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OM-4420 212 049D September 2003 Processes Stick (SMAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator Big Blue Turbo Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Mil_Thank 7/03 Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 2-6. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Sound Level Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Stick And MIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. DC TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Generator AC Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Manufacturing Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Installing Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Using The Optional Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Connecting To Remote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Using Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 3 3 4 4 4 5 5 5 6 7 7 8 8 9 9 10 10 10 10 11 12 12 13 13 14 15 15 16 17 18 19 19 20 21 22 23 24 24 25 26 27 28 28 29 TABLE OF CONTENTS SECTION 8 − ENGINE/GENERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Engine/Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Engine Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Inspecting/Cleaning Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 13 − SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding . . . . . . . . . . . . . . . . . . . . . . . . 13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 14 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 30 30 32 33 34 35 36 37 38 38 42 44 44 45 46 47 54 54 55 55 56 56 56 57 58 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_10/02 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. Marks a special safety message. Means “Note”; not safety related. 1-2. Arc Welding Hazards Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Only qualified persons should install, operate, maintain, and repair this unit. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. During operation, keep everybody, especially children, away. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-7. Read and follow all Safety Standards. SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground — check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first − double-check connections. Frequently inspect input power cord for damage or bare wiring — replace cord immediately if damaged — bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an airsupplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. Return To Table Of Contents OM-4420 Page 1 WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. NOISE can damage hearing. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. MAGNETIC FIELDS can affect pacemakers. FLYING METAL can injure eyes. Allow cooling period before maintaining. Wear protective gloves and clothing when working on a hot engine. Do not touch hot engine parts or just-welded parts bare-handed. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder — explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. 1-3. Engine Hazards MOVING PARTS can cause injury. BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables or servicing 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. Disconnect negative (−) cable first and connect it last. FUEL can cause fire or explosion. Stop engine and let it cool off before checking or adding fuel. Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank — allow room for fuel to expand. Do not spill fuel. If fuel is spilled, clean up before starting engine. Dispose of rags in a fireproof container. Always keep nozzle in contact with tank when fueling. OM-4420 Page 2 Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect negative (−) battery cable from battery. Keep hands, hair, loose clothing, and tools away from moving parts. Reinstall panels or guards and close doors when servicing is finished and before starting engine. Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. Block flywheel so that it will not turn while working on generator components. Return To Table Of Contents STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap. Turn cap slightly and let pressure escape slowly before completely removing cap. ENGINE EXHAUST GASES can kill. Use equipment outside in open, well-ventilated areas. If used in a closed area, vent engine exhaust outside and away from any building air intakes. BATTERY ACID can BURN SKIN and EYES. Do not tip battery. Replace damaged battery. Flush eyes and skin immediately with water. ENGINE HEAT can cause fire. Do not locate unit on, over, or near combustible surfaces or flammables. Keep exhaust and exhaust pipes way from flammables. EXHAUST SPARKS can cause fire. Do not let engine exhaust sparks cause fire. Use approved engine exhaust spark arrestor in required areas — see applicable codes. 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. Do not use compressed air for breathing. Use only for cutting, gouging, and tools. COMPRESSED AIR can cause injury. Wear approved safety goggles. Do not direct air stream toward self or others. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill cap. Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby. HOT PARTS can cause burns and injury. Do not touch hot compressor or air system parts. Let system cool down before touching or servicing. READ INSTRUCTIONS. Read Owner’s Manual before using or servicing unit. Stop engine and release air pressure before servicing. 1-5. Additional Symbols For Installation, Operation, And Maintenance FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. OVERHEATING can damage motors. Turn off or unplug equipment before starting or stopping engine. Do not let low voltage and frequency caused by low engine speed damage electric motors. OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. STATIC (ESD) can damage PC boards. Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. FLYING SPARKS can cause injury. TILTING OF TRAILER can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. Use tongue jack or blocks to support weight. Properly install welding generator onto trailer according to instructions supplied with trailer. Sparks can cause fires — keep flammables away. Return To Table Of Contents OM-4420 Page 3 READ INSTRUCTIONS. ARC WELDING can cause interference. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manuals. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. 1-6. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 1-7. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Bou- levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org and www. sparky.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). 1-8. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. OM-4420 Page 4 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 your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended. Return To Table Of Contents SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-6 . Veuillez lire et respecter toutes ces normes de sécurité. L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants. En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé − remplacer le cordon immédiatement s’il est endommagé − un câble dénudé peut provoquer une électrocution. Mettre l’appareil hors tension quand on ne l’utilise pas. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel. Porter un harnais de sécurité quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. UN CHOC ÉLECTRIQUE peut tuer. Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger. Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. Ne jamais toucher les pièces électriques sous tension. Porter des gants et des vêtements de protection secs ne comportant pas de trous. S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre. LES FUMÉES ET LES GAZ peuvent être dangereux. Ne pas se servir de source électrique àcourant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. Se servir d’une source électrique àcourant électrique UNIQUEMENT si le procédé de soudage le demande. Eloigner votre tête des fumées. Ne pas respirer les fumées. Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Des précautions de sécurité supplémentaires sont requises dans des envi- Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué. Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. ronnements à risque comme: les endroits humides ou lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions assises, à genoux et allongées; ou quand il y a un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder DC semi−automatique de type CV (MIG/MAG), 2) un poste à souder manuel (électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide réduite. Dans la plupart des cas, un poste courant continu de type CV est recommandé. Et, ne pas travailler seul! Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux. Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. Revenez à la table des matières OM-4420 Page 5 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. DES PARTICULES VOLANTES peuvent blesser les yeux. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc. Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien. Porter des gants et des vêtements de protection pour travailler sur un moteur chaud. Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces récemment soudées. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. LE SOUDAGE peut provoquer un incendie ou une explosion. Porter des protections approuvés pour les oreilles si le niveau sondre est trop élevé. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. Si des BOUTEILLES sont endommagées, elles pourront exploser. Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité). Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie. Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact. Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef. Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes. Porteurs de stimulateur cardiaque, restez à distance. Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs. Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état. Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille. Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille. Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publication P-1 CGA énumérées dans les normes de sécurité. 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. OM-4420 Page 6 Revenez à la table des matières L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et sur la PEAU. Ne pas renverser la batterie. Remplacer une batterie endommagée. Rincer immédiatement les yeux et la peau à l’eau. L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide. Observer la polarité correcte (+ et −) sur les batteries. Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu. LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion. Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein. Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son expansion. Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur. Jeter les chiffons dans un récipient ignifuge. Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (−) de batterie de la borne. Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles. Remettre en place les panneaux ou les dipositifs de protection et fermer les portes à la fin des travaux d’entretien et avant de faire démarrer le moteur. Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en route accidentelle du moteur. Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le générateur. LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures. Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur). Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant : Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. LA CHALEUR DU MOTEUR peut provoquer un incendie. DES ORGANES MOBILES peuvent provoquer des blessures. Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection. Arrêter le moteur avant d’installer ou brancher l’appareil. Demander seulement à un personnel qualifié d’enlever les dispositifs de sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de dépannage. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Tenir à distance les produits inflammables de l’échappement. LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter de se brûler. Empêcher les étincelles d’échappement du moteur de provoquer un incendie. Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. 2-4. Dangers liés à l’air comprimé RESPIRER L’AIR COMPRIMÉ peut provoquer des blessures graves ou causer la mort. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un incendie ou une explosion. Ne pas utiliser l’air comprimé pour respirer. Utiliser l’air comprimé seulement pour le coupage, gougeage et les outils pneumatiques. Ne pas couper ou gouger à proximité de produits inflammables. Surveillez et garder un extincteur à proximité. L’AIR COMPRIMÉ peut provoquer des blessures. DES PIECES CHAUDES peuvent provoquer des brûlures et blessures. Porter des lunettes de sécurité approuvées. Ne pas diriger le jet d’air vers d’autres ou soi− même. Ne pas toucher le compresseur ou d’autres éléments du circuit air comprimé chauds. Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la maintenance. L’AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provoquer des blessures. LIRE LES INSTRUCTIONS. Relâcher la pression d’air de l’outillage ou du système avant d’effectuer la maintenance, avant de changer ou de rajouter des éléments ou avant d’ouvrir la purge ou le bouchon de remplissage d’huile. Lisez le manuel d’instructions avant l’utilisation ou la maintenance de l’appareil. Arrêter le moteur et relâcher la pression avant d’effectuer la maintenance. 2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance LA CHUTE DE L’APPAREIL peut blesser. Utiliser l’anneau de levage uniquement pour soulever l’appareil lui-même ; sans chariot, de bouteilles de gaz, remorque, ou autres accessoires. Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. Revenez à la table des matières OM-4420 Page 7 LE SURCHAUFFEMENT peut endommager le moteur électrique. LIRE LES INSTRUCTIONS. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a lieu. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. LES ÉTINCELLES VOLANTES risquent de provoquer des blessures. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. UNE REMORQUE QUI BASCULE peut entraîner des blessures. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles. Laisser l’équipement refroidir ; respecter le facteur de marche nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage. Ne pas obstruer les passages d’air du poste. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. Porter un écran facial pour protéger le visage et les yeux. Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps. Les étincelles risquent de causer un incendie − éloigner toute substance inflammable. Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compresseur (si applicable) suivant ce manuel et le manuel du moteur/compresseur (si applicable). LE SOUDAGE À L’ARC risque de provoquer des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 2-6. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). National Electrical Code, norme NFPA 70, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de la Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : www.cganet.com). Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org). Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site Web : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, norme NFPA 51B, de la National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312) 353−2220, site Web : www.osha.gov). 2-7. Information sur les champs électromagnétiques Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ». Toutefois, les études et l’examen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs électromagnétiques pendant le soudage ou le coupage. OM-4420 Page 8 Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes : 1. Garder les câbles ensemble en les torsadant ou en les fixant avec du ruban adhésif. 2. Mettre tous les câbles du côté opposé à l’opérateur. 3. Ne pas s’enrouler les câbles autour du corps. 4. Garder le poste de soudage et les câbles le plus loin possible de soi. 5. Placer la pince de masse le plus près possible de la zone de soudage. Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus. Revenez à la table des matières SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A 3 Stop Engine Fast (Run, Weld/ Power) Slow (Idle) Start Engine Check engine belt Check Air Cleaner Starting Aid Engine Battery (Engine) Hourmeter (HM) Temperature Circuit Breaker Do Not Switch Under Load Read Operator’s Manual Certified/Trained Mechanic Engine Oil Check Injectors/ Pump Check Valve Clearance Fuel Engine Coolant Temperature Positive Negative Wire Feed Welding Arc Volts Panel/Local Remote Output Direct Current (DC) Alternating Current (AC) Gas Tungsten Arc Welding (TIG) Stick (SMAW) Welding Constant Current (CC) MIG (GMAW) Welding Constant Voltage (CV) Single Phase Air Carbon Arc Cutting (CAC-A) Protective Earth (Ground) DC Electrode Positive DC Electrode Negative Work Connection Electrode Connection On Off V Amperes Three Phase 1 h Hours s Seconds Time Return To Table Of Contents OM-4420 Page 9 SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Mode Weld Output Range CC/DC 20 − 750 A CV/DC 14 − 40 V Rated Welding Output Maximum Open-Circuit Voltage (Nominal) 500 A, 40 Volts DC, 100% Duty Cycle Generator Power Rating Engine Engine Oil Capacity Fuel Tank Capacity 11 qt (10.4 L) 25 gal (95 L) 95 DEUTZ Standard Single-Phase, 4 kVA/kW, 34/17 A, 120/240 V AC, 50/60 Hz 600 A, 44 Volts DC, 60% Duty Cycle Deutz BF4M2011 Oil-Cooled, Four-Cylinder, Turbo-Charged 64 HP Diesel Engine 56 4-2. Sound Level Table Idle Speed (1235 rpm) Weld/Power Speed (1850 rpm) 40 Volts DC At 500 Amps 44 Volts DC At 600 Amps 94.6 Lwa sound power 100.6 Lwa sound power 103.0 Lwa sound power 104.5 Lwa sound power 69.7 dBa at 23 ft (7 m) 74.5 dBA 3.3 ft (1 m) from front panel 75.7dBa at 23 ft (7 m) 78.8 dBA 3.3 ft (1 m) from front panel 78.1 dBa at 23 ft (7 m) 86.0 dBA 3.3 ft (1 m) from front panel 79.6 dBa at 23 ft (7 m) 91.8 dBA 3.3 ft (1 m) from front panel 4-3. Dimensions, Weights, And Operating Angles Dimensions Height 54-1/2 in (1384 mm) (to top of muffler) G 28-1/2 in (724 mm) (mtg. brackets turned in) Do not exceed tilt angles or engine could be damaged or unit could tip. Width 30-3/4 in (781 mm) (mtg. brackets turned out) Depth 69-1/2 in (1765 mm) A 69-1/2 in (1765 mm) B* 55-7/8 in (1419 mm) C* 46-3/8 in (1178) D* 11 in (279 mm) E 27-1/2 in (699 mm) F 1 in (25 mm) G 29-1/2 in (749 mm) H 9/16 in (14 mm) Dia. 4 Holes * With mounting brackets in center position. Dimensions vary with location of mounting brackets. Do not move or operate unit where it could tip. A B C 30° H D 20° 30° 20° Front Panel End F E Weight No Fuel: 1780 lb (807 kg) 802 161-A 803 452 w/Fuel: 1955 lb (997 kg) OM-4420 Page 10 Return To Table Of Contents 4-4. Stick And MIG Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. A. DC Stick Mode 100 Ranges 300 − Max 185 − 525 125 − 400 85 − 250 55 − 125 DC VOLTS 80 60 40 20 0 0 100 200 300 400 500 600 DC AMPERES 700 800 900 1000 400 500 600 DC AMPERES 700 800 900 1000 B. MIG Mode 100 DC VOLTS 80 60 MAX 40 MIN 20 0 0 100 200 300 208 135 / 203 415 Return To Table Of Contents OM-4420 Page 11 4-5. DC TIG Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. 100 Ranges 60−450 40−330 30−220 20−110 DC VOLTS 80 60 40 20 0 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 DC AMPERES 208 136 4-6. Fuel Consumption US Gal./Hr. The curve shows typical fuel use under weld or generator power loads. 3.00 2.75 2.50 2.25 2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 0.00 IDLE 0 50 100 150 200 250 300 350 400 450 500 550 600 DC WELD AMPERES AT 100% DUTY CYCLE Ref. 208 211 OM-4420 Page 12 Return To Table Of Contents 4-7. Duty Cycle And Overheating 100% Duty Cycle At 500 Amperes Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. Continuous Welding 60% Duty Cycle At 600 Amperes 6 Minutes Welding 4 Minutes Resting 212 060-B 4-8. Generator AC Power Curve The ac power curve shows the generator power in amperes available at the 120 and 240 volt receptacles. 150 300 AC VOLTS 125 250 100 200 75 150 50 100 25 50 0 0 0 5 10 15 20 AC AMPERES IN 240V MODE 25 30 0 10 20 30 40 AC AMPERES IN 120V MODE 50 60 193 018 Return To Table Of Contents OM-4420 Page 13 4-9. Manufacturing Rating Label OM-4420 Page 14 Return To Table Of Contents SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Movement Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. OR If unit does not have GFCI receptacles, use GFCI-protected extension cord. OR See Section 5-2 for mounting information. Grounding: 1 Location 2 3 OR Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. OR Grounding 1 GND/PE 2 Electrically bond generator frame to vehicle frame by metal-to-metal contact. 3 Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) install3 6/03 − Ref. 800 652 / Ref. 800 477-A / 803 274 Return To Table Of Contents OM-4420 Page 15 5-2. Mounting Welding Generator Do not weld on base. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit Do not mount unit by supporting the base only at the four mounting brackets. Use cross-supports to adequately support unit and prevent damage to base. 2 Mounting Surface: 1 2 OR Cross-Supports Mounting Brackets (Supplied) Mount unit on flat surface or use cross-supports to support base. Secure unit with mounting brackets. 1 3 Inadequate support. 4 Do not use flexible mounts. 1/2 in Bolt And Washer (Minimum − Not Supplied) 3/8-16 x 1 in Screws (Supplied) To Bolt Unit In Place: Remove hardware securing the four mounting brackets to the base. Reverse brackets and reattach to base with original hardware. 1 Mount unit to truck or trailer with 1/2 in (12 mm) or larger hardware (not supplied). Using Mounting Brackets To Weld Unit In Place: Weld unit to truck or trailer only at the four mounting brackets. 2 Welding Unit In Place Bolting Unit In Place 3 2 4 Tools Needed: 9/16 in install3 6/03 803 274 / 190 250-A / 803 231 OM-4420 Page 16 Return To Table Of Contents 5-3. Installing Spark Arrestor Muffler Stop engine and let cool. 2 Spark Arrestor Muffler Double-Flanged Elbow Nut Flat Washer Mount Bracket Screw Single-Flanged Elbow Rain Cap Clamp Loosely assemble components as shown. 