Miller BIG BLUE 600D User manual

Miller BIG BLUE 600D User manual
January 1994
Form: OM-481B
Effective With Serial No. KD536837
OWNER’S
MANUAL
Big Blue® 600D
CC/CV, DC Welding Generator
For SMAW, GMAW, FCAW, SAW Welding And CAC-A
600 Amps, 44 VDC At 100% Duty Cycle
Deutz F4L912 Air-Cooled, Diesel Engine
3kVA/kW AC Auxiliary Power With Overload Protection
Automatic Shutdown For Low Oil Pressure, High Oil Temperature, Or
Cooling System Failure
Read and follow these instructions and all
safety blocks carefully.
Give this manual to the operator.
Have only trained and qualified persons
install, operate, or service this unit.
For help, call your distributor
Call your distributor if you do not understand
the directions.
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
cover 7/93* − ST-134 686-C
© 1994 MILLER Electric Mfg. Co.
PRINTED IN USA
EMF INFORMATION
NOTE
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION
2-1.
2-2.
2-3.
2-4.
2 − SPECIFICATIONS
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
3
3
SECTION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3 − INSTALLATION
Selecting A Location And Moving Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Exhaust Pipe And Rain Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding The Generator Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote 14 Receptacle Or Terminal Strip Information And Connections . . . . . . . . . . . . . . . .
Installing Optional Ether Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
6
6
7
7
8
9
9
11
SECTION 4 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
SECTION 5 − OPERATING AUXILIARY EQUIPMENT
5-1.
120 Volt Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2.
Optional 240 Volt Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
19
SECTION
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
21
23
23
24
25
25
26
27
28
28
29
30
6 − MAINTENANCE & TROUBLESHOOTING
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil And Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Battery Voltage Or Replacing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking And Replacing Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Ether Starting Aid Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Spark Arrestor Inspection And Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Overspeed Shutdown Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-481B − 1/94
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
SECTION 8 − RUN-IN PROCEDURE
8-1.
Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2.
Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
37
SECTION
9-1.
9-2.
9-3.
9-4.
9 − AUXILIARY POWER GUIDELINES
How Much Power Does Equipment Require? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Much Power Can Generator Supply? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Connections To Supply Standby Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Extension Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
40
41
42
SECTION 10 − PARTS LIST
Figure 10-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-3. Panel, Front Lower w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-4. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-5. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
48
50
52
53
54
SECTION 1 − SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1
2
2
WARNING
• Do not touch live electrical parts.
• Disconnect input power before
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
4
installing or servicing.
when operating.
5
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
6
Safety Alert Symbol
2
Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION
3
ELECTRIC SHOCK can kill.
1
CAUTION means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And Result
4
Safety Instructions To Avoid
Hazard
5
Hazard Symbol (If Available)
6
Safety Banner
Read safety blocks for each symbol shown.
7
7
NOTE
NOTE
Special instructions for best operation − not related to safety.
Turn Off switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 − SPECIFICATIONS
Table 2-1. Welding Generator
Specification
Description
Type Of Output
Constant Current/Constant Voltage (CC/CV), Direct Current (DC)
Rated Weld Output
600 Amperes, 44 Volts DC At 100% Duty Cycle (See Section 2-2)
Amperage Range
45-800 A
Max. Open-Circuit Voltage
95 Volts DC
Welding Process
Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), And Submerged Arc
Welding (SAW); Air Carbon Arc Cutting and Gouging (CAC-A)
Auxiliary Power Rating
Single-Phase, 3 kVA/kW, 120/240 Volts AC, 26 Amperes, 60 Hz
Engine
Deutz F4L912 Air-Cooled, Diesel Engine
Engine Speed (No Load)
Weld/Power Speed: 1850 rpm
Fuel Tank Capacity
19 gal (72 L)
Overall Dimensions
See Figure 3-2
Weight
Net: 2250 lb (1021 kg); Ship: 2380 lb (1080 kg)
Options
See Rear Cover
OM-481 Page 1
2-1. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of
other settings fall between the
curves shown.
A. For Constant Current (CC) Mode
B. For Constant Voltage (CV) Mode
rsb1.1 10/91 − SB-133 004 / SB-133 003
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
•
Do not weld at rated load longer than shown below.
warn7.1 8/93
Chart
Definition
0
10
Duty Cycle is percentage of 10
minutes that unit can weld at
rated load without overheating.
Minutes
100% Duty Cycle At 600 Amperes
Continuous Welding
sb1.1 8/93 − SB-134 397-A
Figure 2-2. Duty Cycle
OM-481 Page 2
2-3. Fuel Consumption
The fuel consumption curve shows
typical fuel use under weld or power
loads.
rsb2.1 10/91 − SB-133 838
Figure 2-3. Fuel Consumption Curve
2-4. AC Auxiliary Power
The ac power curve shows the auxiliary power in amperes available at
the 120 and optional 240 volt
receptacles.
rsb3.1* 2/92 − SB-109 365-B
Figure 2-4. AC Power Curve For 120 And 240 Volt Duplex Receptacles
OM-481 Page 3
SECTION 3 − INSTALLATION
3-1. Selecting A Location And Moving Welding Generator
WARNING
ENGINE EXHAUST GASES can kill.
•
•
HOT ENGINE EXHAUST AND EXHAUST
PIPE can cause fires.
Do not breathe exhaust fumes.
•
Use in open, well-ventilated areas, or vent exhaust
outside and away from building air intakes.
FAL L I NG EQ UI PM ENT can cau se
serious personal injury and equipment
damage.
ENGINE EXHAUST SPARKS can cause
fire.
•
•
•
•
•
•
Use only U.S. Forestry Department approved spark
arrestor and comply with all local, state, and federal
laws.
A spark arrestor is mandatory in all National Forests
and in grass, brush, or forest covered lands in
California, Oregon, and Washington. Check with
state and local authorities in other areas.
Properly maintain the spark arrestor.
Stop engine and allow exhaust system to cool down
before servicing spark arrestor.
Service spark arrestor away from flammables.
Movement
Keep exhaust and pipe away from flammables.
•
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.
TILTING OF TRAILER can result in
personal injury or equipment damage.
•
Install unit properly on trailer (if applicable)
according to trailer manual.
rwarn1.1 3/93
1
1
Lifting Eye
2
Lifting Forks
Use lifting eye or lifting forks to
move unit.
OR
3
Cross Member Support
If using lifting forks, lift only from end
with cross member support (engine
end).
2
3
18 in
(460 mm)
Location
18 in
(460 mm)
18 in
(460 mm)
OR
18 in
(460 mm)
18 in
(460 mm)
rsb20.2* 11/93 − ST-800 477 / ST-134 686-C
Figure 3-1. Movement And Location Of Welding Generator
OM-481 Page 4
NOTE
Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
Inches
Millimeters
A
58
1473
B
32
813
C
68
1727
D
68
1727
E
62-3/8
1584
F
50-1/2
1283
G
46-1/2
1181
H
36
914
J
28-3/16
716
K
13-3/4
349
L
9-3/4
248
R
Engine End
A
C
B
E
H
G
D
F
J
L
Q
N
K
M
P
M
6-1/8
156
N
29-7/8
759
P
32
813
Q
1-1/16
27
R
21/32 Dia.
16 Holes
16.7 Dia.
16 Holes
ST-156 466
Figure 3-2. Overall Dimensions And Base Mounting Hole Layout
1
Engine
End
17.5°
20°
20°
1
Trailer Hitch
Install unit onto trailer according to
trailer manual.
15°
S-0024-B
Figure 3-3. Maximum Welding Generator Tilt Angles
3-2. Installing Exhaust Pipe And Rain Cap
Stop engine and allow to cool.
Do not blow exhaust toward
air cleaner or air intake.
3
1
1
Exhaust Pipe
2
Muffler Pipe
Install exhaust pipe over muffler
pipe. Secure exhaust pipe to top
cover using supplied hardware.
3
Rain Cap
Install so cap opens toward front of
unit.
2
Tools Needed:
1/2 in
rsb19.4* 5/92 − ST-154 087
Figure 3-4. Installing Exhaust Pipe And Rain Cap
OM-481 Page 5
3-3. Connecting The Battery
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.
•
•
•
Stop engine before disconnecting or connecting battery cables.
Always wear a face shield and proper protective clothing when working on a battery.
Do not allow tools to cause sparks when working on a battery.
rwarn2.1 9/91
1
Engine Control Switch
Place switch in the Off position.
1
Remove rear left side panel.
2
Positive (+) Battery Terminal
3
Positive (+) Battery Cable
Connect positive cable first.
2
4
4
Negative (−) Battery Terminal
5
Negative (−) Battery Cable
Connect negative cable last.
Reinstall side panel.
If engine does not crank, check battery voltage according to Section
6-6.
+
−
5
3
Tools Needed:
1/2 in
ST-153 654-A / Ref. ST-131 784-A / Ref. S-0756
Figure 3-5. Connecting The Battery
3-4. Lower Front Panel
Open lower front door.
2
1
1
Equipment Grounding
Terminal (Section 3-5)
2
Remote 14 Receptacle
(Section 3-9)
3
Positive (+) Weld Output
Terminals (Section 3-8)
4
Negative (−) Weld Output Terminals
Close door.
Route all cables under bar.
3
4
Tools Needed:
3/8, 1/2 in
Figure 3-6. Lower Front Panel
OM-481 Page 6
Ref. ST-134 687-A
3-5. Grounding The Generator Auxiliary Power System
1
The generator auxiliary power neutral
is connected to the machine frame.
Equipment Grounding
Terminal
GND/PE
1
Connect To Earth Ground
If Required By National
Or Local Codes
Tools Needed:
1/2 in
rsb5.1 8/93 − Ref. ST-134 687-A / S-027 657-D
Figure 3-7. Equipment Grounding Connection
3-6. Engine Prestart Checks
WARNING
ENG I NE FUEL can cau se fi re or
explosion.
