/16 x 1-1/4...,.......e.e..resanavecariorerDe. 1
2 044 328 HANDLE, switch-range .........e.-——r—reeserrcorererecererconrer rare... 1
3 NAMEPLATE (order by model € serial number) ............—reeorreereneoo. 1
4 54 011 609 SWITCH, toggle SPDT 15 amp 125 volts ,.........re.e.eresrsreaariarrerao. i
5 81 011 617 SWITCH, toggle DPDT 15ampi2bvoits ........ coins. 1
6 PBi,2 084 098 SWITCH, pushbutton36voltsdc ........... iii. 2
7 093 843 PANEL, front-upper ............ cco... PS 1
8 086 706 SPACER, switch-range .............. vr ee teeta aan 1
9 83 089 672 SWITCH, range. .........._e—eceecrarorrioneracarono cananea recamen. 1
10 086 991 BRACKET, support-switch ............._e.emreseemerrorecoorer car reenve, 1
11 Ri 070 698 RHEOSTAT, WW 300 watt 34 ohm .........._eeem_—er—rreeronececarrecmoea 1
12 MS1 011 072 SWITCH, magnetic (consisting Of)............._—.-e-revrecrarecaranerarera 1
13 F *048 317 . FUSE, miniature-glass 14 amp 32 volts ..............eee.rrrseoeaveconmeoa 1
D8 087 970 DIODE, 3ampbB00 volts... oii i i esa 1
14 CB1,2 053 283 CIRCUIT BREAKER, manual reset 1P 15 amp 250 volts ...............—..... 2
15 RC1 604 176 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 125 volts .......... ; 1
15 RC2 +604 103 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 280 volts ........... 1
16 094 006 PLATE, identification (Big 25 Diesel) ..............e—ee-eero0svecaororeneo. 1
16 094 007 PLATE, identification (Big 40 Diesel) ..............—_—.—ee.eresceorereree¡. 1
17 602 178 SCREW, set-socket hd 1/4-20 x 3/8 ............-—-ecesxveredrororrecarvena 1
18 019 755 HANDLE, switch .........eeeeremenrecaororecacvicorerrenneteceo ea. 1
19 084 246 CAP, switch-dust/weather black ..........—.—.——ceo_rrecorreecervearrecieo. 1
20 084 247 CAP, switch-dust/weather red .......... —c_c_eweresenvscoreorrecoerone. 1
21 021 385 BOOT, toggle switch lever ............_.e—ecerccrverredarmereene rento. 2
22 082 788 LIGHT, indicator-holder ............._——.—eemerecconereraynrrarerian ren, 2
23 PL1,2 *048 155 BULB, incandescent 12 volts. ............. coi imines 2
24 082 789 LENS, light-indicator red .............—.—._evrer-recxrrcorarersererieceree. 2
25 HM 032 936 METER, hour 4-40 volts de .............e.—.--eeeserecaroz econo r eme 1
TC-086 538-C
Figure C - Panel, Front-W/Components
*Recommended Spare Parts.
+ Used if unit is equipped W/240 Auxiliary power.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-466 Page 7
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure D Terminal Assembly, Power Output (Fig A Pg 5 Item 116)
1 081 491 BRACKET, mounting-terminal poweroutput ............. iii. 1
2 Neg 039 046 TERMINAL, power output-black (consistingof) ..............c. oil 1
3 601 879 . NUT, hex-fuil 1/2-13 .............e.e000rrrorererreriancaneererne caca 1
4 039 044 ,BUSBAR.........—...e.eerrercanoerrorrrvarecocaeorerv Mapeo. 1
5 601 880 . NUT, hex-jam 1/2-13 ......121 0210010044 aa aa a a aa ae ae ae a ae a ea ne eee ee 00 1
6 039 045 . TERMINALBOARD, black ............... cc... Ne sree 1
7 601 976 . SCREW, cap-hexhd1/2-13x1-1/2 ................ ee eee 0e 1
8 Pos 039047 TERMINAL, power-output-red (consistingof) ............... ccc. 1
9 601 976 . SCREW, cap-hex hd 1/2-13 x 1-1/2 iia 1
10 039 049 . TERMINAL BOARD, red ........14222000 00004 se eee ea ae a na sea ea sea 06 1
11 601 880 . NUT, hex-jam 1/2-13 .....12202 02014 42e sa ea de a see eee ee eee ae a aa ea eee see 0 1
12 039 044 . ВЫ$ ВАВ................ RER RER KLEE RER RER KERN 1
13 601 879 . NUT, hex-fuit 1/2-13 ee a aa da aa see ae nn 0 1
TB-048 150-B
Figure D - Terminal Assembly, Power Output
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-466 Page 8
Dia. Part
Mkgs. No. Description Quantity
Figure E 071 609 Circuit Card, Weld/ldle Contro} {Fig A Pg 5 Item 105)
Ch0,54 035 522 CAPACITOR, mylar0.047 uf 100 volts . o.oo ee eee
C51,52 045 868 CAPACITOR, electrolytic 100 uf 25 volts de ............. 2... erre.
C5B3 080 507 CAPACITOR, tantalum 22 uf 15 voits Lo... ee eee eee
D50,54 070 250 DIODE, 3 amp 500 volts SP... ee a 0 0
D51-53,56,57 026 202 DIiODE, 1 amp 400 voits SP..L..1121 ie eee eee
SCR50,51 080508 THYRISTOR, SCR8.5amp200 volts ...............--eraesrererra aaron.