1 10 1 2 3 4 5 6 7 8 9 10 Mount the muffler with the clean- 9 out plug to the outside. After assembly, final-tighten clamps and hardware. all Be sure to tighten rain cap mounting screw. 7 6 8 5 4 3 Tools Needed: 7/16, 1/2 in 803 453 Return To Table Of Contents OM-4420 Page 17 5-4. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 5 4 1 2 3 4 5 Eye Protection − Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum). 3 Do not overfill battery cells. Wait ten minutes and check electrolyte level. If necessary, add electrolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger Read and follow all instructions supplied with battery charger. 2 Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 amperes. Disconnect charging cables and install battery. When electrolyte is low, add only distilled water to cells to maintain proper level. 6 5 A For 30 Minutes Tools Needed: OR + − rubber gloves 30 A For 12 Minutes glasses drybatt1 1/98 − 0886 OM-4420 Page 18 Return To Table Of Contents 5-5. Connecting The Battery Reinstall cover after connecting battery. Connect Negative (−) Cable Last. + − Tools Needed: 1/2 in 802 168-E / Ref. 202 705 / 802 313 / S-0756-C 5-6. Using The Optional Battery Disconnect Switch Stop engine. 1 1 OFF ON Battery Disconnect Switch The battery disconnect switch disconnects battery voltage from the circuit. When the switch is turned Off, the front panel controls do not work. To run unit, turn switch to On position. To prevent unit from running, turn switch to Off position. The switch may be locked using a customer-supplied padlock. 803 454 / Ref. 803 324 Return To Table Of Contents OM-4420 Page 19 5-7. Engine Prestart Checks Engine Oil Full Diesel Full 803 454 Check all engine fluids daily. Engine must be cold and on a level surface. Unit is shipped with 20W break-in oil. The automatic shutdown system stops engine if oil pressure is too low or coolant temperature is too high. This unit has a low oil pressure shut- down switch. However, some conditions may cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 11. OM-4420 Page 20 Fuel Do not use gasoline. Gasoline will damage engine. Add fresh diesel fuel before starting to prevent air from entering the fuel system (see engine maintenance label for fuel specifications). Leave filler neck empty to allow room for expansion. Engine stops if fuel level is low on units with low fuel shutdown option. Do not run out of fuel or air may enter fuel system and cause starting problems. See engine manual to bleed air from fuel system. Engine Oil After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, Return To Table Of Contents add oil (see maintenance label for engine oil specifications). Cold Weather Starting To improve cold weather starting: Use optional Starting Aid switch (see Section 6-1). Keep battery in good condition. Store battery in warm area. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see Section 8-2). 5-8. Connecting To Weld Output Terminals Stop engine. 1 Positive (+) Weld Output Terminal 2 Negative (−) Weld Output Terminal Stick And TIG Welding For Stick welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right. For Stick and TIG Direct Current Electrode Negative (DCEN), connect electrode holder cable to Negative (−) terminal on right and work cable to Positive (+) terminal on left. MIG And FCAW Welding For MIG welding Direct Current Electrode Positive (DCEP), connect wire feeder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right. Use Process/ Contactor switch to select type of weld output (see Section 6-3). For MIG and FCAW Direct Current Electrode Negative (DCEN), connect wire feeder cable to Negative (−) terminal on right and work cable to Positive (+) terminal on left. Use Process/ Contactor switch to select type of weld output (see Section 6-3). 1 2 Tools Needed: 803 452 3/4 in Notes Start Your Professional Welding Career Now! 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Return To Table Of Contents Over 80,000 trained since 1930! OM-4420 Page 21 5-9. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft 400 ft (105 m) (120 m) Weld Output Terminals Turn off power before connecting to weld output terminals. Welding Amperes 10 − 60% Duty Cycle 60 − 100% Duty Cycle 100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60) 150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95) 200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120) 250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 2/0 (2x70) 300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 2 ea. 4/0 (2x120) 500 2/0 (70) 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 3/0 (3x95) 600 3/0 (95) 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120) 700 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 3/0 (3x95) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120) 4 ea. 4/0 (4x120) 800 4/0 (120) 2 ea. 2/0 (2x70) 2 ea. 3/0 (2x95) 2 ea. 4/0 (2x120) 3 ea. 4/0 (3x120) 3 ea. 4/0 (3x120) 4 ea. 4/0 (4x120) 4 ea. 4/0 (4x120) Do not use worn, damaged, undersized, or poorly spliced cables. * Chart 10 − 100% Duty Cycle is a general guideline and may not suit all applications. If cable overheats occurs (normally you can smell it), use next size larger cable. **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. ( ) = mm2 for metric use S-0007-E− ***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505. Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-4420 Page 22 Return To Table Of Contents 5-10. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information A 24 volts ac. Protected by circuit breaker CB5 (see Section 8-7). B Contact closure to A completes 24 volt ac contactor control circuit. C Output to remote control:+10 volts dc in MIG or Stick mode; 0 to +10 volts dc in TIG mode. D Remote control circuit common. E DC input command signal: 0 to +10 volts from min. to max. of remote control with Voltage/ Amperage Adjust control at max. 24 VOLTS AC REMOTE OUTPUT CONTROL OR I 115 volts, 10 amperes, 60 Hz ac. Protected by circuit breaker CB6 (see Section 8-7). J Contact closure to I completes 115 volt ac contactor control circuit. K Chassis common. G Circuit common for 24 and 115 volt ac circuit. 115 VOLTS AC 803 452 GND NEUTRAL *The remaining sockets are not used. Notes OHM’S LAW VOLTAGE = CURRENT X RESISTANCE CURRENT = VOLTAGE RESISTANCE RESISTANCE = VOLTAGE CURRENT Return To Table Of Contents OM-4420 Page 23 SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) 9 10 12 13 6 5 3 4 125−400 40−330 DO NOT SWITCH UNDER LOAD 85−250 185−525 7 60−450 30−220 55−125 20−110 300−MAX PANEL STAR TING AID REMO TE 8 11 2 1 803 454 / 206 467-A OM-4420 Page 24 Return To Table Of Contents 6-2. Description Of Controls (See Section 6-1) Engine Starting Controls scheduling maintenance. 1 4 Starting Aid Switch (Optional) Use switch to energize starting aid for cold weather starting. Push switch up for 60 seconds to operate the starting aid (intake air heater) before cranking engine (see starting instructions following). 2 Engine Control Switch Use switch to start engine, select engine speed, and stop engine. In Run position, engine runs at weld/power speed. In Run/Idle position, engine runs at idle speed with no generator power or weld load, and weld/power speed with load applied. Fuel Gauge Use gauge to check fuel level. Engine stops if fuel level is low on units with low fuel shutdown option. To check fuel level when engine is not running, turn Engine Control switch to Run/Idle position. 5 Engine Oil Pressure Gauge Normal pressure is 30 − 60 psi (206 − 414 kPa). Engine stops if pressure is below 20 psi (138 kPa). 6 Engine Temperature Gauge To Start: Normal temperature is 212 - 239° F (100 115° C). Engine stops if temperature exceeds 270° F (132° C). If engine does not start, let engine come 7 Above 32 F (0 C): turn Engine Control switch to Start. Release Engine Control switch when engine starts. Use gauge to check battery voltage and monitor the engine charging system. The meter should read about 14 volts dc when the engine is running, and about 12 volts dc when the engine is stopped. to a complete stop before attempting restart. Battery Voltmeter Use the highest range for MIG welding and for cutting and gouging (CAC-A). For most welding applications, use lowest amperage range possible to help prevent arc outages. 10 Voltage/Amperage Adjust Control With Process/Contactor switch in any Stick or TIG setting, use control to adjust amperage within range selected by Ampere Range switch. With Process/Contactor switch in any MIG position, use control to adjust voltage. With Voltage/Amperage Adjust Switch in Remote position, control limits the remote amperage in TIG mode, but has no effect in Stick and MIG modes. Weld output would be about 263 A DC with controls set as shown (50% of 125 to 400 A). The numbers around the Voltage/Amper- age Adjust control are for reference only and do not represent an actual percentage value. 11 Voltage/Amperage Adjust Switch And Remote 14 Receptacle See Section 6-3 for Process/Contactor switch information. Use switch to select front panel or remote voltage/amperage control. For remote control, place switch in Remote position and connect remote control to Remote 14 receptacle RC14 (see Sections 5-10 and 6-4). 9 Weld Meters Below 32 F (0 C) using optional starting aid switch: Turn Engine Control switch to Run/Idle position. Push Starting Aid switch up for 60 seconds. While still holding Starting Aid switch, turn Engine Control switch to Start. Release Engine Control switch and Starting Aid switch when engine starts. Weld Controls Do not switch under load. 12 AC/DC Voltmeter (Optional) To Stop: turn Engine Control switch to Off position. Use switch to select weld amperage range. Voltmeter displays voltage at the weld output terminals, but not necessarily the welding arc due to resistance of cable and connections. Engine Gauges 3 Engine Hour Meter Use gauge to monitor engine running time for 8 Process/Contactor Switch Ampere Range Switch Use all five ranges for Stick welding, and the lowest four ranges for TIG welding. Read the upper set of numbers at each range for Stick welding and the lower set at each range for TIG welding. Return To Table Of Contents 13 AC/DC Ammeter (Optional) Ammeter displays amperage output of the unit. OM-4420 Page 25 6-3. Process/Contactor Switch 1 1 Process/Contactor Switch Weld output terminals are energized when Process/Contactor switch is in an Electrode Hot position and the engine is running. Use switch to select weld process and weld output on/off control (see table below and Section 6-4). Place switch in Remote positions to turn weld output on and off with a device connected to the remote 14 receptacle. Place switch in Electrode Hot positions for weld output to be on whenever the engine is running. Use Stick position for air carbon arc (CAC-A) cutting and gouging. When switch is in a Stick position, the arc drive (dig) circuit provides additional amperage during low voltage (short arc length) conditions to prevent “sticking” electrodes. The arc drive (dig) circuit is disabled when switch is in MIG or TIG positions. Place switch in Electrode Hot - Stick position when using optional ac power plant (see Section 6-4). The engine auto idle option does not work in the Remote-TIG mode. 212 011-A Process/Contactor Switch Settings Switch Setting Process Output On/Off Control Engine Auto Idle Remote − TIG GTAW With HF Unit, Pulsing Device, Or Remote Control At Remote 14 Receptacle Not Active Remote − Stick Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active Remote − MIG MIG (GMAW) At Remote 14 Receptacle Active Electrode Hot − MIG MIG (GMAW) Electrode Hot Active Electrode Hot − Stick Stick (SMAW), Air Carbon Arc (CAC-A) Cutting And Gouging Electrode Hot Active Electrode Hot − Scratch Start TIG Scratch Start TIG (GTAW) Electrode Hot Active OM-4420 Page 26 Return To Table Of Contents 6-4. Using Remote Voltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-10). 