•
•
•
REMOVE FUEL CAP SLOWLY; FUEL
SPRAY may cause injury; FUEL may be
under pressure.
Stop engine before fueling.
Do not fuel while smoking or near sparks or flames.
Do not overfill tank; clean up any spilled fuel.
•
Rotate fuel cap slowly and wait until hissing stops
before removing cap.
USE OF GASOLINE will damage engine.
•
Do not use gasoline.
Lack of lubrication in gasoline damages injector pump
and injectors.
rwarn3.1* 3/93
Check all fluids daily. Engine must
be cold and on a level surface.
4
1/2 in
(13 mm)
FUEL
Add fresh fuel before starting
engine the first time (see
Figure 6-2).
OIL
1
Full
Full
2
Fuel Cap
Do not run out of fuel or air enters
fuel system and causes starting
problems.
2
Oil Dipstick
3
Oil Fill Tube
If oil is not up to full mark, add oil
(see Figure 6-2).
Engine stops if oil pressure is too
low or oil temperature is too high
(see Figure 4-9).
4
Exhaust Pipe
Follow break-in
engine manual.
procedure
in
If unburned fuel and oil collect in
exhaust pipe during break-in, see
Section 8.
Close door
1
3
rsb4.2 11/92 − ST-156 467-B
Figure 3-8. Checking Oil And Fuel
OM-481 Page 7
3-7. Selecting And Preparing Weld Output Cables
1
Weld Output Cable
Determine total cable length in weld
circuit and maximum welding amperes. Use Table 3-1 to select proper cable size.
Use shortest cables possible.
3
Do not use damaged cables.
4
2
OR
2
2
Terminal Lug
Use lugs of proper amperage
capacity and hole size for connecting to work clamp, wire feeder or
electrode holder, and weld output
terminals.
1
3
Wire Feeder
4
Insulated Electrode Holder
5
Work Clamp
Install onto work cable.
10 ft (3 m)
5
For Example,
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
10 ft (3 m)
Tools Needed:
sb6.5* 11/92 − S-0752
Figure 3-9. Selecting And Preparing Weld Output Cables
Table 3-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Welding
Amperes
10 To 60%
Duty Cycle
60 Thru 100%
Duty Cycle
100
150
200
250
300
350
400
500
600
700
800
900
1000
4
3
3
2
1
1/0
1/0
2/0
3/0
4/0
4/0
2-2/0
2-2/0
4
3
2
1
1/0
2/0
2/0
3/0
4/0
2-2/0
2-2/0
2-3/0
2-3/0
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
4-4/0
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
10 Thru 100% Duty Cycle
4
2
1
1/0
2/0
3/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
2-4/0
3
1
1/0
2/0
3/0
4/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-3/0
2
1/0
2/0
3/0
4/0
2-2/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-3/0
1
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
4-4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
OM-481 Page 8
Ref. S-0007-C
3-8. Connecting To Weld Output Terminals
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
Always wear dry insulating gloves.
Do not touch live electrical parts.
Stop engine before making any weld output connections.
Read Safety Precautions at beginning of this manual.
rwarn13.1 2/92
1
Positive (+) Weld Output
Terminals
2
Negative (−) Weld Output Terminals
For Direct Current Electrode Positive (DCEP), connect work cable to
− terminal and electrode holder
cable to + terminal.
For Direct Current Electrode Negative (DCEN), reverse cable connections.
To prevent overheating and damage, two terminals are provided for
each polarity in case more than one
cable is needed to carry current to
a single arc (see Table 3-1). This
unit is not designed to supply multiple arcs.
Tools Needed:
3/8, 7/8 in
1
Ref. ST-134 687-A / ST-145 043
2
Figure 3-10. Weld Output Connections
3-9. Remote 14 Receptacle Or Terminal Strip Information And Connections
A. Remote 14 Receptacle
1
2
A
B
K
J
I
H
C L N
D M
G
E F
1
Remote 14 Receptacle RC3
2
Keyway
3
Plug
4
Threaded Collar
To connect to this receptacle, align
keyway, insert plug, and tighten
threaded collar.
Socket Information:
Remote Contactor
3
Tools Needed:
4
A
24 volts ac. Protected by circuit breaker CB4.
B
Contact closure to pin A completes 24 volts ac contactor control
circuit.
I
115 volts ac. Protected by circuit breaker CB3.
J
Contact closure to pin I completes 115 volts ac contactor control
circuit.
G
Circuit common for 24 and 115 volts ac circuits.
Remote Amperage/Voltage Control
C
Command reference; +10 volts dc.
D
Control circuit common.
E
Input command signal (potentiometer wiper or 0 to +10 volts dc).
K
Chassis common.
The remaining sockets are not used.
3/8 in
sb7.1 3/93 − Ref. ST-145 043 / Ref. S-0004-A / S-0750
Figure 3-11. Remote 14 Connections
OM-481 Page 9
B. Terminal Strip 3T
WARNING
ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.
•
•
•
Do not touch live electrical parts.
Stop engine before making any internal inspection or connections.
Do not connect to Remote 14 receptacle and terminal strip at the same time.
Output (Contactor) can be energized from either the receptacle or terminal strip. Use only one remote control method.
Stop engine.
Remove plug from remote control
cord.
3
Open right side door.
1
Route cord leads through strain
relief.
3T
24VAC
Contactor
A
2
2
Terminal Strip 3T
3
Label
Connect leads to 3T using terminal
information shown in Figure 3-11.
B
Secure cord in strain relief.
C
0-1 k
Remote
A/V
24VAC 10A Feeder Power
Strain Relief
D
0-10VDC
Output
15A
115VAC
Feeder
Power
Circuit Common
115VAC
Contactor
Close door.
Ω
E
G
I
Equipment
Ground
1
K
J
S-138 042
Tools Needed:
ST-134 839-A
Figure 3-12. Terminal Strip 3T Connections
OM-481 Page 10
3-10. Installing Optional Ether Cylinder
WARNING
IMPROPER HANDLING OR EXPOSURE TO ETHER
can seriously harm your health.
•
Follow manufacturer’s safety instructions on cylinder.
INJECTING ETHER WHILE ENGINE IS RUNNING
can damage engine.
•
Do not use Ether Starting Aid while engine is running.
After installing cylinder, wait at least 10 minutes before use to let ether
particles settle to prevent atomizer plugging.
Stop engine. Open side door(s) to
locate ether starting aid.
1
Ether Cylinder
Obtain cylinder.
2
1
Nozzle
Remove protective cover, and
clean nozzle and fitting area on
cylinder.
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove valve cap, and clean fitting
area.
2
Insert cylinder through clamp and
onto fitting.
Tighten clamp when cylinder is tight
in fitting.
Put cap on fitting when cylinder is
removed.
3
4
6
5
Tools Needed:
rsb15.1 6/92A − ST-153 382
Figure 3-13. Installing Ether Cylinder
OM-481 Page 11
SECTION 4 − OPERATING THE WELDING GENERATOR
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
•
ENGINE EXHAUST GASES can kill.
•
•
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
ENGINE FUEL can cause fire or explosion.
WELDING can cause fire or explosion.
•
•
•
•
•
•
•
•
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
•
•
Wear welding helmet with correct shade of filter.
Wear correct eye, ear, and body protection.
•
•
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
1
2
3
4
5
Keep away from moving parts such as fans, belts,
and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
FUMES AND GASES can be hazardous.
•
•
•
Stop engine before fueling.
Do not fuel while smoking or near sparks or flames.
Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
•
•
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
6
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near any welding operations.
See Safety Precautions at beginning of manual for basic welding safety information.
rwarn5.1 10/91
7
1
2
3
8
9
10
16
DC Voltmeter
DC Ammeter
Amperage And Voltage Adjustment Control
Ether Starting Aid Switch (Optional)
Service Engine Air Cleaner
Light (Section 6-2)
Amperage/Voltage Control
Switch
CC/CV Switch
Output (Contactor) Switch
Check Cooling System/Alternator Light (Section 6-2)
Engine Control Switch
Engine Hour Meter
Fuel Gauge
Battery Ammeter
Oil Pressure Gauge/Switch
Oil Temperature Gauge/
Switch
Ampere Ranges Switch
1
Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet
4
5
6
11
12
16
15
14
13
7
8
9
10
11
12
13
14
15
Ref. ST-134 687-A
Figure 4-1. Controls
1
2
3
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct shade
of filter (see ANSI Z49.1).
sb3.1 10/91
Figure 4-2. Safety Equipment
OM-481 Page 12
1
1
Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
Tools Needed:
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1 2/93
Figure 4-3. Work Clamp
1
CC/CV Switch
Use switch to select type of weld
output.
Use constant current (CC) position
for SMAW and CAC-A.
Use constant voltage (CV) position
for wire feeding processes, GMAW,
SAW, and FCAW. When using CV
position, place Ampere Ranges
switch in CV position (see
Figure 4-5).
1
Ref. ST-131 784-A
Figure 4-4. CC/CV Switch
CAUTION
ARCING can damage switch.
•
Do not change Ampere Ranges switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail.
rwarn6.1 2/93
1
Ampere Ranges Switch
Use switch to select weld output
range.
2
2
Amperage And Voltage Adjustment Control
Use control to adjust amperage
within range selected by Ampere
Ranges switch.
1
The numbers are a percentage of
the range selected and not an actual value.
Control may be adjusted while
welding.
Example Of Front Panel Amperage Control
In Example:
Range = 55 to 125 A DC
Percentage Of Range = 50%
Weld Output = 90 A DC (50% of 55 to 125)
Set Range
Set Percentage
Weld Output = 90 A DC
Figure 4-5. Amperage Controls
OM-481 Page 13
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.
rwarn7.1 9/91
Weld output terminals are energized when Output
(Contactor) switch is On and engine is running.
