Miller BIG BLUE 251D User manual

Miller BIG BLUE 251D User manual
 May 1991
FORM: OM-480B
Effective With Serial No. KB051966
MODEL: BIG BLUE” 251D
OWNER'S MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before
installing, operating, or maintaining this equipment. This unit and these
instructions are for use only by persons trained and experienced in the safe
operation of welding equipment. Do not allow untrained persons to install,
operate, or maintain this unit. Contact your distributor if you do not fully
understand these instructions.
MILLER ELECTRIC Mfg. Co.
A Miller Group Ltd., Company
P.O. Box 1079
Appleton, WI 54912 USA
Tel, 414-734-9821
SC-130 895-A
PRINTED IN U.S.A
y
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
LIMITED WARRANTY — Subject to the terms and conditions
hereof, MILLER Electric Mfg. Co., Appleton, Wisconsin war-
rants to its Distributor/Dealer that all new and unused
Equipment furnished by MILLER is free from defect in
workmanship and material as of the time and place of delivery
by MILLER. No warranty is made by MILLER with respect to
engines, trade accessories or other items manufactured by
others, Such engines. trade accessories and other items are
sold subject to the warranties of their respective manufacturers.
if any. All engines are warrantied by their manufacturer for two
years from date of original purchase, except Deutz engines
which have a one year, 2000 hour warranty.
Exceptas specified below, MILLER's warranty does not apply
to components having normal useful life cf less than one (1)
year. such as spot welder tips, relay and contactor points.
MILLERMATIC parts that come in contact with the welding wire
including nozzles and nozzle insulators where failure does not
result from defect in workmanship or material.
MILLER shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of
Equipment to the original user:
1. Arc welders. power sources. robots, and........ 1 year
components
2. Loadbanks .... e 120 1 year
3. Original main power rectifiers ............... 3 years
(labor — 1 year only)
4. All welding guns, feeder/guns and torches .... 90 days
5. All other MILLERMATIC Feeders ............. 1 year
6. Replacement or repair parts, exclusive of lador 60 days
7. Batteries ........... 2.0... 6 months
provided that MILLER is notified in writing within thirty {30} days
of the date of such failure.
As a matter of general policy only, MILLER may honor claims
submitted by the origina! user within the foregoing periods.
e
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
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} replace-
ment or. where authorized in writing by MILLER in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized MILLER service station or (4) payment of or credit
for the purchase price (less reasonable depreciation based
upon actual use} upon return of the goods at Customer's risk
and expense, MILLER's option of repair or replacement will be
FO.B.. Factory at Appleton. Wisconsin. or FO.B. at a MILLER
authorized service facility. therefore. no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure, MILLER shall instruct ihe
claimant on the warranty claim procedures 10 be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE-
SENTATION 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 MERCHAN-
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE.
WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER 1S EXCLUDED 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 NOT FOR CONSUMERS OR
CONSUMER USE. MILLER'S WARRANTIES DO NOT
EXTEND TO, AND NO RESELLER IS AUTHQRIZED TO
EXTEND MILLER'S WARRANTIES TO, ANY CONSUMER.
November 6, 1991 FORM: OM-4808
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 11 - ELECTRICAL DIAGRAMS
Amend Diagram 11-1. Circuit Diagram For Welding Generator (see Page 4 on this Errata Sheet)
Amend Diagram 11-2. Wiring Diagram For Welding Generator (see Pages 2 and 3 on this Errata Sheet)
AMENDMENT TO SECTION 12 — PARTS LIST
Amend Parts List as follows:
Dia. Part Replaced I ;
** Mkgs. No. With Description Quantity
„48-2 200000000 134771 .... 134771 .. PLUG, (gtyctg) ....... iii, 2
‚. 48-............ Added .... 087 34t .. BUMPER, door 1.000 OD x .750 high
(used on engine doors) ........ci iii, 4
‚ 49-95 .......... 110909 .... Deleted |
1 O 089588 .. e149541 .. HOLDER, fuse crtg 60A 250V 2 fuses ............... 1
**First digit represents page no — digits following dash represent item no.
+ Part of 042 358 10/7.5 KVA Auxiliary Power
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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OM-480B Page 2
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OM-480B Page 3
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OM-480B Page 4
OM-4508 — 5/91
RECEIVING-HANDLING
Before unpacking equipment, check carton for any dam-
age that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufactur-
Use the following spaces to record the Model Designa-
tion and Serial or Style Number of your unit. The infor-
mation is located on the data card or the nameplate.
Model
er's Transportation Department.
Serial or Style No.
When requesting information about this equipment, al-
ways provide the Model Description and Serial or Style
Number.
Date of Purchase
TABLE OF CONTENTS
CE RRR RE SE RRR EE.
Section No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1 Introduction RR RR 1
1-2. General Precautions ........ ee 1
1-3. Arc Welding eee 0 4
1-4. Standards Booklet IndeX ............. .... ... i... 5
SECTION 2 — SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1. General Information And Safety . ................. rereraa. 6
2-2. Safety Alert Symbol And SignalWords .................. LL. 6
SECTION 3 — SPECIFICATIONS
3-1. Volt-Ampere Curves .......111 10001 414 aa 1 a a 4 a a a ea a 0e 8
3-2. Duty Cycle ......... ............. ee 8
3-3. Description ............. eee 8
SECTION 4 — INSTALLATION OR RELOCATION
4-1. Location ee ea 9
4-2. Exhaust Extension Installation... ee 10
4-3. Connecting The Battery ....... iii, 10
4-4. Fuel eee 10
4-5. Lubrication .... Lee, 11
4-6. Equipment Grounding Terminal . 1.112210 1 00122404 Rasa 0 11
4-7. Weld Output Connections . 2... eecrere, 11
4-8. Ether Starting Aid (Optional) 1.122110 004144 0 1 44 a 4 ea 41440 12
4-9. Remote Amperage Contro! Receptacie (Optional) ............... 13
SECTION 5 — AUXILIARY POWER
5-1. General ............ e ereerereriaedrenrdorererecrerva 13
5-2. Auxiliary Power While Weiding .............e.e—remerexenere, 13
5-3. Auxiliary Power Plant (Optional) en... ... 14
Section No. Page No
SECTION 6 — EVALUATING AUXILIARY POWER REQUIREMENTS
6-1. Auxiliary Power Generators ............... 0. iin. 16
6-2. Load Evaluation ................. ee 0 17
6-3. Generator Capability erereraaarer m2, 19
6-4. Standby Power Connections ............. iin, 19
6-5. Auxiliary Power Extension Cord Selection . .................... 20
Diagram 6-1. Standby Power Equipment And Connections ............. 20
SECTION 7 - OPERATOR CONTROLS
7-1. Ampere Ranges Switch ............... e eadaaeda0 22
7-2. Amperage/Voltage Adjustment Control ....................... 22
7-3. Engine Control Switch ....... enederorero 23
7-4. Low Qil Pressure Indicator Light .. .......................... 23
7-5. Battery Charge Indicator Light .............. ... ...... ....... 23
7-6. Hour Meter .. raeeenedacacenrane nene da. 24
7-7. Polarity Switch (Optional) . ........ ereoerera. 24
7-8. Remote Amperage Control Switch (Optional) .................. 24
7-9. Oi Pressure And Temperature Gauges (Optional) .............. 24
7-10. Meters (Optional) ....... LL LL LL LL aa 12 24
7-11. Ether Starting Aid (Optional) ........ i... 24
7-12. Low Oil Pressure/High Qil Temperature Shutdown System (Optional) 25
7-13. Overspeed Shutdown System {Optional} . ..................... 25
7-14. High-Altitude Modification (Optional) ......................... 25
SECTION 8 - SEQUENCE OF OPERATION
8-1. Shielded Metal Arc Welding (SMAW) ........................ 26
8-2. Optional Power Plant Operation ............................ 26
8-3. Stating The Engine ......... iii iii, 26
8-4. Stopping The Engine ............ iii... 26
SECTION 9 - MAINTENANCE
9-1. RoutineMaintenance ............. iii. 27
9-2. AirCleaner Service ........... ee. 28
9-3. Fuel/Water Separator And Petcock .......................... 28
9-4. Fuel Filter «ee 30
9-5. CheckingEngineBelt .......... iii. 30
9-6. Battery Replacement Procedure ................ 0... .. 30
9-7. Maintenance-Free Battery Charging ......................... 31
9-8. Governor ............. 2... earerecaadderererereronene ro 31
9-9. Engine Speed Adjustments ................... 2200 arac0, 31
9-10. Replacing Engine Belt ..............00ermeeaperadoracorerce. 32
9-11. Brushes And Slip Rings ............... added dean reee. 33
9-12. Run-In Procedure ............ ee 33
Diagram 9-1. Load Bank Connections ..............._.erereneredoda. 34
Diagram 9-2. Resistance Grid Connections .............—ereresorocra 35
9-13. Ether Starting Aid (Optional) .............e.-.0000..ereore.. 35
9-14. Overspeed Shutdown Valve Adjustment (Optional) .............. 36
SECTION 10 — TROUBLESHOOTING
10-1. General ....... RR RK 37
10-2. BoosterBattery Jump Starting .......... KK 40 37
10-3. Overload Protection... RK 4 4 ee a a ee 0 37
10-4. Troubleshooting ...........22000 0024244444 a a ea a ae sa a nan 0 38
Section No. Page No.
SECTION 11 - ELECTRICAL DIAGRAMS
Diagram 11-1. Circuit Diagram For Welding Generator ................. 43
Diagram 11-2. Wiring Diagram For Welding Generator . ................ 44
SECTION 12 — PARTS LIST
Figure 12-1. Main Assembly ......... 4 a a a 1 aa aa ae 0 46
Figure 12-2. Panel, Frontw/Components ........................... 50
Figure 12-3. Switch, Range ............... ae ea a a 52
Figure 12-4. Generator ........ e enroreaaareenonm 53
Figure 12-5. Terminal Assembly, Pwr Qutput ........................ 54
Optional Equipment ......12022 00010 AA LL LL La LL La 55
LIST OF CHARTS AND TABLES
Table 3-1. Welding Generator Specifications . ...................... 7
Table 3-2. Optional Power Plant Specifications ..................... 7
Chart 3-1. Volt-Ampere Curves ............. iii. 8
Chart 3-2. Duty Cycle... 2... LA a a a a ee a a a a aa aa Le 8
Chart 4-1. Fuel Consumption Curve ......... i... 11
Table 4-1. Weld Cable Size er ee 11
Chart 5-1. AC Power Curve For 120 And 240 Volts Duplex Receptacies
(No Weld Load) ............. 2... 44 4 aa ina. 14
Table 5-1. Optional Power Plant Specifications ...............e e... 14
Chart 5-2. AC Power Curve For 7.5 KVA/KW Auxiliary Power (No
Weld Load) ................ 90000, aaa 15
Chart 5-3. AC Power Curve For 10 KVA/KW Three-Phase Auxiliary Power
(NoWeld Load) ........ i, 15
Table 6-1. Power Requirements . ... 2.0. ene. 18
Table 6-2. Single-Phase Induction Motor Starting KVA/HP Requirements 19
Table 6-3. Cord Lengths For 120Voltboads ....................... 21
Table 6-4. Cord Lengths For240 Voltloads .................. a 22
Table 9-1. Maintenance Schedule .................. rece. 27
Table 9-2. Air Cleaner Service ............ ee eee 29
Table 10-1. Weld/Power Troubleshooting .......................... 39
Table 10-2. Auxiliary Power Troubleshooting. ....................... 40
Table 10-3. Engine Troubleshooting ........... iin... 41
DAN
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
ССС DT ]—]]];—]—]]]]—————T—T———
1-1. INTRODUCTION
We learn by experience. Learning safety through per-
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of oth-
ers teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re-
search, 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 rea-
son for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals, for
personal safety and for the safety of others.
Failure to observe these safe practices may cause seri-
ous 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 cut-
ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
are also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. in addition to the information in this
manual, be sure to consuit flux and electrode manu-
facturers Material Safety Data Sheets (MSDSs) for
specific technical data and precautionary measures
concerning their material.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves,
Medical first aid and eye treatment. First aid facilities and
a qualified first aid person should be available for each
shift unless medica! facilities are close by for immediate
treatment of flash burns of the eyes and skin burns,
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them with
adequate ventilation as described in ANS! Standard
Z49.1 listed in Standards Index. NEVER ventilate with
oxygen. :
Lead -, cadmium -, zinc -, mercury -, and beryllium-bear-
ing and similar materials, when welded (or cut) may pro-
duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each personin
the area as well as the operator must wear an air-sup-
phed respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit toxic
fumes should not be heated unless coating is removed
from the work surface, the area is well ventilated and, if
necessary, while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira-
tor.
Gas leaks in a confined space should be avoided.
leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylindersinto a
confined space.
| eaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod-
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene va-
porsto form phosgene. DO NOT WELD or cut where sol-
vent vapors can be drawn into the welding or cutting at-
mosphere or where the radiant energy can penetrate to
OM-480 Page 1
atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate-
rial; 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, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, venti-
lators. if the work cannot be moved, move combustibles
at least 35 feet away out of reach of sparks and heat; or
protect against ignition with suitable and snug-fitting,
fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire extin-
guishing equipment during and for some time after weld-
ing or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
C. openings (concealed or visible) in floors or walls
within 35 feet may expose combustibles to
sparks
d. combustibies adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions
have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A8.0, listed
7 in Standards index.
This includes: athorough steam or caustic cleaning (ora
solvent or water washing, depending on the combusti-
ble’s solubility) followed by purging and inerting with ni-
trogen or carbon dioxide, and using protective equip-
OM-480 Page 2
ment as recommended in A6.0. Watertilling just below
working level may substitute for inerting.
À container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense of
smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never 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, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN-
DERS, listed 11 in Standards Index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one or more relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulator from service immediately for re-
pair (first close cylinder valve). The following symptoms
indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
Repair. Do NOT attempt to repair. Send faulty regulators
for repair to manufacturer's designated repair center,
where special techniques and tools are used by trained
personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious acci-
dent. (See 1-3C.)
ICC or DOT marking must be on each cylinder. it is an
assurance of safety when the cylinder is properly han-
dled.
identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or alter name, number, or other markings on a cylinder. It
is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate or secure cylinders so they cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradle. Do NOT lift cylinders off
the ground by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al-
low 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 exchanged.
3. Hose
Prohibited use. Never use hose other than that designed
for the specified gas. A general hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferrules or clamps designed for the hose (not ordi-
nary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, siag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate leaks.
Repair leaky or worn hose by cutting area out and splic-
ing (1-2D3). Do NOT tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintless cioth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
that the regulator iniet 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.
Regulator outlet (or hose) connections may be identified
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 be-
fore opening cylinder (or manifold valve) by turning ad-
justing screw in (clockwise). Draining prevents exces-
sive 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 fol-
lowing position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of ivory Lig-
uid* or equivalent per gallon of water). Bubbles indicate
leak. Clean off soapy water after test; dried soap is com-
bustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
F. Leaving Equipment Unattended
Close gas suppiy at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
*Trademark of Proctor & Gamble.
OM-480 Page 3
1-3. ARC WELDING
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, uitraviolet and in-
frared energy radiates, wéldments are hot, and com-
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan-
dards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gas-
shielded arcs are more severe and painful. DON'T GET
BURNED; COMPLY WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As nec-
essary, use additional protective clothing such as leather
jacket or sleeves, flame-proof apron, and fire-resistant
leggings. Avoid outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock-
ets 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 clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when broken,
pitted, or spattered. |
Flash goggles with side shields MUST be worn under the
heimet 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 sepa-
rate room or enclosed bay is best. In open areas, sur-
round the operation with low-reflective, non-combusti-
ble screens or panels. Allow for free air circulation, par-
ticulariy at floor level.
OM-480 Page 4
Viewing the weld. Provide face shields for ail 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. [t 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 ves-
sel. It creates a brittle area that can cause a violent rup-
ture or lead to such a rupture 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 weid-
ing circuit, or in ungrounded, electrically-HOT equip-
ment 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:
Wear dry insulating gloves and body protection 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 dampness or sweat
can not be avoided. Sweat, sea water, or moisture be-
tween body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en-
able dangerous and possibly lethal currents to flow
through the body.
A voltage will exist between the electrode and any con-
ducting object in the work circuit. Examples of concuct-
ing objects include, but are not limited to, buildings eiec-
trical tools, work benches, welding power source cases.
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is off.
1. Grounding the Equipment
Arc welding equipment must be grounded accere:ng to
the National Electrical Code, and the work must be
grounded according to ANS! 249.1 “Safety In Weiding
And Cutting.”
When installing, connect the frames of each unit such as
welding power source, control, work table, and water cir-
culator to the building ground. Conductors must be ade-
quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly fa-
tally. Do NOT GROUND to electrical conduit, or to a pipe
carrying ANY gas or flammable liquid 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 re-
ceptacle, 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 receptacle.
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. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6. Electrode
a. Equipmentwith output on/off control (contactor)
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor-
mally are equipped with devices that permit on-
off control of the welding power output. When so
equipped the electrode wire becomes electri-
cally HOT when the power source switch is ON
and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob-
ject in contact with the electrode circuit unless
the welding power source is off.
b. Equipment without output on/off control (no
contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar proc-
esses may not be equipped with welding power
output on-off control devices. With such equip-
ment the electrode is electrically HOT when the
power switch is turned ON. Never touch the
electrode uniess the welding power source is
off.
7. Safety Devices
Safety devices such as interiocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equipment,
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 all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld-
ing. If, in an emergency, it must be disconnected, guard
against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available near the
welding power source.
F. Protection For Wearers of Electronic Life Sup-
port Devices (Pacemakers)
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
1. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
~ Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126.
2. NIOSH, SAFETY AND HEALTH IN ARC WELD-
ING AND GAS WELDING AND CUTTING ob-
tainable 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 Superinten-
dent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
4, ANSI Standard 287.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainabie from the Ameri-
can National Standards Institute, 1430 Broad-
way, New York, NY 10018.
5. ANSI Standard Za1.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-480 Page 5
6. ANSI Standard 249.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRQOC-
ESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
8. NFPA Standard 51, OXYGEN-FUEL GAS SYS-
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Bafterymarch Park,
Quincy, MA 02269.
9. NFPA Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 1235 Jef-
ferson Davis Highway, Suite 501, Arlington, VA
22202.
12. 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 M9W 1Rg3.