1 803 454 In Example: Process = Stick (Using Remote On/Off) Range = 125 to 400 A DC Min = 125 A DC Max = 400 A DC Example: Combination Remote Amperage Control (Stick) 125−400 40−330 DO NO T SWITCH UNDER LO AD 185−525 85−250 60−450 30−220 Max (400 A DC) 55−125 20−110 300−MAX Min (125 A DC) Set V/A Adjust Switch Set Remote Process Set Range Control Not Used In Remote Stick Mode Adjust Optional Remote Control In Example: Process = TIG (Using Remote On/Off) Range = 40 to 330 A DC Percentage Of Range = 50% Min = 40 A DC Max = About 185 A DC (50% of 40 to 330) Example: Combination Remote Amperage Control (TIG) 125−400 40−330 DO NO T SWITCH UNDER LO AD 185−525 85−250 60−450 30−220 Max (185 A DC) 55−125 20−110 300−MAX Min (40 A DC) Set V/A Adjust Switch Set Remote Process Set Range Set Control Adjust Optional Remote Control 0774 / Ref. 212 011-A / 802 311-A Return To Table Of Contents OM-4420 Page 27 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Receptacles 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz singlephase power at weld/power speed. 1 2 3 If a ground fault is detected, GFCI Reset button pops out and receptacle does not work. Check for faulty tools plugged in receptacle. Press button to reset GFCI1. At least once a month, run en- gine at weld/power speed and press test button to verify GFCI is working properly. 4 3 Circuit Breaker CB1 4 Circuit Breaker CB2 CB1 protects RC1 and the generator winding from overload. If CB1 opens, RC1 and GFCI1 do not work. Place switch in On position to reset breaker. CB2 protects GFCI1 from overload. If CB2 opens, GFCI1 does not work. Press button to reset breaker. If a circuit breaker continues to open, contact Factory Authorized Service Agent. Generator power is not affected by weld output. Maximum output is 2.4 kVA/kW from GFCI1 and 4 kVA/kW from RC1. Maximum output from all receptacles is 4 kVA/kW. EXAMPLE: If 13 A is drawn from RC1, only 7 A is available at GFCI1: (240 V x 13 A) + (120 V x 7 A) = 4.0 kVA/kW 191 624 OM-4420 Page 28 Return To Table Of Contents 7-2. Optional Generator Power Receptacles 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240 V 16 A AC European Receptacle RC1 3 240 V 15 A AC Australian Receptacle RC1 4 240 V 15 A AC South African Receptacle RC1 European Receptacle 5 1 2 6 Receptacles supply 60 Hz singlephase power at weld/power speed. If a ground fault is detected, the GFCI Reset button pops out and the receptacle does not work. Check for faulty tools plugged in receptacle. Press button to reset GFCI1. At least once a month, run en- gine at weld/power speed and press test button to verify GFCI is working properly. Australian Receptacle 5 1 3 5 Circuit Breaker CB2 6 Circuit Breaker CB3 CB2 protects GFCI1 from overload. If CB2 opens, GFCI1 does not work. Place button to reset breaker. 6 CB3 protects RC1 from overload. If CB3 opens, RC1 does not work. Press button to reset breaker. If a circuit breaker continues to open, contact Factory Authorized Service Agent. Generator power is not affected by weld output. South African Receptacle 5 1 4 Maximum output is 2.4 kVA/kW from GFCI1 and 4 kVA/kW from RC1. Maximum output from all receptacles is 4 kVA/kW. EXAMPLE: If 13 A is drawn from RC1, only 7 A is available at GFCI1: 6 (240 V x 13 A) + (120 V x 7 A) = 4.0 kVA/kW 191 624 Return To Table Of Contents OM-4420 Page 29 SECTION 8 − ENGINE/GENERATOR MAINTENANCE Note Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 8-1. Routine Engine/Generator Maintenance Stop engine before maintaining. See also Engine Manual and Maintenance Label. Recycle engine fluids. Service engine more often if used in severe conditions. * To be done by Factory Authorized Service Agent. Every 8 h Check Fluid Levels. See Section 5-7. Wipe Up Spills. FUEL WATER Drain Water From Fuel System. See Section 8-6. Every 50 h Clean And Tighten Weld Terminals. Clean Engine Air Filter. See Section 8-3. Every 100 h Clean And Tighten Battery Connections. Check Engine Air Cleaner Hoses For Cracks And Loose Clamps. Every 250 h Replace Unreadable Labels. 1/2 in. (13 mm) Inspect Belts And Check Tension. Check And Clean Spark Arrestor. See Section 8-4. Clean Radiator. Every 500 h Change Engine Oil Filter. See Section 8-6. Service more often in dirty conditions. Change Engine Oil. See Section 8-6. Repair Or Replace Cracked Cables. OM-4420 Page 30 Return To Table Of Contents Every 1000 h Service Welding Generator Brushes And Slip Rings. Service More Often In Dirty Conditions.* Change Engine Fuel Filters. See Section 8-6. FUEL SLUDGE Drain Sludge From Fuel Tank. See Section 8-6. OR Check Engine Valve Clearance.* Blow Out Or Vacuum Inside. During Heavy Service, Clean Monthly. Every 3000 h Clean/Set Engine Fuel Injectors.* Every 6000 h / 5 Years Replace Engine Timing Belt. Return To Table Of Contents OM-4420 Page 31 8-2. Engine Maintenance Label OM-4420 Page 32 Return To Table Of Contents 8-3. Servicing Air Cleaner Stop engine. Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged element is not covered by the warranty. 1 Engine Air Cleaner The air cleaner primary element can be cleaned but the dirt holding capacity of the filter is reduced with each cleaning. The chance of dirt reaching the clean side of the filter while cleaning and the possibility of filter damage makes cleaning a risk. Consider the risk of unwarrantable equipment damage when determining whether to clean or replace the primary element. If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection. Never clean a safety element. Replace the safety element after servicing the primary element three times. 1 1 2 3 Clean or replace primary element if dirty (see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six cleanings. 4 Optional 5 1 Housing 2 Safety Element (Optional) 3 Primary Element 4 Dust Cap 5 Dust Ejector To clean air filter: Wipe off cap and housing. Remove cap and dump out dust. Remove element(s). Wipe dust from inside cap and housing with damp cloth. Reinstall safety element (if present). Reinstall cap. Do not clean housing with air hose. Clean primary element with compressed air only. Air pressure must not exceed 100 psi (690 kPa). Use 1/8 in (3 mm) nozzle and keep nozzle at least 2 in (51 mm) from inside of element. Replace primary element if it has holes or damaged gaskets. Keep nozzle 2 in (51 mm) from element. Reinstall primary element and cap (dust ejector down). Blow Inspect aircleaner1 9/00 − 803 454 / 153 929-B / 153 585 / Ref. S-0698-B Return To Table Of Contents OM-4420 Page 33 8-4. Inspecting/Cleaning Spark Arrestor Muffler Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 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. 2 Stop engine and let cool. 1 Reinstall cleanout plug. Tools Needed: 3/8 in OM-4420 Page 34 803 452 / 803 230 Return To Table Of Contents 8-5. Adjusting Engine Speed Stop engine and let cool. Engine speed is factory set and should not require adjustment. After tuning engine, check engine no load speed with a tachometer or frequency meter (see table for no load speeds). If necessary, adjust speed as follows: Start engine and run until warm. Turn Process/Contactor switch to Stick − Electrode Hot position. 1 Throttle Rod 2 Locknut Loosen locknuts. Place engine control switch in Run/Idle position. Wait 15 seconds for throttle solenoid to energize and lower engine speed to idle rpm. Turn throttle rod to adjust idle speed. Tighten locknuts. 3 Engine Speed Adjustment Screw 4 Locknut Place engine control switch in Run position. Loosen locknut. Turn screw to adjust weld/power speed. Tighten locknut. Do not set engine speed higher than specified. Stop engine. Close door. 2 1850 rpm Max. (61.6 Hz) 1235 rpm (41.1 Hz) 1 2 3 4 Tools Needed: 3/8, 7/16 in 803 454 / 802 313-A Return To Table Of Contents OM-4420 Page 35 8-6. Servicing Engine Fuel And Lubrication Systems Tools Needed: 3 1 4 5 7 6 2 803 454 Stop engine and let cool. After servicing, start engine and check for fuel leaks. Stop engine, tighten connections as necessary, and wipe up spilled fuel. 1 2 3 Oil Filter Oil Drain Hose And Valve Oil Fill Cap 4 Primary Fuel Filter (Fuel/Water Separator) 5 Petcock 6 Secondary Fuel Filter 7 Fuel Tank Sludge Drain Valve base. See engine manual and engine maintenance label for oil specifications. To drain water from fuel system: Open primary fuel filter petcock and drain water into metal container. Close petcock when water-free fuel flows. To replace primary fuel filter: Turn filter counterclockwise. Remove filter. Apply thin coat of fuel to gasket on new filter. Fill filter with fuel. Install filter and turn clockwise until tight. Bleed air from fuel system according to engine manual. Inspect fuel lines, and replace if cracked or worn. To change oil and filter: Route engine oil drain hose through hole in OM-4420 Page 36 Return To Table Of Contents To replace secondary fuel filter: See engine manual. Close doors. To drain sludge from fuel tank: Beware of fire. Do not smoke and keep sparks and flames away from drained fuel. Dispose of drained fuel in an environmentally-safe manner. Do not leave unit unattended while draining fuel tank. Properly lift unit and secure in a level position. Use adequate blocks or stands to support unit while draining fuel tank. Attach 1/2 ID hose to drain valve. Put metal container under drain, and use screwdriver to open sludge drain valve. Close valve when sludge has drained. Remove hose. 8-7. Engine/Generator Overload Protection Stop engine. When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent. 1 2 Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely. If F2 opens, weld output is low or stops entirely. 4 kVA/kW generator power is still available. 2 Circuit Breaker CB4 (Not Shown) Circuit Breaker CB5 Circuit Breaker CB6 6 Circuit Breaker CB10 (Not Shown) 7 Circuit Breaker CB11 8 Circuit Breaker CB12 9 Circuit Breaker CB13 10 Circuit Breaker CB14 (Not Shown) 9 8 7 4 1 3 4 5 CB4 protects the welding arc drive (dig) circuit. If CB4 opens, electrode may stick to the workpiece more frequently during low voltage (short arc length) conditions. CB4 automatically resets when the fault is corrected. CB5 protects the 24 volt ac output to remote receptacle RC14, and 24 volt output to field current regulator board PC1. If CB5 opens, weld output and 24 volt output to RC14 stops. On units with optional power plant, power at receptacle RC5 also stops if CB5 opens. 