Miller BIG D2 User manual

Miller BIG D2 User manual
March 1979 FORM: OM-460B
Effective With Serial No. HJ149358
MODEL
Big D2
— ее на
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P,O, Box 1079
APPLETON, WI] 54912 USA
PRINTED IN U.S.A.
LIMITED WARRANTY
EFFECTIVE: JANUARY 1, 1979
This warranty supersedes all previous MILLER warranties and is ex-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY —Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to
its Distributor/Dealer that all new and unused Equipment furnished
by Miller is free from defect in workmanship and material as of the
time and place of delivery by Miller. No warranty is made by Miller
with respect to engines, trade accessories or other items manu-
factured by others. Such engines, trade accessories and other
items are sold subject to the warranties of their respective manu-
facturers, if any. At the present time, the manufacturer’s warranty on
the Mag-Diesel engine on DEL-200 is limited to six months and on
all other engines to one year.
Except as specified below, Miller’s warranty does not apply to
components having normal useful life of less than one (1) year, such
as spot welder tips, relay and contactor points, MILLERMATIC parts
that come in contact with the welding wire including nozzles and
nozzle insulators where failure does not result from defect in
workmanship or material.
Miller shall be required to honor warranty claims on warranted
Equipment in the event of failure resulting from a defect within the
following periods from the date of delivery of Equipment to the
original user:
1. Arc welders, power sources and components . . I year
2. Original main power rectifiers. . . . . . . . . . . . 3 years
(labor - 1 year only)
3. All welding guns and feeder/guns . . . . . . . . .. 90 days
4_ All other Millermatic Feeders . . . . . . . . . . . . | year
5. Replacement or repair parts, exclusive oflabor . : . 60 days
6. Batteries . . . 1 1 424 44 4 4 4 4 4 420 . . 6 months
provided that Miller is notified in writing within thirty (30) days of
the date of such failure.
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As a matter of general policy only, Miller may honor claims Y
submitted by the original user within the foregoing periods. 3
In the case of Miller's breach of warranty or any other duty Ne
with respect to the quality of any goods, the exclusive remedies q
therefor shall be, at Miller’s option, (1) repair or (2) replacement or, Y
where authorized in writing by Miller in appropriate cases, (3) the "
reasonable cost of repair or replacement at an authorized Miller ser- й
vice station or (4) payment of or credit for the purchase price (less \
reasonable depreciation based upon actual use) upon return of the ‘
goods at Customers risk and expense. Upon receipt of notice of Y
apparent defect or failure, Miller shall instruct the claimant on the ИР
warranty claim procedures to be followed. Né
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUS.
TOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND
ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN WRIT-
ING, MILLER PRODUCTS ARE INTENDED FOR ULTIMATE
PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR
OPERATION BY PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND
NOT FOR CONSUMERS OR CONSUMER USE. MILLER’ WAR-
RANTIES DO NOT EXTEND TO, AND NO RESELLER IS
AUTHORIZED TO EXTEND MILLER’S WARRANTIES TO,
ANY CONSUMER.
Section No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
ArcWelding ............. PARA AAA eee ea
Standards Booklet Index ............... 2... eneeocordodarerce.
— a $
RON
SECTION 2 — INTRODUCTION
2-1. General LL. 211111 LL LA 4 AL AA A4 Aa 4 4 4 ea 4 a A 4 A4 ea a a aa La ee
2-2. Receiving-Handling .......... 4 4 sa a da AL A aa a aa aa Lee |
2-3. Description .......... . ..md0r0eradaaenenreeaarenreraaanera..
2-4. Safety .....1.. 11111111 LL LL RAA RL A LA A aa a La LL
SECTION 3 — INSTALLATION
3-1. Location ......... e eaerrroenrariererecora eee
3-2. Weld Output Connections fe ee eee
3-3. Equipment Grounding Terminal ......22101 011111 La LL LL
SECTION 4 — ENGINE PREPARATION
-1. Lubrication .....12 101000 LL LL LL AAA ALL La LL LL Le Lana
- 2. Coolant System ......2111 1101 LL LL LL AL LA Ve a ea ALL LL
- 3. Preparing New Battery For Service 2..2... 2... ....
-4. Air Cleaner ..... aereo enaaanaenonananedodod endadoocoeo
4-5. Fuel ........ resreareneoncareneooaraceorecaaeoadararoea
& 4 LB BA
SECTION 5 — FUNCTION OF GENERATOR CONTROLS
5-1. 120 Volts AC Receptacle ........120020100 0014144 a 14 ae a 4 a 4 a a a ae 6
5-2. Range Switch And Fine Adjustment Control .......................
5-3. Volt-Ampere Curves ........ ee ee aa a LL LA
5-4. Duty Cycle ......... ene. LL LL LL LL LL aa LL
5-5. Meters.....1111 01110444 LA ALL LL A A A A RAR aa LL aa LL
5-6. 240 Volts AC Duplex Receptacie ......... i
SECTION 6 — FUNCTION OF ENGINE CONTROLS
{© ©0 >! ©) сло + ©) Ко —
. Run-Stop Control oe
. Throttle Control .....12221 100111 LL LL LL A La AAA LL
. Engine Control Switch... к кк к кк вк в а век вене ееее,
‚ Ihermostart Heater Switch .......... LL LL LL LL
. Start Pushbutton .......... ea eadedeademenereCtóoo
. Battery Charge Indicator Lamp... ......... La aa aa La
. Engine Temperature And Oil Pressure Lamp ................ 0,
. Automatic Idle Control Switch. ......... 2. LL LL
. Hour Meter. ......... er ea aa La LL La LL LL иные
CO) OO С) DEAR
SECTION 7 — SEQUENCE OF OPERATION
7 - 1, Shielded Metal Arc Welding (SMAW) . ....... i.
7-2. Power Plant Operation .......... 2. ee narco
7-3. Starting The Engine . Lo... ea aa a LL AL
7-4. Engine Shutdown Le, |
== TABLE OF CONTENTS RE
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Section No. | Page No.
SECTION 8 — GENERATOR MAINTENANCE
8-1. General ......... rreresedeveca cano aerea erareaaean e 15
8-2. Collector Ring Brushes .............. 9... ed0arrereae naa, 15
8-3. Welding Cables ........ tt A ae A AAA 15
SECTION 9 — ENGINE MAINTENANCE
9-1. Lubrication o.oo 15
9-2, Coolant System Lo ot ee a aoraroracorecorzra 15
9-3. Electrical System... ..... e ae aadodoo 16
9-4. Air Cleaner Service ........ aaa ALL 16
9-5, Fuel Filter Service ........ ea oa aooooreroo, 16
9-6. Spark Arrestor .........1221 1 LL LL LA LL LL
SECTION 10 — TROUBLESHOOTING
PARTS
wnaa SECTION 1- SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE ===
1-7.
INTRODUCTION
We learn by experience, Learning safety through personal
experience, like a child touching a hot stove is harmful,
wasteful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the use of weld-
ing and cutting are described in this manual. Research, devel-
opment, and field experience have evolved reliable equipment
and safe installation, operation, and servicing practices. Acci-
dents occur when equipment is improperly used or main-
tained. The reason for the safe practices may mot always be
given. Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the rules.
Read and understand these safe practices before atternpting
to install, operate, or service the equipment. Comply with
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
Failure to observe these safe practices may cause serious in-
jury or death. When safety becomes a habit, the equipment
can be used with confidence,
These safe practices are divided into two Sections: 1 -
General Precautions, commen to arc welding and cutting; and
2 - Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety are also
available for additional and more complete procedures than
those given in this manual. They are tisted in the Standards
Index in this manual. ANSI Z49.1 is the most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and iocal in-
spection requirements also provide a basis for equipment in-
stallation, use, and service.