13. NWSA booklet, WELDING SAFETY BIBLIOG-
RAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadel-
phia, PA 19103.
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE
HELD HAZARDOUS SUBSTANCES, obtainable
from the American Welding Society, 550 N.W,
LeJeune Rd, Miami, FL 33126.
15. ANSI Standard 288.2, PRACTICE FOR RESP!-
RATORY PROTECTION, obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
UNT
SECTION 2 — SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
The nameplate of this unit uses international symbols for
labeling the front panel controls. The symbols also ap-
pear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per-
sons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 — Safety Rules For Operation Of Arc Weld-
ing Power Source.
OM-480 Page 6
2-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manual to call attention to and iden-
tify different levels of hazard and special instructions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life,
practices which must be followed to avoid minor
áÁL CAUTION statements identify procedures or
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
SECTION 3 — SPECIFICATIONS
DAN
Table 3-1. Welding Generator Specifications
Rated Output | Weiding DC Maximum Maximum |¡Single-Phase AC Weight
At 100% Range Ampere |Open-Circuit | Engine Speed | Auxiliary Power
Duty Cycie DC Ranges Voltage (No Load) While Welding Net Ship
e 130 3 KVA/KW
250 Amperes | 40to400 | 55-130 1475 165. | 1510 165.
At 40 Volts DC | Amperes 90-225 | 95 Volts DC 1850 RPM 26 Amps At 120V (670 kg) | (685 kg)
120-280 60 Hz
200-Max.
Conforms with NEMA EW1 (ANS! C87.1), “ELECTRIC ARC WELDING POWER SOURCES”, Class 1 (100).
Table 3-2. Optional Power Plant Specifications
Voltage Amperage KVA/KW Frequency Maximum Engine Speed
Single-Phase | 120/240 Volts AC | 31 Amps AC 7.5 60 Hz 1850 RPM
Three-Phase 240 Volts AC 24 Amps AC 10 60 Hz 1850 RPM
51-1/8
41-1/8
13-7/8
2-7/8
23-1/2
нь i
Engine End
*36-1/2 in.
(927 mm)
53-3/4 in.
(1365 mm) + ,
de
- ый
24-1/2 in.
y
| : = Wi 8
(620 mm} ~ E D
SC-130 895-A 21/32 in. (16.7 mm)
Diameter
* 41-1/16 in. (1043 mm) to muffler extension. All Holes
I
С
xX
Figure 3-1. Overall Dimensions And Base Mounting Hole Layout
OM-480 Page 7
3-1. VOLT-AMPERE CURVES (Chart 3-1)
(> RATED WELD OUTPUT
The voit-ampere curves show the voltage and amper-
age output capabilities of the weiding power source.
Voltage and amperage adjustment is provided by the
AMPERAGE/VOLTAGE ADJUSTMENT Control.
Curves of other settings fall between the curves shown.
Chart 3-1. Volt-Ampere Curves
100
DC VOLTS
Ls — ——
po ===
e 100 200 300 400 500 600
DC AMPERES
58-070 042-A
3-2. DUTY CYCLE (Chart 3-2)
The duty cycle is the percentage of a ten minute period
that a welding generator can be operated at a given out-
put without overheating and damaging the unit. This
welding generator is rated at 100% duty cycle when op-
erated at 250 amperes. The unit can be operated contin-
uously without causing damage to the unit.
Refer to the Duty Cycle Chart (Chart 3-2) to determine
the output of the welding generator at various duty cy-
cles.
CAUTION: EXCEEDING DUTY CYCLE RAT-
INGS will damage unit.
e Do not exceed indicated duty cycle(s).
OM-480 Page 8
Chart 3-2. Duty Cycle
RATED OUTPUT: 7
WELD AMPERES
30 40 50 60 70 89 80 100
Z DUTY CYCLE
SB-070 999-4
3-3. DESCRIPTION
This unit is a constant current, engine-driven dc arc
welding generator designed for use with the Shielded
Metal Arc Welding (SMAW) process, The welding gen-
erator has a three-cylinder, air/oil-cooled Deutz diesel
engine (F3L-1011). The air cools the oil, and the oil cools
the engine.
In addition to welding capability, this unit can provide up
to 3 kVA/KW of 120 volts (26 amperes) ac electrical
power for operating cord-connected auxiliary equipment
while welding.
This unit is specially prepared for operation in harsh and
corrosive environments.
The following options and accessories can be provided
on the welding generator and are covered in this Own-
ers Manual:
* Single- And Three-Phase Auxiliary Power Plant
(Factory-Instalied Only)
* Weld Meters
* Polarity Switch
* Qil Temperature And Pressure Gauges
* Low Oil Pressure/High Coolant Temperature
Shutdown System (includes above gauges)
* Remote Amperage Control
* Ether Starting Aid
* High-Aititude Modification
* Overspeed Shutdown System
IMPORTANT: For a complete listing of Options and Ac-
cessories, see back cover of this manual.
SECTION 4 — INSTALLATION OR RELOCATION
IMPORTANT: Unless otherwise specified, all direc-
tions, such as left or right, are with respect to the opera-
tor facing the welding generator front panel.
4-1. LOCATION (Figures 3-1 And 4-1)
À proper installation site should be selected for the weld-
ing generator ifthe unit is to provide dependable service
and remain relatively maintenance free.
WARNING: ENGINE EXHAUST GASES can
kill.
e Operate in open, well-ventilated areas, or if
operated indoors, vent engine exhaust out-
side the building.
* Keep engine exhaust outlet away from build-
ing air intakes.
CAUTION: RESTRICTED AIRFLOW causes
overheating and possible damage to internal
parts.
¢ Maintain atleast 18 inches (457 mm) of unre-
stricted space on all sides of unit, and keep
underside free of obstructions.
* 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.
The service life and operating efficiency of this unit are
reduced when the unit is subjected to extreme levels of
dust, dirt, moisture, corrosive vapors, and extreme heat.
A. Lifting Equipment
WARNING: INCORRECT LIFTING will dam-
age internal parts; FALLING EQUIPMENT
can cause serious personal injury and
equipment damage.
e Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other heavy
options, accessories, or devices.
* Use equipment of adequate capacity to lift the
unit.
® [fusing lift forks to handle this unit, be sure the
lift forks are long enough to extend out of the
opposite side of the base.
Using lift forks too short will expose internal com-
ponents to damage should the tips of the lift forks
penetrate the bottom of the unit.
B. Mounting Unit Onto Trailer
CAUTION: UNCONTROLLED TILTING OF
TRAILER can result in personal injury or
equipment damage.
e Install welding generator onto trailer with en-
gine end toward hitch end of trailer.
e Distribute weight so that trailer tongue weight
Is approximately 10% of the gross trailer
welght.
e Follow trailer manufacturers instructions
when mounting welding generator onto trailer.
OPERATION ON UNLEVEL SURFACE can
cause improper lubrication and result in
severe engine damage.
o Operate unit in an approximately level
position.
® See Figure 4-1 for maximum allowable tit for
proper operation.
e Check crankcase oil level with unit on a level
surface.
Exceeding these limits can cause severe engine
damage.
30 ¡y
Side View Of Unit
30°
30°
End View Of Unit 24
Figure 4-1. Allowable Tilt Angles For Welding
Generator Engine
Base mounting holes provide the capability to instal and
secure the unit on a trailer, transport vehicle, or in a per-
manent location. Figure 3-1 gives overall dimens:óns
and base mounting hole layout.
The mounting location should allow sufficient room to re-
move the top cover and side panels for maintenance and
repair functions.
OM-480 Page 9
Use a properly fitting cover (optional) over the welding
generator when not in operation to protect the unit from
the environment. Be sure unit is cool before installing
any cover.
C. Spark Arrestor Considerations
WARNING: ENGINE EXHAUST SPARKS can
cause fire.
es Exhaust spark arrestor must be installed in
accordance with local state, and federal
regulations.
The engine exhaust system on this welding generator is
not equipped with a spark arrestor. A spark arrestor,
maintained in effective working order, is mandatory if
this welding generator is to be operated in a National
Forest or on California Grasslands, brush, or forest
covered land (see Section 4442 of California Public
Resources Code). For other areas, check your state and
local laws. If a spark arrestor (optional) is desired,
contact your dealer/distributor. |
4-2. EXHAUST EXTENSION INSTALLATION
WARNING: HOT ENGINE PARTS can cause
severe burns.
e [f applicable, stop engine, and allow exhaust
system to cool before installing exhaust ex-
tension.
Open left side door, and secure in open position.
2. Install exhaust extension elbow through top cover
opening, onto muffler extension, and position so
that exhaust discharges away from air cleaner in-
take (see Figure 3-1).
3. Secure exhaust extension to muffler extension
using supplied hardware.
4. Close and secure left side door.
4-3. CONNECTING THE BATTERY
WARNING: BATTERY ACID can burn eyes,
skin, destroy clothing, and damage other
material.
e Wear a face shield and proper protective
clothing when working with batteries.
ABNORMAL VOLTAGE can cause damage to
engine electrical components.
* Do not operate engine without battery
connected.
* Do not disconnect battery while engine is
running. |
IMPORTANT: Be sure Engine Control switch is in the
OFF position before connecting battery.
OM-480 Page 10
This unitis equipped with a maintenance-free battery. To
place the unit in service, open and secure the left side
door, connect the negative (-) battery cable to the nega-
tive battery terminal, and close the side door. No other
preparation shouid be required. If the battery does not
supply enough power to crank the engine, charge the
battery according to Section 9-7.
4-4. FUEL (Chart 4-1)
WARNING: REMOVE FUEL CAP SLOWLY:
FUEL SPRAY may cause injury; FUEL may
be under pressure.
es Rotate fuel cap slowly and wait until hissing
stops before removing cap.
WARNING: ENGINE FUEL can cause fire or
explosion.
e Stop engine before checking or adding fuel.
s Do not spill fuel; if spilled, wipe up.
® Do not refuel if engine is hot or running.
e Do not refuel near sparks or open flame.
e Do not smoke while refueling.
® Do not fill fuel tank to top; allow room for
expansion.
USE OF GASOLINE will damage engine.
® Do not use gasoline to fuel a diesel engine.
Lack of lubrication in the fuel will damage the in-
jector pump and injectors.
IMPORTANT: Fill fuel tank with fresh fuel before starting
engine the first time. Do not fill tank to top; allow room for
expansion. 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.
This welding generator is shipped with a small amount
of fuel in the fuel tank and with the fuel shut-off valve, lo-
cated under the fuel tank, in the open position. See the
unit maintenance label and engine Owner's Manual
(Deutz F3L-1011engine) for fuel recommendations. The
capacity of the fuel tank is 11.3 gallons (42.8 liters).
Keep the fuel tank filled to ensure that the injector sys-
tem receives an adequate supply of fuel. If the fuel tank
is allowed to empty, air will enter the system causing
starting problems.
Chart 4-1 illustrates typical fuel consumption under spe-
cific load conditions. Fuel consumption varies from one
engine to another. Different brands of fuel, operating
conditions, condition of the engine, etc., affect the fuel
consumption of this engine.
Chart 4-1. Fuel Consumption Curve
LS. GAL, /HR,
2.00
® -
a q LITERS/HA
1.48
5.67 1.50 E
4.73 1.04 1.256
1.00 E
0.75 =
0.50 |
0.25 |
1850 A.P.M.
3.78 0.83
2.84 0.82
1.88 040
0.96 0.21
0 50 100 150 200 250 300
DC WELD AMPERES AT 100% DUTY CYCLE
SB-137 487
4-5. LUBRICATION
A. Qil Level
The engine is shipped with its crankcase filled with SAE
20 break-in oil. If the oil level is not up to the full mark on
the dipstick, add oil according to the recommendations
in the engine Owner's Manual (Deutz F3L-1011 diesel
engine} before starting the engine.
B. Wetstacking Considerations
Wetstacking is an accumulation of unburned fuel and oil
in the exhaust pipe. The engine may use oil and wets-
tacking may occur during the run-in period if the piston
rings are not seated properly. If cil consumption and
wetstacking occur during run-in period, see Section
9-12.
4-6. EQUIPMENT GROUNDING TERMINAL
À
EQUIPMENT
GROUND
This unit is equipped with a grounding termina! for
grounding the generator case. Since the generator
neutral is connected to the frame, the equipment
grounding terminal must be connected to a proper earth
ground. Additionally, comply with alí national, regional,
and local codes concerning portable generators for the
specific application.
For detailed grounding instructions consult your na-
tional, regional, and local codes. If additional information
regarding your operating circumstances and/or ground-
ing requirements is needed, consult a qualified electri-
cian or your dealer. After determining the extent to which
any grounding requirements apply to your particular
situation, follow them explicitly.
4-7. WELD OUTPUT CONNECTIONS (Figure 4-2)
>
ole RATED WELD OUTPUT
To obtain the full rated output from this unit, it is neces-
sary to select, install, and maintain proper weld cables.
Failure to comply in any of these areas may result in
unsatisfactory welding performance.
A. Weld Cable Selection
Use the following guidelines to select weld cables:
1. Use the shortest possible cables, and place ca-
bles close together. Excessive cable lengths may
reduce output or cause unit overload due to
added resistance.
Table 4-1. Weld Cable Size
Totai Cable (Copper) Length In Weld Circuit Not Exceeding*
Welding |50 ft. Or Less| 100 ft. 150 ft. | 200 ft. 250 ft. 300 ft. | 350ft. 400 ft.
Amperes (15 m) (30 m) (45 m) (60 m) (70 m) (90 m) (105m) | (120m)
10 Thru 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 2 2 1 1/0 2/0 3/0 4/0 4/0
250 1 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1/0 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 2/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 4/0 4/0 4/0 2-2/0 2-3/0 2-4/0 1000 1000
*Weld cable size (AWG and MCM) is based on either a 4 volts or less drop or a current density of more than 300
circular mils per ampere.
5-0008/8-88
OM-480 Page 11
2. Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-cir-
cuit voltage (ocv) of the welding generator (see
Tabie 3-1 for unit maximum ocv rating).
3. Select weld cable size according to maximum
weld output and total length of connecting cables
in weid circuit. For example, if a 25 foot (7.5 m)
electrode holder cable is used with a 25 foot (7.5
m) work cable, select the cable size recom-
mended in Table 4-1 for 50 feet (15 m).
4. Do not use damaged or frayed cables.
B. Weld Cable Preparation
1. Install electrode holder to cable following man-
ufacturer’s instructions. Always use an insulated
electrode hoider to ensure operator safety.
2. Install correct size lugs to remaining end of elec-
trode holder cable and to both ends of work cable.
3. install work clamp onto cable.
C. Weld Cable Connections To Welding Generator
Without Optional Polarity Switch (Figure 4-2)
POSITIVE
NEGATIVE +
WARNING: ELECTRIC SHOCK can Kill.
e Do not touch live electrical parts.
e Stop engine, and disconnect negative (—
battery cable from battery before making any
weld output connections.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
1. Open and secure the left side door, and route the
weld cables through the bracket on the front up-
right to the weld output terminals.
2. For electrode positive/reverse polarity welding:
a. Connect end of electrode holder cable to POSI-
TIVE (+) weld output terminal.
b. Connect end of work cable to NEGATIVE (>)
weld output terminal.
3. For electrode negative/straight polarity welding:
a. Connect end of electrode holder cable to
NEGATIVE (-) weld output terminal.
b. Connect end of work cable to POSITIVE (+)
weld output terminal.
4. (Close and secure left side access door.
OM-480 Page 12
Negative (-) Weld
Output Terminal
Equipment
Grounding
Terminal
Positive (+) Weld
Output Terminal
Ret. 5A-133 520
Figure 4-2. Weld Output Connections
(Electrode Positive/Reverse Polarity
Connection Shown)
D. Weld Cable Connections To Welding Generator
With Optional Polarity Switch (Figure 4-2)
WARNING: ELECTRIC SHOCK can kill.
+ Do not touch live electrical parts.
e Stop engine, and disconnect negative (-)
battery cable from battery before making any
weld output connections.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
1. Open and secure left side access door, and route
weld cables through bracket on front upright to
the weld output terminals.
2. Connect weld cables as follows:
a. Connectend of electrode holder cable to ELEC-
TRODE weld output terminal.
b. Connect end of work cable to WORK weld out-
put terminal.
3. Close and secure left side access door.
4-8. ETHER STARTING AID (Optional)
This unit is shipped without the ether cylinder. Before
this device is operational, an ether cylinder must be ob-
tained and installed. To install the ether cylinder, pro-
ceed as follows:
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm your
health.
e Follow the manufacturer's safely instructions
on the cylinder when handling ether compo-
nents.
IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
cylinder is inserted. If dirt is present in either of these ar-
eas, the system may not work.
1. Open and secure right side door.
2. If applicable, remove protective cap from ether
valve, or remove old ether cylinder from unit.
3. Loosen cylinder clamp, install ether cylinder, and
tighten clamp.
IMPORTANT. After installing or replacing ether cylin-
der, do not use or test ether start system for at least 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
4, Using a liquid soap and water solution, check all
ether start system connections for leaks. If a leak
exists, escaping gas will produce bubbles in the
solution.
5. Close and secure right side door.
4-9. REMOTE AMPERAGE CONTROL RECEPTA-
CLE (Optional) (Figure 7-1)
The 3-socket Remote Amperage Control receptacle, lo-
cated on the welding generator front panel (see Figure
7-1), is used to connect a Remote Amperage Control
rheostat to the internal circuitry of the welding generator.
To connect the Remote Amperage Control to the Re-
mote receptacle, align keyway, insert the three-prong
plug from the Remote Amperage Control into the recep-
tacle, and rotate the plug clockwise.
SECTION 5 — AUXILIARY POWER
POWER OUTPUT RATING
WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
* Do not touch live electrical parts.
* Siop engine, and disconnect negative (-)
battery cable from battery before making in-
ternal inspection or reconnection.
e Ground generator as required by any applica-
ble national, state, and local electrical codes.
The generator neutral is connected to the frame,
therefore, the equipment grounding terminal
must be connected to a proper earth ground.
e Do not connect to any electrical distribution
system normally supplied by utility power un-
less a proper transfer switch and grounding
procedure are employed.
* Keep away from moving parts such as fans,
belts, and rotors.
e Keep ail covers and panels in place while
operating.
Warranty is void if unit is operated with any por-
tion of the outer enclosure removed.
ELECTRIC SPARKS can cause fire.
® Disconnect weld cables when using auxiliary
power.
