Miller BIG 40 DIESEL User manual

Miller BIG 40 DIESEL User manual
April 1982 FORM: OM-466
Effective with Serial No. JC600629
MODEL
BIG 40 DIESEL
OWNERS £
MANUAL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS 5T. P.O. Box 1079
APPLETON, WI] 54912 USA
NWSA CODE NO. 4579
PRINTED IN US. A.
анте
LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed ar implied.
LIMITED WARRANTY - Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Deater 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 15 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 10
the warranties of their respective manufacturers, if any . All
engines are warranted by their manufacturer for one year trom
date of original purchase.
Except as specified below, Miller's warranty does not apply
to components having normai 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 maternal.
Milier 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 1.111111 0 3 years
(labor - 1 year only)
3. All welding guns and teeder/guns ........... . 90 days
4. Allother Millermatic Feeders, ........ 1 year
5. Replacement or repair parts, exclusive of labor . 60 days
6. Batteries. .... 111110111111 11111110 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 anly, Miller may honor claims
submitted by the onginatl user wathin the foregoing penods.
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 ~VOT FOR CONSUMERS OR
CONSUMER USE. MILLER" WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER,
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in
this manual.
AMENDMENT TO SECTION 7 - MAINTENANCE |
Add Figure 7-2. Engine Speed Adjustment
Fuse F2 | ra
Fuse F1 |
Low Speed Adjustment
Nuts |
|
Throttle Arm Bracket
| |
an if |
High Speed Adjustment |
y |
Screw
/ / Cam
Solenoid ‘ Solenoid Plunger -
Low Speed | |
Stop Screw |
Injection Pump |
Throttle Arm TA-085 962.A
Figure 7-2. Engine Speed Adjustments
i
Amend Section 7-7. ENGINE SPEED ADJUSTMENTS (Figure 7-2)
1.
2
3.
4
5/17/82
Start the engine and check weld and idle rpm (no load applied).
Place the AUTOMATIC IDLE switch in the OFF position
Adjust the high speed adjustment screw for 1800 rpm.
Shut down the engine.
Manually push solenoid plunger fully in until it is bottomed in the solenoid body. Be sure that plunger is bottomed
BEFORE injection pump throttle arm hits low speed stop screw. If pump arm hits stop screw before plunger is
fully bottomed, back out low speed stop screw so that arm does not touch it. (The low speed stop screw is not
used for idle speed adjustment on this unit.)
INCORRECT IDLE SPEED ADJUSTMENT can damage idle device.
‘Be sure that injection pump throttle arm does not touch low speed stop screw.
Be sure that solenoid plunger is fully bottomed in solenoid body at idle (1200) rpm.
Start engine and place AUTOMATIC IDLE switch in the ON position.
Loosen the throttle arm bracket securing nuts on solenoid plunger.
Adjust the throttle bracket on solenoid plunger for 1200 rpm, and tighten adjustment nuts. Be sure solenoid
plunger is fully bottomed at idle (1200) rpm.
OM-466 Page À
(Effective With Serial No. JC611576)
Dia. Part Replaced
** Mkgs. No. With Description Quantity
4-60 085 431 Deleted |
4-61 010 615 Deleted
4-62 085 432 Deleted
4-71 151. 048 852 032 933 SOLENOID, 12 volts de 20 amp pull/hold type. ..................c.. 1
4-72 044 357 Deleted
7-8 S3 085628 086708 SWITCH, range ............_eeeeerceocorrvaroreve, SR 1
086 699 STUD, steel 1/2-20 x 1-1/4 (part of engine assembly) .............. 1
086 706 SPACER, switch-range ...........0.0002000 aa casa anna ana ne = 1
**First digit represents page no. - digits following dash represent item nos.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
}
OM-466 Page B |
The nameplate of this unit uses international symbols for labeling the front panel controls. The following definitions
should help the operator become familiar with the symbols and their meanings. The symbols also appear at the ap-
propriate section in the text.
o
SYMBOL DEFINITION | SYMBOL DEFINITION | SYMBOL DEFINITION
AMPERAGE
— CIRCUIT A / \/ | &
| START o © BREAKERS VOLTAGE
ADJUSTMENT
GLOW CLOSED A
00 PLUG I AMPERAGE
WELD
t TIME | ОРЕМ / (>> OUTPUT
/ DO NOT
FUEL 1 SWITCH UNDER | ON
ft LOAD
— ON
_E TEMPERATURE Ny AC
—] OFF
FL ID POWER
BATTERY OUTPUT
Ds TABLE OF CONTENTS (am DI IT
Section No, Page No.
SECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. introduction.............. ee... enanaroraea aa eee 1
1-2. General Precautions ...............— ..2.0e00r0rre ere eno 1
1-3, ArcWeiding................0020 ea a a 00 4
1-4. Standards Booklet index ............ oii iii. 5
SECTION 2 - INTRODUCTION
2-1. General Information And Safety 0 a a a es a au 7
2-2. Receiving-Handling 1110122010 aa a aa a ae a sa a ea ea aa ane à 7
2 - 3. Description RR RR RR RR RK a 7
SECTION 3 - INSTALLATION
3-1. Location eee a ee 7
3 - 2. Ргтераппфо Мему Вапегу Рог Зегисе............................. 8
3 - 3. FUE. ce ee a aa 4 0 9
3-4. Engine Pre-Start Checks ER inne. 19
3-5. Equipment Grounding Terminal ............... 2000. a ecre, 10
3-6. Weid Output Connections :............._—_.ecreerarreoaa eo 10
SECTION 4 - AUXILIARY POWER
4-1. 120 Volts AC Receptacie................. 200 euarerooaa 11
4 - 2. 240 Volts AC Receptacle..................100000 000 0rría ie... 11
4 - 3. 7.5KVA AC Power Plant.............. recorrer rddrarrar ie 11
4 - 4, Field Installation Instructions For 240 Volts Dupiex Receptacie ..... 12
SECTION 5 - OPERATOR CONTROLS
9-1, Ampere Range Switch ............._eoeeere2esrene:arerecenm)— 13
5-2. Amperage And Voltage Adjustment Control. .................... 13
5 - 3. Vol-Ampere Curves... oot i irae ee eta a es 13
5-4. Duty Cycle ee ee 14
5-5. StartPush Button And FuelSwitch ............................ 14
5-6. Safety Shutdown Switch. ii i à 4 à a dau ua a a aa a 14
5 - 7. Glow Plug Push Button ................. 2... 2... eseocorrna 14
5-8. Auto ldie Controi Switch ...............00 ee aa 14
5-9. Battery Charge Indicator Lamp .............o.eeeecee.ededereco. 15
5-10. Engine Temperature And Oil Pressure Lamp..............._...e”. 15
5-11. Time Meter ..............o_ om eaverararerecoreramoreraconaaa 15
5-12. Circuit Breakers..............ee_ 2.2.0 xirerre 0er rr ee 15
5-13. Meters 2. a aa da a aa a aa a Lane PS 18
5-14. Oil Pressure Gauge oo. itt ee 15
5-15. Temperature Gauge ......11210212 0144 4 a 4 a a aa es a a a na ua ana ee 15
5-16. Polarity Switoh 1.100244 46 a a 4 a ea 4 0 a 8 a a 4 a 4 a Va a a a a a aa a ne 15
SECTION 6 - SEQUENCE OF OPERATION
6 - 1. Shielded Metal-Arc Welding (SMAW) . ......................... 16
6-2. 7.5KVA Power Plant Operation ............._.eeeeeeedorecrona. 16
6-3. Starting The Engine ................0.. 00. .reerri er ee 16
6 - 4. Engine Shut Down ..................0 00. a0resxveraaaveneaenaa 16
SECTION 7 - MAINTENANCE
7-1. Generat..........._.oecorcooeorerorerecaraveneenaooaooercoro 16
7-2. Periodic Cleaning And inspection ................. 0... 0000... 16
7-3. AirCleaner Service ............... ea 16
Section No.
7-4. Electrical System. ................00000 0 er00r0raronadia e.
7-5. Servicing The Spark Arrestor .. a aa aa aan
7-6. Brushes And Siip Rings ................. LA a ALL
7-7. Engine Speed Adjustments .................. eee ea
SECTION 8 - TROUBLESHOOTING
8-1. General.............. cou... ee eee.
8-2. TroubleshootingChart............ re terete
8 - 3. Booster Battery Jumper Starting .............. RAS
=mSECTION 1 - SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE=
-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 rmanuais,
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) (oniy).
Reference standards: Published Standards on safety are
also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI 249.1 is
the most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
A. Burn Prevention
Wear protective clothing - leather (or asbestos)
gauntlet gloves, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and siag.