GENERAL PRECAUTIONS
Burn Prevention
Wear protective clothing - leather (or asbestos) gauntlet
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and stag.
Wear heimet with safety goggles or glasses with side shields
underneath, appropriate filter lenses or plates (protected by
clear cover glass), This is a MUST for welding or cutting, (and
chipping} to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken, pitted, or spattered.
See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should
never be handied without gloves.
Medical first aid and eye treatment. First aid facilities and a
qualified first aid person should be available for each shift
unless medical facilities are close by for immediate treatment
of flash burns of the eyes and skin burns.
Ear ptugs should be worn when working on overhead orin a
confined space. A hard hat should be worn when others work
overhead.
Fiammable hair preparations should not be used by persons
intending to weld or cut.
Toxic Fume Prevention
Adequate ventilation. Severe discomfort, iliness or death can
resuit from fumes, vapors, heat, or oxygen enrichment or
depletion that welding {or cutting) may produce. Prevent
them with adequate ventilation as described in ANSI Stan-
dard Z49.1 listed 1 in Standards index, NEVER ventilate
with oxygen.
Lead -, cadmium -, Zinc -, mercury -, and beryliium - bearing
and similar materials, when welded (or cut) may produce
harmfu! concentrations of toxic fumes. Adequate local
exhaust ventilation must be used, or each person tn the area
as well as the operator must wear an air-supplied respirator.
For beryllium, both must be used.
Metals coated with or containing materials that emit toxic
fumes shoutd not be heated unless coating is removed from о
the work surface, the area is well ventilated, or the operator
wears an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided. Leaked gas
in large quantities can change oxygen concentration danger-
ously. Do not bring gas cylinders into a confined space.
Leaving confined space, shut OFF gas supply at source to
prevent possible accumulation of gases in the space if down-
stream valves have been accidently opened or left open,
Check to be sure that the space is safe before re-entering it.
Vapors from chlorinated solvents can be decomposed by the
heat of the arc (or flame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ulira-
violet {radiant} energy of the arc can also decompose tri-
chloroethylene and perchloroethylene vapors to form phos-
gene. DO NOT WELD or cut where solvent vapors can be
drawn into the welding or cutting atmosphere or where the
radiant energy can penetrate to atmospheres containing even
minute amounts of trichloroethyiene or perchloroethylene.
Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached by the
arc, fiame, flying sparks, hot slag or heated material; misuse
of compressed gases and cylinders; and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors, and
through wall or floor openings, out of sight of the goggled
operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment ciean and operable, free of oil, grease, and
(in electrical parts) of metallic particles that can cause short
circuits.
If combustibles are in area, do NOT weld or cut, Move the
work if practicable, to an area free of combustibles. Avoid
paint spray rooms, dip tanks, storage areas, ventilators. [f the
work cannot be moved, move combustibles at least 35 feet
away out of reach of sparks and heat; or protect against
ignition with suitable and snug-fitting, fire-resistant covers or
shields.
Walls touching combustibles on opposite sides should not be
welded on (or cut). Walls, ceilings, and floor near work
should be protected by heat-resistant cavers or shields.
Fire watcher must be standing by with suitable fire ex-
tinguishing equipment during and for some time after weld-
ing or cutting if:
a. appreciable combustibles
tion} are within 35 feet
b. appreciable combustibles are further than 3b feet but can
be ignited by sparks
c. openings (concealed or visible) in floors or walls within 35
feet may expose combustibles to sparks
d. combustibles adjacent to walls, ceilings, roofs, or metal
partitions can be ignited by radiant or conducted heat.
(including building construc-
Hot work permit should be obtained before operation to
ensure supervisor's approval that adequate precautions have
been taken.
After work is done, check that area is free of sparks, glowing
embers, and flames.
An empty container that held combustibles, or that can pro-
duce flammabie or toxic vapors when heated, must never be
welded on or cut, uniess container has first been cieaned as
described in AWS Standard AB.0, listed 3 in Standards index.
OM-460 Page 1
Расе 2
This includes: a thorough steam or caustic cleaning (or a
solvent or water washing, depending on the combustible’s
solubility} followed by purging and inerting with nitrogen or
carbon dioxide, and using protective equipment as recom- |
mended in AG.0. Waterfilling Just below working leve! may
substitute for inerting.
A container with unknown contents should be cleaned {see
paragraph above). Do NOT depend on sense of smell or sight
to determine if 1115 safe to weld or cut.
Hollow castings or containers must be vented before welding
or cutting. They can explode,
Explosive atmospheres. Never weld or cut where the air may
contain flammable dust, gas, or liquid vapors {such as gaso-
line).
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, PRECAU-
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index,
1. Pressure Regulators
Reguiator relief valve is designed to protect only the regula
tor from overpressure; it is not intended to protect any
downstream equipment. Provide such protection with one or
more relief devices.
Never connect a regulator to a cylinder containing gas other
than that for which the regulator was designed.
Remove fauity regulator from service immediately for repair
(first close cylinder valve). The following symptoms indicate
a faulty reguiator:
Leaks - if gas ieaks externally.
Excessive Creep - if delivery pressure continues to rise with
downstream valve closed.
Faulty Gauge - if gauge pointer does not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
Repair. Do NOT attempt repair. Send faulty regulators for
repair to manufacturer's designated repair center, where
special techniques and tools are used by trained personnel.
2. Cylinders
Cylinders must be handled carefully tc prevent leaks and
damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits, They can produce
short circuit arcs that may lead to a serious accident. {See
1-3C.)
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cyiinder is properly handled.
Identifying gas content. Use only cylinders with name of gas
marked on them; do not rely on color to identify gas con-
tent. Notify supplier if unmarked. NEVER DEFACE or alter
name, number, or other markings on a cylinder. It is illegal
and hazardous.
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
Prohibited use. Never use a cylinder or its contents for other
than its intended use, NEVER as a support or roller.
Locate or secure cylinders so they cannot be knocked over.
Passageways and work areas. Keep cylinders clear of areas
where they may be struck.
Transporting cylinders. With a crane, use a secure support
such as a platform or cradle. Do NOT lift cylinders off the
ground by their valves or caps, or by chains, slings, or mag-
nets.
Do NOT expose cylinders to excessive heat, sparks, slag, and
flame, etc. that may cause rupture. Do not allow contents to
exceed 130CF. Cool with water spray where such exposure
exists.
Protect cylinders particutarly valves from bumps, falls, falling
objects, and weather. Replace caps securely when moving
cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify your
suppher,
Mixing gases. Never try to mix any gases in a cylinder.
Never reftll any cylinder.
Cylinder fittings should never be modified or exchanged.
3. Hose
Prohibited use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and biack for inert gases.
Use ferrules or clamps designed for the hose (not ordinary
wire or other substitute} as a binding to connect hoses to
fittings.
No copper tubing splices. Use only standard brass fittings to
splice hose.
Avaid tong runs to prevent kinks and abuse, Suspend hose off
ground to keep it from being run over, stepped on, or other-
wise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by sparks,
slag, and open flame.
Examine hose regularly for leaks, wear, and loose connec-
tions. Immerse pressured hose in water; bubbles indicate
leaks.
Repair leaky or worn hose by cutting area out and splicing
(1-2D3). Do NOT use tape,
4, Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator. Except
for hydrogen, crack valve momentarily, pointing outlet away
from people and sources of ignition. Wipe with a clean lint-
less cloth.
Match regulator to cylinder. Before connecting, check that
the regulator label and cylinder marking agree, and that the
reguiator infet and cylinder outlet match. NEVER CON-
NECT a regulator designed for a particuiar gas or gases to a
cylinder containing any other gas.
Tighten connections. When assembling threaded connections,
clean and smooth seats where necessary. Tighten. If connec-
tion leaks, disassemble, clean, and retighten using properly
fitting wrench.