The weld output terminals are electrically ener-
gized when the engine is running.
e Watch for fire.
e Keep a fire extinguisher nearby, and know
how to use it.
LOW VOLTAGE AND FREQUENCY can dam-
age electrical equipment.
e Turnofforunplug allelectrical equipment con-
nected to auxiliary power before starting or
stopping the engine.
When starting or stopping, the engine has low
speed which causes low voltage and frequency.
5-1. GENERAL
Calculate load requirements before connecting equip-
ment to the auxiliary power receptacles or junction box
(see Section 6).
5-2. AUXILIARY POWER WHILE WELDING
A. General
This unitis equipped with duplex receptacles onthe front
pane! for use with cord-connected auxiliary equipment.
The generator is capable of providing a total of 3 kVA/
KW of 60 Hz, single-phase ac power while welding.
IMPORTANT: The 3 kVA/kW is shared by all front panel
receptacles. The combined loading of all front panel
receptacles cannot exceed 3 kVA/kW.
IMPORTANT, This unit is designed to supply single-
phase, 60 Hz volts ac auxiliary power when the engine is
operating at nominal weld/power speed (1850 rpm) only.
OM-480 Page 13
MPORTANT: Auxiliary power output is independent of
the AMPERE RANGES switch and AMPERAGE/VOL-
TAGE ADJUSTMENT control positions.
B. 120V AC Dupiex Receptacle Specifications
(Chart 5-1)
120V NAC
The two 120V receptacle each provide 120 volts ac, 26
amperes of 60 Hz, single-phase power for use while
welding. Each half of these receptacles can provide 15
amperes of 120 voits ac power, but total load cannot ex-
ceed 26 amperes.
IMPORTANT: /f this unit is equipped with the optional
240V receptacle (see Section 5-2C), only one 120V re-
ceptacie is provided on the front panel.
C. Optional 240V AC Duplex Receptacle Specifica-
tions (Chart 5-1)
240V NAC
The optional 240V receptacle provides 240 volts ac, 13
amperes of 60 Hz, single-phase power for use while
welding. Each half of this receptacle can provide 13 am-
peres of 240 voits ac power, but total load cannot exceed
13 amperes.
D. Connections
The duplex receptacles are for use with cord-connected
auxiliary equipment. Plug in or turn on equipment when
engine is running at weld/power speed (1850 rpm).
E. Overload Protection
Circuit breakers CB1 and CB2 protect the receptacles
from overload. Whenever an overload occurs and CB1
and/or CB2 opens, the receptacles will not operate prop-
erly. See Section 10-3C for circuit breaker resetting pro-
cedures.
The 3 KVA/KW auxiliary power windings of the generator
are overload protected by design. However, the cus-
tomer must supply auxiliary equipment overload protec-
tion if required.
Chart 5-1. AC Power Curve For 120 And 240 Volts
Duplex Receptacles (No Weld Load)
130 260
125 250 +
120 240 }
15 20}
(2 un 3 KW
= #0 = 220 |
> =>
о 105 7, 20 |
< «С
100 200}
95 #01}
90 +180 }
0 0 1 1 | !
0 5 10 15 20 25
AC AMPERES IN 240V MODE
o 10 20 30 40 50
AC AMPERES IN 120V MODE
56-109 365-8
5-3. AUXILIARY POWER PLANT (Optional)
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Disconnect weld cables when using auxiliary
power.
The weld output terminals are electrically ener-
gized when the engine is running.
A. 10 KVA/KW Three-Phase Or 7.5 KVA/KW Single-
Phase AC Power Plant Specifications (Table 5-1,
Charts 5-2 And 5-3, And Figures 5-1 And 5-2)
The auxiliary power plant is a three-phase, four-wire,
power plant capabie of providing both single- and three-
phase 60 Hz ac power. The unit supplies 120/240 voits
ac, 31/31 amperes of 60 Hz single-phase or 240 voits ac,
24 amperes of 60 Hz three-phase power for use as auxil-
iary power. Combined single-phase and three-phase
loading is acceptable as long as the 24 amperes per
phase rating is not exceeded. The voltage will vary ac-
cording to load (see Charts 5-2 And 5-3).
The power plant can operate 50/60 Hz or 60 Hz equ'p-
ment and tools or provide standby power service to rural,
residential, or other buildings requiring 240 volts three-
phase power.
Table 5-1. Optional Power Plant Specifications
Voltage Amperage | KVA/KW | Frequency Maximum Engine Speed
Single-Phase | 120/240 Volts AC | 31 Amps AC 7.5 60 Hz 1850 RPM
Three-Phase 240 Volts AC 24 Amps AC 10 60 Hz 1850 RPM
OM-480 Page 14
Three-Phase Auxiliary Power
A
Generator
Windings
240VAC
240VAC
Junction Box !
NEUTRAL GROUND AS
REQUIRED BY NATIONAL
AND LOCAL ELECTRIC CODES
Single-Phase Auxiliary Power From
Three-Phase Generator
Generator
Windings
120VAC
240VAC x
120VAC
o
Junction Box F3
NEUTRAL GROUND AS
REQUIRED BY NATIONAL
AND LOCAL ELECTRIC CODES
Ref. 5D-116 635-A
Fiqure 5-1. 10 KVA/KW Auxiliary Power Plant Specifications Diagram
Chart 5-2. AC Power Curve For 7.5 KVA/KW Auxil-
lary Power (No Weld Load)
440; 280
130 |
120
p Pa PF
2 to 9 0.8 PF
0.0 PF
q 100 < 2
го] ol
80| 160 ts
0 10 20 30 40 50
AC AMPERES IN 240V MODE
O 20 40 60 80 100
AC AMPERES IN 120V MODE [COMBINED LOADS)
31 AMPERES PER LINE MAXIMUM
SB-134 636
Chart 5-3. AC Power Curve For 10 KVA/KW Three-
Phase Auxiliary Power (No Weld Load)
260 |
M - Yak .0 PF
NT
Ш
о
= 220 =
© et 8 PF
z 200 >
р |
0.0 PF-
180
10 20 30 40 50 80
LINE CURRENT
58-134 637
B. Connections To Junction Box (Figure 5-2)
IMPORTANT: The junction box, located behind the right
side access door, is used for either the 7.5 kVA/kW sing-
le-phase or 10 kVA/kW three-phase auxiliary power
plant connections. Three fuses are provided, one pro-
tects each load line; therefore, a single-phase power
plant connection uses two fuses, and a three-phase
power plant connection uses all three fuses (see Figure
5-2).
For safety and convenience, make ioad connections to
the auxiliary power plant junction box, and routeto an ex-
ternal disconnect switch and/or distribution panel.
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
Keep junction box cover in place while engine
is running.
* Stop engine, and disconnect negative (-)
battery cable from battery before making con-
nections or changing fuses.
e Ground in accordance with NEC, state, and
local codes; install circuit grounding lead (in-
side junction box) to box mounting hardware,
and be sure that a proper ground is connected
to the Equipment Grounding Terminal pro-
vided on the equipment frame.
INCORRECT FUSES can cause equipment
damage.
» Use only fuses of correct size, type, and rating
(see Parts List).
IMPROPER VOLTAGE OR FREQUENCY can
damage equipment.
* Read all equipment instruction manuals be-
fore making connections.
e Use only equipment suitable for operation on
50/60 or 60 Hz power,
* Tur off or disconnect electrical equipment
from 120/240 volts fuse block before starting
or stopping the engine.
es Rotate AMPERAGENOLTAGE ADJUST-
MENT control to 100.
OM-480 Page 15
Junction Box
Junction Box
Cover
Equipment
Grounding
Right Side Terminal
f Unit
Ref. SC-121 576
PTI |
| LL o fe | | |
| | IK |
| оо | | 240 |
Ee еныт
| 3 a 240V |
| | 240\ | | 240V |
o fe | Ÿ { Ÿ |
| | |
| a ı | 120% |
| ; 2 | 120V| | |
| | | | |
| _ Neutral 1 = Г зв |
| Conductor. 3
; Terminal â Grounding |
| == Conductor
Ea — — o o a o Te rminal —— —
Figure 5-2. Power Plant Connections
Open right side access door.
Remove cover from junction box.
install circuit grounding lead, if necessary.
1.
2.
3.
4.
Route all leads through connection into junction
box.
5. Install load leads onto junction box terminals
according to Figure 5-2.
6. Reinstall junction box cover.
7. Close and secure right side access door.
8. Make load connections according to all code and
safety practices.
C. Protection
Line fuses F1, F2, and F3 are provided in the junction
hox to protect each load line. If a fuse opens when equip-
ment use begins, a faultis probably present in the equip-
ment connected to the junction box. If a fuse opens after
prolonged use, an overload condition probably exists.
Correct the fault or reduce the load, and replace fuses
according to Section10-3.
SECTION 6 — EVALUATING AUXILIARY POWER REQUIREMENTS
A ОНООНВОООАООНЕННАНО ООН
6-1. AUXILIARY POWER GENERATORS
A. Introduction
The auxiliary power generated from this unit is most
commonly used in industrial, small business, and resi-
dential applications. For industrial applications, this por-
table unit can be moved to the job site to power portable
tools, lights, compressors, etc. For small business and
residential applications, the generator supplies standby
power during power outages.
it is the installer's responsibility to follow all applicable
codes when installing an auxiliary power generator. ltis
also the installer’s responsibility to determine if the gen-
erator is capable of supplying adequate power for a spe-
cific application. The following sections provide some
guidelines for the installation and operation of an auxilia-
ry power generator.
IMPORTANT: Consult qualified local personnel and fol-
low all applicable codes for safe and proper installation.
B. Safety Considerations
Before this generator may be used to supply auxiliary
power, the installer must first become familiar with and
meet all codes applicable to the installation of an auxilia-
OM-480 Page 16
ry power generator. lt is the installer's responsibility to
follow the applicable rules from the National Electrical
Code (NEC), state, local, and OSHA codes for the instal-
lation and use of auxiliary power generators. The follow-
ing list includes major safety requirements of NEC for
auxiliary power generator installation.
1. Isolation is always required between a portable
generator and other sources of electric power.
Proper isolation procedures prevent possible in-
jury due to feedback from the generator to the pri-
mary source of electric power. Consult qualified
local personnel and foliow all applicable codes for
safe and proper installation.
2. Overcurrent protection, such as fuses or circuit
breakers, is required if a generator is supplying a
permanent installation. Overcurrent protection
may not be required for generators supplying por-
table, cord-connected equipment through recep-
tacles mounted on the generator.
Overcurrent protection may be factory installed if
the generator design and/or receptacle(s) require
overcurrent protection. If the generator design
and receptacte(s) protect themselves from over-
current conditions, circuit protection is not re-
quired and, thus, not factory installed.
3. Grounding requirements depend upon the op-
erating setup for the generator. If the generator
supplies only equipment mounted on the genera-
tor, or cord-connected equipment through gener-
ator-mounted receptacles, the generator frame
does not require grounding. If the generator is
mounted on a vehicle, the vehicle and generator
frames must be connected. If the generator is
supplying a permanent installation or some load
that does not meet the mounting or receptacle
connection exclusion, the generator frame and
one of the supply conductors may have to be
grounded (refer to local codes for specific require-
ments).
A grounding terminal is normally provided on the
generator for grounding the generator case. To
ground the generator case, locate grounding ter-
minal, connect one end of ground cable to
grounding terminal, and connect remaining end
to a proper earth ground using adequate size
cable (refer to NEC for specific requirements).
When a conductor within the generator requires
grounding, a grounding terminal is normally pro-
vided within the generator.
4. Ground fault protection for personnel on con-
struction sites must be provided with one of the
following methods:
a. Ground fault circuit interrupters (GFClI's) are
required on all 15 and 20 ampere 120 voltrecep-
tacles not part of permanent wiring, and on all
receptacles with a grounded neutral conductor.
GFCIs are generally not required on portable
and vehicle-mounted generators rated not more
than 5 kW with circuit conductors isolated from
the frame, and on generators not connected to
15 or 20 ampere, 120 volt receptacles.
b. An assured equipment grounding program
may be used instead of GFCl's to provide
ground fault protection for personnel on con-
struction sites. Refer to NEC for specific pro-
gram procedures.
6-2. LOAD EVALUATION (Tables 6-1 And 6-2)
Before connecting or operating the auxiliary power gen-
erator, the installer must determine if the generator is ca-
pable of supplying adequate power for a specific appli-
cation. Load and generator evaluation is essential for
satisfactory generator and equipment operation (see
Table 6-1).
A. Types Of Loads
Load requirements depend on the type of load con-
nected to the generator. There are two types of loads, re-
sistive and non-resistive. A resistive load, such as a light
bulb, requires a constant amount of power from the gen-
erator. A non-resistive load, such as a portable grinder,
requires variable amounts of power from the generator.
Because a grinder requires more power for motor start-
ing and is rarely used with a constant, even pressure,
the load requirements can change greater than the oper-
ator anticipates.
The following sections provide information on how to de-
termine running load and motor-starting requirements
(see Sections 6-2B and C).
B. Running Load Requirements
The total running ioad applied to the generator is caicu-
lated by adding up all the individual loads. Some equip-
ment is rated in amperes, others in watts. The require-
ments for most equipment are provided on its name-
piate.
EXAMPLE 1: {fa drill requires 4.5 amperes at 115 volts,
caiculate its running power requirement in watts.
VOLTS x AMPERES = WATTS (EQUATION 1)
(Equation 1 provides an actual power
requirement for resistive loads, or an
approximate running requirement for
non-resistive loads.)
115V x 4.5A = 520W
Therefore, the individual load applied by the drill is 520
watts.
EXAMPLE 2: If a flood lamp is rated at 200 watts, the
individual load applied by the lamp is 200 watts. If three
200 watt flood lamps are used with the drill from Example
1, add the individual loads to calculate total load.
(200W + 200W + 200W) + 520W = 1120W
Therefore, the total load applied by the three flood lamps
and drill is 1120 watts.
C. Motor-Starting Requirements
Starting amperage requirements are many times the
running amperage of the motor. Starting requirements
must be determined to assure that the generator is capa-
ble of starting the motor without damaging it. This can be
done by examining the motor nameplate and identifying
the code letter specifying the starting kVA/HP required.
Table 6-2 lists common motor start codes with their start-
ing kVA/HP requirement.
If the kKVA/HP requirement, motor horsepower, and volt-
age rating are known, the starting amperage can be cal-
culated.
OM-480 Page 17
Table 6-1. Power Requirements*
APPROXIMATE
APPROXIMATE
APPROXIMATE
APPROXIMATE
INDUSTRIAL MOTORS RATING STARTING WATTS | RUNNING WATTS FARM EQUIPMENT RATING STARTING WATTS RUNNING WATTS
Split Phase 1/8 HP 800 300 Stock Tank De-Icer 1000 1000
1/6 HP 1225 500 Grain Cleaner 1/4 HP 1650 650
1/4 HP 1600 600 Portable Conveyor 1/2 HP 3400 1000
1/3 HP 2100 700 Grain Elevator 3/4 HP 4400 1400
12 HE. 3175 875 Milk Cooler 2900 1100
Milker (Vacuum Pump) 2 HF 10500 2800
Capacitor Start- 1/3 HP 2020 720
Induction Aun 1/2 HP 3075 975 FARM DUTY MOTORS 1/3 HP 1720 720
34 HP 4500 1400 Sid. (e.g. Conveyors, 1/2 HP 2575 975
1 HP 6100 1600 Feed Augers, Air 3/4 HP 4500 1400
1-1/2 HP 8200 2200 Compressars) + HP 6100 1500
2 HP 10550 2850 1-1/2 HP 8200 2200
3 HP 15900 3800 2 HP 10550 2950
5 HP 23300 6800 3 HP 15900 3900
5 HP 23300 6800
Capacitor Start- 1-1/2 HP 8100 2000 High Torque {e.g. Barn 1.1/2 HP 8100 2000
Capacitor Run 5 HP 23300 6000 Cleaners, 5a Unipaders, 5 HP 23300 6000
7-1/2 HP 35000 8000 Silo Hoists, Bunk Feeders) 1/2 HP 35000 5000
10 HP 46700 10700 10 HP 25700 10700
3-12 Cu Ft Mixer 1/2 HP 3300 1009
Fan Duty 1/8 HP 1000 doc High Pressure 1 8 Gai/Min 500 PSI 3150 950
1/6 HP 1400 — 550 Washer 2 Gai:Min 550 PSI 4500 1400
t/4 HP 1850 550 2 Gal/Mir 700 PSI 6100 1500
1/3 HP 2400 800
1/2 HP 3500 1199
contmacron — | mating | Arno | ares | mesvmwiaL | manne | eno Mao | aaa,
Hand Drill 1/4" 350 350 Coffee Maker 1750 1750 Typ.
3/8" 400 400 Elec. Range E" Element 1500 1500
1/2" 600 500 8" Element 2100 2100
Circular Saw 6-1/2" 500 500 Oven 6000 6000
7-1/4" 900 900 Microwave 625W 2800 2000
3-1/4" 1400 1400 Television {Solid-State} B&W 100 100
Table Saw 8" 4500 1500 Color 300 300
10” 6300 1800 Radio 50-200 50-200
Band Saw 14” 2500 1100 Refrg Or Freezer 3100 800
Bench Grinder 6" 1720 720 Shallow well Pump 1/3 HP 2150 750
8" 3900 1400 1/2 HP 3100 1000
10° 5200 1600 Sump Pump 1/3 HP 2100 800
Air Compressor 1/2 HP 3000 1000 1/2 HP 3200 1050
1 НР 6000 1500 Dishwasher {Cool Dry) 2100 700
1-1/2 HP 8200 2200 (Hot Dry) 2850 1450
2 HP 10500 2800 Clothes Dryer Gas 2500 700
Electric Chain Saw 1-1/2 HP, 12" 1109 1100 Electric 7550 5750
2 HP, 13” 1100 1100 Automatic Washer 3450 1150
Electric Trimmer Standard 9” 350 350 Gas Or Fuel Oil
Heavy Duty 127 500 500 Furnace Blower 1/8 HP 800 300
Electric Cultivator 1/3 HP 2100 700 1/6 HP 1250 500
Elec. Hedge Trimmer 18" 400 400 1/4 HP 1600 600
Flood Lights HID 125 100 1/3 HP 2100 700
Metal Halide 313 250 1/2 HP 3225 875
Marcury | Cereal Ar Conditioner 10,000 BTU 3700 1500
& Sodium 1000 1400
Vapor 1250 1000 20,000 BTU 5800 2500
Submersible Pump 400 GPH 600 200 24,000 BTU 8750 3800
Centrifugal Pump 900 GPH 900 500 32.000 BTU 11500 5000
Floor Polisher 3/4 HP 16" 4500 1400 40,000 BTU 13800 6000
1 HP 207 6100 1600 : Garage Door Opener 1/4 HP 1650 550
High Pressure Washer 1/2 HP 3150 950 1/3 НР 2125 725
3/4 HP 4500 1400 E ectric Blanket Portable 400 400
1 HP 6100 1600 Jenumiditier 1450 650
55 Gal. Drum Mixer 1/4 HP 1900 700 Vacuum Cleaner Standard 800 800
Wet & Dry Vac 1.7 HP 900 900 Deluxe 1100 1100
2-1/2 HP 1300 1300 Lights As Indicated
Оп Ви
Toaster 2 Slice 1050 1050
4 Slice 1650 1650
Hair Dryer 300-1200 300-1200
tram 1200 1200
*Motors require up to two or three times their starting wattage when starting under load.