1
1
Output (Contactor) Switch
Use switch to select way of controlling unit output.
For front panel control, place switch
in On position.
For remote control, place switch in
Remote position (see Section 3-9).
Figure 4-6. Remote Controls
1
Amperage/Voltage Control
Switch
Use switch to select way of controlling amperage and voltage
adjustment.
1
For front panel control, place switch
in Panel position.
For remote control, place switch in
Remote position.
Example Of Combination Remote Amperage Control
2
Remote Foot Control
3
Remote Amperage Control
See example below.
Set Switches
Set Range
Set Percentage
3
Min (55 A DC/CC)
2
In Example:
Min = 55 A DC/CC
Percentage Of Range = 50%
Max = 90 A DC/CC (50% of 55 to 125)
Max (90 A DC/CC)
Adjust Remote Control
Figure 4-7. Amperage/Voltage Control Switch
OM-481 Page 14
S-0774 / S-0769
WARNING
INJECTING ETHER WHILE ENGINE IS RUNNING can damage engine.
•
Do not use Ether Starting Aid while engine is running.
After installing cylinder, wait at least 10 minutes before use to let ether particles settle to prevent atomizer plugging.
1
2
Engine Control Switch
Use switch to start and stop engine.
1
To start, turn switch to Start position
and release as soon as engine
starts. Do not engage starter while
flywheel is rotating.
In Run position, engine runs at weld
speed all the time.
To stop engine, turn switch to Off
position.
If unit has optional overspeed shutdown kit, engine stops automatically when speed exceeds normal
rpm.
2
Ether Starting Aid Switch
Push switch up and release while
cranking engine. Ether is sprayed
into engine manifold when switch is
released.
rsb16.1* 4/92
Figure 4-8. Engine Control Switch And Optional Ether Starting Aid Switch
1
2
1
Engine Hour Meter
Use meter to check total operating
hours (see Section 6-1).
2
Fuel Gauge
Use gauge to check fuel level in fuel
tank.
3
Battery Ammeter
Use ammeter to check amperage
output to the battery. The ammeter
reads near 0 (zero) when the engine is running. If ammeter is at a
negative number, the battery is discharging. Stop engine, and do not
run until problem is fixed.
4
Oil Pressure Gauge/Shutdown Switch
Use gauge/switch to check oil pressure. Normal operating pressure is
about 50 psi (345 kPa). If oil pressure drops to 30 psi (207 kPa),
switch closes and engine stops.
5
Oil Temperature Gauge/Shutdown Switch
Use gauge/switch to check oil temperature. Normal operating temperature is about 225°F (107° C). If oil
temperature rises to 250°F (121°
C), switch closes and engine stops.
5
4
3
rsb6.1* 2/92
Figure 4-9. Engine Hour Meter And Gauges
OM-481 Page 15
1
1
DC Voltmeter
Voltmeter displays voltage at the
weld output terminals, but not necessarily the welding arc due to
cable resistance, poor connections, etc.
2
2
DC Ammeter
Ammeter displays amperage output of unit.
Figure 4-10. Voltmeter And Ammeter
WARNING
BUILDUP OF SHIELDING GAS can harm health or kill.
•
Shut off shielding gas supply when not in use.
warn1.1 9/91
2
1
4
OR
1
Shielding Gas Cylinder
2
Valve
3
Gun Trigger
4
Foot Control
Open valve on cylinder just before
welding.
Gun trigger or foot control turns
weld output and gas flow on and off.
Close valve on cylinder when finished welding.
3
sb5.2 2/92 − S-0621-C
Figure 4-11. Shielding Gas
Install &
Connect
Equipment
Select
Electrode
Insert
Electrode
Into Holder
Put On
Personal Safety
Equipment
Set Controls
Start Engine
Turn On Auxiliary
Equipment
Begin Welding
rsb8.1 9/92
Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Turn On Auxiliary
Equipment
Put On
Personal Safety
Equipment
Turn On
Wire Feeder
Set Controls
Turn On
Shielding Gas
Start Engine
Begin Welding
rsb7.1 9/92
Figure 4-13. Sequence Of Gas Metal Arc Welding (GMAW)
OM-481 Page 16
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Turn On
Wire Feeder
Put On
Personal Safety
Equipment
Set Controls
Turn On
Auxiliary
Equipment
Start Engine
Begin
Welding
Figure 4-14. Sequence Of Flux Cored Arc Welding (FCAW)
Install &
Connect
Equipment
Install & Prepare
Wire Feeding
System
Turn On Feeder
Install & Prepare
Flux System
Turn On
Flux System
Put On
Personal Safety
Equipment
Set Controls
Start Engine
Begin Welding
Figure 4-15. Sequence of Submerged Arc Welding (SAW)
Install &
Connect
Equipment
Connect
Compressed Air
Supply
Start Engine
Turn On
Auxiliary
Equipment
Select
Carbon
Electrode
Put On
Personal Safety
Equipment
Insert Electrode
Into Torch
Set Controls
Turn
On Air
Supply
Begin
Cutting Or
Gouging
Figure 4-16. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A)
OM-481 Page 17
SECTION 5 − OPERATING AUXILIARY EQUIPMENT
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
•
ELECTRIC SPARKS can cause fire.
Do not touch live electrical parts.
Stop engine before making internal inspection or
reconnection.
Ground generator according to all applicable
national, state, and local codes.
Connect equipment grounding terminal to a proper
earth ground.
Do not connect to any electrical distribution system
normally supplied by utility power unless a proper
transfer switch and grounding procedure are
employed (see Section 9).
MOVING PARTS can cause serious
injury.
•
•
Keep away from moving parts such as fans, belts,
and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
•
If using auxiliary power only and not welding,
disconnect both welding cables to prevent live
electrode from causing electric shock and fire
hazards.
• Watch for fire.
• Keep a fire extinguisher nearby, and know how to
use it.
The weld output terminals are electrically energized
when the engine is running and the contactor, if
applicable, is energized.
LOW VOLTAGE AND FREQUENCY can
damage electrical equipment.
•
Turn off or unplug all electrical equipment connected
to auxiliary power receptacles before starting or
stopping the engine.
When starting or stopping, the engine has low speed
which causes low voltage and frequency. rwarn8.1 10/92
5-1. 120 Volt Duplex Receptacles
1
1
120 V 15 A AC Duplex Receptacle RC1
2
120 V 15 A AC Duplex Receptacle RC2
Receptacles supply 60 Hz singlephase power at weld/power speed.
Maximum output from either receptacle is 3 kVA/kW.
3
3
Circuit Breakers CB1 And
CB2
CB1 protects RC1 and CB2 protects RC2 from overload. If CB1 or
CB2 opens, the receptacle does
not work. Press button to reset
breaker.
2
4
Total Auxiliary Power Output
Combined output of all receptacles
limited to 3 kVA/kW output of the
generator.
EXAMPLE: If 14 A is drawn from
one 120 V duplex receptacle, only
11 A is available at the other 120 V
duplex receptacle:
(120 V x 14 A) + (120 V x 11 A) = 3.0
kVA/kW
4
Ref. ST-145 043
Figure 5-1. Auxiliary Power Receptacles And Circuit Breakers
OM-481 Page 18
5-2. Optional 240 Volt Duplex Receptacle
1
240 V 13 A AC Duplex Receptacle RC1
Receptacle supplies 60 Hz singlephase power at weld/power speed.
Maximum output from this receptacle is 3 kVA/kW.
3
1
2
2
120 V 15 A AC Duplex Receptacle RC2 (Section 5-1)
3
Circuit Breakers CB1 And
CB2
CB1 and CB2 protect the 120 V and
240 V receptacles from overload. If
CB1 or CB2 opens, the 240 V receptacle and one half of the 120 V
receptacle does not work. 120 volts
may still be present at the 240 volt
receptacle. Press button to reset
breaker.
4
Total Auxiliary Power Output
Combined output of all receptacles
limited to 3 kVA/kW output of the
generator.
EXAMPLE: If 10 A is drawn from the
240 V receptacle, only 5 A is available at the 120 V receptacle:
(240 V x 10 A) + (120 V x 5 A) = 3.0
kVA/kW
4
Ref. ST-145 043 / ST-145 304
Figure 5-2. Optional 240V Duplex Receptacle And Circuit Breakers
See Section 9
Auxiliary Power
Guidelines
Install &
Connect
Equipment
Start Engine
Place Engine
Control Switch In
Run Position
Turn On Auxiliary
Equipment
Begin Operation
rsb11.1* 2/93
Figure 5-3. Sequence Of Auxiliary Equipment Operation
OM-481 Page 19
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
•
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
ENGINE EXHAUST GASES can kill.
•
•
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
ENGINE FUEL can cause fire or explosion.
•
•
•
Stop engine before fueling.
Do not fuel while smoking or near sparks or flames.
Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
•
•
OM-481 Page 20
Keep away from moving parts such as fans, belts,
and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
HOT PARTS can cause severe burns.
•
•
Allow cooling period before servicing.
Wear protective gloves and clothing when working
on a hot engine.
ENGINE EXHAUST SPARKS can cause
fire.
•
•
•
•
•
Use only U.S. Forestry Department approved spark
arrestor and comply with all local, state, and federal
laws.
A spark arrestor is mandatory in all National Forests
and in grass, brush, or forest covered lands in California, Oregon, and Washington. Check with state
and local authorities in other areas.
Properly maintain the spark arrestor.
Stop engine and allow exhaust system to cool down
before servicing spark arrestor.
Service spark arrestor away from flammables.
Maintenance to be performed only by qualified persons.
rwarn9.1 10/93
6-1. Routine Maintenance
100 Hours
Stop engine before maintaining.