Wear helmet with safety goggles or glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover giass). 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.
Mot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift uniess 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 shouid not be used by per-
sons intending to weld or cut.
=
B. Toxic Fume Prevention
Adequate ventilation. Severe discomfort, iliness 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! Standard Z49.1 listed 1 in Standards
index. NEVER ventilate with oxygen.
i.ead -, cadmium -, zinc -, mercury -, and beryilium -
bearing and similar materials, when welded {or cut) may
produce harmful concentrations of toxic fumes. Ade-
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be us-
ed.
Metals coated with or containing matenals that emit
toxic fumes should not be heated unless coating is
removed from the work surface, the area is weil 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 should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into
a confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chiorinated solvents can be decomposed
by the heat of the arc (or flame} to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating pro-
ducts. The ultraviolet tradiant) energy of the arc can
also decompose trichloroethylene and per-
chioroethylene vapors to form phosgene. DO NOT
WELD or cut where soivent 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.
ОМ-466 Раде 1
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
and short circuits.
BE AWARE THAT flying sparks or falling stag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, cut of sight
of the goggled operator. Sparks and siag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operabie, free of oil, grease,
and (in electrical parts} of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weid 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). Wails, 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
feat but can be ignited by sparks
с. openings (concealed or visible) in floors or
walls within 35 feet may expose com-
bustibles to sparks
d. combustibles adjacent to wails, 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
never be weided on or cut, uniess container has first
been cleaned as described in AWS Standard Аб.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 level may substitute for inerting.
Page 2
À 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 weid or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode,
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline}. |
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in
this manual, and those detailed in CGA Standard
P-1, PRECAUTIONS FOR SAFE HANDLING OF
COMPRESSED GASES iN CYLINDERS, listed 6 in
Standards index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
reguiator 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 ciose cylinder valve;. The following
symptoms indicate a fauity regulator:
Leaks - if gas leaks externaily.
Excessive Creep - if delivery pressure continues to
rise with downstream vaive 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
reguiators 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.)
ICC 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; de 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 s¢ 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,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, 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 hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder,
Cylinder fittings should never be modified or exchang-
ed.
3. Hose
Prohibited use, Never use hose other than that designed
for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
: gases.
- Use ferruies or clamps designed for the hose (not or-
dinary wire or other substitute} as a binding to connect
hoses to fittings.
No copper tubing splices. Use oniy 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 axcess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. immerse pressured hose in water; bubbles in-
dicate leaks.
Repair leaky or worn hose by cutting area out and splic-
ing (1-2D3). Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outiet away from people and sources of ignition. Wipe
with a ciean lintless cloth.
Match reguiator to cylinder. Before connecting, check
that the regulator label and cylinder marking agree, and
that the reguiator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. 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.
Reguiator outlet (or hose) connections may be iden-
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in {clockwise}. Draining prevents ex-
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly, When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
reguiators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in-
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
*Trademark of Proctor & Gamble.
OM-466 Page 3
FF. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
1-3. ARC WELDING - Comply with precautions in
1-1, 1-2, and this section. Arc Welding, properiy 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. lts radia-
tion can damage eves, penetrate lightweight clothing,
reflect from tight-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shieided 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.
Protect filter plate with a ciear 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, -
Page 4
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 enclosed 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. |t 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, electricaily-HOT
equipment can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SiT, LIE,
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp-
ness or sweat can not be avoided. Sweat, sea water, or
moisture between body and an electrically HOT
part ~- or grounded metal - reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
1. Grounding the Equipment
When 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 fataliy. Do NOT GROUND to electrica!
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 lead 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 receptacie, 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-
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to
join 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. Cabies with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation,
6. Electrode Wire
Electrode wire becomes electrically HOT when the
power switch of gas metal-arc welding equipment is ON
and weiding gun trigger is pressed. Keep hands and
body clear of wire and other HOT parts.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equip-
ment, shut OFF all power and remove line fuses (or lock
or red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull ail 115 voits 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.
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, 2501 NW 7th St., Miami, FL
33125.
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 Z87.1, 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 StandardZ41.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-466 Page 5
10.
Page ©
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO-
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.0, WELDING AND CUT-
TING CONTAINERS WHICH HAVE HELD COM-
BUSTIBLES obtainable from the American
Welding Society, 2501 NW 7th Street, Miami,
* FL 331256.
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 Atiantic Avenue,
Boston, MA 02210.
11.
12.
13.
14.
15.
CGA Pamphiet 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.
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 Wziding Society,
2501 NW 7th Street, Miami, FL 33125.
ANSI Standard 288.2 "Practice for Respiratory
Protection” obtainable from the American Na-
tional Standards Institute, 1430 Broadway, New
York, NY 10018.
e SECTION 2 - INTRODUCTION EA
Weiding Welding Current Ranges Open-Circuit Power |
Rated Current In Amperes Voltage While Overall Weight
Output Range Coarse Ranges | Fine Range Range Welding Dimensions Net Ship
300 Amps MIN.-65 .
From Min. 55 3 KVA ‘
40 vois DC| To 85.210 — | To Max. Of Te 120 or 240 Volts AC | Win - 24-3/4 in. (629 mm) | 1650 ibs. | 1690 ibs.
100% 450 Amps 110-270 Each Coarse 95 25 or 12.5 Amps. | eight - 53-1/4 in. (1352 mm)| 748 kgs.) (767 kgs.)
Duty Cycle 190-MAX. Range Volts DC 50/80 Hertz AC
Figure 2-1, Specifications
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.
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 ail ap-
plicable codes such as, but not limited to, those listed at
the end of Section 1 - Safety Ruies For Operation Qf
Arc Welding Power Sourcs,
Safety instructions specifically pertaining to this unit ap-
pear throughout this manual highlighted by the signal
words and which identify
different levels of hazard.
EZLN statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal word, LLU LENT, 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 weiding generator is
driven by a diesel engine. The unit is designed to pro-
duce a dc output for Shielded Metal-Arc Welding
(SMAW). A duplex receptacle, located on the front
panel, provides up to 3 kva of 120 volts or 240 volts,
50/60 Hertz ac power, to operate lights, power tools,
etc., while welding.
Optional equipment includes weld meters and remote
amperage control. This unit can provide 240 volts ac at
the front panel when the 240 volts ac duplex option is
installed. |
Es SECTIÓN 3 - INSTALLATION E
3-1. LOCATION (Figure 3-1)
EXZUNINGE ENGINE EXHAUST GASES can kill.
® (Operate in open well ventilated areas or if
operated indoors vent engine exhaust outside the
building.
e Keep engine exhaust vent outlet away from
building air intakes.
ENGINE EXHAUST SPARKS can cause fire.
e Exhaust spark arrestor must be installed in accor-
dance with local, state, and federal regulations.
The engine exhaust system on this weiding generator
has not been equipped with spark arrestor uniess it was
specifically ordered as an optional accessory. A 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.
IMPROPER LIFTING OF EQUIPMENT can result in
personal injury and equipment damage.
e (Use equipment of adequate capacity to lift the
unit, ,
e /fusing lift forks to handle this unit, be sure the lift
forks are long enough to extend out of the op-
posite side of the base.
Using lift forks too short will expose internal com-
ponents to damage shouid 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.
OM-466 Page 7
-—
re — OO —
5
„ен (=
—
|
=— | \— 217/32 in. Dia. |
| 116.7 mm) D Base Mounting Mola Dimensions
53-1/4 in. | [= = = 1 y E All Holes Inches — | Millimaters
(1352 mm) À J | E | a | 278 | m
1 . . t Е | в | 91/2 241.3
EG C | 26-15/16 684.2
| D | 34-3/4 382.7
| E | 46-174 1174.8
| F | 58-1/8 1501.8
Ш |, G 60 1624
<< TN. ° ° H 7/8 22.2
" | | 23-1/4 590.5
— | | J | 24-3/4 628.6
24-3/4 in.” Engine End ;
{629 mm) T
J
ТВ-086 534
Figure 3-1. Dimensions And Base Mounting Hole Layout
e See Figure 3-2 for maximum allowable tift for pro-
per operation.
e Check crankcase oil level with unit on a level sur-
face.
Exceeding these limits can cause severe engine
damage.
RESTRICTED AIR FLOW causes overheating and
possibile damage to internal parts.
e Maintain at least 18 inches (457 mm) of
unrestricted space on afl 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.
e Distribute weight so that trailer tongue weight is
approximately 10% of the gross trailer weight.
e Follow trailer manufacturer's instructions when
mounting welding generator onto trailer.