OM-480 Page 18
EXAMPLE 3: Caiculate the starting amperage required
for a 230V, 1/4 HP motor with a motor start code of G.
Calculate the starting amperage using the following
equation:
(EQUATION 2)
kVA/HP x HP x 1000
= STARTING AMPERAGE
VOLTS
Volts = 230
HP = 1/4
Using Table 6-2, Code G results in kVA/HP = 6.3
6.3 x 1/4 x 1000
230
= B.85A
Therefore, starting the motor requires 6.85 amperes.
Table 6-2. Single-Phase induction Motor Starting
KVA/HP Requirements
Motor Start
Code Letter KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
| 2 | < | г | ЖЕН 0
Ita code letter is not present on the motor nameplate, ap-
proximate starting amperage is equal to six times run-
ning amperage. This is a reasonable approximation for
all applications where the generator rated amperage is
at least twice the motor requirement. If the generator-to-
motor-size ratio is less than 2:1, acquire the needed in-
formation to properly determine the motor-starting re-
quirement.
6-3. GENERATOR CAPABILITY
A. Auxiliary Power Output
Different types of loads require different types of output.
When a nonmotor load is applied, generator output goes
to the ampere requirement of the equipment. When a
motor load is applied, the generator attempts to supply
motor-starting amperage causing output to drop to a low
voltage because the starting amperage is many times
the running amperage. |
The total load requirements must not exceed the gener-
ator capability. When combining motor (non-resistive)
and resistive loads, compare the total load required by
the equipment to the generator output. Limit load re-
quirements to the capabilities of the generator. For best
performance and load handling, only use approxi mately
90% of the available output. The 10% margin allows for
more satisfactory engine governor response to chang-
Ing load situations. When loading the generator, always
apply the largest non-resistive (motor) load first, add
non-resistive loads in succession from largest to small-
est, and add resistive loads last.
B. Operation
It is the installer's responsibility to follow all applicable
safety codes and guidelines for the installation and oper-
ation of an auxiliary power generator. Always start en-
gine and bring up to speed before starting any auxiliary
equipment connected to the auxiliary power receptacles
or junction box. Before stopping the engine, be sure to
turn off the auxiliary equipment.
The installer should check for proper generator/load op-
eration. If a motor does not start within 5 seconds. turn
off power to it or the motor will be damaged. This 5-sec-
ond-maximum-time rule should be applied to all motor-
starting situations to prevent damage to the start wind-
ing. If 90% of rated voltage is present across the mo-
tor terminals when running under load, then it is
safe to assume that it is properly running within the
capabilities of the generator.
6-4. STANDBY POWER CONNECTIONS (Diagram
6-1)
The block diagram shown in Diagram 6-1 includes the
proper equipment and connections required for the gen-
erator to supply standby power during emergencies or
power outages.
IMPORTANT: Consult qualified local personnel and fol-
low all applicable codes for safe and proper installation.
The following step numbers match the circled numbers
within Diagram 6-1,
1. Locate the power company or service meter. dis-
connect switch, and main overcurrent protection.
2. if necessary, obtain and install a double-pote.
double-throw transfer switch between the service
meter and disconnect switch.
IMPORTANT: Double-pole, double-throw transfer
switch rating must be the same as or greater thar '"e
main overcurrent protection.
3. If necessary, obtain and install circuit breakers or
fused disconnect switch to protect generator *om
overload conditions.
4. Select conductors of adequate amperage capac-
ity for the current rating of the generator and over-
current protection (see Section 6-5).
S. Install terminals or plug of adequate amperage
capacity onto end of cable.
OM-480 Page 19
6. Make connections according to all codes and
safety practices.
7. Turn off or unpiug all auxiliary equipment con-
nected to generator before starting or stopping
engine. When starting or stopping, the engine has
low speed which causes low voltage and frequen-
cy. For best performance and load handling, limit
load to approximately 80% of the available out-
6-5. AUXILIARY POWER EXTENSION CORD
SELECTION (Tables 6-3 And 6-4)
Extension cords may be necessary if power is supplied
to tools or load a distance from the generator. Select
cords of adequate amperage capacity, and use the fol-
lowing Tables 6-3 and 6-4 to select conductor size ac-
cording to cord tength. Use the shortest cords possible
because excessive cord lengths may reduce output or
cause unit overload due to added resistance.
put.
© 240V
120/240 Volt | <— Service }
бонг) <— or y 120V
Three-Wire Power Company 1207 *
Service < Meter Y 1
©
Double-Pole,
Double-Throw
Transfer Switch
Neutral Conductor
Circuit
Breakers
Or Fused
Disconnect
Switch
240V "| -
207 © O
Y
Ÿ Service —>
Disconnect
120V Ÿ Switch >
Г And Main
120V Overcurrent Load
1 L Protection —>
Fi
| — Ground Conductor
©
Conductors Of
eel. A0 Extension Cord
IMPORTANT: Circled numbers
match steps in Section 6-4.
» Ÿ
~ 1
120/240 Voit > y 120V
Single-Phase < Ñ
Three-Wire 4 120V
Generator Output | — 4
Connection > 4
| <
=
S-0405
Diagram 6-1. Standby Power Equipment And Connections
OM-480 Page 20
Table 6-3. Cord Lengths For 120 Voit Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
—
rere | van a e e fo | @ | m
> 600 (108) (65) (42) a0)
5 340 (122) 76) (46) (30) (19)
10 1200 | (129) on (53) (a) (19) (75)
"5 1800 0) | @ | @ | @ | a ©)
20 2400 (69) (42) 26) 15) ©)
25 3000 55) (32) 9) 7
30 3600 (46) 26) 15) 41)
35 4200 38) (23) as)
+ 4900 34) | 0 | am
45 5400 (30) (19)
50 6000 26) (15)
*Conductor size is based on maximum 2% voltage drop
OM-480 Page 21
Table 6-4. Cord Lengths For 240 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
cumentin | Mei Pa Pe [os | | æ | m
9 1200 (213) 137) (64) (67)
7 1680 (244) | (152 1) (61) (38)
10 2400 (244) (168) pe (es) (38) 31)
5 3600 (183) | (07) | (9) (6) 29 (18)
20 4500 137 | вл) 3) (51) (12)
25 6000 on | (69) (38) 23) |
30 7000 oh (53) (31) 23)
35 8400 76) de) 37)
40 9600 (69 ok 23)
45 10,800 1) bos
50 12,000 63 a
*Conductor size is based on maximum 2% voltage drop
SECTION 7 — OPERATOR CONTROLS
7-1.
AMPERE RANGES SWITCH (Figure 7-1)
AMPERE RANGES
The AMPERE RANGES switch provides five coarse am-
perage ranges. The range of each switch position is dis-
played on the nameplate.
A
OM-480
CAUTION:
contacts.
ARCING can damage switch
* Do not change the position of the AMPERE
RANGES switch while welding or under load.
Arcing causes the contacts to become pitted and
eventually inoperative.
Page 22 .
AMPERAGE/VOLTAGE ADJUSTMENT CON-
TROL (Figure 7-1)
A/V
AMPERAGE/VOLTAGE ADJUSTMENT
7-2.
The AMPERAGE/VOLTAGE ADJUSTMENT control se-
lects a welding amperage and open-circuit voltage be-
tween the minimum and maximum values of the coarse
range selected by the AMPERE RANGES switch (see
Section 7-1).
The scale surrounding the AMPERAGE/VOLTAGE AD-
JUSTMENT controlis calibrated in percent and does not
indicate an actual amperage or voltage value.
IMPORTANT: The AMPERAGE/VOLTAGE ADJUST-
MENT control may be adjusted while welding.
on
и =
т
сы
Ampere Ranges NM .
Switch — S
5
Hour “et ~~
Low Oil Pressure ——— ||
Indicator Light
4 Ether Starting ——
Aid Switch
AS
Battery Charge
Indicator Light
+ Oil Temperature
Gauge
Engine Control
Switch $ Oil Pressure
Gauge
$ OPTIONAL
NS
e Remote Amperage
Control Switch
€ Remote Amperage
4 Voltmeter
Amperage/Voltage
Adjustment Control
“re
_
a
т 7 4 Ammeter
yd
LT
120 Voits AC
Duplex Receptacles
Receptacle
Circuit Breakers
|
Equipment Grounding
Terminal
Ref, SC.130 895-A
Control Receptacle
(see Section 4-9)
Figure 7-1. Operator Controls
IMPORTANT: To get full power output voltage at the
single- or three-phase auxiliary power junction box, the
AMPERAGE/VOLTAGE ADJUSTMENT contro! must
be set at 100, and the Remote Amperage Control switch,
if applicable, must be in the PANEL position.
7-3. ENGINE CONTROL SWITCH (Figure 7-1)
The Engine Control switch has three positions: START,
RUN, and OFF.
A. START Position
Rotating the switch to the START position starts the
engine. Release the switch as soon as the engine starts,
and the switch will automatically return to the RUN
position.
B. RUN Position
When the Engine Control switch is in the RUN position,
engine speed remains at governed weld/power speed
(1850 rpm).
C. OFF Position
Rotating the Engine Control switch to the OFF position
disconnects voltage from the fuel solenoid, thereby
shutting down the engine.
7-4. LOW OIL PRESSURE INDICATOR LIGHT
(Figure 7-1)
OIL
PRESSURE
The red Low Oil Pressure indicator Light (labeled OIL
PRESSURE on nameplate) comes on if oil pressure
drops to a level that may cause engine damage. If the
light comes on, stop the engine, and determine the
cause. Do not operate the engine until the trouble has
been remedied.
7-5. BATTERY CHARGE INDICATOR LIGHT (Fig-
ure 7-1)
ENGINE
BATTERY
The red ENGINE BATTERY Charge indicator Light
comes on if the alternator fails, or if the engine cooling
OM-480 Page 23
belt breaks. This light SHOULD NOT be on when the en-
gine is running. If the light comes on, the engine shuts
down. Do not operate the engine until the trouble has
been corrected.
7-6. HOUR METER (Figure 7-1)
ENGINE HOURS
This unit is equipped with an hour meter (labeled EN-
GINE HOURS on nameplate). The meter registers the
total hours of engine operation. This information is use-
ful for routine maintenance on the engine.
7-7. POLARITY SWITCH (Optional)
CAUTION;
contacts.
e Do not change the position of the Selector
Switch while under load.
Arcing causes the contact to become pitted and
eventually inoperative.
ARCING can damage switch
The POLARITY switch connects generator output to the
weld output terminals. The switch aliows the operator to
select de electrode negative/straight polarity or dc elec-
trode positive/reverse polarity welding without changing
weld output connections.
IMPORTANT: To be sure that the weld current output
matches the POLARITY switch position, connect the
electrode cable to the ELECTRODE (-) weld output
terminal, and connect the work cable to the WORK (+)
weld output terminal.
7-8. REMOTE AMPERAGE CONTROL SWITCH
(Optional) (Figure 6-1)
[7 REMOTE A/V
WARNING: ELECTRIC SHOCK can kill.
* Do not touch live electrical parts.
* Do not touch weld output terminals when
engine is running.
® Do not touch electrode and work clamp at the
same time.
If remote amperage control is desired, make connec-
tions to the 3-socket Remote Amperage Control recep-
tacle (see Section 4-9), and place the REMOTE Control
switch in the REMOTE position. When a Remote Am-
perage Control is being used, the remote control func-
OM-480 Page 24
tions as a fine amperage or voltage adjustment for the
AMPERAGE/ VOLTAGE ADJUSTMENT control on the
welding generator. For example, if the AMPERAGE/
VOLTAGE ADJUSTMENT control on the welding gen-
erator is set at midrange, the Remote Amperage Control
will provide (from minimum to maximum adjustment)
fine amperage adjustment of one half of the welding gen-
erator output for the range selected. For complete re-
mote control of the output, rotate the AMPERAGE/VOL-
TAGE ADJUSTMENT control to the maximum position.
If remote amperage control is not desired, place the RE-
MOTE Control switch in the PANEL position. Only the
AMPERAGE/VOLTAGE ADJUSTMENT control will ad-
just output.
7-9. OIL PRESSURE AND TEMPERATURE
GAUGES (Optional) (Figure 7-1)
= a ~~
La WWW
The optional Oil Pressure gauge registers the lubricating
system pressure in pounds per square inch (psi). The
pressure registered by the gauge should remain con-
stant for a given engine speed. If the oil pressure fluctu-
ates or drops, stop the engine, and do not operate until
the trouble has been corrected.
IMPORTANT: This unit is equipped with an Oil Pressure
Indicator Light which comes on if the oil pressure drops
to a level that may cause engine damage (see Section
7-4).
The optional Oil Temperature gauge ( namepiate symbol
shown above) registers the temperature of the oi in the
lubricating system. If the oil temperature rises to a level
that may cause engine damage (250°F, 121°C or
above), stop the engine, and do not operate until the
trouble has been corrected.
7-10. METERS (Optional) (Figure 7-1)
The meters are provided to monitor the welding opera-
tion; however, they are not intended for exact amperage
or voltage measurements. These meters are internally
connected to the output circuit.
The voltmeter indicates the voltage at the weld termi-
nals, but not necessarily the actual voltage at the weld-
ing arc (due to cable resistance, poor connections etc).
The ammeter indicates the amperage output of the unit,
7-11. ETHER STARTING AID (Optional) (Figure
7-1)
The cold weather starting components provide a means
of applying a premeasured portion of ether into the mani.
fold. The amount of ether supplied should be sufficient to
permit easy engine starting under cold weather condi-
tions.
Actuating the ETHER STARTING AID switch for one
second while cranking the engine will provide the proper
amount of ether to the manifold. When the switchs actu-
ated, the valve chambers fill with ether. When the switch
Is released, the ether is sprayed into the engine. The
ether starting aid will function only while cranking the en-
gine,
CAUTION: ETHER INJECTION WHILE EN-
GINE IS RUNNING can cause engine
damage.
e Do not actuate ETHER STARING AlD while
engine is running.
7-12. LOW OIL PRESSURE/HIGH OIL TEMPERA-
TURE SHUTDOWN SYSTEM (Optional)
The Low Oil Pressure/High Oil Temperature Shutdown
System will automatically shut down the engine if oil
pressure becomes too low or oil temperature rises to a
level that may cause engine damage. The shut-down oil
pressure range is 15 to 20 psi (103 to 138 kPa). The
shut-down oil temperature is 250° F (121° C).
This system consists of a switch located to the right of
the Engine Control switch, and two switchgauges that
register oil pressure and temperature similar to the
gauges in Section 7-9.
When starting the engine, depress the Low Oil Pressure/
High Oif Temperature Shutdown System switch and hold
in until the engine starts and the OIL PRESSURE light
(see Section 7-4) goes off.
The switch is protected by a fuse. If the fuse opens, the
engine would shut down. See Section 10-3 for fuse re-
placement procedures.
7-13. OVERSPEED SHUTDOWN SYSTEM (Option-
al)
The overspeed shutdown valve stops airflow to the en-
gine at a preset rpm. Whenever conditions exist that al-
low the engine to exceed its normal operational rpm, the
valve will automatically close and stop the engine.
If adjustment of the valve shutdown rpm is necessary,
see Section 9-15.
7-14. HIGH-ALTITUDE MODIFICATION (Optional)
This unit may be equipped with a nonadjustable high-
altitude modification for operations above 5000 it.
(1524 m). Adjustments to the high-altitude option can
only be completed by a Factory Authorized Service Sta-
tion.
SECTION 8 - SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can Kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
¢ Do not touch live electrical parts.
® Stop engine, and disconnect negative (=)
battery cable from battery before inspecting
or servicing.
* Keep away from moving parts such as fans,
belts, and rotors.
e Keep all covers and panels in place while
operating.
Warranty is void if the welding generator is
operated with any portion of the outer enclosure
removed.
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
* Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
e Ventilate to keep from breathing fumes and
gases.
® If ventilation is inadequate, use approved
breathing device.
e [Use in open, well ventilated areas, or vent ex-
haust out of doors.
HOT METAL, SPATTER, SLAG, AND
EXHAUST can cause fire and burns.
e Watch for fire.
* Keep a fire extinguisher nearby, and know
how to use it.
e Allow work and equipment to cool before
handling.
ENGINE FUEL can cause fire or explosion.
e Stop engine before checking or adding fuel.
e Do not spill fuel; if spilled, wipe up.
* Do not refuel if engine is hot or running.
* Do not refuel near sparks or open flame.
* Do not smoke while refueling.
e Do not fill tank to top; allow room for
expansion.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
* Wearers should consult their doctor before
going near arc welding, gouging, or spot weld-
Ing operations.
See Section 1-Safety Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.
OM-480 Page 25
8-1. SHIELDED METAL ARC WELDING (SMAW)
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 6 and 8
before proceeding.
Install and connect unit according to Section 4.
2. Place the REMOTE Control switch, if applicable,
in the desired position (see Section 7-8).
3. Place the POLARITY switch, if applicable, in the
desired position (see Section 7-7).
4. Wear dry insulating gloves and clothing.
5. Connect work clamp to clean, bare metai at work-
piece.
Select proper electrode.
7. Rotate the AMPERE RANGES switch to the de-
sired position (see Section 7-1).
8. Rotate the AMPERAGE/ VOLTAGE ADJUST-
MENT controlto the desired position (see Section
7-2).
Start the engine as instructed in Section 8-3.