8 Hours
Change
Oil
6-3
FUEL
See
Section
3-6
Check
Fluid
Levels
OIL
full
Drain
Water
From Fuel
System
FUEL
WATER
engine
manual
6-3
O
I
L
F U
Wipe
Up
Spills
E
L
6-6
50 Hours
3-8
Clean
Air
Filter
Clean
And
Tighten
Weld
Terminals
10
Change
Oil
Filter
Clean And
Tighten
Battery
Connections
Replace
Unreadable
Labels
250 Hours
6-10
engine
manual
1/2 in.
(13 mm)
6-8
FUEL
SLUDGE
6-3
engine
manual
Check
And
Clean
Spark
Arrestor
500 Hours
−−
OR
−−
200 Hours
−−
6-4
1000 Hours
Tape Or
Replace
Cracked
Cables
Blow Out
Or
Vacuum
Inside
Change
Fuel
Filter
Check
Belt
Tension
Drain
Sludge
From Fuel
Tank
Check
Valve
Clearance
3000 Hours
engine
manual
Clean/Set
Injectors
Do not throw away engine
fluids − take to area recycling
center.
Figure 6-1. Maintenance Schedule
OM-481 Page 21
OM-481 Page 22
Air Filter Service . . . . . . . 50 hours or less − see Owner’s Manual
Air Filter Element . . . . . . AC 302C, Donaldson P10-1222, Fleetguard AF437K,
Fram CAK 253, Purolator AF-2030K
DEUTZ F4L912 DIESEL ENGINE
See Engine Manual for complete engine care.
Give Engine Specification and Serial Number when ordering parts.
Battery . . . . . . . . BCI Group 31
+
Diesel
°F
+10
0
+60
+40
+30
-10
-20
Engine RPM − No Load
Weld/Power . . . . 1850
30
+20
Valve Clearance −Cold
Intake . . . . . . . 0.006 in (0.15 mm)
Exhaust . . . . . 0.006 in (0.15 mm)
Engine Cooling
+30
20W-20
Recommended Oil . . . . . API Service Classification CD/CE
Oil And Filter Change . . . dirty
conditions . . . . . 100 hours or less
normal
conditions . . . . . 125 to 150 hours
Oil Filter . . . . . . . . . . . . . . Deutz 116-0024, Fleetguard LF4056,
Fram PH2842, Hastings P352 or
FP352
Oil Capacity . . . . . . . . . . . 11.5 qt (11 L) or
12 qt (11.4 L) with filter change
°C
+40
10W
Figure 6-2. Maintenance Label
Check
daily.
Cranking Performance at 0°F
(-18°C) . . . . . . . . 815 Amps
Injectors . . . . . . . . . . . . . . Deutz 213-7575
Nozzle . . . . . . . . . . . . . . . Deutz 223-3086
-10
Fuel Capacity . . . . . . . . . 19 gal (72.8 L)
Fuel Grade . . . . . . . . . . . 1-D or 2-D Cetane No. 45 min.
Primary Fuel Filter/
Water Seperator . . . . . . . MILLER 062 342, Fleetguard FF194, Fram P1107
Secondary Fuel Filter . . . Deutz 116-0243, Fleetguard FF5018, Fram P4102
Fill filter with clean fuel before installing − read instructions on filter.
Avoid recirculation of air from hot air
exit to blower intake.
Blower Belt . . Deutz 223-5256,
Gates 7580
Do NOT
use ether.
Have only trained technician maintain injection pump and injectors. AIR, WATER, or
GASOLINE will harm the injection system. If tank is run out of fuel or fuel filter is
changed, bleeding of air is required.
Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours −
see Owner’s Manual
Ref. S-120 629-C
6-2. Maintenance Lights
1
1
2
Service Engine Air Cleaner
Light
If light comes on, service engine air
cleaner (see Section 6-4).
2
Check Cooling System/Alternator Light
If light comes on, engine stops.
Check engine belt (see Section
6-8).
Ref. ST-134 687-A / Ref. ST-131 784-A
Figure 6-3. Maintenance Lights
6-3. Oil And Fuel System Components
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
WARNING
Stop engine.
1
1
See engine manual for fuel filter replacement procedure.
2
4
2
Oil Filter
3
Oil Drain
See engine manual for oil change
procedure.
5
4
Fuel/Water Separator
5
Petcock
Drain water from fuel system as follows: put metal container under petcock, open petcock, and close petcock when fuel appears.
3
6
Tools Needed:
6
Fuel Filter
7/8, 9/16 in
Sludge Drain Plug
Put metal container under drain,
and remove plug to drain sludge.
Reinstall plug when done.
Close side door.
Ref. ST-156 467-B
Figure 6-4. Oil And Fuel System Components
OM-481 Page 23
6-4. Servicing Air Cleaner
CAUTION
MOVING PARTS can cause injury.
•
•
•
DIRTY AIR can damage engine.
•
Keep away from moving parts such as fans, belts,
and rotors.
Stop engine before inspecting or servicing air
cleaner.
Allow engine to cool down before servicing.
7
6
5
4
3
•
2
Do not run engine without air cleaner element in
place or with dirty element.
Wipe out housing with a damp cloth − Do not blow
out inside of air cleaner housing or Donaclone tube
(if equipped) with compressed air.
Loss of engine power and excessive smoke in engine exhaust indicates a dirty element. Clean or
replace element if dirty or damaged.
1
Replace element yearly or after six
cleanings.
Stop engine.
1
Dust Cap
2
Baffle
3
Wing Nut
4
Element
5
Plastic Fins
6
Clamp
7
Housing
Wipe off dust cap. Loosen clamp
and remove cap. Remove baffle
and dump out dust.
Wash
Rinse
Air Dry
Inspect
Remove wing nut and element.
Wipe cap and housing with clean,
damp cloth. Reinstall baffle and cap
to keep dust out of housing.
Do not remove plastic fins when
cleaning element.
8
OR
8
9
Washing
Use Donaldson D-1400 detergent
and water solution.
Allow element to air dry before use.
9
Compressed Air
Keep air nozzle at least 1 in. (25
mm) from inside of element. Maximum air pressure: 100 psi (690
kPa).
Replace element if holes or damaged gaskets are found.
Remove cap and reinstall element.
Reinstall cap (arrows pointing up).
Blow
Inspect
Figure 6-5. Air Cleaner Service
OM-481 Page 24
rsb18.1 2/93 − ST-153 585 / S-0698-B
6-5. Adjusting Engine Speed
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
WARNING
Engine Speed
RPM
Weld/Power
1850
Stop engine.
Engine speeds have been factory
set and should not require adjustment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load
speeds. If necessary, adjust
speeds as follows:
2
1
1
Speed Adjustment Screw
2
Locknut
Loosen nut. Start engine.
Turn screw until engine runs at
weld/power speed. Tighten locknut.
Stop engine.
Close side door.
Tools Needed:
9/16, 7/8 in
ST-134 730-C
Figure 6-6. Engine Speed Adjustments
6-6. Checking Battery Voltage Or Replacing Battery
WARNING
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can burn
eyes and skin.
•
•
Stop engine before disconnecting or connecting
battery cables.
Always wear a face shield and proper protective
clothing when working on a battery.
•
•
•
Do not allow tools to cause sparks when working on
a battery.
Do not use welder to charge batteries or jump start
vehicles.
Observe correct polarity (+ and −) on batteries.
rwarn10.1 9/91
If engine does not crank, check battery voltage as follows:
1
1
Engine Control Switch
Place Engine Control switch in the
Off position.
2 Battery
3 Negative (−) Battery Cable
4 Positive (+) Battery Cable
5 Voltmeter
4
6
3
If battery voltage is less than 12.4
volts, charge battery following battery charger’s instructions.
If battery tests okay but unit does
not crank, contact Factory Authorized Service Station/Service
Distributor.
To replace battery, proceed as
follows:
5
2
Tools Needed:
Disconnect battery cables, negative cable first.
6 Hold Down
Remove hold down and battery. Install new battery and secure with
hold down. Reconnect cables, negative (−) cable last. Reinstall side
panel.
1/2 in
Ref. ST-131 784-A / ST-153 654
Figure 6-7. Checking And Replacing Battery
OM-481 Page 25
6-7. Overload Protection
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
WARNING
A. Circuit Breakers CB3 And CB4
Stop engine.
Open lower front door.
1
Circuit Breaker CB3
CB3 protects the 115 volts ac output to Remote 14 receptacle RC3
and terminal strip 3T. If CB3 opens,
the 115 volts ac output stops.
1
2
Circuit Breaker CB4
CB4 protects the 24 volts ac output
to Remote 14 receptacle RC3 and
terminal strip 3T. If CB4 opens, the
24 volts ac stops.
If a circuit breaker opens, press button to reset breaker.
Close door.
2
Tools Needed:
3/8 in
Ref. ST-145 043
Figure 6-8. Circuit Breakers CB3 And CB4
B. Magnetic Shutdown Switch Fuse F
1
Fuse F protects the magnetic shutdown switch MS1 from damage due
to overload. If F opens, the engine
stops. Do not run engine until problem is corrected.
1
Access Door
Remove screws to open upper front
panel access door.
2
Magnetic Shutdown Switch
MS1
3
Fuse F (See Parts List For
Rating)
Check F and replace if open. Close
and secure access door.
2
Tools Needed:
3
3/8, 1/2 in
ST-156 468
Figure 6-9. Shutdown Fuse F Location
OM-481 Page 26
6-8. Checking And Replacing Alternator Belt
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
WARNING
1
1/2 in (13 mm)
Maximum
2
4
5
3
Tools Needed:
1/2 in, 13 mm
Stop engine.
Push down belt as far as it will go, then measure distance from belt to straight edge.
Recheck tightness of belt. Readjust if
necessary.
If less than 1/2 in (13 mm), belt is okay. If not
okay, adjust belt as follows:
Replace belt if damaged or cracked. Replace
belt as follows:
Remove rear panel.