Adapters. Use a CGA adapter (available from your supplier)
between cylinder and regulator, if one is required. Use two
wrenches to tighten adapter marked RIGHT and LEFT
HAND threads.
Regulator outlet {or hose} connections may be identified by
right hand threads for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder {or manifold valve} by turning adjusting
screw in (clockwise). Draining prevents excessive compression
heat at high pressure seat by allowing seat to open on pressur-
ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Stand to side of regulator while opening cylinder valve,
Open cylinder valve slowly so that regulator pressure in-
creases siowly. When gauge is pressurized {gauge reaches requ-
lator maximum} ieave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
possible leak, For fuel gas, open to less than one turn to
permit quick emergency shutoff.
Use pressure charts (available from your supplier} for safe
and efficient, recommended pressure settings on regulators,
Check for leaks on first pressurization and regulary there-
after. Brush with soap solution (capful of Ivory Liquid” or
equivalent per gallon of water). Bubbles indicate leak. Clean
off soapy water after test; dried soap is combustible.
User Responsibilities
Remove leaky or defective equipment from service immed-
lately for repair. See User Responsibility statement in equip-
ment manual.
Leaving Equipment Unattended
Close gas supply at source and drain gas.
Rope Staging-Support
Rope staging-support should not be used for weiding or cut-
ting operation; rope may bum.
ARC WELDING
Comply with precautions in 1-1, 1-2, and this section. Arc
Welding, properly done, is a safe process, but a careless opera-
tar invites trouble. The equipment carries high currents at
significant voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates, weld-
ments are hot, and compressed gases may be used. The wise
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standards referenced in index.
Burn Protection
Comply with precautions in 1-2.
The weiding arc is intense and visibly bright. Its radiation can
damage eyes, penetrate lightweight clothing, reflect from
light-colored surfaces, and burn the skin and eyes. Skin burns
resemble acute sunburn, those from gas-shielded arcs are
more severe and painful. DON'T GET BURNED; COMPLY
WITH PRECAUTIONS,
1. Protective Clothing
Wear jong-sleeve clothing (particularly for gas-shielded arc) in
addition to gloves, hat, and shoes (1-24). As necessary, Use
additional protective clothing such as leather jacket or
sleeves, flame-proof apron, and fire-resistant leggings. Avoid
outergarments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing. Button
coliar to protect chest and neck and button pockets to pre-.
vent entry of sparks.
2. Eve and Head Protection
Protect eves from exposure to arc, NEVER look at an elec-
tric arc without protection,
Welding helmet or shield containing a filter plate shade no.
12 or denser must be used when welding. Place over face
before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken heimet or shield should NOT be worn;
radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced IM-
MEDIATELY. Replace clear cover plate when broken, pitted,
or spattered.
Flash goggles with side shields MUST be worn under the
helmet to give some protection to the eyes should the helmet
not be lowered over the face before an arc is struck. Looking
at an arc momentarily with unprotected eyes (particularly a
high intensity gas-shielded arc) can cause a retinal burn that
may leave a permanent dark area in the field of vision.
3. Protection of Nearby Personne!
Enclosed welding area. For production welding, a separate
room or enclosed bay is best. In open areas, surround the
*Trademark of Proctor & Gamble,
operation with low-reflective, non-combustible screens or
panels. Allow for free air circulation, particularly at floor
level.
Viewing the weld. Provide face shields for ali persons who
will be looking directly at the weld.
Others working in area, See that all persons are wearing flash
goggles.
Before starting to weld, make sure that screen flaps or bay
doors are closed.
Toxic Fume Prevention
Comply with precautions in 1-2B,
Generator engine exhaust must be vented to the outside air.
Carbon monoxide can kill.
Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipments rated capacity. Do not overioad arc weiding
equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and cause a
fire.
Never strike an arc on a cylinder or other pressure vessel. It
creates a brittle area that can cause a violent rupture or lead
to such a2 rupture later under rough handling.
Compressed Gas Equipment
Comply with precautions in 1-2D.
Shock Prevention
Exposed hot conductors or other bare metal in the welding
circuit, or in ungrounded, electrically-HOT equipment can
fatally shock a person whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur-
face when welding, without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp area with-
out adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat cart
not be avoided. Sweat, sea water, or moisture between body
and an electrically HOT part - or grounded metal - reduces
the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit such as
welding power source, control, work table, and water circula-
tor to the building ground, Conductors must be adeguate to
carry ground currents safely. Equipment made electrically
HOT by stray current may shock, possibly fatally, Do NOT
GROUND to electrical conduit, or to a pipe carrying ANY
gas or a flammable liquid such as oil or fuel,
Thræe-phase connection. Check phase requirement of equip-
ment before installing. If only 3-phase power is available,
connect single-phase equipment to only two wires of the
3-phase line. Do NOT connect the equipment ground lead to
the third (live) wire, or the equipment will become etectri-
calty HOT - a dangerous condition that can shock, possibly
fatally.
Before welding, check ground for continuity. Be sure conduc
tors are touching bare metal of equipment frames at connec-
tions.
If a line cord with a ground lead is provided with the equip-
ment for connection to a switchbox, connect the ground lead
to the grounded switchbox. If a three-prong plug is added for —
connection to a grounded mating receptacie, the ground lead
must be connected to the ground prong only. If the line cord
comes with a three-prong plug, connect to a grounded mating
receptacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
OM-460 Page 3
Page 4
2. Electrode Holders
Fully insulated electrode holders should be used. Do NOT
use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors shouid be used to join
welding cable lengths.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn or
damaged insulation to avoid possibly - lethal shock from
bared cable. Cables with damaged areas may be taped to give
resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected from
hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units should
have insulating covers secured before operation.
6. Electrode Wire
Electrode wire becomes electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger 1s pressed. Keep hands and body clear of wire and
other HOT parts.
7. Safety Devices
Safety devices such as interlocks and circuit breakers should
not be disconnected or shunted out.
Before installation, inspection, or service, of equipment, shut
OFF all power and remove line fuses {or lock or red-tag
switches) to prevent accidental turning ON of power. Discon-
nect all cables from welding power source, and pull all 115
volts line-cord plugs.
Do not open power circuit or change polarity while welding.
If, in an emergency, 1t must be disconnected, guard against
shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and dis-
connect all power to equipment.
Power disconnect switch must be available near the welding
power source.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their {atest revisions and comply as applicable:
1. ANSI Standard 249.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St, Miami, Fla. 33125.
2. ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPA. -
TION AND EDUCATIONAL EYE AND FACE PROTEC.
TION, obtainable from American National Standards
Institute, 1430 Broadway, New Yori, N.Y. 10018.
3. American Welding Society Standard A6.0, WELDING
AND CUTTING CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
4. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING AND CUTTING, obtainable from the
National Fire Protection Association, 470 Atlantic
Avenue, Boston, Mass, 02210.
5. NFPA Standard 518, CUTTING AND WELDING PRO-
CESSES, obtainable same as rtem 4.
6. CGA Pamphlet P-1. SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Avenue, New
York, N.Y. 10036.
7. OSHA Standard 29 CFR, Part 1910, Subpart Q, WELD-
ING, CUTTING AND BRAZING.
SECTION 2 - INTRODUCTION
Rated Welding Welding Current Ranges | Open-Circuit Overall Weight
Amperes Current In Amperes Voltage Dimensions (Pounds)
Output Range Coarse Ranges | Fine Range Range *Power {Inches} Net Ship
Min. - 70 From Min.
aol 40 To 60-115 To Max. 60 To 90 2.5 kva Height - 52 |
100% 275 Amperes 80-170 Of Each Volts DC 120 Volts AC Width - 24-3/4 | 1360 | 1400
Duty Cycle 115 - 240 Coarse 21 Amperes Length- 60-1/2
160 - Max. Range 50/60 Hz.