It is recommended that a properly fitting canvas cover
(optional) be placed over the welding generator when
not in operation to protect the unit from the environ-
ment. Be sure unit is cool before installing any cover.
This welding generator is provided with a lifting eye for
moving the unit and mounting holes in the base rails for
securing the unit in a permanent location, or to a trailer,
or transport vehicle. Figure 3-1 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 panels
for maintenance and repair functions.
The service life and operating efficiency of this unit are
reduced when the unit is subjected to high levels of
dust, dirt, moisture, corrosive vapors, and extreme
heat.
Page 8
— —
rl >.
33°, Side View
a LL
20 ST
20° О
End View
TA G46 152
Figure 3-2. Allowable Tilt Angle
3-2. PREPARING NEW BATTERY FOR SER-
VICE - This unit may be equipped with a maintenance-
free battery, a conventional wet charged battery, or a
dry charged battery. Maintenance-free batteries do not
have conventional vent caps since they do not require
the addition of water during normal service. Once the
battery type is determined, read the following WARN-
ING and proceed to the appropriate section: A.
Maintenance-Free Battery; B. Wet Charged Battery; C.
Dry Charged Battery.
BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
e Wear correct eye and body protection when work-
ing with batteries.
ABNORMAL VOLTAGE can cause damage to
engine electrical components.
® Do not operate engine without the battery con-
nected.
® Do not disconnect the battery while the engine is
running.
A. Maintenance-Free Battery
To place this battery in service connect the negative (-1
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.
NLU CHARGING A FROZEN BATTERY
can cause the battery to explode and result in
serious personal injury or damage to equipment.
e Check the state of the electrolyte solution and
allow battery to warm to 60°F (16°C) before.
charging if electrolyte is frozen or slushy.
Remove the vent caps and refer to Section 3-2C, Steps
7-9 for charging instructions.
C. Dry Charged Battery
1. Obtain battery grade (1.265 specific gravity)
electrolyte solution.
2. Remove battery from unit and place on a level
work table or other suitable surface.
3. Remove vent caps.
RLGLTLTIE BATTERY ACID can burn eyes and
skin and destroy clothing and other materials;
BATTERY GASES can explode and shatter the bat-
tery.
® Wear correct eye and body protection.
e 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.
e Do not lean over battery when testing.
e 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 ceil with a
hydrometer. (Draw in and expel the electrolyte
two or three times from the first celi to be tested
to adjust the temperature of the hydrometer to
that of the electrolyte).
LLLGLILTSR Follow 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.
e Turn battery charger off before making connec-
tion to battery.
® Do not touch or move connections on battery
while battery charger is on.
e 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
voltage.
9. if a corrected specific gravity reading of 1.260 at
80°F (27°C) is not obtained, replace the vent
caps and recharge the battery following the bat-
tery charger manufacturer's instructions.
EL LLILISE BATTERY GASES can explode and
shatter the battery.
e Turn the battery charger off before disconnecting
the charger from the battery.
10. Recheck electrolyte level and add if necessary.
ERE BATTERY ACID is corrosive to
metals.
e Do not pour electrolyte into a metal sink or drain.
11. Thoroughly rinse with water and mutilate empty
electrolyte containers before discarding.
12. Reinstall battery in welding generator.
13. Replace battery holddown and tighten securely.
Do not overtighten.
14. Connect positive (+) battery cable to positive
(+) battery terminal.
15. Connect negative (-) battery cable to negative (-)
battery terminal.
3 - 3. FUEL (Figure 3-3)
КОН ЕМСИМЕ РЧЕ! сап cause fire or ex-
plosion.
e Do not spill fuel, if spilled, wipe up.
OM-466 Page 9
Do not fill fuel tank if engine is hot or running.
Do not refuel near sparks or open flame.
Do. not smoke while refueling.
Do not fill fuel tank completely; cold fuel will ex-
pand when subjected to heat causing overflowing
and spillage.
Fill fuel tank with fresh fuel before
Starting engine the first time, Rust and corrosion
preventative was added to inside 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).
LITERS/HR.
MP. GAL./HR.
U.S. GAL./HR
=
Un
"nd
~
ho
D
wo
& >
“= ha
4.73
3.78
2.84
1.98
.95
x — HH = !
in Ù © U in U
0.25
1: 1
1700 2,FM.
so 100 150 300 750 300 350 1400
DC WELD AMPERES AT 100% DUTY CYCLE
B-086 185
Figure 3-3. Fuel Consumption Chart
3-4. ENGINE PRE-START CHECKS
A. Qil Lavel
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 ethyiene
glycol-base anti-freeze must be added to protect unit.
3-5. EQUIPMENT GROUNDING TERMINAL
(Figure 3-4) - 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.
Page 10
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 electrician 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
Tarminal
Positive Weld
Qutput Terminal
== ss
TB-086 535
Negative Weld
Output Terminal
Figure 3-4. Weld Output Connections
3-6. WELD OUTPUT CONNECTIONS (Figure
3-4) - To obtain the full rated output from this unit, itis
necessary to select, install, and maintain proper welding
cables. Failure to comply in any of these areas may
result in less than satisfactory welding performance,
A. Welding Cables
If welding cables were not ordered with this unit, the
steps listed should be followed to ensure the best
welding performance:
1. Keep cables as short as possible and place cables
close together. Excessive cable length adds
resistance which may reduce output or cause
overloading of the unit.
Table 3-1. Weld Cabie Size
WELDING *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 1/0
150 2 2 2 1 1/0 2/0 3/0 3/0
200 1 1 1 1/0 2/0 3/0 4/0 4/0
250 1/0 1/0 1/0 2:0 3/0 4/0 4/0 2-2/0
300 2/0 2/0 2/0 3/0 4/0 4/0 2-2/0 } 2-3/0
350 3/0 3/0 3/0 4/0 4/0 2-2/0 { 2-3/0 | 2-3/0
400 3/0 3/0 3/0 4/0 2-2/0 | 2-3/0 § 3-2/0 | 2.4/0
A-002 702-A
NOTE: “A. 50 FEET OR LESS.
*8. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
190% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY ОР МОТ ОМЕН 300
CIRCULAR MILS PER AMP.
*С. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE QPEN-CIRCIUIT VOLT-
AGE (CCV) OF THE WELDING GENERATOR MUST BE
USED. WHILE MOST WELDING GENERATORS HAVE
AN OPEN-CIRCUIT VOLTAGE OF LESS THAN 100
VOLTS, SOME WELDING GENERATORS OF SPECIAL
DESIGN MAY HAVE HIGHER OPEN-CIRCUIT
VOLTAGE.
2. Select adequate size weiding 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) cable 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. if necessary, instali electrode hoider to cable
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. install work cilamp to cable.
B. installation (Figure 3-4)
RUSSE ELECTRIC SHOCK can kit.
e Do not touch live electrical parts.
® 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 panel.
SE Ee ОЛООАНЯ SECTION 4 - AUXILIARY POWER suma E E
RINDE 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 /solate 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.
® 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 26 A #\ AC
Up fo 3 kva of 120 volts ac 50/60 Hertz power is
avallable 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 total
load on the receptacle cannot exceed 26 amperes. The
130
AC POWER VOLTS
100 { { |” | de Lo L
0 5 19 15 20 25 30 36 40
AC POWER AMPERES
Figure 4-1. AC Power Curve For 120 And 240 Volts
AC Receptacie (No Weld Load
Condition)
voltage at the receptacle will vary according to the ap-
plied power and weid load. The voltage at various loads
can be determined from Figure 4-1.
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 weid
rpm. The voitage at the receptacle will vary according to
the applied power and weld load. The voltage at various
loads can be determined from Figure 4-1.
4 - 3. 7.5 KVA AC POWER PLANT (Figures 4-2 €
4-3)
À. General
The terminais, located behind the left side door, provide
7.5 kva of 120/240 voits ac 31 amperes, 50/60 Hertz
single-phase power for operating power tools or pro-
- viding 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.
100
30
30
DC VOLTS
©
т “а
0 100 200 300 400 500 600
DC AMPERES
Figure 4-2. AC Power Curve For 120/240 Volits AC
Terminals {No Welding Load
Condition)
OM-466 Page 11
B. Connection Procedure
KULISSE ELECTRIC SHOCK can kill.
® Keep junction box cover in place while engine is
running.
® 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 {inside 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.
e Use fuses no larger than 45 ampere rating.
IMPROPER VOLTAGE OR FREQUENCY can
damage equipment.
® Read all equipment instruction manuals before
making connections.
e Use only equipment suitable for operation on
50/60 Hz power.
e Turn off or disconnect electrical equipment from
120/240 volts fuse block before starting or stopp-
ing engine.