4
1
Fan Pulley
Loosen hex nut on bracket.
2
Alternator Pulley
3
Engine Belt
Loosen hex nuts, pivot alternator counterclockwise, and remove belt. Install new belt,
pivot alternator clockwise, adjust tightness,
and tighten hex nuts. Recheck tightness of
new belt after operating engine 15 minutes
and again after 20 hours.
A V-belt drives the engine cooling fan and alternator. To check tightness of belt, proceed
as follows:
5
Place straight edge along top of pulleys.
Alternator Bracket
Alternator Pivot Hex Nut
Loosen hex nut. Pivot alternator clockwise
until belt is tight. Tighten hex nuts.
Reinstall guard and rear panel.
Ref. ST-134 730-B
Figure 6-10. Checking And Replacing Alternator Belt
OM-481 Page 27
6-9. Optional Ether Starting Aid Maintenance
WARNING
IMPROPER HANDLING OR EXPOSURE TO ETHER can seriously harm your health.
•
Follow manufacturer’s safety instructions on cylinder.
Stop engine.
1
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.
1
Ether Cylinder
2
Valve
3
Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and
valve fitting is clean.
3
33 oz
(935 g)
15 oz
(425 g)
Full
2
Replace cylinder according to Section 3-10.
Empty
rsb17.1 4/92 − ST-153 382 / S-0692
Figure 6-11. Optional Ether Starting Aid Maintenance
6-10. Optional Spark Arrestor Inspection And Cleaning
READ SAFETY BLOCKS at start
of Section 6 before proceeding.
WARNING
Stop engine and allow to cool.
3
1
Spark Arrestor
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
1
3
2
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
Exhaust Pipe
Stop engine and allow to cool.
Reinstall cleanout plug.
ST-800 463
Figure 6-12. Spark Arrestor Inspection and Cleaning
OM-481 Page 28
6-11. Optional Overspeed Shutdown Valve Adjustment
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
WARNING
Stop engine.
10
9
The overspeed shutdown valve
protects the engine from damage
due to high engine speed. If the engine stops, the valve may be
closed.
8
Shutdown speed is between 1950
and 2100 rpm. Use a tachometer to
check shutdown speed as follows:
Open right side door and remove
rear panel.
2
3
1
1
Air Cleaner
2
Hose Into Air Cleaner
3
Hose Clamp
Loosen clamp and remove hose.
4
Plastic Cap
5
High Speed Stop Screw
6
Lock Nut
Remove plastic cap from screw.
Loosen nut. Turn screw out (toward
front of engine) several turns.
7
Speed Control Lever
8
Overspeed Shutdown Valve
Start engine and increase speed by
moving lever toward high speed
stop screw. Note engine rpm when
valve closes and stops engine.
Engine End
If shutdown speed is not between
1950 and 2100 rpm, adjust as
follows:
9
Lock Nut
10 Valve Adjustment Screw
Loosen nut and turn screw one turn
(clockwise to increase and counterclockwise to decrease shutdown
rpm). Tighten nut.
Check shutdown speed and repeat
adjustment if needed.
Stop engine.
Turn high speed stop screw in until
screw touches lever. Tighten lock
nut on screw and reinstall plastic
cap.
Install hose and hose clamp. Install
rear panel and close side door.
7
6
5
4
If necessary, adjust engine speed
according to Section 6-5.
Tools Needed:
3/8 in
Ref. ST-800 469 / ST-134 730-C
Figure 6-13. Overspeed Shutdown Valve Adjustment
OM-481 Page 29
6-12. Troubleshooting
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
•
ENGINE FUEL can cause fire or explosion.
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Stop engine before installing or servicing.
Keep all panels and covers securely in place.
•
•
•
ENGINE EXHAUST GASES can kill.
•
•
Do not fuel while smoking or near sparks or flames.
Do not overfill tank; clean up any spilled fuel.
MOVING PARTS can cause injury.
•
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
•
HOT PARTS can cause severe burns.
•
•
Stop engine before fueling.
Allow cooling period before servicing.
Wear protective gloves and clothing when working
on a hot engine.
Keep away from moving parts such as fans, belts,
and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
Troubleshooting to be performed only by qualified
persons.
rwarn11.1 11/91
Table 6-1. Welding Trouble
Trouble
No weld output.
Remedy
Be sure Ampere Ranges switch is not set between positions.
Figure 4-5
Place Output (Contactor) switch in On position, or place switch in
Remote 14 position and connect remote contactor to Remote 14
receptacle or terminal strip 3T.
3-9,
Figure 4-6
Check and secure connections to Remote 14 receptacle or terminal strip 3T.
3-9
Reset circuit breaker CB3 and/or CB4.
6-7
Have Factory Authorized Service Station/Service Distributor
check brushes and slip rings, and circuit boards PC1 and PC2.
−−
Disconnect equipment from auxiliary power receptacles.
Erratic weld output.
Check and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Tighten lead connections to Ampere Ranges switch.
High or low weld output voltage.
OM-481 Page 30
5-1, 5-2
−−
Figure 4-3
−−
Figure 4-5
Have Factory Authorized Service Station/Service Distributor
check circuit boards PC1 and PC2.
−−
Check and adjust engine speed.
6-5
Check CC/CV switch position.
Wire feeder not operating.
Section
Figure 4-4
Have Factory Authorized Service Station/Service Distributor
check circuit board PC1.
−−
Reset circuit breaker CB3 and/or CB4.
6-7
Table 6-2. Auxiliary Power Trouble
Trouble
Remedy
Section
No output at 120 volt or optional 240
volt ac receptacles RC1 and RC2.
Reset circuit breaker CB1 and/or CB2.
5-1, 5-2
Low or high auxiliary power output voltage.
Adjust engine speed.
6-5
Have Factory Authorized Service Station/Service Distributor
check brushes and slip rings, and resistor R3.
−−
Table 6-3. Engine Trouble
Trouble
Engine does not start.
Engine suddenly stops.
Remedy
Section
Have Factory Authorized Service Station/Service Distributor
check engine control switch S1.
−−
Check fuel level.
3-6
Check battery and replace if necessary.
6-6
Check oil level. Engine stops if oil temperature is too high or oil
pressure is too low.
3-6
Check Magnetic Shutdown switch MS1 Fuse F and replace if
necessary.
6-7
Check engine battery charging system according to engine service manual.
−−
If Check Cooling System/Alternator light is on, check and replace
engine belt.
6-8
Check oil level. Engine stops if oil temperature is too high or oil
pressure is too low.
3-6
Check Magnetic Shutdown switch MS1 Fuse F and replace if
necessary.
6-7
Check engine speed. Optional overspeed shutdown stops engine if speed exceeds normal rpm.
6-5
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine.
8
Battery discharges between uses.
Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.
−−
Periodically recharge battery (approximately every 3 months).
6-6
Replace battery.
6-6
OM-481 Page 31
SECTION 7 − ELECTRICAL DIAGRAMS
Figure 7-1. Circuit Diagram For Welding Generator
OM-481 Page 32
SD-145 039-A
OM-481 Page 33
Figure 7-2. Wiring Diagram For Welding Generator
OM-481 Page 34
Coat with dielectric grade, nonconductive, electric
grease (MILLER Part No. 146 557) or equivalent.
SD-145 037-B
OM-481 Page 35
SECTION 8 − RUN-IN PROCEDURE
mod7.1 2/93
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
•
MOVING PARTS can cause injury.
•
Do not touch live electrical parts.
Always wear dry insulating gloves.
•
Stop engine before inspecting, making or changing
connections, or servicing.
Do not leave unattended when engine is running.
ENGINE
MAY
USE
OIL
AND
WETSTACKING may occur during
run-in period.
Keep all panels and covers securely in place.
•
HOT ENGINE EXHAUST, EXHAUST
PIPE, and ENGINE EXHAUST SPARKS
can cause fire.
•
•
Keep away from moving parts such as fans, belts,
and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
•
•
•
Keep exhaust and pipe away from flammables.
Watch for fire; keep extinguisher nearby.
Check oil level several times a day during run-in
period, and add oil if needed.
See engine manual for run-in information.
Do not idle engine longer than necessary.
Piston rings seat faster if engine runs at weld/power
rpm, and the welding generator is kept loaded during
the run-in period.
HOT PARTS can cause severe burns.
•
ENGINE EXHAUST GASES can kill.
•
•
•
Do not breathe exhaust fumes.
Use in open, well-ventilated areas, or vent exhaust
outside and away from any building air intakes.
Stop engine and let load bank or grid cool before
touching.
Wear protective gloves and clothing when working
on hot equipment.
Have only qualified persons perform run-in procedures.
1
Welding Generator
2
Rated Weld Output
Run diesel engines near rated output during run-in period to properly
seat piston rings and prevent
wetstacking.
RATED WELD OUTPUT
3
____
____
____
__%
____
MAX OCV
VOLTS
AMPERES
DUTY CYCLE
MAX RPM
3
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
2
1
Figure 8-1. Wetstacking
OM-481 Page 36
8-1. Run-In Procedure Using Load Bank
READ SAFETY BLOCKS at start of
Section 8 before proceeding.
WARNING
2
1
4
3
Stop engine.
1
Selector switch (if present) in either DC
position.
Load Bank
3 Weld Cables
Connect load bank to generator weld output
terminals using proper size weld cables with
correct connectors. Observe correct polarity.
Turn all load bank switches Off. If needed,
connect load bank to 115 volts ac wall
receptacle or generator auxiliary power
receptacle.
2
S-0683
Start engine and run for several minutes.
Welding Generator
Adjust load bank switches and generator A/V
control so load equals rated generator output
(see nameplate).
Place A/V range switch in maximum position,
A/V control in minimum position, and Output
Check generator and load bank meters after
first five minutes then every fifteen minutes to
be sure generator is loaded properly.