5 CB6 protects the 115 volt ac output to remote receptacle RC14. If CB6 opens, 115 volt output to RC14 stops. CB10 protects the engine battery circuit. If CB10 opens, the engine will not crank. CB10 automatically resets when the fault is corrected. CB11 protects the engine wiring harness. If CB11 opens, weld output stops (generator power is still available). CB12 protects the field flashing circuit. If CB12 opens, the generator may not excite at start-up and weld and generator power output may not be available. CB13 protects the engine shutdown circuit. If CB13 opens, the engine cranks but does not start. Press button to reset breaker. CB14 protects the throttle solenoid. If CB14 opens, the engine will not run at idle speed. CB14 automatically resets when the fault is corrected. Ref. 803 229 Return To Table Of Contents OM-4420 Page 37 SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting Tables A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor switch in a Electrode Hot position, or place switch in a Remote position and okay at ac receptacles. connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-10 and 6-1). Check position of Ampere Range switch. Reset circuit breaker CB11 (see Section 8-7). Reset circuit breaker CB5 (see Section 8-7). Check for faulty remote device connected to RC14. Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10). Have Factory Authorized Service Agent check connector board PC6 and connections. Check fuse F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor. No weld output or generator power Disconnect equipment from generator power receptacles during start-up. output. Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor. Reset circuit breaker CB12 (see Section 8-7). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. Erratic weld output. Check and tighten connections inside and outside unit. Be sure connection to work piece is clean and tight. Use dry, properly stored electrodes. Remove excessive coils from weld cables. High weld output. Check position of Ampere Range switch and Voltage/Amperage Adjust control. Check engine weld/power speed, and adjust if necessary (see Section 8-5). Have Factory Authorized Service Agent check field current regulator board PC1. Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere work when welding in Stick mode. Range switch in highest range. Low weld output. Check engine weld/power speed, and adjust if necessary (see Section 8-5). Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor. Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 8-7). frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5. length) conditions. Low open-circuit voltage. Check engine weld/power speed, and adjust if necessary. No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position. control. Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10). Repair or replace remote control device. OM-4420 Page 38 Return To Table Of Contents Trouble Remedy Constant speed wire feeder does not Reset circuit breaker(s) CB5 and CB13 (see Section 8-7). work. Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10). Repair or replace wire feeder. Low CV weld output. Set Ampere Range switch to highest range. Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1. B. Generator Power Trouble Remedy No generator power output at ac recep- Reset receptacle circuit breakers. tacles; weld output okay. No generator power or weld output. Disconnect equipment from generator power receptacles during start-up. Check fuses F1 and F2, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check integrated rectifier SR1, capacitor C9, and the rotor. Reset circuit breaker CB12. Have Factory Authorized Service Agent check field current regulator board PC1 (see Section 8-7). Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. High output receptacles. at generator power Check engine weld/power speed, and adjust if necessary (see Section 8-5). Have Factory Authorized Service Agent adjust field current resistor R3. Low output receptacles. at generator power Check engine weld/power speed, and adjust if necessary (see Section 8-5). Check fuse F1, and replace if open (see Section 8-7). Have Factory Authorized Service Agent check integrated rectifier SR1, resistor R3, and capacitor C9. C. Engine Trouble Engine will not crank. Remedy Check battery, and replace if necessary. Check battery connections and tighten if necessary. Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 8-7). Have Factory Authorized Service Agent check engine wiring harness and components. Check engine wiring harness plug connections. Turn optional battery disconnect switch to On position (see Section 5-6). Have Factory Authorized Service Agent check Engine Control switch S1, and control relays CR1 and CR2. Engine cranks but does not start. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low. Reset circuit breaker CB13 (see Section 8-7). Have Factory Authorized Service Agent check engine wiring harness and components. Check battery and replace if necessary. Check engine charging system according to engine manual. Have Factory Authorized Service Agent check fuel solenoid FS1. Air in fuel system. See engine manual. Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature Control switch is released. is too high (see Section 5-7). Return To Table Of Contents OM-4420 Page 39 Trouble Engine hard to start in cold weather. Remedy Use optional starting aid switch (see Section 6-1). If Starting Aid switch does not work have Factory Authorized Service Agent check Engine Control switch S2, and control relay CR8. Keep battery in good condition. Store battery in warm area off cold surface. Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for fuel information. Use correct grade oil for cold weather (see Section 8-2 ). Engine suddenly stops. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low. Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature is too high (see Section 5-7). See engine manual. Engine slowly stopped and cannot be restarted. Check fuel level. Check engine air and fuel filters (see Sections 8-3 and 8-6). See engine manual. Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running. Clean top of battery with baking soda and water solution; rinse with clear water. Recharge or replace battery if necessary. Periodically recharge battery (approximately every 3 months). Engine idles, but does not come up to weld speed. Have Factory Authorized Service Agent check idle module PC7. Check for obstructed throttle solenoid. Engine does not run at idle speed. Turn Process/Contactor switch to any position but Remote-TIG. Check for obstructed throttle solenoid. Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1 and linkage (see Section 8-7). Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current transformer CT1. Engine uses oil during run-in period; Dry engine (see Section 11). wetstacking occurs. OM-4420 Page 40 Return To Table Of Contents Notes Start Your Professional Welding Career Now! 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Return To Table Of Contents Over 80,000 trained since 1930! OM-4420 Page 41 SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram For Welding Generator OM-4420 Page 42 Return To Table Of Contents 215 333-A Return To Table Of Contents OM-4420 Page 43 SECTION 11 − RUN-IN PROCEDURE run_in1 8/01 11-1. Wetstacking Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Welding Generator Run diesel engines near rated voltage and current during run-in period to properly seat piston rings and prevent wetstacking. See nameplate, rating label, or specifications section in this manual to find rated voltage and current. 2 1 2 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 run-in. 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. OM-4420 Page 44 Return To Table Of Contents 11-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 4 2 1 Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle. 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 Connect load bank to generator weld output terminals using proper size weld cables with correct connectors. Observe correct polarity. Start engine and run for several minutes. 3 Set load bank switches and then adjust generator A/V control so load equals rated voltage and current of generator (see nameplate, rating label, or the specifications section in this manual). Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. Check oil level frequently during run-in; add oil if needed. After one hour (minimum) place A/V control in minimum position, then turn off load bank to remove load. Run engine several minutes at no load. Stop engine and let cool. 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present. S-0683 Return To Table Of Contents OM-4420 Page 45 11-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 6 Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 2 1 Resistance Grid Use grid sized for generator rated output. 1 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 Connect grid to generator weld output terminals using proper size weld cables with correct connectors (polarity is not important). 4 Voltmeter 5 Clamp-On Ammeter Connect voltmeter and ammeter as shown, if not provided on generator. 3 5 Start engine and run for several minutes. Set grid switches and then adjust generator A/V control so load equals rated voltage and current of the generator (see nameplate, rating label, or the specifications section in this manual). 4 Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. + Check oil level frequently during run-in; add oil if needed. After one hour (minimum), place A/V control in minimum position, then shut down grid to remove load. Run engine several minutes at no load. Stop engine and let cool. 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present. S-0684 OM-4420 Page 46 Return To Table Of Contents SECTION 12 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment 1 2 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Do not use 2-prong plug unless equipment is double insulated. 1 2 3 Be sure equipment has this symbol and/or wording. OR gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577 12-2. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. 1 2 3 1 GND/PE Equipment Grounding Terminal (On Front Panel) Grounding Cable (Not Supplied) Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. 2 3 If unit does not have GFCI receptacles, use GFCI-protected extension cord. Electrically bond generator frame to vehicle frame by metal-to-metal contact. Bed liners, shipping skids, and some running gear insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. S-0854 Return To Table Of Contents OM-4420 Page 47 12-3. Grounding When Supplying Building Systems 1 1 2 Equipment Grounding Terminal Grounding Cable 2 GND/PE Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes. 2 3 ST-800 576-B 12-4. How Much Power Does Equipment Require? 