1. Open left side panel.
Remove cover from junction box.
w №
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
junction 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
Page 12
7. Reinstall cover onto junction box.
8. Close left side panel, and begin operation.
à - 4. FIELD INSTALLATION INSTRUCTIONS FOR
240 VOLTS DUPLEX RECEPTACLE (Figures 4-4 &
4-5) - À 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.
MLLER ELECTRIC SHOCK can kil.
® Do not touch live electrical parts.
® Shut down and disable engine before proceeding
with this installation.
e Remove spark plugs and disconnect negative (-)
battery cable.
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.
Wide AV A directions, such as left or right, are
with respect to the operator facing the welding
generator front panel. Retain all hardware removed dur-
ing this procedure for reinstallation.
Terminal Strip TE1
Duplex Receptacle
Dé
pe Canter Bolt
< insulation Board
TA-059 485
Figure 4-4. Location Of Reconnectable 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 hoard.
3. Remove the 120 VOLTS AC duplex recentacie
from the front panel and disconnect leads No.
111, 3, and 42 from the receptacie.
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 terminal 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.
Lead No. 3
Comey 5
240 VOLTS AC (OPTIONAL)
120 VOLTS AC (STANDARD)
TA-059 743
Figure 4-5. Jumper Link Arrangement On
Terminal Block TE1 For 120 And 240
Volts AC
Ts SECTION 5 - OPERATOR CONTROLS SUN
pre
Battery indicator Lamp \
Oil & Temp Indicator Lamp | DD
Engine Hour Meter \
}
/
Ampere Range
ee Switch
\
Amperage & Voltage
Adjustment Controi
п
Power Output
Fuel Switch
CI |
Auto Idie Switch Ty 0,0 ~
A —
~~
e |
Glow Plug Push Button ;
Start Pushbutton
Safety Shutdown Switch
120 Volts AC
Circuit Braakers
Figure 5-1, Front Panel Controls
5-1. AMPERE RANGE SWITCH (Figure 5-1)
A
AMPERAGE RANGES
The AMPERE RANGE switch provides five course
amperage ranges. The range of each switch position is
displayed on the nameplate.
ME ARCING can damage switch con-
DO NOT SWITCH UNDER LOAD
e Do not change the position of the AMPERE
RANGE switch while welding or under load.
Arcing causes the contacts to become pitted and even-
tuaily inoperative,
5-2. AMPERAGE AND VOLTAGE ADJUST-
MENT CONTROL (Figure 5-1)
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
switch. The scale surrounding the AMPERAGE &
VOLTAGE ADJUSTMENT control is calibrated in per-
cent and does not indicate an actual amperage value.
5 - 3. VOLT-AMPERE CURVES (Figure 5-2} - The
volt-ampere curves show the voltage and amperage
output capabilities of the weiding generator at min. and
max. of each coarse range. Voltages and amperage ad-
justment within each range is provided by the
AMPERAGE & VOLTAGE ADJUSTMENT control,
190
ag
50 kE
40
D £ VOLTS
207
о 100 200 300 400 500 500 700 ago
DC AMPERES
Figure 5-2. Voit-Ampere Curves
OM-466 Page 13
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 cycie 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.
ANNIVER EXCEEDING DUTY CYCLE RATINGS
will damage the welding generator.
e Do not exceed duty cycles indicated on duty cycle
chart.
RATED OUTPUT —
500
WY
hid
Le
a 400
=
a
= 300
=
250
30 40 50 60 70 80 90 100
% DUTY CYCLE
Figure 5-3. Duty Cycie Chart
5-5. START PUSH BUTTON AND FUEL SWITCH
(Figure 5-1)
FUEL — START
Jon
OL.
Placing the FUEL switch in the ON position will energize
the welding generator ignition circuitry. When the FUEL
switch is in the ON position, hoiding the SAFETY
SHUTDOWN 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 OFF position when the
engine is not running to prevent the battery from
discharging.
REENGAGING STARTER MOTOR
while fiywheel is rotating can damage starting
components.
® Do notreengage starter motor until starter pinion
and flywheel have stopped rotating. :
Раде 14
5 - 6. SAFETY SHUTDOWN SWITCH (Figure
5-1) - The Safety Shutdown switch will automatically
shut down the engine if oil pressure drops to an unsafe
level or water temperature becomes too high. When
starting the engine, depress the Safety Shutdown
switch and hold in until the engine starts and the OIL &
TEMP light goes off.
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
00
GLOW
PLUG
The GLOW PLUG push button is provided to aid initial
engine start up. When the GLOW PLUG push button is
depressed, glow piugs in the cylinder head heat up pro-
viding a warm air-fuel mixture for combustion. At 70°F
(21°C) ambient temperature, the GLOW PLUG push
button should be depressed and held closed approx-
imately 10 seconds; at 32°F (00°C) approximately 20
seconds; at -4°F (-20°C) approximately 25 seconds.
Cartridge fuse F4 protects the ignition
circuitry from damage caused by glow plug failure. If F4
opens, the glow plugs are disconnected from the igni-
tion circuitry. F4 is located on the throttle solenoid
mounting bracket behind the left-hand engine compart-
ment door.
5 - 8. AUTO IDLE CONTROL SWITCH (Figure 5-1)
AUTO IDLE
Y ON
< OFF
The automatic idling device saves fuel by allowing the
engine to idle when the welding generator is not 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 receptacles.
When an arc is struck, the engine speed will increase to
weld 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 Metal-Arc Welding
(SMAW) provided accessory power equipment is not
being operated from the 120 VOLTS AC receptacle or
120/240 volts ac terminals.
B. OFF Position
When the AUTO IDLE control switch is in the OFF posi-
tion, the engine will run at governed weld rpm (1850).
LOW VOLTAGE AND FREQUENCY
can damage electrical equipment.
® 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
(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 6 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 Ignition switch is in the
RUN position and the engine is NOT operating.
LAMP
5-11. TIME METER
ENGINE HOURS
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
———
©
o
1 crosep
| | OPEN
The auxiliary power windings on the welding generator
are protected from overload by CIRCUIT BREAKERS
CB1 and СВ2. На 120 volts overload occurs, both CB1
and CB2 open interrupting output, If a 240 volts
overload occurs, either CB1 or CB2 opens interrupting
output. Remove the load, determine the cause of the
overload, and manually reset the CIRCUIT
BREAKERIS).
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 voitage at the
welding arc {due to cable resistance, poor connections,
gtc.). The ammeter indicates the current output of the
unit.
9-14. 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 shouid 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. |
9-15. 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 wilf 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,
PETITE IE ARCING can damage switch con-
tacis.
® 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.
ОМ-466 Page 15
Ss SECTION 6 - SEQUENCE OF OPERATION Dt Ds
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.
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.
e ¡Wear correct eye, ear, and body protection.
See Section 1 - Safety Rules For Operation Of Arc
Weiding Power Source for protective information.
6-1. SHIELDED METAL-ARC WELDING (SMAW)
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 control switch in the
desired position and commence welding.
6-2. 7.5 KVA POWER PLANT OPERATION
1. Ensure that the engine has been prepared for
operation as instructed in Section 3.
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 counterclockwise).
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 ¡DLE control switch in the ON
position.
3. Расе the FUEL switch in the ON position.
4. Depress and hold the GLOW PLUG push button
{see Section 6-9),
5. Press the START push button and SAFETY
SHUTDOWN push button.
6. When the engine starts, release the START push
button. When the OIL & TEMP light goes off,
release the SAFETY 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.
VE SECTION 7 - MAINTENANCE mss Ss sm
RIZLGDILISE HOT ENGINE PARTS can cause
severe burns.
e Wear protective gloves and clothing when work-
ing on a hot engine.
MOVING PARTS can cause serious injury.
® Keep clear of moving parts.
e 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
Manufacturers Manual (TMD-27). 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 ex-
ternal engine surfaces.
Page 16
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 ¢lean 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.
Periodically inspect the labels on this
unit for legibility. All precautionary labels must be main-
tained in a clearly readable state and replaced when
necessary. See the Parts List for part number of precau-
tionary labels.
7 - 3. AIR CLEANER SERVICE (Figure 7-1) - The
air cleaner is one of the most important parts of the
Follow 1. Stop angine.
5. Wipe out element chamber
7. Reinstall element.
Compressad air is recommended
when element will be re-used
immediately because a washed
element must be dried before
re-use. However, washing does
Re-Use
Compressed Air
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.S.1.
with clean, damp cloth.