After one hour (minimum) turn off load bank
to remove load. Run engine several minutes
at no load.
4
Engine Exhaust Pipe
Stop engine and allow it to cool. Repeat
procedure if wetstacking is present.
Figure 8-2. Load Bank Connections
8-2. Run-In Procedure Using Resistance Grid
READ SAFETY BLOCKS at start of
Section 8 before proceeding.
WARNING
1
2
6
4
+
3
Stop engine.
1
Connect grid to generator weld output terminals using proper size weld cables with
correct connectors (polarity is not important).
Resistance Grid
Use grid sized for generator rated output.
4
Turn Off grid.
2
Welding Generator
Place A/V range switch in maximum position,
A/V control in minimum position, and Output
Selector switch (if present) in either DC
position.
3
Weld Cables
5
Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter as shown, if
not provided on generator.
Start engine and run for several minutes.
Adjust load with generator A/V control and
grid switches so load equals rated generator
output (see nameplate).
S-0684
Check generator and meters after first five
minutes then every fifteen minutes to be sure
generator is loaded properly.
After one hour (minimum), place A/V control
in minimum position, and then shut down grid
to remove load. Run engine several minutes
at no load.
6
Engine Exhaust Pipe
Stop engine and allow it to cool. Repeat
procedure if wetstacking is present.
Figure 8-3. Resistance Grid Connections
OM-481 Page 37
SECTION 9 − AUXILIARY POWER GUIDELINES
mod 3.1 9/92
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
Install and ground generator according to all applicable codes, such as OSHA and National Electrical Code.
Disconnect both welding cables when using auxiliary power.
Use all code-required methods for shock and overcurrent protection.
Have only qualified persons make electrical connections.
9-1. How Much Power Does Equipment Require?
1
1
2
3
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
A light bulb is a resistive load and
requires a constant amount of
power.
2
Non-Resistive Load
Equipment with a motor, such as a
drill, is a non-resistive load and
requires more power while starting
the motor than when running (see
Figure 9-3).
3
3
Rating Data
Volts and amperes, or watts required to run equipment. Determine power required as shown in
Figure 9-2.
S-0623
Figure 9-1. Power Required By Different Types Of Equipment (Loads)
VOLTS x AMPERES = WATTS
This equation provides an actual power requirement for resistive loads, or an approximate running requirement for non-resistive
loads.
EXAMPLE 1: If a drill requires 4.5 amperes at 115 volts, calculate its running power requirement in watts.
115 V x 4.5 A = 520 W
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.
(200 W + 200 W + 200 W) + 520 W = 1120 W
Therefore, the total load applied by the three flood lamps and drill is 1120 watts.
Figure 9-2. Calculating Power Required To Run Equipment
OM-481 Page 38
Table 9-1. Approximate Power Requirements For Typical Equipment*
Industrial Motors
Split Phase
Starting
Watts
Running
Watts
1/8 HP
800
300
Stock Tank De-Icer
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
1/2 HP
3175
875
Milk Cooler
Rating
Farm Equipment
Rating
Starting
Watts
Running
Watts
1000
1000
2900
1100
Milker (Vacuum Pump)
2 HP
10500
2800
720
Capacitor Start-
1/3 HP
2020
720
FARM DUTY MOTORS
1/3 HP
1720
Induction Run
1/2 HP
3075
975
Std. (e.g. Conveyors,
1/2 HP
2575
975
3/4 HP
4500
1400
Feed Augers, Air
3/4 HP
4500
1400
Compressors)
Capacitor StartCapacitor Run
Fan Duty
Contractor
Hand Drill
1 HP
6100
1600
1 HP
6100
1600
1-1/2 HP
8200
2200
1-1/2 HP
8200
2200
2 HP
10550
2850
2 HP
10550
2850
3 HP
15900
3900
3 HP
15900
3900
5 HP
23300
6800
5 HP
23300
6800
1-1/2 HP
8100
2000
High Torque (e.g. Barn
1-1/2 HP
8100
2000
5 HP
23300
6000
Cleaners, Silo Unloaders,
5 HP
23300
6000
7-1/2 HP
35000
8000
Silo Hoists, Bunk Feeders)
7-1/2 HP
35000
8000
10 HP
46700
10700
10 HP
46700
10700
1/8 HP
1000
400
3-1/2 Cu. Ft. Mixer
1/2 HP
3300
1000
1/6 HP
1400
550
High Pressure 1.8 Gal/Min
500 PSI
3150
950
1/4 HP
1850
650
Washer 2 Gal/Min
550 PSI
4500
1400
1/3 HP
2400
800
700 PSI
6100
1600
1/2 HP
3500
1100
Rating
Starting
Watts
Running
Watts
Rating
Starting
Watts
Running
Watts
1/4”
350
350
Coffee Maker
3/8”
400
400
Elec. Range
1/2”
600
6-1/2”
2 Gal/Min
Residential
1750
1750 Typ.
6” Element
1500
1500
600
8” Element
2100
2100
500
500
Oven
6000
6000
7-1/4”
900
900
Microwave
625W
2800
2000
8-1/4”
1400
1400
Television (Solid-State)
B&W
100
100
9”
4500
1500
Color
300
300
10”
6300
1800
Radio
50-200
50-200
Band Saw
14”
2500
1100
Refrig. Or Freezer
3100
800
Bench Grinder
6”
1720
720
Shallow Well Pump
8”
3900
1400
Circular Saw
Table Saw
Air Compressor
Electric Chain Saw
10”
5200
1600
1/2 HP
3000
1000
1 HP
6000
1500
1-1/2 HP
8200
2200
2 HP
10500
2800
1-1/2 HP, 12”
1100
1100
Sump Pump
Dishwasher
Clothes Dryer
1/3 HP
2150
750
1/2 HP
3100
1000
1/3 HP
2100
800
1/2 HP
3200
1050
(Cool Dry)
2100
700
(Hot Dry)
2850
1450
Gas
2500
700
Electric
7550
5750
2 HP, 14”
1100
1100
Automatic Washer
3450
1150
Standard 9”
350
350
Gas Or Fuel Oil
1/8 HP
800
300
Heavy Duty 12”
500
500
Furnace Blower
1/6 HP
1250
500
1/3 HP
2100
700
1/4 HP
1600
600
Elec. Hedge Trimmer
18”
400
400
1/3 HP
2100
700
Flood Lights
HID
125
100
1/2 HP
3225
875
Metal Halide
313
250
10,000 BTU
3700
1500
Mercury
1000
20,000 BTU
5800
2500
Sodium
1400
24,000 BTU
8750
3800
Vapor
1250
1000
32,000 BTU
11500
5000
Submersible Pump
400 GPH
600
200
40,000 BTU
13800
6000
Centrifugal Pump
900 GPH
900
500
1/4 HP
1650
550
3/4 HP, 16”
4500
1400
1/3 HP
2125
725
1 HP, 20”
6100
1600
Electric Blanket
Portable
400
400
1/2 HP
3150
950
Dehumidifier
1450
650
3/4 HP
4500
1400
Vacuum Cleaner
1 HP
6100
1600
55 Gal. Drum Mixer
1/4 HP
1900
700
Lights
Wet & Dry Vac
1.7 HP
900
900
Toaster
2-1/2 HP
1300
1300
Electric Trimmer
Electric Cultivator
Floor Polisher
High Pressure Washer
Central Air Conditioner
Garage Door Opener
Hair Dryer
Iron
Standard
800
800
Deluxe
1100
1100
2 Slice
1050
4 Slice
1650
1650
300-1200
300-1200
1200
1200
As Indicated On Bulb
1050
*Motors require up to two or three times their starting wattage when starting under load.
OM-481 Page 39
Table 9-2. Single-Phase Induction Motor Starting Requirements
Motor Start Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
2
VOLTS 230
CODE M
HP
1/4
1
AC MOTOR
AMPS 2.5
Hz
60
PHASE 1
3
1
Motor Rating Label
2
Motor Start Code
Determine power required to start
motor using Table 9-2. Determine
starting amperage required as
shown in Figure 9-4.
3
Running Amperage
Requirement
If code is not present, multiply
running requirement by six. Generator amperage output must be at
least twice the motor’s running
amperage requirement.
S-0624
Figure 9-3. Power Required To Start Motor
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE 3: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table 9-2, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
230
= 12.2 A
Therefore, starting the motor requires 12.2 amperes.
Figure 9-4. Calculating Amperage Required To Start A Motor
9-2. How Much Power Can Generator Supply?
1
1
2
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. SB-140 092-A / S-0625
Figure 9-5. Limits Of Generator
OM-481 Page 40
9-3. Typical Connections To Supply Standby Power
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
WARNING
Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. Locate the power company service meter (Figure 9-6, Item 1), and main and branch overcurrent protection (2),
and install equipment as shown in Figure 9-6.
1
240 V
120/240 Volt
60 Hz
Three-Wire
Service
120 V
Neutral
120 V
2
240 V
3
120 V
Load
120 V
7
CB
4
or
F1
5
6
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
1
Power Company Service Meter
2
Main And Branch Overcurrent
Protection
3
Double-Pole, Double-Throw Transfer
Switch
Obtain and install correct switch.
Switch rating must be same as or greater
than the branch overcurrent protection.
4
Circuit Breakers Or Fused Disconnect
Switch
Obtain and install correct switch.
5
Extension Cord
Select as shown in Section 9-4.
6
Connections To Generator
Connect terminals or plug of adequate
amperage capacity onto cord. Follow all
applicable codes and safety practices.
Turn off or unplug all equipment connected
to generator before starting or stopping
engine. When starting or stopping, the
engine has low speed which causes low
voltage and frequency.