*Power available while welding is dependent on the amount of welding current being used and position of FINE ADJUSTMENT controi.
2-1.
Figure 2-1. Specifications
To
Exciting
Alternator
Starter
Solenoid
=
Engine
Control
Switch
51
ma
tz Volt
Battery
Automatic”
Idle Control
Switch (54)
Stator | w
_ Revolving > Windings | * | Reactor
Field Power | d Z1
120 Volts AC
Receptacle
RC1
A Im
| Aiternator/ Fuse* utomatic
Regulator F2 [die Control
2 Cirçuit
Main Negative
Rectifier Output
SR3 Terminal
N Positive
Stabilizer Qutput
22 Terminal
+ Optional
— № Electrical Connection
— uw Mechanical Coupling
LH Magnetic Coupling
| TA-008 824-A
To Engine
Thrattle
Idie*
Solenoid —
TS1
Figure 2-2. Functional Diagram
GENERAL
This manual has been prepared especially for use in familiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
. RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight biti wilt be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Styte) Numbers of the equipment be supplied.
. DESCRIPTION
NOTE
This welding generator has reconnectable capability
to provide 240 volts ac auxiliary power at the
front panel if the optional receptacle kit is ordered.
Should preparation and installation {or information
if factory installed) be desired, see Section 5-6 for
complete instructions, and delete all reference to
120 volts ac dupiex receptacle and replace with
| 240 voits ac duplex receptacle. i
This welding generator is driven by a diesel engine. The
unit ls designed to produce a de output for Shielded
Metal-Arc Welding (SMAW), A receptacle provides 120
volts ac, at 50/60 Hertz, to power lights, tools, etc,
while welding. Power available while welding is dependent
on the amount of welding current being used and the
position of the FINE ADJUSTMENT control. When weld-
ing is not being performed and the FINE ADJUSTMENT
control is set to maximum 2.5 kva of 120 volts ac, 21
amperes of power is available at the receptacle.
. SAFETY
Before the equipment is put into operation, the safety sec-
tion at the front of this manual should be read compietely.
This will help avoid possible injury due to misuse or improper
welding applications.
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a hazard to per-
sonnel.
IMPORTANT
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
I ment. ; B
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
OM-460 Page 5
a
3-1. LOCATION {Figure 3-1)
Page 6
A proper installation site should be selected for the welding
generator if the unit is 10 provide dependable service, and
remain relatively maintenance free.
IMPORTANT E
If this welding generator is to be mounted on a trailer
{optional}, ensure that the engine end is mounted
toward the front (hitch end) of the trailer to maintain -
proper weight distribution. Also ensure that the
tongue weight of the trailer is approximately 10% of
the gross vehicle weight, It is recommended that a
properly fitting canvas cover (optional) be placed over
the welding generator when not in operation to
protect the unit from the environment.
EA
If this unit is to be operated indoors, it should be
located in a place where the exhaust fumes from the
engine can be vented cut of the building. Failure to
comply with proper venting may result in serious
> bodily injury or loss of life. -
IMPORTANT В
The engine exhaust system on this welding generator
has not been equipped with a spark arrestor unless it
was specifically ordered as an optional accessory. A
spark arrestor, maintained in effective working order,
is mandatory if this welding generator is to be
operated in a National Forest, or on California
grasslands, brush, or forest covered land (see Section
4442 of California Public Resources Code). For other
1 areas, check your state and local laws. ]
A proper installation site permits freedom of air movement
into and out of the welding generator, and also least subjects
the unit to dust, dirt, moisture, and corrosive vapors. A
minimum of 18 inches of unrestricted space must be main-
tained between the welding generator front and rear panels
and the nearest obstruction. Also, the underside of the
welding generator must be kept completely free of ob-
structions. The installation site should also permit easy re-
moval of the outer enclosure for maintenance functions.
ен 24-3/4 — +
52" *
*Add 2" For Weathercap
» SECTION 3 - INSTALLATION EA
IMPORTANT
Do not place any filtering device over the intake air
passages of the welding generator as this would
restrict the volume of intake air and thereby subject
the internal components to an overheating condition
and subsequent failure. Warranty is void if any type of
filtering device is used.
Holes are provided in the base for mounting purposes. Figure
3-1 gives overall dimensions and the base mounting hole lay-
out.
On most welding generators a lifting device is provided for
moving the unit. However, if a fork lift vehicle is used for
lifting the unit, be sure that the lift forks are long enough to
extend completely under base.
IMPORTANT
The use of lift forks too short to extend out of the
opposite side of the base will expose internal compon-
ents to damage should the tips of the lift forks pene-
i trate the bottom of the unit. 1
3-2. WELD OUTPUT CONNECTIONS (Figure 3-2)
To obtain the full rated output from this unit, it is necessary
to select, instail, and maintain proper welding cables. Failure
to comply in any of these areas may result in less than
satisfactory welding performance.
CAUTION - |
Ensure that the unit is completely shut down before
i making any weld output connections. |
A. Location
The POSITIVE and NEGATIVE terminals are located behind
the left side access panel. Once the weld cables have been
connected to the terminals, the cables ere to exit from the
welding generator as shown in Figure 3-2,
2-7/8
_ $
$
J ? 9.1/2
у" - cp
N 21/32 Dia. 26-15/16
12 Holes
34-3/4
46-1/4
59-1/8
ENGINE END
мн 23-1 /4”' — — — == (= 11/16"
м 24-3/4”'
TB-007 983-A
Figure 3-1. Overall Dimension And Base Mounting Hole Layout
Table 3-1. Weld Cable Size
Before connecting the weld cables to the output terminals,
select the desired polarity and make connections as follows: Loo] TOTAL LENGTH OF CABLE | COPPER) IN WELD CIRCUIT
. AMPER *50 100 150 200 250 300 350 400
DC Straight Polarity: Connect the electrode cable to the == 7 > 170 о
negative (—) output terminal and the work cable to the eo 3 : > : 10 2/0 30 3/0
positive (+) output terminal. 200 > > 1 мо 12/0 | 300 4/0 10
о 250 1 1 | 1/0 |120 3/0 lavo [| 4/0 | 2-2/0
DC Reverse Polarity: Connect the electrode cable to the 300 |1/0 vo | 20 {30 |4/0 |} 4/0 2.2/0 | 2-3/0
positive (+) output terminal and the work cable to the
negative (—) output terminal. A-002 702
NOTE: *A. BO FEET OR LESS.
B. Welding Cables
If welding cables were not ordered with this unit, the steps
listed should be followed to ensure the best welding
performance:
1. It is recommended that the welding cables be kept as
short as possible, be placed close together, and be of
adeguate current carrying capacity. The resistance of the
welding cables and connections causes a voltage drop
which is added to the voltage of the arc. Excessive cable
resistance may result in overioading as well as reducing
the maximum current output capability of this unit.
Proper operation is to a great extent dependent on the use
of welding cables and connections that are in good
condition and of adequate size. An insulated electrode
holder must be used to ensure the operator's safety.
2. Use Table 3-1 as a guide for selecting correct cable size for
the anticipated maximum weld current which wili be
used. Table 3-1 shows total cable length, which includes
the electrode and work cable. Example: If the electrode
holder cable is 75 feet long and the work cable is 25 feet
long, select the size cable that is recommended for 100
feet at the maximum weld current that is to be used.
3. Do not use damaged or frayed cables.
4. Follow the electrode holder manufacturer's instructions
for installing the electrode holder onto the electrode cable.
5. Use correct lugs on the weld cable to connect the work
clamp and to connect the cables to the weld output ter-
minals. Install the cables to the output terminals according
to Section 3-2A.