10. Connect desired accessory equipment to the
auxiliary power receptacles (see Section 5-2).
11. Place the Engine Control switch in desired posi-
tion (see Section 7-3).
12. Energize accessory equipment, if applicable.
13. Wear welding helmet with proper filter lens ac-
cording to ANSI 243.1.
14. Insert electrode into electrode holder.
15. Begin welding.
8-2. OPTIONAL POWER PLANT OPERATION
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 6 and 8
before proceeding.
Install and connect unit according to Section 4.
2. Make connection to the 120/240 volts fuse block
as instructed in Section 5-3.
3. Rotate the AMPERAGE/ VOLTAGE ADJUST-
MENT control to the 100 (maximum) position.
4. Ifapplicable, place the optional REMOTE Control
in the PANEL position.
5. Start the engine according to Section 8-3. Power
may be obtained from the auxiliary power junction
box whenever the engine is running.
8-3. STARTING THE ENGINE
IMPORTANT: Read entire engine Owner's Manual
F3L-1011 diesel engine before operating engine.
OM-480 Page 26
1. Engine Prestart Checks
a. Oil Level
Check engine oil level. If oil level is low, fill to top
mark on dipstick (see engine Owner’s Manual
for selection specifications).
If oil consumption and wetstacking occur during
run-period, see Section 9-12.
b. Fuel Level
WARNING: REMOVE FUEL CAP SLOWLY:
FUEL SPRAY may cause injury; FUEL may
be under pressure.
e Rotate fuel cap slowly and wait until hissing
stops before removing cap.
Check fuel level. If necessary, fill tank with fresh,
clean fuel (see engine Owner's Manual for fuel
specifications).
2. Rotate the Engine Control switch to the START
position. If necessary, depress the ETHER
STARTING AID switch and Low Oil Pressure/
High Oil Temperature Shutdown switch (if unit is
equipped with these options) while rotating the
Engine Control switch -- release ETHER START-
ING AID switch after one second.
4) CAUTION: REENGAGING THE STARTER
MOTOR while flywheel is rotating or
EXCEEDING RATED CRANKING TIME can
damage starting components.
e Do not reengage starter motor until starter
pinion and flywheel have stopped rotating.
® Оо not exceed engine manufacturer's maxi-
mum cranking time.
Allow two minutes cooling time before attempt-
ing to restart engine.
3. As soon as the engine starts, release the Engine
Control switch and Low Oil Pressure/High Oil
Temperature Shutdown switch, and allow the en-
gine to warm up for approximately three minutes
with no weld or power load applied.
IMPORTANT: /funitis equipped with optional overspeed
shutdown valve, the engine will shutdown if the normal
operating rom is exceeded (see Section 9-14).
8-4. STOPPING THE ENGINE
1. Stop welding and all other operations, and turn off
all auxiliary equipment.
2. Allow the engine to run for afew minutes to permit
the internal engine temperatures to equalize.
Increase the time if the engine has been operat-
ing for an extended period or at full load.
3. Rotate the Engine Control switch to the OFF
position.
SECTION 9 — MAINTENANCE
9-1. ROUTINE MAINTENANCE (Table 9-1)
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List for part numbers of
precautionary labels.
WARNING: ELECTRIC SHOCK can Kitt.
® Do not touch live electrical parts.
e Stop engine, and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
* Keep away from moving parts such as fans,
belis, and rotors.
HOT ENGINE PARTS can cause severe
burns.
e Wear protective gloves and clothing when
Working on a hot engine.
BATTERY ACID can burn eyes, skin, destroy
clothing, and damage other material.
e Wear correct eye and body protection.
Maintenance to be performed only by qualified
A. Cables And Wiring
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-1 before
proceeding.
Check interconnecting wiring and connections for tight-
ness and flaws. Be sure that the weld output cabie
connections are clean and tight. Check the insulation for
breaks or other signs of damage. Repair or replace ca-
bles or wiring as necessary.
B. Battery
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-1 before
proceeding.
Inspect the battery for loose connections, damaged
cables, corrosion, cracked case or cover, loose
holddowns, and loose or deformed terminal posts.
Clean and tighten connections, replace cables, or
persons. replace battery if necessary.
Table 9-1. Maintenance Schedule
Frequency* Maintenance
Every day. Check fuel and oil levels (see Section 4-4, and engine Owner's Manual,
Deutz F3L-1011 engine).
Every 40 hours.
Empty air cleaner dust cap (see Section 9-2).
Every 100 to 150 hours.
Check cables, wiring (see Section 9-1A), and battery (see Section 9-1B)..
(see Section 9-1D).
Units in heavy service environments: Check labels; clean and inspect unit
Change fuel/water separator (see Section 9-3).
Every 250 hours.
Inspect and service spark arrestor, if applicable.
Every 350 hours.
Inspect internal parts of optional shutdown valve for cleanliness, closing action of
valve, and signs of wear around moving parts (see Section 9-14). Remove and clean
valve with a suitable solvent, if necessary. Do not lubricate valve components.
Every 750 hours.
Change oil and filter (see engine Owner's Manual, Deutz F3L-1011 engine).
Every 1000 hours.
9-1D).
Check brushes, slip ríngs, and belts (see Sections 9-5 and 9-11). Check all
labels (see IMPORTANT block, Section 9-1). Clean and inspect unit (see Section
Change fuel filter (see Section 9-4).
*Frequency of service is based on unit operated 40 hours per week. Increase frequency of maintenance if usage ex-
ceeds 40 hours per week.
OM-480 Page 27
C. Oil And Filter
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-1 hefore
proceeding.
Change the oil and filter according to instructions on unit
maintenance label and -in engine Owner's Manual
(Deutz F3L-1011 engine). Use correct type and grade of
oil as listed in instructions for expected temperature
range before next oil and filter change.
IMPORTANT: This engine is equipped with a Low Oil
Pressure Indicator Light. If oil pressure drops to a level
that may cause engine damage, the indicator light
comes on. If the light comes on while the engine is run-
ning, immediately shut down the engine and determine
the cause. Do not operate the welding generator until the
trouble has been remedied.
D. Cleaning And Inspecting
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-1 before
proceeding.
When performing routine oil changes at intervals
specified on the unit maintenance label, clean and
inspect the unit as follows:
1. Keep the inside of the welding generator clean by
blowing out the unit with clean, dry compressed
air.
2. Wipe oil and fuel spills from engine immediately to
avoid accumulation of dust.
3. Check for fluid leaks indicating loose oil or fuel
connections. Tighten loose connections, and
clean oil or fuel spills off engine.
IMPORTANT: See the engine Owner’s Manual (Deutz
F3L-1011 engine} for complete engine care.
9-2. AIR CLEANER SERVICE (Table 9-2)
4 CAUTION: DIRTY AIR can damage engine.
® Do not operate engine with dirty air cleaner
element in place.
e Do not operate engine without air cleaner ele-
ment in place.
The air cleaner is one of the most important parts of the
engine from the standpoint of engine life. If dirty air gets
OM-480 Page 28
into the engine, it can cause major engine damage within
a few operating hours. Every 50 hours or less depending
on conditions, empty the dust cup, and inspect the ele-
ment.
IMPORTANT. A dirty air cleaner element is usually ac-
companied by a loss of power and smoke in the engine
exhaust,
When it becomes necessary to service the air cleaner in
the field, follow the steps in Table 9-2. Keep a spare ele-
ment on hand for replacement. New elements are avail-
able from your welding equipment distributor.
9-3. FUEL/WATER SEPARATOR AND PETCOCK
WARNING: ENGINE FUEL can cause fire or
explosion.
* Stop engine before working on fuel system.
e Do not spill fuel; ¡f spilled, wipe up.
* Do not service fuel filter if engine is hot or
running.
* Do not service fuel filter near sparks or open
flame.
* Do not smoke while servicing fuel filter.
e Keep a fire extinguisher nearby, and know
how to use it.
Maintenance to be performed only by qualified
persans.
A. Fuel/Water Separator
The primary fuel/water separator, located below the fuel
tank on the right side of the welding generator, is pro-
vided to drain off water from the fuel system. Before
starting the engine for the first time each day, open the
petcock on the bottom of the separator, and drain the
water into a metal container. Close the petcock at the
first signs of fuel. The fuel/water separator should be
changed every 125 hours of operation or every four
months, whichever occurs first.
B. Petcock
A petcock is provided to drain off sediment from the fuel
tank. Once a week drain the sludge into a metal con-
tainer. If the fuel is extremely dirty, drain the sludge daily.
Table 9-2. Air Cleaner Service
1. Stop engine.
5. Wipe out element chamber
7. Reinstall element.
Follow with clean, damp cloth.
These 2. Wipe off cover before 8. Replace cover.
opening air cleaner. 6. Inspect new element and all
Easy gaskets for shipping damage before use.
Steps: 3. Remove cover.
4. Remove element.
1. Don't attempt to service air 3. Don't leave open air cleaner exposed 5. For Donaclone air cleaners,
cleaner with engine running. to blowing dust while you clean element. don't blow out Donaclone tube
Replace cover. section without element, cover
Important 2. Don't blow out the inside of and inner cover (if any)
the air cleaner with compressed 4. If air cleaner is horizontally mounted, correctly installed or you will
air. be sure that dust cup is positioned so blow dust into the engine.
arrows point up.
How To Clean element by one of the re-use. However, washing does (When cleaning Cyclopac
following methods: a better job and must be used when elements, do not remove
Clean exhaust soot has lodged in fine pores plastic fin assembly — back-
Elements Compressed Air or Washing. of the filter media. Use Donaldson D-1400 flowing with compressed ar or
For detergent which contains a special washing will remove dust from
Compressed air is recommended additive for removing soot and carbon. beneath the fin assembly)
Re-Use when element will be re-used
immediately because a washed
element must be dried before
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.
Replace element after 6 cleanings or
annually, whichever occurs first.
Washing
1. Soak element 15 minutes or more
in Donaldson D-1400 and water solution.
See carton for full instructions.
2. Rinse unt! 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.
Inspection
Place bright light inside
element and rotate element
slowly. If any rupture, holes
or damaged gaskets are
discovered — replace.
5 209 2.39
OM-480 Page 29
9-4. FUEL FILTER (Figure 9-2)
WARNING: ENGINE FUEL. can cause fire or
explosion.
e Stop engine before working on fuel system.
* Do not spill fuel; if spilled, wipe up.
* Do not service fuel filter if engine is hot or
running.
* Do not service fuel filter near sparks or open
flame.
® Do not smoke while servicing fuel filter.
e Keep a fire extinguisher nearby, and know
how to use tt.
Maintenance to be performed only by qualified
persons.
This welding generator is equipped with a spin-on
secondary fuel filter, located on the right side of the
engine. The fuel filter should be replaced after 1000
hours of operation, or more often depending on the
quality of fuel used and how dusty and dirty the location
is in which the engine is being used. To replace the fuel
filter, refer to the engine Owner's Manual.
9-5. CHECKING ENGINE BELT (Figure 9-1)
This unitis equipped with a single V-belt which drives the
engine cooling fan and the alternator. To check the en-
gine belt, proceed as foliows:
IMPORTANT: The belt MUST BE checked for tightness
after the first 50 hours of operation and after every 1000
hours thereafter.
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
* Stop engine, and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
* Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
* Wear protective gloves and clothing when
working on a hot engine.
Maintenance to be performed oniy by qualified
persons.
1. Remove rear panel.
2. Place a straight edge from the top of the blower/
alternator pulley to the top of the crank puiley.
3. Pull the engine belt down away from the straight
edge as far as it will go, and measure the distance
from the belt to the straight edge. The belt must
not exceed a distance of 1/2 in. (12.7 mm) from
the straight edge. If the distance is greater than
1/2 in., adjust the belt as follows:
OM-480 Page 30
a. Loosen the two hex-head bolts on the belt
adjustment bracket (adjustment bracket is
located behind the idle pulley). and slide bracket
up, towards top of unit.
b. Tighten hex-head bolts in adjustment bracket.
4. Check the belt for tightness as instructed at be-
ginning of Step 3. If necessary, repeat Steps 3a
and b.
5. Reinstall rear panel onto unit.
Guard For
Blower/Alternator
"TN =
Blower/
Alternator
Pulley _ |
Belt
Adjustment
Bracket
Crank Pulley
SA-126 179-A
Figure 9-1. Checking And Replacing Engine Belt
9-6. BATTERY REPLACEMENT PROCEDURE
WARNING: SPARKS OR FLAMES can cause
BATTERY GASES to explode: BATTERY
ACID can burn eyes and skin.
e Stop engine before disconnecting or con-
necting battery cables.
e Keepsparks, flames, cigarettes, and other ig-
nition sources away from batteries.
e Do not allow tools to cause sparks when
working on a battery.
e Always wear a face shield and proper protec-
tive gloves and clothing when working on a
battery.
Use the following procedure to prevent sparks when re-
moving or installing a battery:
1. Be sure engine is fully stopped, and Engine Con-
trol switch is in the OFF position.
2. Locate battery in unit.
3. Open door or remove panels as necessary.
4. Disconnect negative (-) battery cable first and
positive (+) cable last.
5. Remove holddown device.
O ONO
10.
Remove battery.
Install new (or charged) battery.
Reinstall and secure holddown device.
Connect positive (+) cable first and negative (—)
cable last.
Securely reinstall or close doors or panels.
MAINTENANCE-FREE BATTERY CHARGING
CHARGING A FROZEN
WARNING:
BATTERY can cause the battery to explode
and result in serious injury or damage to
equipment; BATTERY ACID can burn eyes,
skin, destroy clothing, and damage other
material; BATTERY GASES can explode and
shatter battery.
* Allow battery to warm up to 60° F (16° C) be-
fore charging if battery is frozen.
eo Wear a face shield, proper protective cloth-
ing, and remove all metal jewelry.
® Do not spill or splash battery fluid.
® Do not apply pressure to walls of filled battery
— Use battery carrier, or place hands on oppo-
site corners when lifting battery.
® Keep sparks, flames, cigarettes, and other
ignition sources away from batteries.
es Use enough ventilation to keep battery gases
from building up during and for several hours
after battery charging.
* Turn off battery charger before making con-
nections to battery.
e Do not touch or move connections on battery
while battery charger 1s on.
* Do not lean over battery when charging.
* 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.
e Turn off battery charger before disconnecting
charger from battery.
Remove battery from unit, and place on a level
worktable or other suitable surface.
If battery has removable vent caps, check the
condition of the electrolyte as follows:
a. Checkelectrolyte temperature in one of the cen-
ter celis with a battery thermometer. For each
10°F (6°C) increment above 80°F (27°C), a cor-
rection factor of 0.004 specific gravity must be
added to the specific gravity reading taken in
Step 2b. For each 10°F (6°C) increment below
80°F (27°C), 0.004 must be subtracted from the
reading taken in Step 2b.
b. Check the specific gravity of each cell with a
hydrometer. (Draw in and expel the electrolyte
two or three times from the first cell to be tested
to adjust the temperature of the hydrometer to
that of the electrolyte.)
c. Ifacorrected specific gravity reading of 1.225 at
… 80°F (27°C) is not obtained, replace the vent
caps and recharge the battery following the
battery charger manufacturer's instructions.
3. Ifthe battery does not have removable vent caps,
check the condition of the battery as follows:
a. Check the stabilized open-circuit voltage of the
battery. For a 12 volt battery, any reading below
12.4 volts indicates the battery needs charging.
Disconnect both battery cables from the battery,
and allow battery voltage to stabilize for several
hours.
b. If the stabilized open-circuit voltage is below
12.4 volts, charge the battery following the
battery charger manufacturer’s instructions.
4. Remove damp cloth from battery.
5. Reinstall battery into unit.
6. Replace battery holddown, and tighten securely.
Do not overtighten.
7. Connect positive (+) battery cable to positive (+)
battery terminal.
8. Connect negative (=) battery cable to negative (>)
battery terminal.
9-8. GOVERNOR
The governor has been set at the factory and should not
require further adjustment.
9-9. ENGINE SPEED ADJUSTMENTS (Figure 9-2)
WARNING: ELECTRIC SHOCK can Kill.
e Do not touch live electrical parts.
e Stop engine before inspecting, maintaining,
Or servicing.
MOVING PARTS can cause serious injury.
* Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
e Wear protective gloves and clothing when
working on a hot engine.
Maintenance to be performed only by qualified
persons.
The engine speeds have been factory adjusted and
should not require frequent readjustment. After tuning
the engine, check the speeds with a tachometer. With no
load applied, the weid/power speed shouid be 1850 rpm.
If necessary, adjust the speeds as follows:
1. Open and secure right side panel.
2. Loosen nut on end of engine speed adjusting
screw (see Figure 9-2).
OM-480 Page 31
Engine End
Of Unit
Engine
Control
Switch
Right Side
Of Unit
Secondary
Fuel Filter
Speed Contral
Lever
7 Engine Speed
Adjustment Screw
A
SA-140 283
Figure 9-2. Engine Maintenance And Engine Speed Adjustments
3. Start the engine as instructed in Section 8-3.
4. Adjust the weld/power speed as follows:
IMPORTANT: All directions, such as clockwise and
counterclockwise, are with respect to the operator facing
the engine end of the unit.
a. To increase weld/power speed, rotate the
engine speed adjustment screw counter-
clockwise.
b. To decrease weld/power speed, rotate the
engine adjustment screw clockwise.
5. When the weld/power speed reaches 1850 rpm,
prevent the adjustment screw from turning, and
tighten the securing nut.
6. Stop engine.
7. Close and secure side panel.
9-10. REPLACING ENGINE BELT (Figure 9-1)
WARNING: ELECTRIC SHOCK can Kill.
e Do not touch live electrical parts.
e Stop engine, and disconnect negative (—
battery cable from battery before inspecting,
maintaining, Or servicing.
OM-480 Page 32
MOVING PARTS can cause serious injury.
* Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
e Wear protective gloves and clothing when
working on a hot engine.
Maintenance to be performed only by qualified
persons.
Remove rear panel.
Remove guard from blower/alternator pulley.
Loosen the two hex-head bolts on engine belt
adjustment bracket (adjustment bracket is lo-
cated behind idle pulley), and slide bracket down
as far as it will go.
Remove belt.
Install new belt over the three pulleys with
grooved side of belt in towards pulleys.
Slide engine belt adjustment bracket up towards
top of unit until the belt is tight, and tighten hex-
head bolts in adjustment bracket.
Check belt for tightness according to Section 9-5.
Reinstall guard securely onto biower/alternator
puiley.