7
Connections To Load
S-0405-A
Figure 9-6. Standby Power Equipment And Connections
OM-481 Page 41
9-4. Selecting Extension Cord
Use Table 9-3 and Table 9-4 to select extension cords. Use shortest cords possible because long cords may reduce
output or cause unit overload.
Table 9-3. Cord Lengths For 120 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
Current
In Amperes
Load In Watts
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Table 9-4. Cord Lengths For 240 Volt Loads
Maximum Allowable Cord Length In Feet (Meters)
For Conductor Size (AWG)*
Current
In Amperes
Load In Watts
5
1200
7
1680
10
2400
15
4
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-481 Page 42
6
NOTES
OM-481 Page 43
SECTION 10 − PARTS LIST
8
9
10
11
12
13
Fig 10-4
3
Fig 10-2
15
4
5
6
14
16
17
7
2
1
18
19
20
21
22
23
65
66
67
68
69
99
98
97
77
Fig 10-3
96
95
82 81 80 79 77 78 68
76
75
67
83
92
91
90
6
6
89
84
88
81
87
86
85
Figure 10-1. Main Assembly
OM-481 Page 44
71
72
94
93
70
74 73
28
29
27
30
26
25
31
24
32
31
54
64
34
63
35
36
33
37
38
39
47
62
46
48
49
50
61
51
53*
52
41
42
59 58
57
48
47
56
55
43
44
45
40
60
Fig 10-5
*Includes Item 54
ST-134 499-B
OM-481 Page 45
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
. . 1 . . . . . . . . . . . Fig 10-2
. . 2 . . . . . . . . . . . 118 790
. . 3 . . . . . . . . . . . Fig 10-4
. . 4 . . . . . . . . . . . 087 341
. . 5 . . . . . . . . . . . 010 914
. . 6 . . . . . . . . . . . 026 947
. . 7 . . . . . . . . . . . 118 640
. . . . . . . . . . . . . . . . 121 699
. . 8 . . . . Z1 . . . 117 270
. . 9 . . . . . . . . . . . 131 188
. . 10 . . . R3 . . . 128 862
. . 11 . . . . . . . . . . 118 643
. . 12 . . . . . . . . . . 017 479
. . 13 . . . . . . . . . . 108 081
. . 14 . . . . . . . . . . 134 456
. . 15 . . . . . . . . . . 118 644
. . 16 . . BAT . . 012 724
. . 17 . . . . . . . . . . 032 452
. . 18 . . . . . . . . . . 010 460
. . 19 . . CR2 . . 090 104
. . 20 . . . . . . . . . . 601 851
. . 21 . . . . . . . . . . 145 023
. . 22 . . TE4 . . 038 621
. . . . . . . . . . . . . . . . 038 620
. . 23 . . . . . . . . . . 145 035
. . 24 . . . . . . . . . . 117 219
. . 25 . . . . . . . . . +131 688
. . 26 . . . . . . . . . . 117 486
. . 27 . . . . . . . . . . 118 073
. . 28 . . . . . . . . . . 108 487
. . . . . . . . . . . . . . . . 131 752
. . 29 . . . . . . . . . . 131 186
. . 30 . . . . . . . . . . 004 130
. . 31 . . . . . . . . . . 147 923
. . 32 . . . . . . . . . +131 222
. . . . . . . . . . . . . . . . 120 629
. . 33 . . . . . . . . . . 119 861
. . 34 . . . . . . . . . . 119 851
. . 35 . . . . . . . . . . 133 067
. . 36 . . . . . . . . . . 010 863
. . 37 . . S11 . . . 118 067
. . 38 . . . . . . . . . . 089 129
. . 39 . . . . . . . . . . 133 066
. . 40 . . . . . . . . . . 045 657
. . 41 . . . . . . . . . . 021 115
. . 42 . . . . . . . . . . 021 114
. . 43 . . . . . . . . . *020 319
. . 44 . . . . . . . . . . 021 117
. . 45 . . . . . . . . . . 021 116
. . . . . . . . . . . . . . . . 004 115
. . 46 . . . . . . . . . . 023 313
. . 47 . . . . . . . . . . 601 945
. . 48 . . . . . . . . . . 071 731
. . 49 . . . . . . . . . . 116 707
. . 50 . . . . . . . . . . 602 246
. . 51 . . . . . . . . . . 071 730
. . 52 . . . . . . . . . . 071 890
. . 53 . . . . . . . . . . 130 435
. . 54 . . . . . . . . . . 066 271
. . . . . . . . . . . . . . . . 131 208
. . . . . . . . . . . . . . . . 010 014
OM-481 Page 46
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ANGLE, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUMPER, door 1.000 OD x .750 high rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANGER, minerallic No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, insul .250-20 x 1.000 lg x .312thd . . . . . . . . . . . . . . . . . . . . . . . . .
. . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FRAME, mtg reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW adj 375W 50 ohm w/mtg bracket . . . . . . . . . . . . . . . . . . . . . .
. . UPRIGHT, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BATTERY, stor 12V 750crk 185 RSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, stl slflkg hex .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 4P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, strip term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, rain 3.000 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment can cause serious injury . . . . . . . . . . . . . . .
. . PANEL, engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, end engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning do not run engine when door is open . . . . . . . . . . . . . . . . . . . .
. . DOOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LATCH, paddle series 300 w/lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, elb air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose 2.062-3.000clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, vacuum air flow elect indicator 12-24VDC . . . . . . . . . . . . . . . . . . . . .
. . PIPE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, elb air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BAND, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CLAMP ASSEMBLY, cup air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . WING NUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAP, dust air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BAFFLE, dust cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose 3.000-3.250clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexhd .625-18 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl .656 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .875 OD x 12ga wall x 2.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENGINE, deutz dsl elec (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STOP, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .750dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
6
1
5
1
3
1
1
1
1
2
2
1
1
1
1
1
1
8
1
1
2
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
4
4
1
4
4
4
1
1
1
2
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . 010 021
. . . . . . . . . . . . . . . . 602 247
. . 55 . . . . . . . . . . 159 013
. . 56 . . . . . . . . . . 159 012
. . 57 . . . . . . . . . . 118 452
. . 58 . . . . . . . . . . 034 116
. . 59 . . . . . . . . . . 131 322
. . 60 . . . . . . . . . . Fig 10-5
. . 61 . . . . . . . . . . 119 801
. . 62 . . . . . . . . . . 134 550
. . 63 . . . . . . . . . . 132 712
. . 64 . . . . . . . . . . 119 797
. . 65 . . . . . . . . . +159 014
. . 66 . . . . . . . . . . 089 351
. . 67 . . . . . . . . . . 134 836
. . . . . . . . . . . . . . . . 023 562
. . 68 . . . . . . . . . . 099 542
. . 69 . . . . . . . . . . 145 281
. . 70 . . . . . . . . . . 117 227
. . . . . . . . . . . . . . . . 601 965
. . . . . . . . . . . . . . . . 602 213
. . . . . . . . . . . . . . . . 601 872
. . 71 . . . . . . . . . . 062 342
. . 72 . . . . . . . . . . 083 553
. . 73 . . . . . . . . . . 161 656
. . 74 . . . . . . . . . . 134 834
. . 75 . . . . . . . . . . 089 120
. . 76 . . . . . . . . . . 073 433
. . 77 . . . . . . . . . . 119 486
. . 78 . . . . . . . . . . 081 646
. . 79 . . . . . . . . . . 601 965
. . 80 . . . . . . . . . . 602 213
. . 81 . . . . . . . . . . 601 872
. . 82 . . . . . . . . . . 121 823
. . 83 . . . . . . . . . . 131 189
. . 84 . . . . . . . . . . 131 127
. . 85 . . SR3 . . 142 505
. . 86 . . . . . . . . . . 010 494
. . 87 . . . . . . . . . . 116 981
. . 88 . . . . . . . . . . 131 124
. . 89 . . . . . . . . . . 131 125
. . 90 . . . . . . . . . . 131 123
. . 91 . SHUNT . 072 426
. . 92 . . . . . . . . . . 146 240
. . 93 . . . . . . . . . . 122 354
. . 94 . . . . . . . . . . 107 343
. . 95 . . . . . . . . . . 024 035
. . 95 . . . . . . . . ♦134 234
. . 96 . . . . . . . . . . Fig 10-3
. . 97 . . . . . . . . . . 120 188
. . 98 . . . . . . . . . . 134 792
. . 99 . . . . . . . . . +127 304
. . . . . . . . . . . . . . . . 089 256
. . . . . . . . . . . . . . . . 137 610
. . . . . . . . . . . . . . . . 131 243
. . . . . . . . . . . . . . . . 131 750
..
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..
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..
..
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..
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..
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..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
CLAMP, stl cush .562dia x .343mtg hole (ground load support) . . . . . . . . . . . .
WASHER, flat stl sae .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, pipe stl elbow M 1/2tbg x .500NPT . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, oil drain 11.000 3/4 swivel fem 1/2MNPT . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, stl cush .625dia x .468mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHUTDOWN KIT, rsv type governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE, air manifold exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIPE, muffler extension elb 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE, air manifold exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, SAE .375 ID x .620 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, hose .312-.875clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, hose .645-.828clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, hose brs barbed elb M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, cap stl hexwhd slflkg .375-16 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, stl hex jam .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASE, filter fuel w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, stl hexhd .625-18 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, hose .375-.450 clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBE, pick-up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, brs barbed M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, cap stl hexwhd slflkg .375-16 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, stl hex jam .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning do not lift from this end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, firewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, rect RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER, si 0ph 300A 400PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, rect LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIELD, heat lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIELD, heat lower LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIELD, heat upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHUNT, meter 50MV 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GUARD, splash fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROMMET, rbr neck filter fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAP, tank fuel 2 in IPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAP, flame arrestor tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front lower w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, stl cush 1.750dia x .531mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, neg term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, pos term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BUS BAR, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
1
1
1
1
1
6ft
2
3
2
1
2
2
2
1
1
4
4ft
1
1
2
1
4
4
4
1
1
1
3
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦Part of 042 185 Optional FA-4 Flame Arrestor − Strainer Fuel Cap.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 47
1
2
3
Includes
Item 4
5
6
7
6
25
8
26
27
24
23
9
22
10
21
4
11
20
9
19
18
17
16
12
15
14
13
ST-134 500
Figure 10-2. Panel, Front w/Components
OM-481 Page 48
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 1)
. . 1 . . . . S3 . . . 131 213 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2 . . . . . . . . . . . 118 340 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 3 . . . . R1 . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . 4 . . . . . . . . . . . 072 590 . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5 . . . . S8 . ♦021 467 . . SWITCH, tgl SPST MC 3A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 6 . . . S4,5 . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 7 . . . . S6 . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 8 . . . . S1 . . . 144 641 . . SWITCH, ignition 5 posn w/out handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 9 . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . . . .
. . 10 . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 11 . . . . . . . . . . 119 974 . . LEVER, switch chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 12 . . . FG . . . 118 066 . . GAUGE, fuel elec 12V neg grd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 146 358 . . SENDER, fuel gauge (locate on main assembly, not shown) . . . . . . . . . . . . . .
. . 13 . . . A1 . . . 118 060 . . METER, amp DC 60-0-60 2.250dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 14 . . . . . . . . . . 129 870 . . GAUGE, pressure oil 25-30 PSI preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 128 829 . . KIT, oil line 44.000 in 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 15 . . . . . . . . . . 129 837 . . GAUGE/SWITCH, temp oil mech 250deg setting . . . . . . . . . . . . . . . . . . . . . . . .
. . 16 . . . HM . . . 118 058 . . METER, hour 12-24VDC 2.250dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 17 . . . . . . . . . . 082 788 . . HOLDER, light ind only bayonet base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 18 . . PL1,3 . *048 155 . . BULB, incand flg base 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 19 . . . . . . . . . . 082 789 . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 20 . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 21 . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 22 . . . . . . . . . . 090 231 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 23 . . . A2 . . . 164 875 . . METER, amp DC 50MV 0-1K scale 2.5 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 24 . . . V1 . . . 164 872 . . METER, volt DC 0-100 scale 2.5 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 25 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . .
. . 26 . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 27 . . . . . . . . ♦021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
2
1
♦Part of 041 480 Optional Ether Starting Aid
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 49
OM-481 Page 50
2
3
4
1
5
6
7
8
24
23
10
11
22
21
12
20
13
Figure 10-3. Panel, Front Lower w/Components
25
9
14
15
16
18
18
17
1
19
9
ST-134 501-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-3. Panel, Front Lower w/Components (Fig 10-1 Item 96)
1 . . . . . . . . . . . . . 038 612 . . TERMINAL ASSEMBLY, pwr output (consisting of) . . . . . . . . . . . . . . . . . . . . . .
2 . . . . . . . . . . . . . 601 840 . . . . NUT, brs hex .500-13 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 . . . . . . . . . . . . . 601 839 . . . . NUT, brs hex .500-13 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 . . . . . . . . . . . . . 038 847 . . . . BUS BAR, term pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 . . Neg/Pos . . 038 613 . . . . TERMINAL BOARD, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 . . . . . . . . . . . . . 038 900 . . . . STUD, brs .500-13 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 . . . . . . . . . . . . . 602 247 . . . . WASHER, flat stl SAE .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 . . . . . . . . . . . . . 605 787 . . . . WASHER, lock stl intl tooth .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 601 976 . . SCREW, cap stl hexhd .500-13 x 1.500 (bus bar to terminal) . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 044 942 . . NUT, locking .500-13 (bus bar to terminal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 . . . . C1,2 . . . . 136 736 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 . . . . . . . . . . . . 131 122 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 . . . CB1,2 . . +139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . . . .
12 . . RC1,2 . . +039 864 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V Arrow Hart 5965V
. . . . . . . RC1 . . ♦604 103 . . RECEPTACLE, str dx grd 2P3W 15A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 025 234 . . PLUG, str grd 2P3W 15A 250V Arrow Hart 5666V
13 . VR1/R4 . . 046 819 . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 . . . RC3 . . . . 143 976 . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 134 734 . . CONNECTOR, circ 14 pin plug Amp 213571-2
. . . . . . . . . . . . . . . . 134 731 . . CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
. . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 or
. . . . . . . . . . . . . . . . 143 922 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3
15 . . . . . . . . . . . . 020 279 . . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 . . CB3,4 . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . .
17 . . . C3 . . . . 113 142 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 . . C4-11 . . . 138 695 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 . . . . 3T . . . . . 038 601 . . BLOCK, term 30A 9P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 . . . . . . . . . . . . 083 030 . . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . .
22 . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 . . . . . . . . . . . . 010 916 . . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating lower (order by model and serial number) . . . . . .
25 . . . . . . . . . . . . 039 885 . . CONNECTOR, circ protective cap Amphenol 9760-20 . . . . . . . . . . . . . . . . . . .
2
4
2
1
1
2
2
2
2
2
2
1
2
2
1
1
1
14
1
2
1
8
1
1
5
3
1
1
1
+Circuit Breakers (CB1,2) and Receptacle (RC2) remain the same for 042 943 Optional Duplex Receptacle Kit 240V.
♦Part of 042 943 Optional Duplex Receptacle Kit 240V.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 51
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-4. Control Box (Fig 10-1 Item 3)
. . 1 . . . . 2T . . . 129 939
. . 2 . . . . . . . . . . . 131 339
. . 3 . . . CR1 . . 044 588
. . 4 . . . . . . . . . . . 020 225
. . 5 . . . MS1 . . 118 072
. . . . . . . . . . F . . . *048 317
. . 6 . . . . . . . . . . . 122 216
. . 7 . . . . 1T . . . 098 828
. . 8 . . . SR1 . . 035 704
. . 9 . . . . D1 . . . 128 299
. . 10 . . PC2 . . 145 207
. . . . . . . . PLG2 . . 115 092
. . . . . . . . . . . . . . . . 113 746
. . 11 . . . . . . . . . . 110 375
. . 12 . . PC1 . . 166 203
. . . . . . . . PLG1 . . 135 275
. . . . . . . . . . . . . . . . 114 066
. . 13 . . . . . . . . . . 603 107
. . 14 . . SR2 . . 097 353
. . 15 . . . R2 . . . 130 515
. . BLOCK, term 10A 19P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENCLOSURE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, nyl .875 clamp dia x .500 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, magnetic shutdown 12VDC (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . . FUSE, mintr gl 14A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, blk 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 10A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE, board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, nprn slit bk .156 ID x .343 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE/SCR, bridge integ 2SCR 3 diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
1
1
1
8
8
1
1
15
1ft
1
1
2
15
14
13
12
11
10
9
3
8
4
7
5
6
ST-134 502-A
Figure 10-4. Control Box
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 52
Item
No.
Part
No.
Description
Quantity
Figure 10-5. Generator (Fig 10-1 Item 60)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
. . . 049 650
. . . 018 614
. . . *151 299
. . . 600 270
. . . 152 044
. . . 013 367
. . +140 096
. . . 039 207
. . . 083 751
. . . 024 617
. . . 053 390
. . . 083 748
. . . 145 021
. . . 601 965
. . . 153 299
. . . 143 220
. . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH SET, elect collector (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRUSH, contact elect clrg .375 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, holder brush brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAFFLE, air gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining ext 1.272 shaft x .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball rdl sgl row 1.370 x 2.830 x .600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, exciter/endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexwhd slflkg .375-16 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1
1
1
2
1
1
1
1
1
1
1
6
1
1
12
9
11
7
2
3
10
8
6
5
4
1
13
16
15
14
ST-134 503-B
Figure 10-5. Generator
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 53
Item
No.
Part
No.
Description
Quantity
Optional Equipment
. . . . . . . . . 042 497
. . . . . . . . . 034 074
. . . . . . . . . . 113 342
. . ES1 . . 046 410
. . . . . . . . . 073 100
. . . S8 . . 021 467
. . . . . . . . . 021 385
. . . . . . . . . 020 185
. . . . . . . . . 035 325
. . . . . . . . . 042 480
. . . . . . . . . 134 613
. . . . . . . . . 123 205
. . . . . . . . . 123 207
. . . . . . . . . 122 613
. . . . . . . . . 087 341
. . . . . . . . . 136 474
. . . . . . . . . 042 440
. . . . . . . . . 134 768
. . . . . . . . . 131 864
. . . . . . . . . 134 770
. . . . . . . . . 134 764
. . . . . . . . . 121 416
. . . . . . . . . 023 313
. . . . . . . . . 042 185
. . . . . . . . . 042 943
OM-481 Page 54
. . STARTING AID KIT, diesel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STARTING AID KIT, diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ADAPTER, atomizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ATOMIZER, .125 L elb orf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TUBING, vinyl .375dia (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, tgl SPST MC 3A 250V (Fig 10-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BOOT, tgl switch lever (Fig 10-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, pipe brs elb st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, ether starting air caution etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, locking nameplate (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HINGE, cover front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COVER, panel front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BOLT, U stl .312-18 x 1.500 wide x 4.937 deep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUMPER, door 1.000 OD x .750 high rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STRIP, reinforcing panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIESEL AIR INTAKE AUTO SHUTDOWN, (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, vacuum air flow elect indicator 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . VALVE, overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PIPE, air cleaner elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOSE, rdtr str 2.750 ID x 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP, hose 3.000-3.250clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FA-4 FLAME ARRESTOR-STRAINER FUEL CAP, (Fig 10-1) . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE KIT, duplex 240V (Fig 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1ft
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
4
1
1
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