6. Ensure that all connections are clean and tight.
—]a e SECTION 4 - ENGINE PREPARATION
NOTE
See the Engine Manufacturer's manuai (4.108 Engine)
for complete engine care.
4 - 1. LUBRICATION (Figure 4-1)
This engine was shipped from the factory with its crankcase
filled with the correct amount and type of break-in oil unless
otherwise ordered. Check the oi level before attempting to
operate the engine, It should be up to the MAX mark on the
dipstick. Add a quality brand of diese! oil if the oil level is
low. See the oil selection chart, Table 9-1, in Section 9.
Keep Crankcase Oi!
At This Level
IMIN [MAX
Never Operate Engine
| | With Cil Below This Level
TA-200 716-5
Г
Figure 4-1. Oil Level
*B. CABLE SIZE IS BASED ON DIRECT CURRENT (DC),
100% DUTY CYCLE AND EITHER A 4 VOLTS OR LESS
DROP OR A CURRENT DENSITY OF NOT OVER 300
CIRCULAR MILS PER AMP.
*C. WELD CABLE INSULATION WITH A VOLTAGE
RATING TO WITHSTAND THE OPEN-CIRCUIT VOLT-
AGE (OCV) OF THE WELDING GENERATOR MUST BE
USED.
3-3. EQUIPMENT GROUNDING TERMINAL (Figure 3-2)
Normally, engine-driven welding generators do not require
grounding. However, since this unit has auxitiary power plant
capability, grounding of the frame and case may be required.
A grounding terminal has been provided on the front panel
for this purpose (refer to Figure 3-2}. For detailed grounding
instructions consult your local codes and the latest edition
of the National Electrical Code.
Positive
Weld -
Terminal
Equipment
Grounding
Terminal
Negative .
Weld
Terminal
Reverse Polarity Shown
TB-007 934-5
Figure 3-2. Weld Output Connections
After about 50 to 75 hours of running time, drain the break-
in oil and change the oii filter. See the oil selection chart,
Table 9-1, in Section 9 for correct oil type and grade to use
after the break-in oil is drained.
IMPORTANT
This engine may use oil during the break-in period
(first 50-75 hours of operation). Check the oii level
several times a day during this period. Do not dle
the engine longer than necessary for start-up and
shutdown procedures during the break-in period.
Piston rings, etc., will seat faster if the engine 15
run at weld rpm (1850) and the welding generator
is kept loaded as much as possible.
4-2. COOLANT SYSTEM
The liquid capacity of the coolant system in this welding
generator is 7 quarts (U.S, Measure). This unit is shipped
from the factory with the proper amount of water and anti-
freeze to permit operation of the unit at temperatures down
to OCF.
IMPORTANT В
If this welding generator is to be operated in tempera-
tures which are below 09F, additional anti-freeze will
have to be added to the coolant system or the liquid in
the system will freeze and cause the engine to overheat.
OM-460 Page 7
4-3. PREPARING NEW BATTERY
The coolant system is equipped witn a 180°F thermostat. If
the thermostat should fail, ensure that the replacement has
an equal temperature rating.
IMPORTANT
If the thermostat should fail, replace it immediately,
Do net run the engine without a thermostat. If the
thermostat remains closed, the engine will overheat, If
the thermostat remains open, or the engine is run
without a thermostat, the engine wilt run cold. As a
result, excess carbon will accumulate, wetstacking will
accur, and the oil will become contaminated with
e sludge.
The radiator for this engine is equipped with a pressurized
cap which is rated at 7 psi. If this cap is ever replaced, ensure
that the replacement cap has a rating of 7 psi.
Caution should be exercised at all times when remov-
ing the radiator pressure cap. The cap will turn to an
almost full open position, at which point a provision
has been made to permit venting built up pressure
within the radiator. Allow the pressure to escape
before completely removing the cap from the radiator
neck. When removing the cap, it is recommended that
a glove or rag be used to protect the operator's hand
from possible exposure to extremely hot coolant.
IMPORTANT
When the engine is operated in extremely cold weather
(below QPF}, it may not be able to warm up to oper-
ating temperature, if the engine is run cold, wetstack-
ing will occur and fuel will accumulate in the oil pan.
To prevent the engine from running cold when oper-
ating in extremely cold weather, restrict the air flow
through the radiator. This may be accomplished by
covering 1/2 to 2/3 of the radiator with cardboard,
plywood, or other material at hand.
RVICE
TY
FOR SE
IMPORTANT
EPR a.
LE Pa ОА
Never attempt to operate the engine without the bat-
tery connected. Do not attempt to remove the battery
while the engine is running.
IRD
A. Wet Charged Battery
Page 8
Connect the negative battery cable to the negative {—)
terminal on the battery. This is all that is required to
put the battery into service providing it has not dis-
charged during transportation and warehousing. If the
. battery has enough power to start the engine, it will
„ Charge up while the engine is running.
The wet charged battery is shipped with the electralyte solu-
tion added and normally in an operational status. However,
due to long periods of idleness, the battery may become
weak and require charging. The battery should have a specific
gravity reading of 1.260 {at 80°F) when fully charged. If the
battery requires charging, refer to Section 4-3B, Step 4.
Dry Charged Battery
This battery is shipped in a dry state. To prepare the
new battery for operation obtain electrolyte and proceed
as follows:
EE) Br ETT
Put on protective eye cover and clothing prior to pour-
„ ing the electrolyte solution,
1. Remove the battery from the unit and place it on a level
work table or other suitable area.
2. Fiil the battery cells to the required level with electrolyte.
3. Place a battery thermometer in one of the center cells and
check the specific gravity of each cell with a battery
hydrometer.
4. The battery should have a specific gravity of 1.260 (at
800F} prior to installation. If this condition is not met,
charge the battery as follows:
BE EEN ы TTL TE "Te D
AN
Ensure that the battery caps are removed before charg-
ing. Failure to do so may cause the battery to explode
should overcharging occur.
a. Use an automotive type battery charger. This battery
should be charged at about a 3.5 ampere rate until
correct electrolyte conditions are met. Lower charging
rates can be used; however, the time to obtain the
correct electrolyte conditions will be longer.
b. When the battery is charged, disconnect it from the
charger and recheck the electrolyte level. Add if neces-
sary. Install the battery caps.
c. Rinse the empty electrolyte containers with water
before discarding. Since battery acid is corrosive to
metals, do not pour inte a metal sink or drain. Rinse
and mutilate the empty electrolyte container before
discarding. If acid has accidentally spilled on the bat-
tery or work area during filling or charging, neutralize
with soda or ammonia solution and flush off with
clear water. Use the same procedure if acid is spilled
on clothing.
5. Reinstall the battery in the unit ensuring that the ground
cable is connected to the negative ( — ) battery terminal.
4-4. AIR CLEANER
This engine is equipped with a dry element type air cleaner,
The air cleaner requires no initial service.
4-5. FUEL
IMPORTANT
ARCE A NT alt
Do not attempt to use gasoline to power this diesel
engine. The use of gasoline will cause damage to the
engine.
Ec a
Do not attempt to fill the fuel tank with the engine
running. Do not fill the fuel tank completely as cold
fuel will expand when exposed to outside temperature
in a warm climate or to engine heat. if the tank is too
fuil, it will overflow causing a potential fire hazard.
Never allow fuel to drain on the engine or other com-
, ponents,
The engine manufacturer recommends that diesel fuels with
an A.S.T.M./D975-66T, Nos. 1D or 2D specification be used
for this engine. Use No. 1D diesel fue! for betow OCF opera-
tion only. The capacity of the fuel tank is 17-1/2 U.S. gal-
tons. A fuel shutoff valve is located under the fuel tank. The
vaive is in the open position when the unit leaves the factory.