Reinstall rear panel onto unit.
9-11. BRUSHES AND SLIP RINGS (Figure 9-3)
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Stop engine, and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
* Wear protective gloves and clothing when
working on a hot engine.
Maintenance to be performed only by qualified
persons,
Brush life is very good under most operating conditions.
Inspect brushes and slip rings every six months or when-
ever excitation voltage is lost. Be sure that slip rings are
clean and brushes are free to move. If the welding gen-
erator has been operating under extremely dusty or dirty
conditions, increase the frequency of inspection.
IMPORTANT: [f the welding generator has not been
used for an extended period of time, oxidation may form
on the slip rings causing excitation voltage to be lost.
1/2 in. (12.7 mm)
Minimum
pS \
[Le] MT LAT La] 1]
JAI
5-0234
Figure 9-3. Brush Replacement
Under normal use, slip rings discolor to a dark brown.
Clean slip rings if a buildup of brush material is present.
Clean rings with a 220 or finer sandpaper, and polish
rings with crocus cloth. Never use emery cloth because
part of the emery will embed itself into the rings and, in
turn, destroy the carbon brushes.
Replace brushes if they become chipped or broken or if
less than 1/2 in. (12.7 mm) of brush material will be left at
next projected inspection interval.
9-12. RUN-IN PROCEDURE
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
* Stop engine before inspecting, connecting,
or servicing.
* Do not leave live unit unattended when
engine is running.
e Keep all panels, covers, and guards
securely in place while engine is running.
MOVING PARTS can cause severe injury.
e Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
o Wear protective gloves and clothing when
working on hot engine parts or components.
CAUTION: LOW OIL LEVEL can damage
engine; ENGINE MAY USE OIL AND WETS-
TACKING may occur during run-in period.
* Check oil level several times a day during
run-in period, and add oil if required.
* See engine Owner's Manual (Deutz
F3L-1011 diesel engine) for run-in informa-
tion.
e Do not idle engine longer than necessary
during run-in period.
e Piston rings seat faster if engine runs at
weld/power rpm, and the welding generator
is kept loaded during the run-in period.
The run-in procedure for diesel engines is different than
those associated with gasoline engines. Diesel engines
must be run at near-rated load during the run-in period to
ensure proper seating of piston rings and to prevent
wetstacking. Wetstacking Is an accumulation of un-
burned fuel and oil in the exhaust pipe. Wetstacking can
occur during the run-in period If the engine is left at idle
rpm too long, or the welding generator is not heavily
loaded.
If wetstacking occurs, complete one of the following pro-
cedures to dry the engine (see engine Owner's Manual,
Deutz F3L-1011 diesel engine). À resistance load is re-
quired to fully load the generator during the run-in proce-
dure. À load bank or resistance grid may provide a con-
stantioad for run-in, however, a load bank is preferred. If
a load bank is available, proceed with the run-in proce-
dure provided in Subsection A. If a resistance grid is be-
ing used, proceed to Subsection B.
OM-480 Page 33
Welding
Generator
Positive (+) Negative (=)
Weld Output ~~ + "Weld Output
Termina!
Terminal В 7
«
Load Bank
L
A
Voltmeter
And
Ammeter
—e |
e +
Weld
Cables
5.0455
Diagram 9-1. Load Bank Connections
A. Run-In Procedure Using Load Bank (Diagram
9-1)
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-12 be-
fore proceeding.
1. “Stop engine.
IMPORTANT: Weld cables supplied with load bank may
be inadequate for run-in procedure. Use weld cables of
proper size with appropriate connectors to connect load
bank to generator (see load bank Owner's Manual).
2. Connect cables from load bank to generator weld
output terminals observing correct polarity (see
Diagram 9-1).
3. Place all load switches in the OFF position.
IMPORTANT: /fload bank requires 115 volts ac, it may
be connected to the welding generator auxiliary power
receptacle, if applicable.
4. If applicable, place Polarity Selector switch in a
DC position (see Section 7-7).
5. Place welding generator Range switch in the
maximum position.
6. Placewelding generator AMPERAGE/VOLTAGE
ADJUSTMENT control in the minimum position.
7. Start engine as instructed in Section 8-3, and al-
low engine to warm up for approximately three
minutes.
8. Adjust load bank switches and generator AM-
PERAGE/VOLTAGE ADJUSTMENT control to
provide a load equal to rated generator output.
For example, if rated generator output is 350 am-
peres, 40 volts at 100% duty cycie, adjust
switches until values indicated by load meters
equal rated generator output.
9. Allow engine to run under load for at least one
hour. Check engine and load bank meters after
OM-480 Page 34
the first five minutes and every 15 minutes there-
after to be sure equipment is operating properly.
10. After running engine under load for at least one
hour, remove load by shutting down load bank.
11. Allow engine to idle for approximately three min-
utes to permit internal engine temperatures to
equalize.
12. Stop engine, and disconnect load bank cables.
13. Allow exhaust system to cool.
14. Inspect inside of exhaust pipe. If pipe is dry. the
run-in procedure is complete. If pipe is coated
with a wet, black, tar-like substance, repeat run-in
procedure.
B. Run-In Procedure Using Resistance Grid (Dia-
gram 9-2)
WARNING: Read and follow safety informa-
tion at beginning of entire Section 9-12 be-
fore proceeding.
1. Stop engine.
2. Obtain resistance grid adequately sized for rated
output of welding generator.
3. Obtain two weld cables of proper size to connect
resistance grid to generator (see Section 4-8)
4, If a voltmeter and ammeter are not provided on
the welding generator, obtain a voltmeter and
clamp-on dc ammeter.
5. If applicable, place Polarity Selector switch in the
DC position (see Section 7-7).
6. Place welding generator Range switch ~ the
maximum position.
7. Place welding generator AMPERAGE. VOLTAGE
ADJUSTMENT control in the minimum position.
8. Adjust grid switches and generator AMPERAGE/
VOLTAGE ADJUSTMENT control to provide a
load approximately equal to rated generator out-
put.
Welding
Voltmeter And Generator
Ammeter
(If so equipped) FT
Weld Output
Terminais
(Polarity Not
Important) В
Weld
$ Voltmeter
« A
/
Resistance Grid
Input And Output
Receptacles
+ Clamp-On
DC Ammeter
Pa
+ Required if welding generator is not equipped with meters.
5-0457
Diagram 9-2. Resistance Grid Connections
For example, if rated generator output is 350 am-
peres, 40 volts at 100% duty cycle, adjust
switches until values indicated by meters equals
rated generator output.
9. Connect one weld cable to grid input receptacle
and remaining weld cable to grid output recep-
tacle (see Diagram 9-2).
10. If a voltmeter and ammeter are provided on the
welding generator, proceed to Step 10. If meters
are not provided, connect voltmeter and clamp-
on dc ammeter as shown in Diagram 9-2.
11. Connect remaining ends of weld cables to gener-
ator weld output terminals (polarity is not impor-
tant).
12. Start engine as instructed in Section 8-3, and al-
low engine to warm up for approximately three
minutes.
CAUTION: ARCING can damage switch
contacts.
* Do not change the position of the grid
switches while engine is running.
Arcing causes the contacts to become pitted
and eventually inoperative.
13. Check meters. Adjust load with generator AM-
PERAGE/VOLTAGE ADJUSTMENT control or, if
necessary, by changing positions of grid switches
until values indicated by meters equal rated gen-
erator output.
14. Allow engine to run under load for at least one
hour. Check engine and meters after the first five
minutes and every 15 minutes thereafter to be
sure equipment is operating properly
15. After running engine under load for at least one
hour, remove load by shutting down resistance
grid.
16. Allow engine to idle for approximately three min-
utes to permit internal engine temperatures to
equalize.
17. Stop engine, and disconnect weld cables.
18. Allow exhaust system to cool.
19. Inspect inside of exhaust pipe. If pipe is dry, the
run-in procedure is complete. if pipe is coated
with a wet, black, tar-like substance, repeat run-in
procedure.
9-13. ETHER STARTING AID (Optional)
CAUTION: ETHER INJECTION WHILE EN-
GINE IS RUNNING can cause engine dam-
age.
¢ Do not actuate ETHER STARTING AID while
engine is running.
The ether used in the cold weather starting aid system
is contained in a replaceable cylinder located behind the
right side door on the center portion of the frame. No indi-
cator is provided to show the amount of ether left in the
cylinder; therefore, itis recommended that a spare cylin-
der be kept on hand. Generally, the ether cylinder is
empty if the engine fails to start in cold weather while util-
izing the cold weather starting system.
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm your
health.
e Follow the manufacturer's safety instructions
on the cylinder when handling ether compo-
nents.
The ether cylinder can also be weighed to determine the
amount of ether inside. The cylinder weighs 33 ounces
(236 gr) when full, and it weighs 15 ounces (425 gr) when
empty. To replace the ether cylinder, see Section 4-8.
IMPORTANT: Before installing the ether cylinder, be
sure that the nozzle on the ether cylinder hose and the
fitting into which the ether cylinder is inserted are both
clean. If dirt is present in either of these areas, the sys-
tem may not work. Also, check for damage to the valve
gasket which is located on the inside of the fitting into
which the ether cylinder hose is inserted. Replace the
valve gasket if it is worn or damaged.
OM-480 Page 35
IMPORTANT: After installing or replacing ether cylin-
der, do not use or test ether start system for atleast 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
9-14. OVERSPEED SHUTDOWN VALVE ADJUST-
MENT (Optional) (Figure 9-4)
WARNING: ELECTRIC SHOCK can kill.
* Do not touch live electrical parts.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
e Wear protective gloves and clothing when
working on a hot engine.
This procedure requires the engine to be run-
ning. Oniy qualified persons familiar with andfol-
lowing standard safety practices are to perform
this procedure.
The overspeed shutdown valve stops airflow to the en-
gine at a preset rpm. Whenever conditions exist that al-
low the engine to exceed its normal operational rpm, the
valve will automatically close and stop the engine.
If adjustment of the valve shutdown rpm is necessary,
proceed as follows:
1. Useandinstall, if not provided on unit, atachome-
ter to check engine rpm.
2. Open and secure right side panel, and locate en-
gine speed adjustment screw (see Figure 9-2).
3. Remove rear panel.
Top Cover
Hose Clamp
Rear Of
Unit
Adjustment
Screw
Overspeed
Valve
Locknut
Ref. SA-139 543-A
Shutdown —
4. Loosen hose clamp securing air cleaner hose to
the air cleaner (see Figure 9-4).
5. Remove air cleaner hose, and locate overspeed
valve (see Figure 9-4).
6. Start engine and increase speed by moving
speed control lever away from the engine speed
adjustment screw (see Figure 9-2). Observe
valve and note engine rpm when valve closes and
engine stops.
7. If rpm was between 1950 and 2100 rpm rpm at
shutdown, proceed to Step 10. Otherwise, pro-
ceed to Step 8.
8. Wait a few minutes after engine shutdown for
overspeed shutdown vaive to reset itself. Loosen
locknut on overspeed shutdown valve (see Fig-
ure 9-4), and rotate adjustment screw one turn.
Clockwise rotation increase shutdown rpm; coun-
terclockwise rotation decrease shutdown rpm.
Retighten locknut.
9. Repeat Steps 6 thru 8 until setting is between
1950 and 2100 rpm.
10. Stop engine.
11. Reinstall air cleaner hose over valve, and secure
hose with clamp removed in Step 4.
12. Reinstall rear panel, and close and secure right
side panel.
IMPORTANT: Shutdown valve maintenance should be
done approximately every three months. Inspect inter-
nal parts for cleanliness, closing action of valve, and
signs of wear around moving parts. Remove and clean
valve with a suitable solvent, if necessary. Do not lubri-
cate valve components.
Air Cleaner
Air Cleaner
Hose
58-140 284
Figure 9-4. Overspeed Shutdown Valve Location
OM-480 Page 36
SECTION 10 - TROUBLESHOOTING
UNE CES
10-1. GENERAL
itis assumed that proper installation has been made, ac-
cording to Section 4 of this manual, the operator is famil-
iar with the function of controls, the welding generator
was functioning properly, and the trouble is not related
to the welding process.
10-2. BOOSTER BATTERY JUMP STARTING
If it is necessary to jump start this unit, use the following
safety precautions and the step-by-step procedures in
order of appearance.
WARNING: BATTERY GASES OR A DAM-
AGED BATTERY can explode thereby shat-
tering the battery; BATTERY ACID can burn
eyes, skin, destroy clothing, and damage
other material; MOVING PARTS AND iM-
PROPER CONNECTIONS can cause serious
personal injury and damage equipment.
* Keep sparks, flames, cigarettes, and other ig-
nition sources away from battery.
e Ensure that all personnel are a safe distance
from batteries and clear of moving parts while
starting.
® Do not jump start a frozen or completely dis-
charged battery.
* Do not jump start a battery which has loose
terminals or one having evidence of damage
such as a cracked case or cover.
® Be sure that vent caps are tight and level on
both batteries and cover both batteries with a
damp cloth.
* Wear correct eye and body protection, and re-
move all metal jewelry.
* Keep jumper cables clear of moving parts.
e Ensure that both batteries are of the same
voltage.
e Do not jump start a trailer mounted welding
generator with the towing vehicle battery un-
less the trailer is completely disconnected
from the towing vehicle.
e Do not jump start a vehicle mounted welding
generator from the vehicle battery.
* !fbooster battery is installed in vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
® Do not jump start by applying power to weld
output receptacles or terminals.
* Do not allow jumper cables to contact any
other metal while attaching or removing ca-
bles.
1. Use properly insulated jumper cables of ade-
quate size.
2. Connect ends of one cable to positive (+) termi-
nals of each battery.
3. Connect one end of other cable to negative (>)
terminal of booster battery.
4. Connect remaining end of cable to welding gen-
erator engine block at least 18 inches (457 mm)
from battery (do not connect to welding generator
case, frame, or equipment grounding terminal as
damage to equipment can result).
5. Wait at least one minute after connecting cables
before starting engine.
6. Start engine following procedures outlined in
Section 8 (Sequence of Operation) of this manual
and allow engine to return to ¡dle speed. if the unit
does not start after cranking for twenty seconds,
stop the jump starting procedure. More than
twenty seconds seldom starts the engine unless
some mechanical adjustment is made.
7. Remove jumper cable from engine block.
8. Remove other end of same cable from booster
battery negative (—) terminal.
9. Remove other Jumper cable from weiding genera-
tor battery positive (+) terminal.
10. Remove remaining end of cable fram booster bat-
tery positive (+) terminal,
11. . Discard damp cloths.
10-3. OVERLOAD PROTECTION
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Stop engine, and disconnect negative (—) bat-
tery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious personal
injury.
* Keep away from moving parts such as fans,
belis, and rotors.
HOT ENGINE PARTS can cause severe
burns.
* Wear protective gloves and clothing when
working on a hot engine.
INCORRECT FUSE can damage unit.
® Be sure replacement fuse is same size, type,
and rating.
OM-480 Page 37
A. Replacement Of Optional Power Plant Fuses
WARNING: Read and follow safety informa-
tion at beginning of entire Section 10-3 be-
fore proceeding.
Fuses F1, F2, and/or £3 protect the optional 10 or 7.5
power plant circuitry from overload. Should any or all
fuses open, there would be no auxiliary power output.
To replace fuses F1, F2 and/or F3, proceed as follows:
1. Open right side door, and remove cover from
power plant junction box.
2. Check and replace fuses F1, F2, and F3, as re-
quired.
3. Reinstall junction box cover, and reinstall right
side door.
Fuse F is located on the bottom of the switch assembly
MS1 directly behind the front panel. To replace fuse F at
switch MS1, proceed as follows: |
Open right side door.
2. Locate fuse F on bottom of MS1.
3. Remove and check fuse F, and replace if neces-
sary.
4. Close and secure right side door.
B. Replacement Of Low Oil Pressure/High Oil Tem-
perature Shutdown System Fuse
WARNING: Read and follow safety informa-
tion at beginning of entire Section 10-3 be-
fore proceeding.
Fuse F is located on the bottom of the switch assembly
MS1 directly behind the front panel. To replace fuse F at
switch MS1, proceed as follows:
Open right side door.
Locate fuse F on bottom of MS1.
Remove and check fuse F, and replace if neces-
sary.
4. Close and secure right side door.
C. Circuit Breakers CB1 And CB2
WARNING: Read and follow safety informa-
tion at beginning of entire Section 10-3 be-
fore proceeding.
NE —
o © | © ©
CB1 CB2
OM-480 Page 38
Circuit breakers CB1 and CB2, located below the 120V
duplex receptacles, protect the receptacles from over-
load. If CB1 opens, output to the 120V receptacle RC1
stops. If CB2 opens, output to the 120V receptacle RC2
stops. If CB1 or CB2 open, locate and correct problem,
and manually reset the circuit breaker(s).
If this unit is equipped with the optional 240V duplex re-
ceptacle RC1, when either CB1 or CB2 opens, output to
the 240V receptacle and half of the 120V receptacle
stops.
IMPORTANT: /fa circuit breaker opens when use of aux-
iliary equipment begins, a fault is probably present in the
auxiliary equipment. If a breaker opens after prolonged
equipment use, an overload condition is probably pres-
ent.
10-4. TROUBLESHOOTING (Tables 10-1, 10-2, And
10-3)
WARNING: ELECTRIC SHOCK can kill.
* Do not touch live electrical parts.
e Stop engine, and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
* Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
* Wear protective gloves and clothing when
working on a hot engine.
Troubleshooting to be performed only by quali-
fied persons.
The following tables are designed to diagnose and pro-
vide remedies for some of the troubles that may develop
in this welding generator.
Use these tables in conjunction with the circuit diagram
while performing troubieshooting procedures. If the
trouble is not remedied after performing these proce-
dures, contact the nearest Factory Authorized Service
Station. in all cases of equipment malfunction, strictly
foliow the manufacturer’s procedures and instructions.
Table 10-1. Weld/Power Troubleshooting
WELDING TROUBLE
PROBABLE CAUSE
REMEDY
No weld output.
AMPERE RANGES switch S3
is between positions.
Place S3 in proper position (see Section 7-1).
Optional POLARITY switch S2
is between positions.
Place POLARITY switch S2 in proper position.
Poor contact between slip rings
and brushes.
Clean slip rings (see Section 9-11). Replace
brushes according to Section 9-11.
Field excitation circuit.
Contact the nearest Factory Authorized Service
Station.