These 2. Wipe off cover before opening 8. Replace cover,
Easy air cieaner. 6. inspect new element and
Steps: all gaskets for shipping damage
3. Remove cover. before use.
4. Remove aiamant.
Important 1. Don't attempt to service air 3. Don't leave open air cleaner 5. For Donacione 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
4. 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 cieaning Cyciopac
Clean following methods: when exhaust soot has lodged in elements, do not remove plastic
fine pores of the filter media. fin assembly - back-flowing with
Elements Compressed Air or Washing. Use Donaidson D-1400 detergent compressed air or washing wiil
For which contains a special additive
for removing soot and carbon,
Replace element after 6 cleanings
or annually, whichever
occurs first.
Washing
1. Soak element 15 minutes or
more in Donaidson D-1400 and
water sclution, See carton for full
instructions.
2. Rinse until water is clear
{Maximum water pressure
40 P.S.1.}
3. Air-dry or use warm flowing
: air, max. 160°F. Do not use
| compressed air or light bulbs.
remove dust from beneath the
fin assembly.)
inspection
Place bright light inside element
and rotate element slowly. If
any rupturs, holes or damaged
gaskets are discovered - replace.
Figure 7-1. Air Cleaner Service .
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.
Te LE A dirty air cleaner element is usually
accompanied by a loss of power and black smoke in the
engine exhaust.
When it becomes necessary to service the air cleaner in
the field, follow the steps in Figure 7-1. It is recom-
mended that a spare element always be kept on hand
for replacement. New elements are available from your
distributor.
DIRTY AIR can damage engine.
® Do not operate engine with dirty air cleaner ele-
ment in place.
® Do not operate engine without air cleaner element
in place,
7-4. 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,
OM-466 Page 17
B. Battery
BATTERY ACID can burn eyes and
skin and destroy clothing and other material.
® 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 clean
mineral-free or distilled water to bring the electrolyte in
each cell up to the level indicator.
7-5. SERVICING THE SPARK AR-
RESTOR - Internal combustion engines operating in a
highly combustible environment are a common fire
hazard. Glowing carbon particies biown out with the ex-
haust can retain sufficient heat to 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 shouid 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 outiet tube with a flashlight or other light
source. Visually examine the vanes and the
outlet 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
C'ILILISE EXHAUST SPARKS can cause fire.
® (lean spark arrestor/ muffler in a non-combustible
environment,
1. Stop the engine and allow the exhaust system to
cool.
2. Remove the cleancut 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,
Page 18
3. Start the engine to blow collected particles out
the cleanout hole. ff 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 - 6. 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 siip 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 material is noted, it may be
necessary to clean the slip rings. Use a 3/0 or finer
sandpaper followed by a crocus cloth. Never use emery
cloth as part of the emery will embed itself into the rings
and in turn destroy the carbon brushes,
Replace the brushes if they become chipped or broken
or if less than 1/2 inch of brush material is left.
7 - 7. ENGINE SPEED ADJUSTMENTS
The idle control solenoid is mounted
on brackets above the injector pump cover on the left
side of the engine. The high speed adjustment screw is
located in the end of the injector pump cover toward the
front panel,
1. Start the engine and check rpm (no load
applied).
2. Adjust the high speed adjustment screw for
1800 rpm.
3. loosen the locking nut on the idle control
© solenoid plunger.
4. Place the AUTO IDLE control switch in the ON
position.
DUS UII Be sure the low speed screw on the
injector pump cover does not touch the throttle arm.
5. Adjust the low speed adjustment nut on the
solenoid plunger for 1200 rpm. Tighten the lock-
ing nut,
CD SECTION 8 - TROUBLESHOOTING A
8 - 1. GENERAL - It is assumed that proper installa-
tion has been made, according to Section 3 of this
manuai, and that the welding generator has been func-
tioning properly until this trouble developed.
8 - 2. TROUBLESHOOTING CHART
EZUNINOER ELECTRIC SHOCK can kill.
e Do not touch five electrical parts.
® Shut down engine and disconnect negative (-)
battery cable from battery before internally in-
specting or servicing.
MOVING PARTS can cause severe injury.
e Keep clear of moving parts.
HOT ENGINE PARTS can cause severe burns.
Troubleshooting of internal parts to be performed only
by qualified persons.
The following chart and the chart provided in the Engine
Manufacturers 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-
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. In all cases of equipment
matfunction, the manufacturers recommendations
should be strictly foliowed.
Wear protective gloves and clothing when work-
ing on a hot engine.
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 $3 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.
Poor contact between slip
rings and brushes.
Clean the slip rings (see Section 7-6).
High or low voltage at 120
volts receptacle RC1 and
weld output terminals.
Improper engine speed.
Check the engine speed. The engine must run at
1850 rpm when AUTO IDLE control switch is OFF
and no load is applied (see Section 7-7).
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 fuei tank cap. If the cap
is equipped with an adjustable vaive, rotate the
valve to the OPEN position.
OM-466 Page 19
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.
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
serio
e
REMOTE CONTROL
EQu
us personnel injury and damage equipment.
Keep sparks, flames, cigarettes, and other ignition
sources away from batteries.
Ensure that all personnel are a safe distance from
batteries while starting.
Do not jump start a frozen or completely discharg-
ed battery.
Do not jump start a battery which has loose ter-
minals or one having evidence of damage such as
a cracked case or cover.
Keep vent caps in place and cover batteries with a
damp cloth.
Wear correct eye and body protection.
Keep clear of moving parts.
Ensure that both batteries are the same voftage.
Do not jump start a trailer mounted welding
generator with the towing vehicle battery unless
the trailer is completely disconnected from the
towing vehicle,
Do not jump start a vehicle mounted welding
generator from the vehicle battery.
If booster battery is installed in a vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
Do not jump start by applying power to weld out-
put receptacles or terminals.
wy Г
| EZ >
10.
11.
A АС POWER
COPTION AL?
Use properly insulated jumper cables of ade-
quate size.
Connect ends of one cable to positive (+) ter-
minals of each battery.
Connect one end of other cable to negative (-)
terminal of booster battery.
Connect remaining end of cable to weiding
generator engine block tdo not connect to
welding generator case, frame, or equipment
grounding terminal as damage to equipment can
result).
Wait at least one minute afer connecting cables
before starting engine.
Start engine following procedures outlined in
Section 6 (Sequence Of Operation) of this
manual.
Remove jumper cable from engine block.
Remove other end of same cable from booster
battery negative (-) terminal.
Remove other jumper cable from welding
generator battery positive ( +) terminal.
Remove remaining end of cable from booster
battery positive (+) terminal.
Discard damp cloth,
- MEUTHAL GROUND AS REQUIRED
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Tesessune ECERTACLE po E. 1 [— wEto METERS(OPTIONAL)
© Se 7 = A0 SHUNT 13 SERIES :
DEF o Er TT: - E CONMECTES IN LINE 20
AUN $05 = RUNNING = =m
a
MGS
Page 20
a
Han x
PRESSURE
чи.
57
a
a
Г
Too,
de HOLD IN
TO START
+ F Ir ;
=
ETARTER 1
1 fi -
i
ahora alo jaf
ñ
-
CAUTION
ALTER TO INSTRUCTIONS dEFORE
ATTEMÉTING PO INSTALL OPERATÉE
TAL TA EH ARE UT
HOUR METER
= POLAMITY Sw iQPTIOMAL)
TW TH POLARITY Sw OPTION,
LEADS 19 2JO GOTO POLARITY
Sw. RATHER TMAN CUTPUT
| 6 “4 SfUDS OUTPUT STUDS ARE
с: NEGATIVE POSITIVE LABELED ELECTRODE 6 WORK.