{MPORTANT
Fill the fuel tank with fresh fuel before starting the
engine for the first time. This will dilute the fuel that
was added to the tank at the time the unit was
manufactured and prevent the injectors from be-
coming clogged by stale fuel. The fuel tank should
be topped off {but not overfilled) at the end of each
working day to prevent condensation from forming in
the fuel tank and to reduce chances of running out of
1 fuel the next working day. i
This welding generator is shipped from the factory with a
small amount of fuel in the fuel tank. Keep the fuel tank
fairly full to ensure the injector system receives an adequate
supply of fuel. if the fuel tank is allowed to become empty,
air will enter the system making the engine hard to restart.
With the system kept full of fuel, chances of air entering the
system are almost nonexistent.
If the engine is difficult to start or runs roughly when started,
the problem more than likely is air in the fuel system. Refer
to the engine handbook for information on bleeding the
system of air.
Figure 4-2 illustrates typical fuel consumption under specific
load conditions. Fuel consumption will vary from one engine
to another. Different brands of fuel, operating conditions,
condition of the engine, etc., will affect the fuel consumption
of this engine.
Range
Switch
5-1.
SECTION 5- FUNCTION
Fine Adjustment
Ро пиний Control
120 Volts
Receptacle
ma
Circuit
Ereaker
TB-007 984-A
Figure 5-1. Front Control Panel
120 VOLTS AC RECEPTACLE (Figure 5-1) {For Op-
tional 240 Volts AC Receptacle, See Section 5-6)
IMPORTANT
Rotate the FINE ADJUSTMENT control to the
100 position when 120 volts ac power is desired
from the 120 VOLTS AC receptacie. A low voltage
output (approximately 85 volts ac) is possible when
the FINE ADJUSTMENT control is at MIN. posi-
tion and engine speed is 1850 rpm.
IMPORTANT
Ensure that the AUTOMATIC IDLE CONTROL
switch (optional) located on the front control
panei, is in the OFF position when electrical equip-
ment is being operated from the 120 VOLTS AC
receptacle. See the FUNCTION OF ENGINE CON-
TROLS section for complete instructions on the
operation of the automatic idling device.
LITERS/HR.
4-6.
OF GE
1.7 2.0
1.46 1.75
1.25 1.5
1.04 125
0.83 10 cia
0.a2 0,75 veut
0.4 05
tôt ÉTÈLÉ WITH DEVICE
0.4 0.75 e
= = 25 50 75 100 125 150 175 200 225 250
= = OC WELD AMPERES AT 100% DUTY CYCLE
о 8 8-007 695
= vi
= =
Figure 4-2. Fuel Consumption Chart
FUEL/WATER SEPARATOR
À fuel/water separator is located on the right side of the
engine, below the fuel tank. A drain plug is provided on the
bottom of the separator (primary fuel filter) to remove any
water that it may have trapped. Before starting the engine for
the first time each day, loosen the drain plug and drain a
small amount of fuel into a metal container. If water has
accumulated in the separator, it will be seen in the bottom of
the container. Continue to drain the separator until water is
no longer evident.
“CAUTION \
“EE.
Drain the fuel into a metal container. Do not allow
fuel to drain onto the engine or other components.
Dispose of the fuel safely.
se io
NERATOR CONTROLS
2.5 kva of 120 volts ac, 21 amperes, 50/60 Hertz power
is available at this receptacle for operating 120 volts ac or
120 volts universal power tools, lights, etc., when the
welding generator is being operated at weld rpm.
The voltage at this receptacle will drop below 120 volts
when the engine speed is reduced to idling rpm. The tow
voltage may damage the 120 volts electrical equipment
connected to this receptacle.
The receptacle is protected by a 25 ampere circuit break-
er located on the front control panel. Should an overload
condition oecur, it would be necessary to manually de-
press the circuit breaker to reset it.
The voltage will vary in accordance with the load applied
to 120 VOLTS AC receptacle.
. RANGE SWITCH AND FINE ADJUSTMENT CON-
TROL {Figure 5-1)
IMPORTANT
Do not change the position of the Range switch while
welding, as this causes arcing across the contacts of the
switch. This arcing causes the contacts to become
pitted and eventually inoperative
a o o
The contacts of the FINE ADJUSTMENT control
are of the continuous type, thereby making it pos-.
sible to adjust this control while welding.
The Range switch provides five coarse amperage ranges. The
range of each switch position is displayed on the nameplate.
The FINE ADJUSTMENT control permits the operator to ’
select a welding current between the minimum and maxi-
mum values of the coarse range selected by the Range
switch, The scale surrounding the FINE ADJUSTMENT
control is calibrated from 0-100 percent in increments of
10. When using this control, the operator is selecting a
percentage of the coarse range in Use and not an actual
amperage value.
OM-460 Page 9
5-3,
VOLT-AMPERE CURVES (Figure 5-2)
The volt-ampere curves show the output voltage and cur-
rent of the welding generator available at any point from
the minimum to maximum of each coarse current range.
The FINE ADJUSTMENT control, controis the output be-
tween the minimum and maximum curves of each coarse
current range that is shown.
DC VOLTS
5-5.
WELDING AMPERES
50 190 150 290 250 200 350
DC AMPERES 5.005 722
- -A
Figure 5-2. Volt-Ampere Curves
Load voltage is predetermined to a large extent by the
arc characteristics. With the use of the volt-ampere curves
it is possible to determine what the weld current will be
at a particular arc voltage. Remember, the volt-ampere
curves show the minimum and maximum curves of each
coarse current range. When the FINE ADJUSTMENT con-
tro! is adjusted, the volt-ampere curve will fall between
the minimum and maximum curves of the particular
coarse current range in Use,
DUTY CYCLE (Figure 5-3)
The duty cycle of a welding generator is the percentage
of a ten minute period that a welding generator can
safely be operated at a given output. This welding gener-
ator is rated at 100 percent duty cycle. This means that
the welding generator can be safely operated at rated load
continuously. If the welding amperes are increased beyond
rated output, the duty cycle will decrease. Figure 5-3 en-
ables the operator various duty cycles.
IMPORTANT [8
Exceeding the indicated duty cycie will cause dam-
age to the internal components of the welding gen-
= erator.
RATED OUTPUT —
400
Lad
o
о
pr
wy
a
bh
o
o
150
20 . 25 30 40 50 60 70 80 90 190
%DUTYCYCLE
B-053 851
Figure 5-3. Duty Cycle Chart
METERS {Optional}
This welding generator can be equipped with meters. The
meters are for monitoring the welding operation and serve
as an indication of the welding process. The meters are
not intended for exact current of voltage measurements.
These meters are internally connected to the weld output
terminals. The voltmeter will indicate the voltage at the
weld output terminals, but will not necessarily indicate
the actual voltage at the welding arc. The ammeter will
indicate the current output of the welding generator.
Page 10
5-6.240 VOLTS AC DUPLEX RECEPTACLE (Op-
A.
B.
tional }{Figure 5-1)
Available Power And Protection For Receptacle
This welding generator is equipped with a voltage change-
over terminal strip TE1 and proper stator to provide re-
connection capability for 240 volts ac. Although the cap-
ability for either 120 or 240 volts ac is present, an op-
tional kit must be purchased if 240 volts is desired at the
front panel.
2.5 kva of 240 volts ас, 10.5 amperes, 50/60 Hertz
power is availabie at the duplex receptacle for operating
power tools, lights, etc., when the welding generator is
being operated at weld rpm.
This receptacle is protected by a 25 ampere circuit
breaker located on the front control panel. Should an
overload condition occur, it would be necessary to
manually depress the circuit breaker to reset it.
5 NOTE Y
The FINE ADJUSTMENT control must be set at
100 (maximum) when using the 240 VOLTS AC
dupiex receptacie on the front panel,
The voltage will vary in accordance with the load applied
to the 240 VOLTS AC receptacle.