Optional REMOTE switch S9 in
REMOTE position and Remote
Amperage device not con-
nected.
Place S9 in PANEL position, or install Remote
Amperage Control device.
Incorrect or poor connection to
Optional Remote Control re-
ceptacle RC3.
Check and secure connection to RC3.
Erratic weld output.
Damp or wrong type of elec-
trode.
Use dry, properly stored electrode. Be sure that
electrode is the correct size and type.
Connection at electrode and/or
work.
Check connections. Be sure connections are
clean and tight.
Loose or dirty connections.
Check connections both inside and outside unit.
Erratic weld and power output.
Poor contact between slip rings
and brushes.
Clean slip rings (see Section 9-11). Repiace
brushes according to Section 9-11.
High welding or auxiliary output
voltage.
High engine speed.
Check and adjust engine speed according to
Section 9-8. (Maximum voltages should not ex-
ceed 132 volts for 120 volts output and 264 volts
for optional 240 volts output.)
No output at 120 volts ac or op-
tional 240 volts ac duplex re-
ceptacles RC1 and RC2; no
weld output.
Auxiliary equipment connected
to receptacie(s) RC1 and/or
RC? when the unit was turned
on.
Be sure that all auxiliary equipment is discon-
nected from RC1 and RC2 before starting unit.
Poor contact between slip rings
and brushes.
Clean slip rings (see Section 9-11). Replace
brushes according to Section 9-11.
OM-480 Page 39
Table 10-2. Auxiliary Power Troubleshooting
AUXILIARY POWER
TROUBLE
PROBABLE CAUSE
REMEDY
No auxiliary power output at
120 volts ac and/or optional
240 volts ac receptacies.
Receptacle circuit breakers CB1
and/or CB2 open.
Reset CB1 and/or CB2 (see Section 10-3C).
High or iow voltage at 120 volts
ac or optional 240 volts ac aux-
iliary power receptacles RCH
and/or RC2.
Incorrect engine speed.
Check and adjust engine speed according to
Section 9-9. The engine must run at weid/
power speed (1850 rpm) when Engine Con-
trol switch S1 is in the RUN position and no
load is applied.
Low 120 and/or 240 volts ac
output at optional auxiliary
power junction box.
AMPERAGE/VOLTAGE ADJUST-
MENT control R1 not set at 100.
Rotate R1 to 100.
Poor contact between slip rings
and brushes.
Ciean slip rings (see Section 9-11). Replace
brushes according to Section 9-11.
Incorrect engine speed.
Adjust engine speed (see Section 9-9).
Optional Remote Amperage Con-
trol not set at maximum.
Set Remote Amperage Control to maximum
position.
Optional REMOTE switch S9 in
REMOTE position, and no Remote
Amperage Control device con-
nected.
Place 59 in PANEL position, or install Re-
mote Amperage Control device.
High welding or auxiliary pow- | High engine speed. Check and adjust engine speed according to
er output voltage. Section 9-9. (Maximum voltages should not
exceed 132 volts for 120 volts output and
264 volts for optional 240 volts output.)
No optional 7.5 kVA/KW single- | Improper connections. Check connections according to Section
phase or 10 kVA/KW three-
phase ac power plant output;
weld output is normal and 120
and/or optional 240 volts ac
auxiliary power is present at
duplex receptacles.
5-3.
Fuses F1, F2, and/or F3 open.
Check fuses F1, F2, and/or F3 (see Section
10-3), and replace if necessary.
OM-480 Page 40
Table 10-3. Engine Troubleshooting
ENGINE TROUBLE
PROBABLE CAUSE
REMEDY
Engine does not start.
Out of fuel.
Fill fuel tank, and air vent fuel system (see
engine Owner's Manual).
Battery problem.
Check engine battery charging system ac-
cording to Engine Service Manual. Engine
Service Manual not supplied — contact Fac-
tory Authorized Service Station.
Inspect the electrical system (see Section
9-1. If the battery requires recharging, see
Section 9-7, and follow all applicable safety
procedures and the battery charger man-
ufacturer’s instructions. If the battery does
not charge, replace the battery (see Section
9-6).
Engine Control switch S1.
Check $1, and replace if necessary.
Engine trouble.
See engine Owner's Manual
F3L-1011 engine).
(Deutz
Fuse on optional Low Oil Pressure/
High Oil Temperature Shutdown
System switch MS1 open.
Replace fuse on MS1 (see Section 10-3).
Engine suddenly shuts down.
8-pin plug from engine wiring har-
ness disconnected from 8-socket
receptacle on engine.
Be sure that wiring harness plug is secure in
engine receptacle.
Optional shutdown
valve.
overspeed
See Section 9-14.
Battery discharges between
uses.
Engine Control switch left in posi-
tion other than OFF.
Place S1 in OFF position whenever unit is
not in use.
Buildup of acid on top of battery
(white-gray substance).
Clean battery with baking soda solution, and
rinse with clear water.
Infrequent use.
Periodically recharge battery (approximate-
ly every 3 months) (see Section 9-7).
Battery.
Check and replace battery, if necessary.
Engine siowly stopped; unable
to restart engine.
If applicable, inside valve of fuel
cap in CLOSED position.
Rotate valve to OPEN position.
Engine trouble.
See engine Owners Manual
F3L-1011 engine).
(Deutz
OM-480 Page 41
NOTE
OM-480 Page 42
SECTION 11 —- ELECTRICAL DIAGRAMS
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OM-480 Page 43
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ENGINE
Diagram 11-2. Wiring Diagram For Welding Generator
OM-480 Page 44
(LOIL-!
SPLICE
DIAIWELD STATOR]
AC
REACTOR
NEG. /ELECTRODE
O
POS. /WORK
O
SA(IT-AJ
EXCITER
STATOR
WELD
STATOR
Wiring Diagram No. SD-142 564-A
OM-480 Page 45
SECTION 12 - PARTS LIST
Figure 12-1. Main Assembly
OM-480 Page 46
27
28
29
30
Fig 12-4 — 55
SD-129 956-A
OM-480 Page 47
Item Dia. Part ВЕ
No. Mkgs. No. Description Quantity
Figure 12-1. Main Assembly
1 089517 STRAP, fuel tank .......... 2. ea a ea a A La a Le 2
2 134 771 PLUG, protective .640sq (used on engine doors also) .............. 6
3 107 972 TANK, fuel (consisting ofj .................er.eeca0edareraxaoooa. 1
4 115000 - CAP, fuel large RR 1
605288 FITTING, pipe galv plug sghd .250NPT ......................... 1
5 020 185 FITTING, pipe brselbow st 1/8NPT ............................ 1
6 124973 FITTING, 5г5 Багбей М 1/ВТВС х 1/8МРТ ....................... 1
7 125 687 HOSE, nprn SAE 125 10 х .343 OD (order by ft) ................. ft
8 125704 FITTING, hose brssplice 1/8tbg ...... oii... 1
9 097 507 STRIP, rbradh back 1.125x1.000x20500 ..................... 2
10 +124 592 UPRIGHT, basecenter .......... i 1
11 017479 SEAL, weather lifteye ..... ee ae 1
12 111 352 BATTERY, stor 12V 380crk 80rev ........... 2... ae 1
13 108 081 TERMINAL PROTECTOR. battery post mtg .................... 2
14 124941 CABLE, batpos .....112111 0041004 4 a AAA a LL LL da LL 1
15 127 019 BOLT, Lstl 312-18 х 10.000 ..... A LL aan à 1
16 124 668 HOLDDOWN, battery ..... 11111111 La a ea Ada a LL LL 1
17 010460 STUD, stl.312-18x 10.000 ......... 22... 00000 enerara. 1
18 047 812 CABLE, batneg ...... 029.00: 00recieaerareaaodaor ana 1
049026 SCREW, cap stl hexhd 10mm een. 1
19 R4,VR1 046 819 SUPPRESSOR ee 1
20 124606 BRACKET, mtg-rectifier .. 2.000 0000 aaa. 1
21 SR3 142506 RECTIFIER, si3ph 350A eee à 1
22 +124 766 COVER, top . «oe 1
22 Ф+127 693 COVER, top . ee 1
23 107 990 LABEL, use diese! fuel only ........ ea a a ea a 1
126 488 LABEL, diesel engine maintenance ...........eesdrrraorareroa. 1
24 035968 1VWASHER, flat rbr 3.625 ID x 5.875 OD x .O62thk ................. 1
25 108 487 LABEL, warning falling equipment etc. . ......................... 2
26 124 885 PANEL, rear ... 2... e 4 ererededeerena neon oo 1
27 005710 LABEL, caution this panel must be in etc ...........e e een... 1
28 +124 865 GUARD, belt RR a da 0 1
29 107343 GROMMET, rbrneck ......... iin, 1
30 124 945 AIR BOX oe ee 1
31 124 986 AIR CLEANER, intake (consistingof) ........... oo. 1
32 126 876 - NUT, wing air cleaner ........ iii iii, 1
33 126 878 - NUT, wing air cleaner . ........ ieee. 1
34 126875 DUST EJECTOR, aircleaner ...........c iii 1
35 126881 - COVER, aircleaner ieee ee 1
36 126 877 - RING, E air cleaner i ee ee eee ee 1
37 *126 880 - ELEMENT, air cleaner ii ee eee n 1
38 126 874 - O-RING, air cleaner ......11011 100100 4 4 4e 4 4 4 a 4 4 a aa a 1 LL 110 1
39 010863 CLAMP, hose 2.062 - 3.000 cip dia .............. 0200000000, 1
40 124 985 HOSE, air cleaner to engine ............—.oeese0ecorararenre e 1
41 010862 CLAMP, 1.812 - 2.500 clp dia ..... 2... uercadvada 1
42 124 984 BRACKET, mtg air cleaner .. 2.022010 0014044 aa a ea ea ea eee 2
43 121509 LABEL, warning do not run engine etc ee eee 4
44 087 336 LATCH ......... 00000000. .00d0rerecererdvecrecenenaa. 2
45 125744 NUT, stl slflkghex mscr 10mm... o.oo ee 2
46 602 243 WASHER, flat sti std 375 ....... 2... в. вл уу волов eee 4
47 124689 STUD, stl 10mm x 7.000 iii iti ei ce ee 2
48 124690 BAFFLE, air ee ee ee 1
49 603 120 STRIP, felt .125 x .750 x 28.250 ...........esmeorereercesaoreoro, 2
50 123 042 ENGINE, Deutz dsl elec .................0s. 00 .rreredeorerce. 1
PLGS 124 346 HOUSING, plugnylon8contact . ......... coi, 1
128 287 STUD, adjusting throttle . ......... iii i ea ane à 1
OM-480 Page 48
item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-1. Main Assembly (Continued)
51 124 402 BRACKET, mtg engine RH .................... aa ea Là 1
52 601 945 SCREW, capstlhexhd 625-18 x4.000 ......................... 4
53 071731 WASHER flat stl 656 ID x 2.250 OD x .187thk ................... 4
54 601851 NUT, st! siflkg hex reg 625-18 ........... iii... 4
55 Fig 12-4 GENERATOR ....... RR a Ra LE 1
56 124406 BRACKET, mtg engine LH ....................0rerececerereoa 1
57 124 681 MANIFOLD, exhaust muffler .............. ee ere teas 1
58 109591 CLAMP, muffler 1.750dia ............ La ae ee a a a a 1
59 124 866 PIPE, muffler extension elb .............. ee a La Va 1
60 +124 687 DOOR, side RH ........ 2. .e00rereedononerereaoarero 1
+124 685 DOOR, side LH ....... ea A A de a aa a aa LV 1
089 343 RIVET, nyi .250dia x 1.000 19 ............. 2... LL a aa 6
61 004 130 BRACKET, support door ........ ee eee a 2
62 601 9655 SCREW, cap sti hexhd .375-16 x 1.000... 11111111 11111110 4
63 124607 STRIP, mtg separator fuel ...................... 5..0... 1
64 601871 NUT, st! hex jam 375-16 ..... 4 a a ae a a A aa a 10
65 602 213 WASHER, lock stl split 375 ................ ......... aaa 10
66 134 835 HOSE, SAE .312 ID x ‚560 OD (order by ft) ...................... 3ft
67 010323 CLAMP, hose .250-.625¢clpdia ........ i... 4
68 039 599 FITTING, brs barbed M5/16tbg x 1/4NPT ....................... 3
69 010678 FITTING, pipebrselbst1/4NPTLH ................ 0. ..... 3
70 106 278 ВАЗЕ, Нег мм/абар!ег ................... 5..5... aa LL LL 1
71 106 467 FILTER, fuelspin-on ........ ie, 1
72 124409 BASE ..........rerereraa0enmoecerreracacereronerer, 1
73 071 890 RETAINER, mount eng/gen .............. no... 4
74 071730 TUBING, stl .875 OD x 12ga wall х 2.375 ......... 0 кн... 4
75 072 848 TUBING, nprn .875 0 х 2.5000 ОО х 2.000 .........,........... 4
76 108 163 FRAME, mtg reactor € fuel tank ............. 2.0000. 1
77 010146 CLAMP, nyl .625 clamp dia .............e seres eee 1
78 081499 BRACKET, mtg strip terminal ................ 222200000 10 1
79 123794 EDGE TRIM, (order by ft) ........ coi ie 1ft
80 038 621 BLOCK, term 30A 4P | een enero 1
038 620 LINK, jumperterm blk 30A ..... 09000. e 0 2
81 053 967 INSULATION, rectifier ..... . ereredereareran o, 1
82 +113932 GUARD, panel rept (consisting of) ....... o.oo 1
83 113 730 - LABEL, warning stop engine before etc ................. 2... 1
84 111 310 UPRIGHT, base front ................ PA енневувавеененее. 1
007 025 SCREW, capstlhexhd 625-11 x1.250 .............. ccc... . 2
085 980 NUT, sti hex full fnsh .625-11 . ea 4
602218 WASHER, lock stlsplit 625 1210104 04044 444 a 4e 4 a da a 4
85 CR3 115693 RELAY, enci 12VDC SPDT ....112000 1010044 4 a ea 4 a a a a 4 a aa a 10 1
86 128288 PANEL, mtg components ......1124 2000001444 ra a a a a ea 0 1
87 17 038621 BLOCK, term 30A4P e aa 1
88 D1,2 128299 DIODE BOARD, (consisting of) ................. e 2
89 SR1,2 035 704 RECTIFIER, integ 30AÀ 600V ......11 1111111111 LL 4 a 2
90 +093 559 PANEL, frontlower .. 1.112110 11111124 1e 44 4 ae a a ea 0 1
90 ¢+127 695 PANEL, frontlower . _e.eresroroec rre acie y
91 134 792 LABEL, warning general precautionary ....................... t
44041965 POLARITY REVERSING SWITCH, (consistingof} .............. 1
90 +110598 - PANEL, frontiower ................... 000000, ara '
91 134792 - LABEL, warning general precautionary ...................... 1
92 010647 - PIN, spring cs .156 X 1.250 ....... ie 2 1
93 059866 -HANDLE, switch .......... iii i. 1
94 52 086309 SWITCH, polarity ........ iii a a a a a a a ee 0 1
95 110909 - ANGLE, mtg panel ......122220 01444 Le VA 44 se 4 ea a a a a a a 10 1
OM-480 Page 49
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-1. Main Assembly (Continued)
96 Fig 12-2 PANEL, front-w/components ..............—....e m2... 2... e... 1
97 21 129074 REACTOR .......... eee oeaaonaaarananana 1
98 Fig 12-5 TERMINAL ASSEMBLY, pwr output .........e—._—.—.oc.rereeroerera 1
99 R2,3 128862 RESISTOR, WW adj375W500hm ............. iit, 2
100 085 656 STRIP, mig resistor ....... iii ieee iia ene 1
101 010314 VALVE, shut-offfuel .......... iii, 1
102 097 829 BOLT, Jstl .250-20x2.750 ............. cc... eee 4
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
+ Part of optional 042 322 Lockup Package.
¢ ¢ OPTIONAL |
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-480 Page 50
13 12 11
1” Fig 12-3
SC-130 264-A
10
Figure 12-2. Panel, Front w/Components
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-2. Panel, Front w/Components (Fig 12-1 Нет 96)
1 S3 114193 SWITCH, range (Fig 12-3) ..... i i i ie 1
2 R1 605 960 RHEOSTAT, WW 300W 340hm .......... iin. 1
3 59 *011 609 SWITCH, tgl SPDT 15A 125VAC ..........eemeredodrereaearo 1
4 RC3 6032 897 RECEPTACLE, twlk grd 2P3W 15A125V ....................... 1
032898 PLUG, twlk grd 2P3W 15A 125V Hubbell 4270C
5 CB1,2 139266 CIRCUIT BREAKER, manreset iP 15A250VAC ................. 2
6 RC1,2 039864 RECEPTACLE, strdxgrd2P3W 15A 125V ...................... 2
073690 PLUG, str grd 2P3W 15A 125V PES 5266-DF
€ 9042 593 RECEPTACLE KIT, duplex 240V (consistingof) .................. 1
5 CB1,2 139266 - CIRCUIT BREAKER, manreset 1P15A250VAC ................ 2
6 RCH 604 103 - RECEPTACLE, strdx grd 2P3W 15A250V ..................... 1
6 RC? 039864 - RECEPTACLE, str dx grd 2P3W 15A 125V ......... a... 1
140684 - PLATE, identreceptacie ............ 2.2.2. nada 1
7 601 836 NUT, brs hex .250-20 jam hvy .......... iii. 3
8 083 030 STUD, brs grd .250-20 x 1.750 RR aa aa à 1
9 PLATE, ident control rating (order by model and serial number) ...... 1
10 A2 00045559 METER, amp DC 50MV 0-500 scale ......... 2... a à 1
11 V 664046654 METER,voltDCOQ-100scale ............... iu... 1
12 119014 LEVER, Switch black i. 1
13 ++047 842 GAUGE, pressure 5-100 lbs .......120 00004004 sa aa ea aa a aa 1
13 +++129 860 GAUGE, pressure oil 0-100 lbs .......22020420 12211111 aa sa ea 1
14 ++047 841 GAUGE, temperature mechanical ............................. 1
14 +++129 837 GAUCGE/SWITCH, temp oil mech ............e. 022. eredrode e. 1
15 082788 HOLDER, lightind ........... i iii. 2
16 PL1,2 *048 155 BULB, incandflgbase 12V . ... La a ea a ana 4e 2
17 082 789 LENS light ind red ..................rermederereaaeararadoon 2
18 **021 385 BOOT, tgl switch lever .............. o 2es0d00d0rarerarovocena 1
19 HM 145247 METER, hour 4-40VDC ........—....o_.eenedrecarerenaenovoroa 1
20 602 178 SCREW, setstisch .250-20 x .375 .......... 2.2... 02... 000. 1
21 019755 HANDLE, switch rheostat ............_eeeresrorererevarenmero, 1
22 010647 PIN, spring CS .156 x1.250 .... 2... a La A aa ae 1
23 019754 HANDLE, switchrange ............ iii. 1
24 NAMEPLATE, (order by model & serialnumber) .................. 1
25 58 021 467 SWITCH, tgl SPST MC 3A 250V .......... 5..5... веке... 1
26 Si 144641 SWITCH, ignition 5posn . ee a a a a a ana à 1
27 127618 PANEL, frontupper......... ee eee 0 1
€ Part of Optional 006 122 Remote Control Facilities Option.