SR50 035 841 RECTIFIER, integrated 1.5 amp 200 volts ........... ae ea a a ae a aa aa aa en
080 506 HEAT SINK, dual ............eeeecrcorareeeavecarertererenarerearenena,
080 509 GROMMET, No 8/10 screw 5/16 sa .......1222000 004411 a ee ea 4e 40 ce
2
2
1
2
5
D55 037 243 DIODE, zener 18 volts 1 watt.........42411 141111102041 RR RR RR RR ка. 1
Q50 000 088 TRANSISTOR, 800 MA 40 volts iii tee einen. 1
QS1 039 355 TRANSISTOR, unijunction 15 MA 40 voits .. 11.100011 0 aa a 0 ea aa ue a ea 00 1
R50,53 000 039 RESISTOR, carbon 2 watt 680 Ohm... it ie eee eee eases 2
R51,56 605 919 RESISTOR, carnpon 0.25 watt 47 ohm ............. e. 4 a 4 a a a a a ee ea 1100 2
R52 B05 816 RESISTOR, carbonG.2b watt 1K ohm... RK a aa 11 aa ae» 1.
RB4 035 824 RESISTOR, carbon film 0.25 watt270o0nm ........._.eeoeeeeeereorecraaana 1
R57 052 146 RESISTOR, carbon film 0.25 watt820K ohm... citi iii 40 1
R58 053 572 RESISTOR, carbon fim 0.25 watt 12K ohm... oo. ii eee ean 1
R59 052 138 RESISTOR, carbon film 0.2b watt 20K ohm «o.oo ie eee eee 1
REC 035 822 RESISTOR, carbon film 0.25 watt 10 ohm o.oo ver eee reas 1
R61,62 030 026 RESISTOR, carbon 0.5 watt 560 ohm .............eeeee.exerrar 0 ereren., 2
R63 003 272 RESISTOR, carbon film 0.25 watt 1 meg ohm ........... i iia... 1
R64 071 595 RESISTOR, carbon fim 0.25 watt22chm ....... coi iia. 1
2
1
1
3
R53
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
TA-048 151-A
Figure E - Circuit Card, Weld/!die Control
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 9
Parts For Optional Equipment
Quantity
Model
Dia. Part Cylinder
Mkgs. No. Description 3&4
A2 046 559 METER, amp de 50MV 0-500 scale ........... coin,
F1,2 *012 625 FUSE, cartridge 45 amp 250 volts ........ aaadarerreecaninnameanererameranoeona
039 169 hHOLDER, fuse-cartridge 60 amp 250 volts ..........—_eeeeeeereoenvoerecanoreconoea
080 497 FUSEBOX...........2222 2110 a een aa ee aa 10e» AAA nennaenm
+079 496 COVER, fuse bOX oii i tit i asst teen aaa
044 383 LABEL, warning 120/240 voltjunction box ............_—.ee_eeíerrecenvorermeráre..
030 170 BUSHING, snap-in3/41Dx1inchhole.......... citi iterate aaa
601 158 BLANK, snap-in 7/8 inch... eae aa
601 165 BLANK, button-pluglinchdia.......... ci einen an»
048 488 CLAMP, 1inchdiax1/2inchwide ............. iii.
603 107 HOSE, 5/32IDx11/320D{orderby ft) .. viii ce ieee
RC3 032 897 RECEPTACLE, twistlock-grounded2P3W 15amp 125volts ......................
$2 086 309 SWITCH, polarity (consisting of) ............._._.ereveeerecerrearo mor rcar vane
059755 .BRACKET, mtg-switch front............_w—ee_eerrceoaorrrrecsonrerscerca» 0 eee
059746 STOP, switch .............—.oeeercerrveraoreaareneraasnorrereoeenoenon ao.
079 490 SHAFT, switch ..........eecerereanarecaaar—eraaarervormnerararverrenverec e.
059 742 .BRACKET, switch-rear ............ee_reremorresvecernredrare rr vesmrerenoAD. ..
059 736 .INSULATOR, fixed-end switch............eoeoeeeczenrasorrntt eo areo ee 0
059 735 ..INSULATOR, shaff-switceh ...........e._e_e_eererrommeoneoecomear rea na rorDe..
059 750 . BLADE, contact-movable single ............2224020 000 4e a ae a a a aa a aa a aa ea ae en
079 491 .SPACER, shaft-switch........1220 4024 40e i et ites vecamerve,
059 749 BLADE, contact-straight . ...... iii trea +
059 748 . BLADE, contact-angle oti ee eae aaa
059 866 HANDLE ii eit tee tee eit era
010 647 PIN, spring 5/32 x 1-1/4 «ooo teeta aa
Sh 011 608 SWITCH, toggle SPDT 18amp 125 velts ....... iia
605 577 TUBING, 1/2 inch (order by ff) er a ae nee +
Shunt 030081 sSHUNT, meter 50 MV 500 amp ..........—.eee.ereccoarrrconeenveconreanececan.
003 645 BUS BAR, shunt/secondary stud ............e.eeeexceceranorrrenenereanmerea,
\ 046 654 METER, volts de 0-100 scale ............ 2... 2. aa a 4 4 4 ae eee de ee a a aa au 00
047 841 GAUGE, temperature 100/250 degree ..........2202000 00040 a ae as ae eee 0
047 842 GAUGE, pressure 0-80 Ibs..............—ee.eereredacereareerereeeoneecmrren_.
047 843 TUBING KIT, pressure gauge ..........2242100 0411 eee a a a a ee a a a a a ee a ae ee aa 0e 6
602 946 FITTING, pipe-brass tee 1/8 NPT ................0aarecarerrerronireeanr nero,
041 670 SERVICE INDICATOR KIT... .........—r.semeerecereirararere emareracennene
091 703 SHUTTER ASSEMBLY, radiator ..........._eeeee-resceritrecarerverereci ne.
—
SSSR SRN ANS RS Raa Saas —
+
o четы mah om = = | = | к
*Recommended Spare Parts
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-466 Page 10
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