1 ELESTRODE* WORK*
B-085 657
Figure 8-1. Circuit Diagram
April 1982 FORM: OM-466
Effective With Serial No. JC§00629
MODEL
BIG 40 DIESEL
104
Figure A - Main Assembly
OM-466 Page 1
26
23 24 25
42 47 42 46
53 748
54
Also Includes
Items 57 Thru 74
TD-0B6 537
79 78 7776 9 595857
OM-466 Page 2
item Dia. Part
No. Mkags. No. Description Quantity
Figure A Main Assembly
1 017 430 STRAP, mounting-fueltank ........ i rns 1
2 010 434 STRIP, rubber 1/2 X 2 X 2 vi i 4 a A Aa aa a ea 0 ae ea 4 4 a ea ae 06 2
3 085 384 TANK, fuel {consisting of) ......... iii errar 1
4 049 192 .CAP 000redreraerarorerearaaoeroaaarcacrarercarecveco. 1
605 288 FITTING, pipe-plug sq. hd 1/4 NPT .....L.1 1110 44 aa 4 ea a a ea a a ee 1
5 020 185 FITTING, pipe-brass elbow street 1/8 NPT .............eosreceacerercera. 1
6 604 313 FITTING, brass-barbed male 1/4 TBG x 1/8NPT............o...emceemeeno, 3
7 604 314 HOSE, neoprene No. 1 (order by ft) ........ cirri iii. 5ft
8 010 314 VALVE, shut-off fU@. 0.00 KK i 4 eee 4 4 ee a aa inns 1
9 604 308 FITTING, brass-barbed male 1/4 TBGx 1/4 NPT ee iit. 3
10 017 479 SEAL, weather-lift eye ....... RR 4 a a ea a a a aa run 1
11 601 945 SCREW, cap-hex hd 5/8-18x4 11.121 ae eee 4
12 071 731 WASHER, flat 21/32 10 x2-1/4 0D ...........eresoovercrarece ca ercer 4
13 084 454 ANGLE, mounting-engine ............—e——ec_e._._eerecerrvrraavercrear vena, 2
14 071 890 RETAINER, mount-engine/ generator ............._—.e——receorecrerere ce 4
15 071 730 TUBING, steel 7/8 OD x 12 ga wail x2-1/8.............r.—.....—revrrexeeves 4
16 083 476 TUBING, neoprene 2-1/2 OD x 7/8 1D x2.........../Ñ.recooarared iveco, 4
17 030 342 TRAY, slide-battery ..........._ooceeeececccorarer ie amenorrea ecan 1
18 032 452 CABLE, battery-positive 31 incheslong.................... La a ae sa aa 04 1
19 082 582 HOLDDOWN, battery...........11111 2404 ie ieee ie naan 1
20 082 533 DOOR, access-battery .............oee.0ee0ereedcocicoorvcarrorererece, 1
21 010 875 CLAMP, muffler 2 inch dia................oc_.esererevesra ecrcarereocen o. 1
22 071 596 MUFFLER, exhaust..........11101010000 00044 4 4e a a 4 da a a nee ea sa 0000000 1
23 017 389 CAP, weather-exhaust No. 4.........—.o_ ee vee_ee_c_ceceveerorenorormoemen.. 1
24 012 378 LABEL, use no petrol o eoeeeéecereacereroc oro rreramereco, 1
25 035 968 WASHER, neoprene........0000 00000804 4 a 4 aa ea ae a 44e a sian 1
26 085 534 COVER, top ....1200 0004444 4e ee a 4 ae 4 4e 4 0 8 a etre eae 0 0 1
27 027 529 PIN, cotter 1/4-3-1/2 11.102010 i tt ti 0 aa 04 4 4e 8e a a a a a 4 6 6
28 004 130 BRACKET, support-door........110000 402000 aa a 4 ae 4444 tirana, 2
29 045 657 AIR CLEANER, intake (consisting à AA RAA AAA 1
30 021 116 .CAP, dust. 0.000000 it ie tt ie tie eee eee a ia a 1
31. 021 117 ‚NUT, WIR RR RR KRANKER KR 1
32 *020 319 ELEMENT. ..... coi. et ieee tee ee 1
33 021 115 BAND, MOUNTING ..............._—...0e0s0roorirrere e aaiecer ee e 1
34 021 114 ,CLAMP ASSEMBLY .......... 02. 000daadoavedasaoveeredarrasrervera, 1
004 115 BAFFLE, dustcap................... ee re ea 1
35 010 863 CLAMP, hose 2-1/16-3clampdia ........... coin, 2
36 086 456 HOSE, air cleaner ..........coo.resrvrevircoreereaaceraeraror ed recaren, 1
37 004 828 CATCH, door............eee.eesegcnarerrenvonvorereoorreceororereva, 2
38 084 979 HOSE, radiator iti i a 44e ee ei 1
39 010 862 CLAMP, hose 1-13/16-2-1/2 clamp dia .............eomevrsresredrcoríee, 3
40 011 198 LABEL, dangerfan ......e..._.eeceeecaredveceda co e anar anna, 2
41 +053 966 GUARD, fan...........eodevrdcocarenecoaaavanaraeeroerearevdetereco. 2
42 010 861 CLAMP, hose 1-1/16-2clampdia ........... VPN 3
43 605 839 RADIATOR (consisting Of)... iii eee 1
44 605 982 . CAP, radiator 7 lbs pressure iii ett a a 08 1
45 081 500 ENCLOSURE, radiator ...........eo eee eee tna» 1
46 006 015 FITTING, pipe-brass drain cock 1/4 NPT........ J a aa are see 1
47 083 730 HOSE, radiator-lower ........ ......_.ee.eomeverrveresrererevecormoera, 1.
48 084 841 ENGINE, diesel-electric (consisting Of)...........00200 000000 nana sea eee 000 1
49 . BLADE, fan {see engine parts list) OP "e 1
50 084 740 .STRIP, adiusting ................... 2... iia eae me. 1
51 605 430 . PULLEY, single belt ................. 020020000000 .0 rear a a ea a a ae ee 1
52 083 713 .BELT, V1 1112014444 AA a 4 4 4 444 a 4 a a 4 ee 4 A ee a 4 ee a 1
53 605 429 . АСТЕВМАТОВ, 35 атр 12 мо $. ........... 5..2... квн 4 2 ae ea ea eee 1
54 084 496 BRACKET, MOUNTING .. «coi i tet it cit ea aa 4 eee aa a 260 Ce 1
Page 3
item Dia. Part
No. Mkgs. No. Description Quantity
Figure A Main Assembly (Cont'd.)
55 602 887 . FITTING, pipe-brass plug hex hd 1/4 NPT 1.111100 a aa 1 a a Lena ee 1
56 061 327 .GASKET....10012 0244024 444 a 4 A ee ra 4 A A4 ee 4 a 4 A a 4 ee eae 1
57 58 011 917 .SWITCH, pressure2P ............. a 200 00xáísdedecedanaravnnaoracana, 1
58 602 946 . FITTING, pipe-brass tee 1/8 NPT ...........o__ecorecordecroearoe carecen. 1
59 57 025 473 . SWITCH, pressure-oil 8 psi ..............—...eeeeexeecerevaseri verde en.. 1
60 085 431 , BRACKET, mounting-speed control. .........._e eee oerreciereorena 1
61 010 615 . SPRING, extension. .........c_.eeeeeeeerorvereonoedrorerrenrrere ran, 1
62 085 432 . CLIP, mounting-spring.............._..0.0-Ñes+reeiíerereeoreareroceee rea, 1
63 084 766 . LINK, connecting-throttle/solenoid ............ cc iii iin. 1
64 084 767 , BRACKET, mounting-solenoid ............._.— _—reervrecsrvesrecorrerveca 1
65 084 770 .BRACKET, mounting-fuse...........oooeomrceorceZrzeÑeecorrecocanrececeE 1
66 CRI 070 109 . CONTACTOR, solenoid 12 voltsdc400amp ............ cco. 1
67 046 432 . HOLDER, fuse-panel mounting (consisting of) ..............—....eeeem.... 1
059 139 ., CAP, fuse holder .............c_ec_ _o..reevareracerecarore ce cer. 1
68 F3 *O11 116 . FUSE, miniature-glass slo-blo 7 amp ........ iii, 1
69 F4 *084 389 . FUSE, cartridge 80 amp 32 volts. 1.220200 200004 4 a nee a a aa a da ea nee 1
70 084 390 . HOLDER, fuse-cartridge 80 amp. ..........eoeoeeeorecdecorevrrerar area 1
71 TS 048 852 . SOLENOID, 12 voitsdc 20 amp pulil/hoid type. ......... cotinine. 1
72 044 357 . SPRING, compression .......02 0004414444 4e 8 a 8e 8 a a 4 4 a a 4 ae a a a a aa a da a 1
73 56 025 474 . SWITCH, thermo-temp ............—eonmorcoo. nadaa nionadorercioene. 1
74 . GASKET (see engine parts list) ..............—..eeeereroadeccevoan er en | 1
75 084 488 ADAPTER, aircleaner ................... PS 1
76 010 678 FITTING, pipe-brass elbow street 1/4 NPT iii, 1
77 083 553 BASE, filter-w/adapter. ..................... Ce ee ea 1
78 062 342 SEPARATOR, fuel-filter Sr water ........ coi ee eens 1
79 084 541 BRACKET, mounting-filterfuel . ............. iii iii, 1
80 Figure B GENERATOR ASSEMBLY (PGB)... coi iii cena, 1
81 071 881 PIPE, exhaust. . . oo oii i i ee ee ae 4 1
82 005 612 DOOR, side cco iii tte ee RK eee a 2
83 010 515 BOLT, J 9/16-18. 0000000000000 Le de 8 A 4 sa ee a aa a ra ae 0 4
84 017 477 ROD, holddown-battery ................ea_eer_ecoerrccrorrevererarercec, 2
85 BAT *012 724 BATTERY, 12 volts 95 amp ........._.....eorccooorocoaaoarerrerdo rara 1