¢¢ OPTIONAL
+ + Part of Optional 041 568 Meter Kit Option.
++Part of Optional 042 334 Meter Kit Option.
+++Part of Optional 042 318 Automatic Shutdown Option.
*Recommended Spare Parts.
* Part of Optional 042 320 Starting Aid Kit.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-480 Page 51
Item Part o
No. No. Description Quantity
114 193 Figure 12-3. Switch, Range (Figure 12-2 Hem 1)
1 114235 BRACKET, mtg switch (consisting of) ...................... 1
2 010 671 - SPRING, ext x .312 OD x .042 wire x 1.875 pld .................. 1
3 017428 LOCATOR, quadrant ......... eee een 1
4 004998 CONTACT BOARD ASSEMBLY, switch range (consistingof) ......... 1
5 100623 - GUIDE, contactboardmovable ............... coi... 3
6 011 012 -SHIM, guide contact board ............ cin... 3
7 011 980 + CONTACT BOARD, movable switch ...................... ..... 2
8 004999 - CONTACT BOARD, stationary ......_ec_erererevorverereererre. 2
9 011 645 - CONTACT ASSEMBLY, movable (consistingof) .................. 3
10 011075 + - SPRING, pressure . .. ii tee eee eee 1
11 011953 --CONTACT ..... ee rerrarenrececereraaernaverocao ano, 2
12 011074 --SPRING, pressure ............o—meerrerererareaeererverar e 1
13 011644 CONTACT, stationary .............eceerecorenri eee rerororren 15
4
2
SB-011 273 8 Includes 11 12
ltem 10
A >
J
®
%
t 8
13
58-911 109
Figure 12-3. Switch, Range
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-480 Page 52
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-4. Generator (Fig 12-1 Item 55)
1 049 650 BRACKET, mtg brushholder ........... i... 1
2 018614 BRUSH SET, (consisting of) ...... ci iii iia 3
3 *044 755 - BRUSH 2 0200d0drereveenarananananoondoa, 1
4 600270 -HOLDER, brush ............ iii... Cer eee 1
5 018665 - CAP, brushholder . .......... i i ian 1
6 013 367 LABEL, warning moving parts can cause serious injury etc .......... 1
7 124 855 GUARD, starter ........ 2... earererererercerera, 1
8 +137 747 STATOR, generator (consisting of) ..............e_eerevereec... 1
8 Ф+140 100 STATOR, generator (consisting of) ...................00 0000... 1
3 039207 -BAFFLE, air generator .............. 2.0000... acia. 1
10 089736 ROTOR, generator (consisting of) ................ 2.0008... 1
11 024 617 - RING, retaining-ext . . ... arerecrerxa ade. 1
12 053390 BEARING, ball ...... ere ee aa ee aa ea ane 1
13 069 737 - FAN,rotor 111111111000 1 LL LL La Le a 4 a a a a a a a a a a 1
035776 - KEY, .375x .375X 2.000 .... i ee 1
14 044 374 STATOR, exciter aux pwr 120/240 ............... 2.2... 2... 1
15 049 235 ENDBELL, generator 2... ..eeaarerererea neo 1
16 086 863 SCREW, cap st! hexwhd siflkg .375-16 x 1.000 ................... 14
17 004 203 STRIP, nyl.050x4.000x8.000 ......... iin... 2
SD-110 922
Figure 12-4. Generator
*Recommended Spare Parts. —
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
¢ Part of Optional 042 308 10/7.5 kVA Auxiliary Power Option.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-480 Page 53
Item Dia. Part o
No. Mkgs. No. Description Quantity
Figure 12-5. Terminal Assembly, Pwr Output (Fig 12-1 Item 98)
108 127 BRACKET, mig term pwr output ............—.—eoeooeeerecerereoo.
Neg 039 046 TERMINAL, pwr output black (consisting of) .....................
Pos 039 047 TERMINAL, pwr outputred (consistingof) .......................
601 879 NUT, sti hexfullfnsh 500-13 ........ iii...
039044 -BUSBAR,termbd ......... ee
601880 - NUT, sti hex jam .500-13 .......... iii iii.
039 045 - TERMINAL BOARD, black ...........—....ee0mereracareoee a
039 049 - TERMINAL BOARD, red ...........—._eeeeacdoaroraedrerena e.
601 976 - SCREW, cap stl hexhd .500-13x1.500 ........................
O1 М ©) сл о СО ГО —
—h e A Ad de sk
1 Cn, 8.
,
ST
SAN
г 3 >
A
Û
Ref. 58-048 150-C
Figure 12-5. Terminal Assembly, Pwr Output
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-480 Page 54
Dia. Part ВЕ
Mkgs. No. Description Quantity
Optional Equipment
006 122 REMOTE CONTROL FACILITIES, (consistingof) ................. 1
RC3 032 897 - RECEPTACLE, twlk grd 2P3W 15A 125V . .. iii. 1
59 011609 - SWITCH, tg! SPDT 15A 125V aaa 1
034 508 CONNECTOR, blk 30A ...................... RAS 1
042318 AUTOMATIC SHUTDOWN, low oil pressure & hi oil temp (consisting of) 1
110 958 - SWITCH, automatic shutdown (consistingof) .................... 1
D8 070250 --DIODE, rect 3A 600V..........—.—.—.e—.eererecoreaerervonencaa. 1
MSH 011072 -- SWITCH, magnetic (consistingof) . ........................... 1
F *048 317 -- FUSE, mintr gl 14A 32V 1.122110 0 4 044 0 a da a Va A Va Aa 1
129 860 - GAUGE, pressure oll 0-100 Ibs. . LL LL 1
129 937 - GAUGE/SWITCH, temp oil mech ...... aaa 1
128 829 - KIT, oil line 44.000 in 1/8NPT x 10mm......... ......... 1
128 633 - FITTING, pipe brs adapter 1/8NPT x 12mm ..................... 1
042320 STARTING AID KIT, diesel (consisting of) ........................ 1
58 021467 - SWITCH, tgl SPST MC 3A 250V ............ 2... ana 1
021385 = - BOOT, tal switch lever ........ enana 1
034074 - STARTING AID KIT, diesel ...... i, 1
046 410 - ATOMIZER, .125 LH elb of .......... era aereo 1
127 265 ADAPTER, atomizer .... 2... a a a aa a a 1
127303 BRACKET, migfuelfilter ....... 2.2... enana 1
035 325 LABEL, ether starting aid caution etc .......................... 1
020185 - FITTING, pipe brs elb st 1/BNPT ........ eee aero, 1
010 021 - CLAMP, stl cush .562diax .343mighole ....................... 1
605 321 “NUT, stl hex 468-32... i aerea enn, 1
073157 - TUBING, ny! .078 1D x.125 0D .............. 2.0... 4
041568 METERKIT, A&VDC (consistingof) ........................... 1
A? 046 559 - METER, amp DC 50MY 0-500 scale ................ 2. e... 1
\ 046654 METER, volt DC 0-100 scale ............ 2.2000. ae 1
SHUNT 030 081 - SHUNT, meter 50MV 500A .......... 290900. aaa aa ea 1
111786 - STRIP, migshunt .. 4 4 4 4 4 4 4 a aan 1
003645 ВОЗ ВАН, shunt/secstud ......... 4 a 1 ee ae aa a ea à 1
042358 10/7.5 KVA AUXILIARY POWER, (consistingof) .................. 1
134903 FUSEBOX ................ SA 1
F1-3 *089 5685 - FUSE, crtg 35A 250V ........... 00000000. a, 3
089588 - HOLDER, fuse crtg 60A 250V ............... 2.220 0r0r0ere,. 1
132444 LABEL, warning auxiliary pwr .............. ee... ur... 1
+140 100 - STATOR, generator (see Fig 12-4) ............. ii... 1
+134 902 COVER, fuse box .... RR a a a 1
048489 -CLAMP, nyl 1.000 clip dia ............ iii... 1
057360 - BLANK snap-innyl 1.375 mighole . ................... ........ 1
604 102 - CONNECTOR, clampcable 1.000 ........... i... 2
113932 - GUARD PANEL (consisting of) .................... .. ....... 1
113730 - LABEL, warning stop engine before .......................... 1
026 947 STAND-OFF, insul .250-20 x 1.000 Ig x .312thd .................. 1
042 322 LOCKUP PACKAGE, (consistingof) ...... cin... 1
127 694 - HINGE, cover .....1111 01011 LL VAL LA A a a La Aa aa LL 1
127692 - COVER, panel front .............. 2.2... 0000, ara. 1
087 341 - BUMPER, door 1.000 OD x .750 high .......................... 2
+127 693 COVER, MOD. RR ae 1
+127 695 - PANEL, front lower ........100210001 0101111 LL LL LA La aa LL LL 1
136 473 STRIP, reinforcing panel... 4 en a aa a aa ee 1
041 965 POLARITY REVERSING SWITCH, (see Fig 12-1) ................. 1
042334 METER KIT, engine gauges (consistingof) ....................... 1
047 842 GAUGE, pressure 5-100 1bs .... oe 1
047 841 - GAUGE, temperature mechanical ............................. 1
128 828 - FITTING, brs adapter bushing 14mm x .625-18UNF . .............. 1
128 633 - FITTING, pipe brs adapter 1/8NPT x 12mm ..................... 1
128829 KIT, oil line 44.000 in 1/8NPT x 10mm... ....... un... 1
OM-480 Page 55
Dia. Part
Mkgs. No. Description Quantity
Optional Equipment (Continued)
042 482 = HIGH ALTITUDE KIT, (consisting of) ....... ivi, 1
004 956 - SEAL, blank lead .......... ee, 1
042436 DIESEL AIR INTAKE AUTO SHUTDOWN, (consisting of) ........... 1
131 864 VALVE, overspeed ..... ee, 1
134769 -PlPE,aircleanerelb .......... 0. a ee aa a a a aa ae 1
134764 :HOSE, rdtr str 2.750 1D x 2.000 ................. 2 erario. 2
023313 -CLAMP, hose 3.000 — 3.250 elp dia ................ 2... ... 4
135 071 - CAP, rain 2.500 1D ........... 2.0.0 000.a0aaa naa, 1
135076 - COVER, top ........ 1044 44 4e a ae ea a a a a 4 a a a a aa 40 1
134 767 - PIPE, muffler extension elb .........211201100 1111111111 aa LL 1
042 593 RECEPTACLE KIT, duplex 240V (see Fig 12-2) ................... 1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-480 Page 56
OPTIONS AND ACCESSORIES
3000-4 FOUR-WHEEL
TANDEM TRAILER.
(#041 015)
The tandem axie design enabies
this trailer to ride smoothly over
rough terrain. The unit is equipped
with fenders. lights. a leveling jack.
2 in. (50 mm) ball hitch. and safety
chains. The two-wheel. self-
actuating hydraulic brake system
operates automatically as pressure
IS put against the tongue of the
trailer. Another feature is a break-
away device which would
automatically tock the brakes should
the trailer become loose. A-hand-
operated parking brake is standard.
Specifications: |
Total Width: 72-1/4 in. (1.8 m)
Tread: 63 in. (1.6 m)
Length: 163-1/2 in. (4.2 m)
Height of Bed: 19 in. (480 mm)
Road Clearance: 10 in. (254 mm)
GVWR: 3000 65. (1360 Ка)
Shipping Wt: 757 Ibs. (343 kg)
TOOL BOX
(#040 638)
For use with four-wheel trailers.
Keeps tools handy. Sturdy steel
construction with hinged cover. 5 in.
(130 mm) divider in center of box.
Attachment hardware included.
Height 11 in. (280 mm). depth 10 in.
(254 mm). length 44 in. {1120 mm).
CC-4 CANVAS COVER
(#040 144)
Heavy-duty. olive drab, waterproof,
and miidew resistant.
EDT 2400-2 TWO-WHEEL
TRAILER
(#041 722)
A 2100 lbs. (953 kg) capacity trailer
has a welded structural steel frame,
heavy-duty axie with roller bearing
nubs and leaf spring suspension.
Mounting holes for all large Miller
engine driven welding generators
are pre-punched. Hardware for.
mounting is provided. Also included
is a jack stand for raising and
lowering the tongue. safety chains.
and universal tongue mounting for
optional hitches. An optional fender
and light kit is required when trailer
IS used on the highway.
Note: Hitch must be ordered separately.
Specifications:
GVWR: 2400 Ibs. {1090 kg)
Trailer weight: 300 Ibs. (136 kg)
Trailer capacity: 2100 lbs. (953 kg)
Total width {without optional
fender kit): 62 in. (1.8 m)
Total length (without optional hitch):
96 in. (2.4 m)
Width of bed: 40-1:21n. (1029 mm)
Track width: 53-1:2 in. (1359 mm)
Height of bed: 21 in. (533 mm)
Tire size: P205D-14
Shipping weight: 300 Ibs. (136 kg)
The EDT 2400-2 trailer. when equipped
with fender and light kit and 2 in. (50 mm)
ball hiteh. and the No. 3000-4 trailer
conform to all applicable U.S. Federal
Motor Vehicle Safety Standards in effect
on date of manufacture.
NO. 4WA WELDING ACCESSORIES
(#040 045)
35 ft. (10.7 mi No 2 0 electrode
cable with electrode hoider and lug,
30 ft. (9 m) No 2 0 work cable with
lugs attached. welding helmet, and
wire scratch brush.
NO. 84X FOUR-WHEEL
TANDEM TRAILER
(#042 150
For off-the-road use only. The
tandem axle torsion bar design
enables this trailer to ride smoothiy
over rough terram.
Note: Hitch must be ordered separately.
When ordering off-road trailers, the
purchase order must include the
statement, “For off-the-road use only.”
FENDER AND LIGHT KIT
(#042 198)
Includes fenders. 12 voit light set.
FA-1 LOCKABLE FLAME
ARRESTOR FUEL CAP
(#041 056 Field only)
HITCHES
CLEVIS
(#042 151)
For use with No. 84X trailer.
Shipping weight 11 Ibs. (5 kg)
CLEVIS
{Not for highway use)
(#041 726)
For use with EDT 2400-2 trailer.
Shipping weight 11 Ibs. (5 kg)
2 in. (50 mm) BALL
(4042 153)
For use with No. 84X trailer.
Shipping weight 5 !bs. (2 kg)
2 in. (50 mm) BALL
(#041 724)
For use with EDT 2400-2 trailer.
Shipping weight 5 lbs. (2 kg)
3 in. (76 mm) LUNETTE EYE
(#042 152)
For use with No. 84X trailer.
Shipping weight 8 Ibs. (4 kg)
2-1/2 in. (64 mm) LUNETTE EYE
(#041 725)
For use with EDT 2400-2 trailer.
Shipping weight 9 Ibs. (4 kg)
3 in. (76 mm) LUNETTE EYE
(4041 628 Factory)
For use with 3000-4 trailer.
Shipping weight 9 Ibs. (4 kg)
6/89
OPTIONS AND ACCESSORIES
WELD AMMETER AND VOLTMETER
(#041 568 Factory)
(#041 569 Field)
Installs on welder control panel.
POLARITY REVERSING SWITCH
(#041 965 Factory)
(#041 966 Fieid)
AUXILIARY POWER
(#042 308 Factory)
Extends the range of this product by
adding additional auxiliary power,
which is available while not welding.
The 10 KVA three-phase kit is easily
reconnectable to 7.5 KVA single-
phase 1.0 power factor 60 Hz,
120/140 VAC. Connections made at
a junction box inside side panel.
LOCKUP PACKAGE
(#042 322 Factory)
(#042 323 Field)
A iockable, hinged, clear high-
impact plastic panel covers controls.
(Padlock not included).
STARTING AID KIT
(#042 320 Factory)
(#042 321 Field)
SPARK ARRESTOR
(#042 317 Field only)
Mandatory when operating on
California grasslands, brush or forest
covered land and ali National
Forests. For other areas, check your
state and local laws.
HF-250 SERIES
High Frequency Arc Starter
and Stabilizer
HF-250D-1 115 Volt (#042 149)
HF-250-2 230 Volt (#041 780)
A Portable 250 amp unit for 50, 60,
and 100 Hz input.
RCGD-40A REMOTE CONTROL
FACILITIES |
(#006 122 Factory)
(#041 112 Field)
Required for use with Remote
Control RHC-3-GD34A.
RHC-GD34A
REMOTE HAND CONTROL
(#041 122)
AUTOMATIC SHUTDOWN KIT
(#042 318 Factory)
(4042 319 Field)
Ideal for rental or fleet operators.
Consists of a high oil temperature
and a low oil pressure switchgauge.
Switchgauges are easy to install and
factory preset for maximum engine
protection.
EQUIPMENT REQUIRED
FOR GAS METAL ARC AND
FLUX CORED ARC WELDING
Listed by model and catalog
sheet index number
VOLTAGE SENSING WIRE
FEEDERS
For connection to standard power
source.
S-32P COMPACT, PORTABLE
WIRE FEEDER
Index No. M/6.25
For .023 - 5/64 in.(0.6 - 2.0 mm;
hard and flux cored wire.
S-32S PORTABLE WIRE FEEDER
Index No. M/6.21
For .023 - 5/64 in. (0.6 - 2.5 mm.
hard and flux cored wire.
S-32SL PORTABLE WIRE
FEEDER .
Index No. M/6.21
For 5/64 - 7/64 in. (2 - 2.8 mm: hard
and flux cored wire.
ENGINE METER KIT
(4042 334 Factory)
(4042 335 Field)
Designed to monitor critical engine
operating parameters. Consists of
individual oil temperature and oi
pressure gauges.
6.89
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