Installation Of 240 VOLTS AC Duplex Receptacle
CAUTION |
Ensure that the engine is completely shut down be-
fore attempting any connections or examination of
components on or near terminal strip TE1.
IMPORTANT |
Before proceeding with this installation, familiarize
yourself with the circuit diagram provided in the
Troubieshooting Section of this manual.
NOTE §
All directions, such as left or right, are with re-
spect to the operator facing the welding generator
y front panel.
NOTE
Retain ail hardware removed during this procedure
for reinstallation.
1. Shut down the welding generator and raise the
‘right side panel.
2. Remove center boit from insulation board (see Fig-
ure 5-4), remove and retain insulation board.
3. Remove 120 VOLTS AC duplex receptacie RCH lo-
cated on front panel (see Figure 5-4). Remove
leads and allow to hang free.
4. Connect leads removed from RC1 to the 240 volts
ac duplex receptacle RC2 {one in each side of re-
ceptacie).
5. Instali RC2 in front panel.
Duplex Receptacle
Terminal Strip TE1
Center Bolt
Insulation Board
TA-059 485
Figure 5-4. Location Of Reconnectable Components
6. Affix suppiied 240 VOLTS AC label over existing
120 VOLTS AC designation for duplex receptacle
on:nameplate,
SECTION 6- FUNCTION
7. Remove and retain jumper links from terminal strip
TE! (see Figure 5-5).
8. Move lead No. 3 (only lead on jumper fink side}
from terminal B to terminal A (same side of TE1).
See Figure 5-5).
9. Position jumper links on TE1 for 240 volts (see
Figure 5-5).
10. install insulation board over TE1 and secure with
bolt.
11. Lower right side panel of welding generator and re-
sume operation.
Lead No. 3
A
e
PC
ml FT D
o |
120 VOLTS AC (STANDARD) 240 VOLTS AC OPTIONAL)
TA-059 243
Figure 5-5. Jumper Link Arrangement For 120 And
240 Volts AC
OF ENGINE CONTROLS vemo
Run-5top
Control
Throttle*
Control
Low Qil Pressure &
High Coolant Temperature
Indicator Lamp
*Models Without Automatic ldle Option Only
6-1.
Figure 6-1.
RUN-STOP CONTROL (Figure 6-1)
The Run-Stop control, located on the front control panel,
provides the operator with a means of stopping the engine.
When the Run-Stop control is pulled out, it will cut off the
flow of fuel to the fuel injector pump and stop the engine,
When the engine is to be started, the control must be pushed
in as far as it will go.
Whenever starting or stopping the engine, the Run-Stop con-
trol must be locked in the position that is being used. To lock
the control, rotate it as far as it will turn in a clockwise
direction. To unlock the control, rotate it 90 degrees
counterclockwise.
. THROTTLE CONTROL (Models Without Automatic
idle Option Only) (Figure 6-1}
The speed of the engine is controlled by the Throttle
control located on the front panel. When starting the en-
gine, the control should be pulled fully out to the Weld
position until the engine starts. Once the engine has start-
ed, the contro! should be pushed fully in to the Idle po-
sition and left in this position for approximately three
minutes to allow the engine to warm up.
©
©
©
de
Engine Controls
7 Engine Control Switch
ооо оо о ан риннднн Start Pushbutton
ss
“Thermostart® Heater Switch
Battery Charging TB-097 984- A
indicator Lamp
Before shutting the engine down, the Throttie control should
be returned to the idle position for approximately three
minutes to allow engine temperatures to stabilize.
Regardiess of whether the Throttie control is in the Idle or
Weld position, the control must be located in the position
being used. To lock the control, rotate it as far as it will turn
in a clockwise direction. To unlock the control, rotate it 90
degrees counterclockwise,
6-3. ENGINE CONTROL SWITCH (Figure 6-1)
NOTE
re.
lacing the Engine Control switch in the OFF position
will not stop the engine, The Run-Stop control must
be placed in the Stop position in order to stop the
engine.
IMPORTANT 8
To prevent the battery from discharging, place the
Engine Control switch in the OFF position when the
welding generator is not in use,
OM-460 Page 11
Page 12
ON Position
Placing the Engine Control switch in the ON position ener-
gizes the engine control system causing the OIL & TEMP
indicator iamp to light, the AMPS indicator {amp to light,
and the TOTAL HOURS meter {optional} to run. The switch
must be placed in the ON position befare the engine can be
started and should remain in this position until the engine has
been shut down.
OFF Position
Placing the Engine Control switch in the OFF position
removes battery voltage from the engine contro! system and
the exciter alternator field. This prevents the battery from
discharging when the welding generator is not in use.
. THERMOSTART HEATER SWITCH (Figure 6-1)
The “thermostart” heater system provides burning fuel to the
intake manifold of the engine to aid starting in cold weather.
When the spring-loaded THERMOSTART HEATER switch is
held in the HEAT position, the thermostat coil in the intake
manifold becomes extremely hot. When the thermostat coil
attains a specific temperature, it opens a heat actuated valve
causing fuel to flow onto the hot thermostat and ignite.
When starting the engine in cold weather, hold the
THERMOSTART HEATER switch in the HEAT position
for 15-20 seconds; then depress the START pushbutton.
Release the switch and the pushbutton as soon as the en-
gine starts. The spring-loaded THERMOSTART MEATER
switch should return to the OFF position when it is re-
leased.
. START PUSHBUTTON (Figure 6-1)
The START pushbutton actuates the starter solenoid causing
the starter motor to run. The START pushbutton must be
released as soon as the engine has started.
Bay TERY CHARGE INDICATOR LAMP (Figure
6-1
The AMPS warning lamp will illuminate when engine battery
charge current is not flowing. it is normal for this lamp to
ilfuminate when the Engine Control switch is in the ON posi-
tion and the engine is not operating.
ENGINE TEMPERATURE AND OIL PRESSURE
LAMP (Figure 6-1)
The OIL & TEMP warning lamp will illuminate if the oil
pressure decreases below 8 psi or if the coolant temperature
increases above 240°F. It is normal for this lamp to illumi-
i UTioN |
Never, under any circumstances, operate the welding
generator with any portion of the outer enclosure
open or removed. In addition to being a hazard to
personnel, weather protection to the internal com-
ponents of the unit will be greatly reduced. Warranty
is void if the welding generator is operated wtih any
portion of the outer enclosure open or removed.
IMPORTANT À
Ensure all electrical equipment connected to the 120
VOLTS AC receptacle is turned off before starting or
stopping the engine. When starting or stopping, the
engine has low speed which causes low voltage at the
output receptacle of the generator. This could result in
damage to electrical equipment.
6-9.
SECTION 7 - SEQUENCE OF OPERATION =
7-1.
. AUTOMATIC
nate when the Engine Control switch is in the ON position
and the engine 1s not operating.
IDLE CONTROL SWITCH (Op-
tional) |
The automatic idling device saves fuel by allowing the en-
gine to idle when the generator is not loaded. The
AUTOMATIC IDLE CONTROL switch controls the opera-
tion of this device.
ON Position
When the AUTOMATIC IDLE CONTROL switch is in the
ON position, the engine will remain at idle rpm until an
arc is struck. When an arc is struck the engine speed will
increase to weld rpm. Approximately 10 seconds after the
arc Is broken, the engine will return to idle rpm. This
time delay is non-adjustable,
The ON position may be used for Shielded Metal-Arc
Welding (SMAW] provided accessory power equipment is
not being operated from the 120 VOLTS AC receptacie.
OFF Position
When the AUTOMATIC IDLE CONTROL switch is in the
OFF position, the engine runs at governed weld rpm
(1856). This position must be usad whenever the 120
VOLTS AC receptacle is utilized.