1 3 2 1 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 is a non-resistive load and requires approximately six times more power while starting the motor than when running (see Section 12-8). 3 3 Rating Data Rating shows volts and amperes, or watts required to run equipment. AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. 4.5 A x 115 V = 520 W The load applied by the drill is 520 watts. EXAMPLE 2: 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 The total load applied by the three flood lamps and drill is 1120 watts. S-0623 OM-4420 Page 48 Return To Table Of Contents 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty Rating Starting Watts Running Watts 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/8 HP 1/6 HP 1/4 HP 1/3 HP 1/2 HP 800 1225 1600 2100 3175 2020 3075 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 1000 1400 1850 2400 3500 300 500 600 700 875 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 400 550 650 800 1100 12-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std. (e.g. Conveyors, Feed Augers, Air Compressors) High Torque (e.g. Barn Cleaners, Silo Unloaders, Silo Hoists, Bunk Feeders) 3-1/2 cu. ft. Mixer High Pressure 1.8 Gal/Min Washer 2 gal/min 2 gal/min Refrigerator or Freezer Shallow Well Pump Sump Pump Rating 1/4 HP 1/2 HP 3/4 HP 2 HP 1/3 HP 1/2 HP 3/4 HP 1 HP 1-1/2 HP 2 HP 3 HP 5 HP 1-1/2 HP 5 HP 7-1/2 HP 10 HP 1/2 HP 500 PSI 550 PSI 700 PSI 1/3 HP 1/2 HP 1/3 HP 1/2 HP Return To Table Of Contents Starting Watts Running Watts 1000 1650 3400 4400 2900 10500 1720 2575 4500 6100 8200 10550 15900 23300 8100 23300 35000 46700 3300 3150 4500 6100 3100 2150 3100 2100 3200 1000 650 1000 1400 1100 2800 720 975 1400 1600 2200 2850 3900 6800 2000 6000 8000 10700 1000 950 1400 1600 800 750 1000 800 1050 OM-4420 Page 49 12-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet & Dry Vac OM-4420 Page 50 Rating Starting Watts Running Watts 1/4 in 3/8 in 1/2 in 6-1/2 in 7-1/4 in 8-1/4 in 9 in 10 in 14 in 6 in 8 in 10 in 1/2 HP 1 HP 1-1/2 HP 2 HP 1-1/2 HP, 12 in 2 HP, 14 in Standard 9 in Heavy Duty 12 in 1/3 HP 18 in HID Metal Halide Mercury Sodium Vapor 400 gph 900 gph 3/4 HP, 16 in 1 HP, 20 in 1/2 HP 3/4 HP 1 HP 1/4 HP 1.7 HP 2-1/2 HP 350 400 600 500 900 1400 4500 6300 2500 1720 3900 5200 3000 6000 8200 10500 1100 1100 350 500 2100 400 125 313 1000 1400 1250 600 900 4500 6100 3150 4500 6100 1900 900 1300 350 400 600 500 900 1400 1500 1800 1100 720 1400 1600 1000 1500 2200 2800 1100 1100 350 500 700 400 100 250 Return To Table Of Contents 1000 200 500 1400 1600 950 1400 1600 700 900 1300 12-8. Power Required To Start Motor 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 1 2 3 4 2 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage. 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 kVA/HP x HP x 1000 VOLTS = STARTING AMPERAGE EXAMPLE: 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, Code M results in kVA/HP = 11.2 11.2 x 1/4 x 1000 = 12.2 A Starting the motor requires 12.2 amperes. 230 S-0624 12-9. How Much Power Can Generator Supply? 1 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 1 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. ST-800 396-A / S-0625 Return To Table Of Contents OM-4420 Page 51 12-10. Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. 1 2 Utility Electrical Service 3 Transfer Switch 4 Fused Disconnect Switch (If Required) Welding Generator Output 5 Essential Loads Have only qualified persons perform these connections according to all applicable codes and safety practices. Switch transfers the electrical load from electric utility service to the generator. Transfer load back to electric utility when service is restored. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. Install correct switch (customer-supplied). Switch rating must be same as or greater than the branch overcurrent protection. Customer-supplied equipment is required if generator will supply standby power during emergencies or power outages. 1 Utility Electrical Service 2 Transfer Switch (Double-Throw) 3 Fused Disconnect Switch Install correct switch (customer-supplied) if required by electrical code. 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular (utility) system voltage and wiring. Connect generator with temporary or permanent wiring suitable for the installation. 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. 5 Essential Loads Generator output may not meet the electrical requirements of the premises. If generator does not produce enough output to meet all requirements, connect only essential loads (pumps, freezers, heaters, etc. − See Section 12-4). Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-4420 Page 52 Return To Table Of Contents 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (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 Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts) 5 1200 7 1680 10 2400 15 4 6 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 Return To Table Of Contents OM-4420 Page 53 SECTION 13 − SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7/97 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent contamination of tungsten electrode. 13-1. Selecting Tungsten Electrode Amperage Range - Gas Type♦ - Polarity Electrode Diameter DC − Argon − Electrode Negative/Straight Polarity DC − Argon − Electrode Positive/Reverse Polarity AC − Argon − Using High Frequency AC − Argon − Balanced Wave Using High Freq. .010” Up to 15 * Up to 15 Up to 10 .020” 5-20 * 5-20 10-20 Pure Tungsten (Green Band) .040” 15-80 * 10-60 20-30 1/16” 70-150 10-20 50-100 30-80 3/32” 125-225 15-30 100-160 60-130 1/8” 225-360 25-40 150-210 100-180 5/32” 360-450 40-55 200-275 160-240 3/16” 450-720 55-80 250-350 190-300 1/4” 720-950 80-125 325-450 250-400 .010” Up to 25 * Up to 20 Up to 15 .020” 15-40 * 15-35 5-20 .040” 25-85 * 20-80 20-60 1/16” 50-160 10-20 50-150 60-120 3/32” 135-235 15-30 130-250 100-180 1/8” 250-400 25-40 225-360 160-250 5/32” 400-500 40-55 300-450 200-320 2% Thorium Alloyed Tungsten (Red Band) 3/16” 500-750 55-80 400-500 290-390 1/4” 750-1000 80-125 600-800 340-525 .010” * * Up to 20 Up to 15 .020” * * 15-35 5-20 .040” * * 20-80 20-60 1/16” * * 50-150 60-120 3/32” * * 130-250 100-180 Zirconium Alloyed Tungsten (Brown Band) 1/8” * * 225-360 160-250 5/32” * * 300-450 200-320 3/16” * * 400-550 290-390 1/4” * * 600-800 340-525 ♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended. The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. OM-4420 Page 54 Return To Table Of Contents 13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding 1 2 Tungsten Electrode Balled End Understand and follow safety symbols at start of Section 14-1 before preparing tungsten. 1 Ball end of tungsten before welding by applying either an ac amperage slightly higher than what is recommended for a given electrode diameter (see Section 13-1), or a dc electrode positive amperage. 1-1/2 Times Electrode Diameter 2 Ref. S-0161 13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding 1 1 2 2 Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2-1/2 Times Electrode Diameter 1 2 3 1 2 Stable Arc Flat Diameter of this flat determines amperage capacity. 3 4 Grinding Wheel Straight Ground 1 2 3 4 Arc Wander Point Grinding Wheel Radial Ground 4 Ideal Tungsten Preparation − Stable Arc 1 2 3 4 Wrong Tungsten Preparation − Wandering Arc Ref. S-0161 / Ref. S-0162 Return To Table Of Contents OM-4420 Page 55 SECTION 14 − GUIDELINES FOR TIG WELDING (GTAW) 14-1. Positioning The Torch Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 3 1 Workpiece Make sure workpiece is clean before welding. 2 2 Work Clamp Place as close to the weld as possible. 4 3 4 5 90° Torch Filler Rod (If Applicable) Tungsten Electrode Select and prepare tungsten according to Sections 13-1, and 13-2 or 13-3. 1 Tungsten extension is the distance the tungsten extends out gas cup of torch. Arc length is the distance from the tungsten to the workpiece. 10−15° As a general guide, start with an extension and arc length equal to diameter of tungsten. 4 5 10−25° ST-161 892 14-2. Torch Movement During Welding Tungsten Without Filler Rod 75° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75° Welding direction Form pool Tilt torch Remove rod 15° Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B OM-4420 Page 56 Return To Table Of Contents 14-3. Positioning Torch Tungsten For Various Weld Joints 90° Butt Weld And Stringer Bead 70° 20° 20° “T” Joint 70° 10° 20° 40° Lap Joint 70° 20° 30° 90° Corner Joint 70° 20° ST-162 003 / S-0792 Return To Table Of Contents OM-4420 Page 57 SECTION 15 − PARTS LIST Hardware is common and not available unless listed. 15 3 16 17 2 18 19 1 6 7 14 13 20 11 5 21 10 4 12 9 22 8 121 113 23 24 120 110 119 − Figure 15-5 104 13 114 112 111 − Figure 15-2 118 105 106 107 108 115 116 109 117 − Figure 15-3 Figure 15-1. Main Assembly OM-4420 Page 58 Return To Table Of Contents 36 34 35 33 37 31 30 32 29 28 27 59 58 26 39 57 53 25 38 51 49 50 60 61 56 55 62 54 52 45 47 42 43 44 63 46 64 48 122 41 123 40 62 65 66 72 67 68 77 76 73 75 74 69 70 71 93 − Figure 15-4 78 79 81 87 85 94 95 96 97 98 86 82 80 99 83 88 84 100 101 91 102 89 92 90 103 803 455 Return To Table Of Contents OM-4420 Page 59 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-1. Main Assembly . . . 1 . . . . . . . . . . . . . . 189824 . . . 2 . . . . . . . . . . . . . . 189828 . . . 3 . . . . . . . . . . . . . . 206601 . . . 4 . . . . . Z1 . . . . . 208277 . . . 5 . . . . . . . . . . . . . . 038620 . . . . . . . . . . . 1T . . . . . 189549 . . . 6 . . . . . . . . . . . . . . 038621 . . . 7 . . . . . . . . . . . . . . 081499 . . . . . . . . . . . . . . . . . . . . 138027 . . . . . . . . . . . . . . . . . . . . 010146 . . . 8 . . SR4, SR5 . . 035704 . . . 9 . . . . CB4 . . . . 045061 . . . 10 . . . . . . . . . . . . . . 206352 . . . 11 . . . . . T1 . . . . . 205636 . . . 12 . . . . . . . . . . . . . . 201697 . . . 13 . . . . . . . . . . . . . . 173352 . . . 14 . . . . . . . . . . . . . . 189708 . . . 15 . . . . . . . . . . . . . . 194485 . . . 16 . . . . . . . . . . . . . . 189764 . . . . . . . . . . . . . . . . . . . *192938 . . . . . . . . . . . . . . . . . . . *192939 . . . . . . . . . . . . . . . . . . . . 206556 . . . 17 . . . . . . . . . . . . . . 189763 . . . 18 . . . . . . . . . . . . . . 206351 . . . 19 . . . . . . . . . . . . . . 189464 . . . 20 . . . . . . . . . . . . ♦209612 . . . 21 . . . . . . . . . . . . ♦209597 . . . 22 . . . . . . . . . . . . . ♦209611 . . . 23 . . . . . . . . . . . . . . 196220 . . . 24 . . . . . . . . . . . . . . 192362 . . . 25 . . . . . . . . . . . . . +206603 . . . 26 . . . . . . . . . . . . . . 189052 . . . 27 . . . . . . . . . . . . . . 190198 . . . 28 . . . . . . . . . . . . . . 176103 . . . 29 . . . . . . . . . . . . . . 176104 . . . 30 . . . . . . . . . . . . . . 143915 . . . 31 . . . . . . . . . . . . . . 205702 . . . 32 . . . . . . . . . . . . . . 205749 . . . 33 . . . . . . . . . . . . . . 603767 . . . 34 . . . . . . . . . . . . . . 010875 . . . 