86 047 812 CABLE, battery-negative ...........cc_eeooececrendonedorevesreceneortao.. 1
87 053 606 UPRIGHT, base-center..... re tee eee eee 1
88 601 851 NUT, self-locking hex 5/8-18 1022000121 LL Lea a sa ea ae 00 adan 4
89 - 010266 SPRING, extension .............eo.erereiecocrrororocaareserrererarerve, 2
30 017 420 LATCH, dogr..........e _.eevdoerevaiaeacoareorecarverderncaararce aaa, 2
91 010 144 CLAMP, nylon ..........ee.e0rensorddarrecdoereararaaacraoacercaor ana 1
92 603 107 HOSE, neoprene-slit (order by ft) ............... e e. .e... ea 0 2ft
93 ТЕ! 038 621 BLOCK, terminal 30 amp 4 pole .............e..0ec0e.000carev e ee 1
038 620 LINK, jumper-terminal block ...............__—.eceee0d0reoresr eran, e.. 2
94 053 967 INSULATION, rectifier .....1000 00200124 aa da 4 a a a ee ea a ea ea a ae 0 a 40 1
95 081 499 BRACKET, mounting-rectifier. ............ iii. Cee 1
96 035 860 RECTIFIER ASSEMBLY (consistingof) ........... cco iii. 1
97 SR1,2 035 704 . RECTIFIER, integrated 30 amp 600 volts .............—e_eceseorerverarano.. 2
98 031 926 HEAT SINK ............r0e000ec0aroareavenadoecdorceraarareenerrarmerv. 1
39 085 577 BASE ........... 00 rmerer area eenadidanerenrerereroreraroneneen ene, 1
100 049 082 UPRIGHT, base-front......... .... _...0c000 0 0800dearer rene erere.. 1
101 РС1 071 609 CIRCUIT CARD, weld/idle control (Fig. EPgS8}............ coin, 1
102 C1,R5 084 274 CAPACITOR/RESISTOR, w/mounting bracket ..........._—eeecevooccrreo. 1
103 +005 601 PANEL, front-lower ......... ...o eN e.r.re.e..eedarecierervecenroreode ena 1
104 046 392 LABEL, general precautionary.......1.0.02002000 00424 ea 4 da a sa a ae de er 1
105 027 657 LABEL, caution equipment ground.........000 00044404 4 4 4 a 4 4 4 A 1
106 FIGURE C PANEL, front-w/components (Pg8) ......... iii... 1
OM-466 Page 4
item Dia, Part
— No. Mkgs. No. Description Quantity
Figure A Main Assembly (Cont'd.)
107 CT1 081 359 TRANSFORMER, control/idte .........1141000 014 a a Lea a a aan la Le 1
108 081 983 STRIP, mounting-transformer............... 2.0200... edarecore con 1
109 Figure D BRACKET, mounting-power output (Pg 8) ............._ 2.0002... 1
110 Z1 084 814 REACTOR (consisting of)................00s0s000v0rie een naaoraraner 1
084 815 .COIL, left hand ................e—eesreciee. ree ee e eno aaaor anna 1
071 683 , COIL, center .................e...srerreererecrenrecara ceranearar rara 7
084 816 .COIL, right hard 20ER RR RR RR à 1
111 085 551 FRAME, mounting-reactor/fuel tank ..............e _.eesrrecrirocearararo, 1
112 R2,3 030 060 RESISTOR, WW adi. 375 watt 20 ohm ............eereverooororarenrecere. 2
113 085 656 STRIP, mounting-resistor ............c_w_eoeceererrecarerorereserarere, 1
114 071 388 STRIP, rubber ............._— _eererrereearec:oroecoreoecaaeracenrecceo 2
*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 NUMBER WHEN ORDERING REPLACEMENT PARTS.
Dia.
Mkgs.
Part
No.
Description
Quantity
Parts For Optional Equipment
‘A2
F1,2
Shunt
046 559
*012 625
039 169
080 497
079 496
030 170
601 158
601 165
030 081
003 645
V 046654
025 234
047 842
047 841
602 946
041 056
METER, amp dc 50 MV 0-500 scale
FUSE, cartridge 45 amp 250 volts
HOLDER, fuse-cartridge 60 amp 250 volts
FUSE BOX
COVER, junction box
BUSHING, snap-in3/4 Dx linchhole...................... eee
BLANK, snap-in 7/8 inch
BLANK, button-plug 1 inch dia..... ee eee ee ee eee 0
SHUNT, meter 50 MV 500 amp
BUS BAR, shunt/secondary stud... .... ART
METER, voitdc0-100scale.......................... ee
CAP, straight-grounded 2P3W 15 amp 250 volts. ...................000 000
GAUGE, pressure 0-80 Ibs.
no" ENN oF FoF oy
4 7 & tv EB 0 4 4 4 чи чи вв ни 4 a mom ¥% N a RP T+ =m 4 8 4 4
4 1 #4 a4 AECA E OO] GU UA UA AO EA
+ = = = =m wm EA EA AA NP EAU EUA
VE EE EAU] OU] x mE =m w 4 gu
т чечня чм BF 4 BE 4 F FF 3 4 pp = pp Fg EEK KON к вин ан ни тн ян un d ¥% mw gu
"= ити °F & 4 ® = & на ни нана % w EF 4 ча ца ини ци нина няни яч 4 mm uw ok w dh kk od %w =m oz ®
* = чм # § F EF OU RHR & & & F ENE " mow 4k ¥# # F mw 4 4 1 KE 4 % §g 4 4 = FN PK OF OM a uu
чин начав ни wv vz vv a = = oo = # & FF 4 xo 4 4 % 4 F 4 4 # A 4% § a yg x pom om mow om ok d я
GAUGE, temperature-mechanical 100/250 deg. ...... ee eee
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Page 5
FITTING, pipe-brass tee 1/8 NPT 1.111111 LL a LA Aa aa a ea a ea de a a a aa nan
FA-1 FLAME ARRESTOR FUEL CAP
75 1 CL CC A нии в ини яч тва
a TA —=
[tem Dia. Part
No. Mkgs. No. Description Quantity
Figure B Generator (Fig A Pg 4 item 80)
1 0438 650 BRACKET, mtg-brush holder ...................... Cea 1
2 018 614 BRUSH SET {consisting Of) «ooo KT 1
3 *044 755 .CAP, brush holder ...........ee_eeenserrnoreveren e. eee 1
4 600 270 . HOLDER, Brush .. oct RR ee eee eens 1
5 018 665 . CAP, brush holder RR RR RR 4 0 1
6 013 367 LABEL, caution-compression release ...........—..ecoeecrergeeaedan e ro.. 1
7 085 274 GUARD, generator ............—.ee scr eecrii rr rirece, rare receorea ra 1
8 085 548 STATOR, generator or ............. RER RR RR KEN ' 1
8 085 918 STATOR (used w/7.5 kva option) 100 KR a 0000 1
9 039 207 BAFFLE, air-generator ..............oc_eee.rireroyareoorerceererer oca 1
10 084 452 ROTOR, generator (consisting of) ..............e.e_ecoe.é.. eas 1
11 024 617 . RING, retaining-external .............eeoemrerevcerecoreco cacereoreee 40 1
12 053 390 . BEARING, ball .............._.0ee0..0srác0carecede:,adararoconeroa 1
13 035 917 .FÁN, TOtor............eecesendcoreooaredadervecaoderaerearerooorano 1
035 776 .KEY, 3/8x3/8x2.......r.c0e0ad0rareoaarezarrneoreecrarani evade, 1
14 044 374 STATOR, exciter-aux power 120/240..............—.e——e—..ecxecsedócccie. 1
15 049 235 ENDBELL, generator ...............eeeseerredveracio.i ver ere ec ear. 1
16 049 652 BARREL, rectifier .................oe,e RR à 1
17 SR3 072 182 DIODE ASSEMBLY, straight polarity (consistingof) ...................... 1
18 025 305 .INSULATOR......... e... 00.002. 00ureredrca RR ea au 0 2
19 037 956 . DIODE, rectifier 275 amp 300 volts straight polarity ..................... 3
20 000 901 .CAPACITOR, ceramic 0.01 uf 500 volts de ........ cc. iii. 2
046 455 .CAPACITOR, ceramic 0.01 uf 500 volts de ............... 2..5... ууу. 1
R4,VR1 046 819 SUPPRESSOR ......... .. Ce ee ee 1
21 025 306 INSULATOR ............ 00 r0recrieciaare orar ererenaanrearonedveroona 4
22 049 653 BUS BAR, rectifier ,................ 2.00 2020 e 0d00rcdcreroareeaoa 2
23 SR3 072 950 DIODE ASSEMBLY, reverse polarity (consistingof) ...................... | 1
24 037 957 . DIODE, rectifier 275 amp 300 voitsreversepolarity...................... 3
25 025 305 .INSULATOR................ ee et KR EG 2
000 901 . CAPACITOR, ceramic 0.01 uf 500 volts de ..............ec_e e .ereceneo. 2
046 455 , CAPACITOR, ceramic 0.01 uf 500 volts de ..........e..._.2.emeverevro 1
TD-085 796
17 Figure B - Generator
*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
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure C Panel, front-w/components
1 010 836 PIN, spring-compression ............eeeceercosdererrrerere ce en ee
2 044 328 HANDLE, switch-range .........cec__.reeerevecorecsrvervecovermarereron.