35 . . . . . . . . . . . . . . 205712 . . . 36 . . . . . . . . . . . . . . 205748 . . . 37 . . . . . . . . . . . . . . 176230 . . . 38 . . . . . . . . . . . . . . 206552 . . . 39 . . . . . . . . . . . . . . 202633 . . . 40 . . . . . . . . . . . . . . 191577 . . . 41 . . . . . . . . . . . . . . 191809 . . . 42 . . . . . . . . . . . . . . 209632 OM-4420 Page 60 . . Panel, Gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Engine Extension LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reactor, AC Environmental Rda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block, Term Assy Standard W/Clamp (includes) . . . . . . . . . . . . . . . . . . . . . . . . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . . . . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Edge Trim, Style Tl750−b2x1/16 Black W/Clips 3.750 . . . . . . . . . . . . . . . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . . . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extrusion, Rubber (order by ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner, Intake (Engine) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe, Air Cleaner Intake Deutz (Turbo Hose To Air Cleaner Hose) . . . . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lever, Switch Lockout Disconnect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch, Disc Battery 2P 6−36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . . . Mount, Sgl Stud 1.5 Dia X 1.000 Lg .312−18 Stud . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cap, Weather Exhaust No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe, Exhaust Deutz Bf4m2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support, Cover E−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose, Tubing Oil Assyw/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . Return To Table Of Contents 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-1. Main Assembly (Continued) . . . 43 . . . . . . . . . . . . . . 206548 . . . . . . . . . . . . . . . . . . . . 193256 . . . . . . . . . . . . . . . . . . . . 195748 . . . . . . . . . . . . . . . . . . . . 195746 . . . . . . . . . . . . . . . . . . . . 195745 . . . . . . . . . . . . . . . . . . . *067265 . . . . . . . . . . . . . . . . . . . *066217 . . . . . . . . . . . . . . . . . . . . 208041 . . . . . . . . . . . . . . . . . . . . 193230 . . . . . . . . . . . . . . . . . . . . 194403 . . . . . . . GLOW PLUG ♦190059 . . . 44 . . . . . . . . . . . . . . 207203 . . . . . . . . . . . . . . . . . . . . 208042 . . . 45 . . . . . . . . . . . . . *207808 . . . 46 . . . . . . . . . . . . . . 209675 . . . 47 . . . . . . . . . . . . . . 209633 . . . 48 . . . . . . . . . . . . . . 209621 . . . 49 . . . . . . . . . . . . . . 207269 . . . 50 . . . . . . . . . . . . . . 206749 . . . 51 . . . . . . . . . . . . . . 206558 . . . 52 . . . . . . . . . . . . . . 209623 . . . 53 . . . . . . . . . . . . . . 201749 . . . 54 . . . . . . . . . . . . . . 201006 . . . 55 . . . . BATT . . . . 190897 . . . 56 . . . . . . . . . . . . . . 108081 . . . 57 . . . . . . . . . . . . . . 190206 . . . 58 . . . . . . . . . . . . . . 190207 . . . 59 . . . . . . . . . . . . . . 203430 . . . 60 . . . . . . . . . . . . . +201183 . . . 61 . . . . . . . . . . . . . . 176108 . . . 62 . . . . . . . . . . . . . . 176106 . . . 63 . . . . . . . . . . . . . +206602 . . . 64 . . . . . . . . . . . . . . 212286 . . . 65 . . . . . . . . . . . . . . 199849 . . . 66 . . . . . . . . . . . . . . 071731 . . . 67 . . . . . . . . . . . . . . 191812 . . . 68 . . . . . . . . . . . . . . 071890 . . . 69 . . . . . . . . . . . . . . 071730 . . . 70 . . . . . . . . . . . . . . 083476 . . . 71 . . . . . . . . . . . . . . 135205 . . . . . . . . . . . . . . . . . . . . 199505 . . . 72 . . . . . . . . . . . . . . 165271 . . . 73 . . . . . . . . . . . . . . 176529 . . . 74 . . . . . . . . . . . . . . 113854 . . . 75 . . . . . . . . . . . . . . 176528 . . . 76 . . . . . . . . . . . . . . 173336 . . . 77 . . . . . . . . . . . . . . 066298 . . . 78 . . . . . . . . . . . . . . 191816 . . . 79 . . . . . . . . . . . . . . 206297 . . . 80 . . . . . . . . . . . . . *192744 . . . . . . . . . . . . . . . . . . . . 199383 . . . . . . . . . . . . . . . . . . . . 191819 . . Engine, Deutz Dsl Elec Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Adapter, Engine Deutz 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Flywheel, Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Sender, Coolant Temp & 130c Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Spacer, Stl .323 Id X .625 Od X .141 Thk (Alternator) . . . . . . . . . . . . . . . . 1 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Adaptor, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Fan, Engine Cooling 18.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Spacer, Stl .800id X 1.188od X .090 Thk (Fan Hub Bolt) . . . . . . . . . . . . . . 1 . . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Hose, Tubing Oil Assyw/Fittings 27.040lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Guard, Fan LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Shroud, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Ftg, Brs Adapter Long 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Bolt, J Stl .312−18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . 1 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 8 . . Panel, Engine Extension R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Guard, Fan RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Screw, 625−11x4.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . Bracket, Mtg Engine R.h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 4 . . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4 . . Hose Assy, Oil Drain 32.000 Lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.666 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Ring (Oil Drain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Bracket, Mtg Fuel Filter/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Hose, Sae .312 Id X .560 Od X 8.000 (Fuel Filter To Fuel Pump) . . . . . . 1 . . Hose, Sae .312 Id X .560 Od X 14.000 (Fuel Tank To Fuel Filter) . . . . . . 1 Return To Table Of Contents OM-4420 Page 61 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-1. Main Assembly (Continued) . . . 81 . . . . . . . . . . . . . . 174064 . . . . . . . . . . . . . . . . . . . . 196036 . . . . . . . . . . . . . . . . . . . . 125663 . . . . . . . . . . . . . . . . . . . . 175936 . . . . . . . . . . . . . . . . . . . . 127994 . . . . . . . . . . . . . . . . . . . . 127648 . . . . . . . . . . . . . . . . . . . . 124974 . . . . . . . . . . . . . . . . . . . . 601868 . . . . . . . . . . . . . . . . . . . . 126388 . . . . . . . . . . . . . . . . . . . . 089800 . . . . . . . . . . . . . . . . . . . . 108941 . . . . . . . . . . . . . . . . . . . . 156733 . . . 82 . . . . . . . . . . . . . . 190992 . . . 83 . . . . . . . . . . . . . . 085963 . . . 84 . . . . . . . . . . . . . . 206604 . . . 85 . . . . . . . . . . . . . . 199592 . . . 86 . . . . . . . . . . . . +200 989 . . . 87 . . . . . . . . . . . . . . 206464 . . . 88 . . . . . . . . . . . . . 189 975 . . . 89 . . . . . . . . . . . . . 208 141 . . . 90 . . . . . . . . . . . . . 189 826 . . . 91 . . . . . . . . . . . . . . 191626 . . . 92 . . . . . . . . . . . . . +189827 . . . 93 . . . . . . . . . . Figure 15-4 . . . 94 . . . . . . . . . . . . . . 189245 . . . 95 . . . . . . . . . . . . . . 124253 . . . 96 . . . . . . . . . . . . . . 189912 . . . 97 . . . . . . . . . . . . . . 189909 . . . 98 . . . . . . . . . . . . . . 189913 . . . 99 . . . . . . . . . . . . . . 190142 . . 100 . . . . . . . . . . . . . 189910 . . 101 . . . . . . . . . . . . . 189908 . . 102 . . . . . . . . . . . . . 181572 . . . . . . . . . . . . . . . . . . . . 196219 . . 103 . . . . . . . . . . . . . 191446 . . 104 . . . . . . . . . . . . . 209094 . . 105 . . . . . . . . . . . . +212224 . . 106 . . . . . . . . . . . . . 191897 . . 107 . . . . . . . . . . . . . 200864 . . 108 . . . . . . . . . . . . . 212046 . . 109 . . . . R3 . . . . . 189699 . . 110 . . . . . . . . . . . . . 191512 . . 111 . . . . . . . . . Figure 15-2 . . 112 . . . . . . . . . . . . . 189731 . . 113 . . . . . . . . . . . . . 203260 . . 114 . . . . . . . . . . . . . 191448 . . 115 . . . . . . . . . . . . . 206609 . . 116 . . . . . . . . . . . . . 182761 . . 117 . . . . . . . . . Figure 15-3 . . 118 . . . CT1 . . ♦202130 . . 119 . . . . . . . . . Figure 15-5 . . 120 . . . . . . . . . . . . . 193453 . . 121 . . . PC1 . . . . 207397 . . 122 . . . . . . . . . . . . . 208024 . . 123 . . . . . . . . . . . . . 206613 . . . . . . . . . . . . . . . . . . . . 049525 . . . . . . . . . . . . . . . . . . . . 049525 OM-4420 Page 62 . . Idle, Solenoid Assy (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Arm Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Joint, .250−28 Type Sp Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rod, Throttle 5.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Joint, .250−28 Type Spf Female Rod End . . . . . . . . . . . . . . . . . . . . . . . . Clevis, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid, 12vdc Pull/Hold Type 1” Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 250−28 .44hex .27h Stl Pld Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 250−20 .44hex .22h Stl Pld .58d Flange Defor . . . . . . . . . . . . . . . . . . . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 250−28 .44hex .13h Stl Pld Sem Cone Wshr.51d . . . . . . . . . . . . . . . . Keeper, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) . . . . . . . . . . . . . Channel, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Latch, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hinge, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank, Fuel 23.0 Gal (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc . . . . . . . . . . . . . . . . . . . . . Ftg, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sender, Fuel Gauge 9.750 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc . . . . . . . . . . . . . . . . . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose, Sae .250 Id X .500 Od X 26.000 (Fuel Return Line) . . . . . . . . . . . . . . Extrusion, Rubber w/Adhesive 1.000 x 1.000 (order by ft.) . . . . . . . . . . . . . . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Do Not Weld On Base CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Manufacturing Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xfmr, Current Sensing (Auto Idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return To Table Of Contents 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 1 4 1 1 1 4 1 1 1 1 1 1 1 1 6ft 1 1 4 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 4 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-1. Main Assembly (Continued) . . . . . . . . . . . . . . . . . . . . 212045 . . . . . . . . . . . . . . . . . . . ♦195118 . . . . . . . . . . . . . . . . . . ♦209238 . . . . . . . . . . . . . . . . . . ♦209240 . . . . . . . . . . . . . . . . . . ♦209236 . . . . . . . . . . . . . . . . . . ♦209241 . . . . . . . . . . . . . . . . . . ♦209242 . . . . . . . . . . . . . . . . . . ♦189975 . . . . . . . . . . . . . . . . . . ♦155146 + . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . . . Kit, Lock-Out Vandalism (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close . . . . . . . . . . . . 1 1 1 1 1 1 1 4 3 When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 212 045. Recommended Spare Parts. * ♦Optional To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. 10 5 11 23 22 4 21 3 1 2 13 18 15 24 17 16 6 19 7 12 8 9 14 20 21 803 456-A Figure 15-2. Control Box Assembly Return To Table Of Contents OM-4420 Page 63 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-2. Control Box Assembly − (Figure 15-1 Item 111) . . . 1 . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . . . . 4 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . 201077 . . Control Box, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206736 . . Harness, Control Box, Weld Control LH (includes) . . . . . . . . . . . . . . . . . . . . . . 6 . CB11, CB12 . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . 7 . . . . SR1 . . . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . . 8 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204737 . . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . CR2,3,5,6 . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . 12 . . . . CR11 . . . . 173069 . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . 13 . . . . PC7 . . . . 195706 . . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . TD1 . . . . 207139 . . Timer, Delay On Make/Break Open 3−60 Sec 12vdc . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . +201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . 209273 . . Label, Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206375 . . Harness, Engine Deutz Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . CB10 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156734 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . CB14 . . . . 205927 . . . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . CB13 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 . . . . . 021467 . . . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177859 . . . . Conn, Body 5 Terminal (For Ignition Switch S1) . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . CR4 . . . . 113247 . . . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C8/D8,C14/D14 189701 . . . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . CR1 . . . . 214876 . . . . Relay, Encl 6 vdc spst 35A/14 vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . R8 . . . . . 214863 . . . . Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . CR8 . . ♦155309 . . Contactor, Solenoid 12vdc Continuous 400a Inrush . . . . . . . . . . . . . . . . . . 2 2 3 1 1 1 2 1 1 1 1 1 3 1 5 1 1 1 1 1 1 1 4 6 1 1 1 1 1 5 2 2 1 1 1 ♦Optional *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-4420 Page 64 Return To Table Of Contents Hardware is common and 5 not available unless listed. 4 3 2 1 6 7 8 11 9 10 12 13 47 14 46 15 45 16 44 17 18 43 42 41 23 36 35 40 39 32 34 38 33 21 20 25 26 22 24 37 19 27 28 31 30 29 803 457 Figure 15-3. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-3. Panel, Front w/Components (Figure 15-1 Item 117) . . . 1 . . . . . . . . . . . . . . 207467 . . .............................. ... 2 ........................ . . . 3 . . . . . . . . . . . . . . 201580 . . . . . 4 . . . . CT3 . . ♦209274 . . . . . 5 . . . . . S3 . . . . . 208278 . . Plate, Screened Ident Control Rating (When Ordering This Item The Namplate Should Also Be Ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Screened (Order By Model And Serial Number) Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xfmr, Current (Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return To Table Of Contents 1 1 1 1 OM-4420 Page 65 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-3. Panel, Front w/Components (Continued) . . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range Switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . . 6 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . . . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . 9 . . . . CB5 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CB6 . . . . 139266 . . . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .221 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . S1 . . . . . 176606 . . Switch, Ignition 4 Position W/Out Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . S2 . . . ♦021467 . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 . . . . CB1 . . . . 201083 . . Circuit Breaker, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (includes) . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . CB2 . . . . 093996 . . . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . . 16 . . . GFCI1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . RC1 . . . . 147632 . . . . Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . +201106 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . 163167 . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . . . . . 22 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . 200910 . . Label, Warning Electric Shock And Moving Parts Ce . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . 193260 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . 193258 . . Cover, Receptacle Gfci Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . . . . 30 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . 119014 . . Lever, Switch Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . HM1 . . . . 118058 . . Meter, Hour 12−24vdc 2.25 Dia High Profile Stainles . . . . . . . . . . . . . . . . . . . 38 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . . . . 39 . . . . BAT . . . . 193228 . . Meter, Volt DC 8 − 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . . . . 40 . . . . TEMP . . . . . . . . . . . . . Gauge, Engine Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . OIL . . . . . . . . . . . . . . . Gauge, Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 . . . . . A1 . . . ♦164873 . . Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . V1 . . . ♦164874 . . Meter, Volt AC/DC 0− 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . OM-4420 Page 66 Return To Table Of Contents 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 3 4 2 1 1 1 1 1 2 1 2 8 2 2 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-3. Panel, Front w/Components (Continued) .................... . . . . . . . . . . PLG6 . . . . . . . . . . . . . . PLG8 . . . . .................... . . . . . . . . . PLG13 . . . .................... .................... .................... .................... .................... .................... .................... .................... 193158 114063 193184 147992 158465 088731 135873 187654 196602 059712 024103 120304 025234 . . Harness, Unit Weld Control − CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . . Clip, Component .437 Dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blank, Snap−in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blank, Snap−in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug, Str Grd 2p3w 15a 250v *6−15p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 3 1 10 1 1 2 1 ♦Optional + When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 212 045 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. 15 11 16 14 17 13 10 18 12 9 19 8 20 21 7 6 5 3 22 23 4 1 2 26 28 29 25 24 27 30 31 34 33 32 803 327 Figure 15-4. Generator Return To Table Of Contents OM-4420 Page 67 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-4. Generator (Figure 15-1 Item 93) . . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375−16x1.50 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring 2.859 ID X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . STATOR . . +208287 . . Stator, Weld Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . 176106 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . ROTOR . . . 210446 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . 172555 . . Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . . . . . . . . 602159 . . Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . . 604950 . . Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . 139341 . . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . *190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . . . . 30 . . . . . . . . . . . . . . 188560 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . 189142 . . Brushholder, Generator (Brushes Not Included − See Item 29) . . . . . . . . . . . 32 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . . . 34 . . . . . . . . . . . . . . 604534 . . Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6 6 1 1 1 1 8 1 2 1 1 1 1 1 1 1 4 10 10 8 4 4 1 6 6 6 4 4 4 3 3 1 2 2 2 + When ordering a component originally displaying a precautionary label, the label should also be ordered. Order label individually or as part of Label Kit 212 045. *Recommended Spare Parts. ♦Optional To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-4420 Page 68 Return To Table Of Contents Hardware is common and not available unless listed. 4 3 2 1 5 6 7 8 9 802 279-A Figure 15-5. Main Rectifier Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-5. Main Rectifier Assembly (Figure 15-1 Item 119) . . . . . . . . . . SR3 . . . . ... 1 .............. ... 2 .............. ... 3 .............. ... 4 .............. . . . 5 . . . . PC3 . . . . ... 6 .............. ... 7 .............. . . . 8 . D3, D5, D7 . . . . 9 . D2, D4, D6 . 208279 188137 188517 188135 134201 201449 188136 188493 208334 208335 . . Rectifier Complete (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection Board, Rectifier Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus Bar, Conn Bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . . . Circuit Card Assy, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diode, Rect 275. A 300v Sp Do−9 *1n4048(037956 W/R . . . . . . . . . . . . . . . Diode, Rect 275. A 300v Rp Do−9 *1n4048r(037957 W/ . . . . . . . . . . . . 1 1 3 2 3 1 8 2 3 3 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Return To Table Of Contents OM-4420 Page 69 Effective January 1, 2003 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Your distributor also gives you ... Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts — 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Maxstar 150 Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor Unless Specified * * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Maxstar 85, 140 Spot Welders Load Banks Racks Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) 4. 6 Months — Batteries 5. 90 Days — Parts * MIG Guns/TIG Torches * * * * * * * Induction Heating Coils and Blankets APT & SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate Spoolguns Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.) 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 8/03 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters − United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03
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