3 NAMEPLATE (order by model & serialnumber) ...........................
4 8&4 011 609 SWITCH, toggle SPDT 15 amp 125 vOoltS coin,
5 $1 011 611 SWITCH, toggle DPDT 15amp 125volts ............ iii...
6 PB1,2 084 098 SWITCH, pushbutton 36 volts de ....... citi a ea a a a a a a 4 a aa ec aa 40
7 085 685 PANEL, front-upper .........oe...e..ee0srorervenorarecoanevorcedraroarcrenaa
8 53 085 628 SWITCH, range............ec_.eresresrvecoiarrereorrnoceniecroaoa rv arero,
9 070 217 BRACKET, support-switch .......... —eeecoresrecesderacenavedaarerecer
10 1861 070 698 RHEOSTAT, WW 300 watt 34 ohm .........._ececeronrecoasororsareerena.
11 MS? 011 072 SWITCH, magnetic (consisting of) ................eoeoeeevrecarrerererea.
12 F *048 317 . FUSE, miniature-glass 14 amp 32 volts ..............eeec_eeeeecocnocano0s
13 CB1,2 053 283 CIRCUIT BREAKER, manual reset 1P 15 amp 250 volts ............... ee.
14 RC 604 176 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 125 volts ...........
14 RC2 +604 103 RECEPTACLE, straight-duplex grounded 2P3W 15 amp 250 volts ...........
— M PO MN mdd dl Pra ld od eh BN eh ed ed ed =
15 602 178 SCREW, set-socket hd 1/4-20 x 3/8 ............_—e.mmmeradareocrereroorea
16 019 755 HANDLE, switch ..........e._e__._e..resoarereoercororooarrecunooarana
17 084 246 CAP, switch-dust/weather black ..............coonocoereeeocororrerecamere
18 084 247 CAP, switch-dust/weather red ..... et eee eee eee
19 021 385 BOOT, toggle switch lever ............eñ.—r_eecvrvcerireronerereearearen..
20 082 788 LIGHT, indicator-hoider ..... Ce ee AA 4 4 a 4 ee a 4 ea a a aa
21 PL1,2 %*048 155 BULB, incandescent 12 volts...................... aa ana ana aa aa LL Lane
22 082 789 LENS, light-indicator red ........L111 1100044 a 4 4 ae 4 aa 4 4 ee a 4 8 aa a eae,
23 HM 032 936 Meter, hour 4-40 volts de .................ece.. tt 0 4 4 0 0 4 4 a ea a a aa na a a»
TC-086 838
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.
Page 7
item Dia. Part
No. Mkgs. No. Description - Quantity
Figure D Bracket, Mounting - Power Output {Fig A Pg 5 Item 109)
195 081 481 BRACKET, mounting-terminal poweroutput .. .................. ovina... 1
196 Neg 039 046 TERMINAL, power output-biack (consisting of} ............ iran... 1
197 601 879 . NUT, hex-fuil 1/2-13 000000000000 RR 4 ae a aa a ee ane 0 ee 1
198 039 044 .BUS BAR iii iii i i te a ea 1
199 601 880 . NUT, hex-jam 1/2-13 i i i te a eorrecrerearonao ano 1
200 039 045 . TERMINAL BOARD, black . ... oii ii cei 4 ee a aa a aa a a a ae a au + 1
201 601 976 . SCREW, cap-hex hd 1/2-13 x 1-1/2 11.111010 00 ae a ea ea a Ve a a de a en aa 00 1
202 Pos 039047 TERMINAL, power-output-red (consisting of) ..............._.eeeeeeoeeeree.. 1
203 601 976 . SCREW, cap-hex hd 1/2-13 x 1-1/2 1.111212 10 04141 La da a ea a ee ea a nca 4 1
204 039 049 . TERMINAL BOARD, red..............cecesrcvedoareriaareracecacrardsaran en 1
205 601 880 . NUT, hex-jam 1/2-13 ........ R RR RK RR a ae en 6 1
206 039 044 . BUS BAR oii i ee ee A ee 4 A4 A ea ea a aa 0 1
207 601 879 . NUT, Nex-full 1/2-13 11.111200 1 00104 2e 4 4 4 ee a a ee 4 4 a 4 a a ee aa ae aa ea aa aan 1
195
> 196
200
— 201
J
78-048 150-4
Figure D - Bracket, Mounting - 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 Circuit Card, Weld/idle Control (Fig A Pg 5 Item 101)
C50,54 035 522 CAPACITOR, mylar 0.047 uf 100 volts .........._...o _eeeeeso0rerra dere an 2
C51,52 031 651 CAPACITOR, tantalum BB uf 20 volts de . ..... cite 2 Rae aan 2
C53 080 507 CAPACITOR, tantalum 22 uf 15 volts Le eee eee ean 1
D50,54 027 369 DIODE, rectifier 3 amp 600 volts straight polarity .....0..00000 r anne 2
DS1,52,53, |
56,57 026 202 DIODE, rectifier 1 amp 400 volts straightpolarity ............................. 5
DS5 037 243 DIODE, zener 18 volts 1 watt ...........—......r er... asireacxriere venvrervecvas 1
Q50 000 088 TRANSISTOR, 800 MA 40 voits. 1.110204 4020 0 8 814 0 4 aa 4 0 a 4 4e ee a ua aa au» 1
Q51 039 355 TRANSISTOR, unijunction 15 MA 40 volts. ......102101 0004 4 a aa aa a aan an 1
R50,53 000 039 RESISTOR, carbon 2 watt 680 ohm ............._emeeo—rrnacicredono recae». 2
R51,56 605 919 RESISTOR, carbon 0.25 watt 47 onm .......111121110 LL LA La aa aa aa aa ee 2
R52 505 916 RESISTOR, carbon 0.25 watt TK ohm .......... 2... 00. sr eriasierereo. 1
R54 035 824 RESISTOR, carbon film 0.25 watt 270 ohm ............ RR 1
R57 052 146 RESISTOR, carbon fim 0.26 watt 620K ohm ......... oii 4 a aa a a a ana 0 1
R58 053 572 RESISTOR, carbon film 0.25 watt 12Kohm ........ iii 4 a aa a en aa ua» 1
R59 052 138 RESISTOR, carbon film 0.20 watt 20K ohm .... cc viii tei cite enemies 1
R60 035 822 RESISTOR, carbon film 0.25 watt 10 onm .........oo.éeoccarare ren enea, a en 1
R61,62 030 026 RESISTOR, carbon 0.5 watt 5680 ohm LL... eee eee 2
R63 003 272 RESISTOR, carbon film 0.25 watt 1 Meg ohm ............ iL, 1
R64 071 595 RESISTOR, carbon film 0.25 watt 22 ohm i ini, 1
SCR50,51 080 508 THYRISTOR, SCR 8.5 amp 200 voits ........1101 010114 4 40e 4 a 4 a aa aa a a aa aa en 2
SR50 035 841 RECTIFIER, integrated 1.5 amp 200 volts ...............eeeeccareonor vere. 1
080 506 HEAT SINK, dual. ...........eex_escoaoraoarierecoc0aai nero ecerronem 1
BE SURE TO PROVIDE MODE
Page 9
COMPONENTS TO BE
REPLACED BY QUALIFIED
PERSONNEL ONLY
Figure E - Circuit Card, Weid/idie Control
L AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
TA-048 151-4
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