IMPORTANT
If 120 volts ac power equipment is going to be
operated from the 120 VOLTS AC receptacle, ensure
that the equipment is “off” until the engine is
operating at fuli speed (1850). The same holds true
when returning the engine to idle. If power tools are
operated while the engine is idling, low veltage and
frequency {resulting from the lower engine idling rpm)
at the power receptacle may cause damage to the 120
volts equipment. À low voltage output (approximately
85 volts ac) is possible when the FINE ADJUSTMENT
control is at MIN. position and engine speed is 1850
rpm.
HOUR METER (Optional)
This unit can be equipped with an hour méter. The
meter, labeled TOTAL HOURS, is located on the front
panel and registers the total hours of engine operation.
This information is useful for routine maintenance on the
engine.
SHIELDED METAL ARC WELDING (SMAW)
1. Ensure that the engine has been prepared as instructed
in Section 4. '
2. Connect the weiding cables to the welding generator as
outlined in Section 3
IMPORTANT
Do not change the position of the Range switch while
welding, as this causes arcing across the contacts of the
switch. This arcing causes the contacts to become
pitted and eventually inoperative, E
eo] |
Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
comply may result in serious or permanent bodily
damage.
3. Rotate the Range switch and FINE ADJUSTMENT
control to the desired position.
4. Start the engine as outlined in Section 7-3.
5. After the engine has warmed up, welding may com-
mence. The FINE ADJUSTMENT control may be ad-
justed while welding.
6. When the welding operation has been completed, shut
the engine down as outlined in Section 7-4.
7-2. POWER PLANT OPERATION
DI. vn errr a
The weld output terminals are electrically energized
when the engine is running. Electrically isolate the
welding cables when not welding and do not touch
the output terminals when the engine is running.
1. Rotate the FINE ADJUSTMENT control to 100.
IMPORTANT
Rotate the FINE ADJUSTMENT control to 100
before connecting power tools or fluorescent lamps
to the 120 VOLTS AC receptacle. If the FINE
ADJUSTMENT control is set at any other position,
the output may be lower than 120 volts. Low volt-
age may damage motors or lamp ballasts. Incan--
descent lamps may be operated at any setting;
y however, the output will be reduced.
2. Start the engine as outlined in Section 7-3.
IMPORTANT
If the unit is equipped with an AUTOMATIC IDLE
CONTROL switch (optional), ensure that the
switch is in the OFF position when power tools or
fiuorescent lamps are to be operated from the 120
VOLTS AC receptacie. Low voltage and frequency
produced at idle rpm could cause damage to
a motors or lamp ballasts.
3. Connect equipment to the 120 VOLTS AC receptacle.
4. When the operation is complete, disconnect the equip-
ment from the 120 VOLTS AC receptacle,
5. Shut the engine down as outlined in Section 74,
7-3. STARTING THE ENGINE
I IMPORTANT
a LE
Check the engine oil level and radiator coolant level.
Ensure no loose parts, etc., are laying in or on the
unit, Make the necessary connections to the generator
before attempting to start the unit. Fill the fuel tank
with the correct grade and type of diesel fuel.
A. Engine Starting In Warm Weather (Above 50° F)
(Models Without AUTOMATIC IDLE CONTROL
Switch)
1, Pull the Throttle control fully out and lock.
2. Push the Run-Stop control fully in and lock.
3. Piace the Engine Control switch in the ON position. The
OIL & TEMP and AMPS indicator lamps should light.
4. Depress the START pushbutton. As soon as the engine
starts, release the START pushbutton and push the
Throttle control fully in, The OIL & TEMP and AMP
indicator lamps should extinguish.
IMPORTANT В
Always ensure that the starter pinion and flywheel
have stopped rotating before reengaging the starter
motor, otherwise the ring or pinion may be damaged. =
IMPORTANT
if the OIL & TEMP or AMPS indicator lamps remain
on after the engine has been started or illuminate
while the engine is running, shut the engine down
immediately. Find and correct the problem before
restarting the engine,
5. Allow the engine to warm up for approximately three
minutes at idle rpm.
6. Pull the Throttie control fully out and lock.
Engine Starting in Cold Weather (Below 50°F)
(Models Without AUTOMATIC IDLE CONTROL
Switch)
NOTE
Steps 1, 2 & 4 may not be necessary when the tem.
a perature is between 15% and 50°F.
1. Ensure the Throttle control is pushed fully in and locked.
2. Ensure that the Run-Stop control is pulled fully out and
locked.
3. Place the Engine Control switch in the ON position. The
OIL & TEMP and AMPS indicator lamps should light.
4. Hold the THERMOSTART HEATER switch in the HEAT
position for 15-20 seconds; then, while still holding the
switch, depress the START pushbutton. After the engine
has revolved several times, release both switches.
5. Pull the Throttle control fuily out and lock.
6. Push the Run-Stop control fully in and lock.
§ IMPORTANT В
Always ensure that the starter pinion and flywheel
have stopped rotating before reengaging the starter
motor, otherwise the ring or pinion may be damaged.
NOTE |
If the engine does not start after the START push-
button has been held for 15 seconds, release the
START pushbutton, hold the THERMOSTART
HEATER switch in the START position for 10
y Seconds, and reengage the starter.
ALERT I CAE EE TEA A M MURS
7. Hold the THERMOSTART HEATER switch in the HEAT
position for 15-20 seconds; then, while still holding the
switch, depress the START pushbutton. As soon as the
engine starts, release both switches and push the Tnhrottie
control fully in. The CIL & TEMP and AMPS indicator
lamps should extinguish.
OM-460 Page 13
Page 14
IMPORTANT
If the OIL & TEMP or AMPS indicator lamps remain
on after the engine has been started or illuminate
while the engine is running, shut the engine down
immediately. Find and correct the problem before
I restarting the engine. |
8. Aliow the engine to warm up for approximately three
minutes at idle rpm.
9. Pull the Throttie control fully cut and lock.
Engine Starting in Warm Weather (Above 50°F)
Models With AUTOMATIC ¡DLE CONTROL
Switch
1. Place the AUTOMATIC IDLE CONTROL switch in
the OFF position.‘
2. Push the Run-Stop control fully in and lock.
3. Place the Engine Control switch in the ON position.
4. Depress the START pushbutton. As soon as the engine
starts, release the pushbutton and place the AUTO-
MATIC IDLE CONTROL switch in the ON position.
The OIL & TEMP and AMPS indicator lamps should
extinguish.
IMPORTANT
Always ensure that the starter pinion and flywheel
have stopped rotating before reengaging the starter
motor, otherwise the ring or pinion may be damaged.
IMPORTANT
if the OIL & TEMP or AMPS indicator lamps remain
on after the engine has been started or itlumirate
while the engine is running, shut the engine down
immediately. Find and correct the problem before
I restarting the engine.
5. Allow the engine to warm up far approximately three
minutes at idle rpm.
6. Place the AUTOMATIC IDLE CONTROL switch in
the desired position. Refer to SECTION 6 — FUNC-
TION OF ENGINE CONTROLS for complete instruc-
tions on operation of the automatic idle device.
Engine Starting in Cold Weather (Below 509F)
models With AUTOMATIC IDLE CONTROL
witch
Steps 1,2 % 4 may not be necessary when the tempera-
| ture is between 159 and 50°F, I
1. Place the AUFOMATIC IDLE CONTROL switch in
the ON position.
2. Ensure that the Run-Stop control is pulled fully out
and locked,
3. Place the Engine Control switch in the ON position. The
OtL 8: TEMP and AMPS indicator lamps should light.
4. Hold the THERMOSTART HEATER switch in the HEAT
position for 15-20 seconds; then, while still holding the
switch, depress the START pushbutton. After the engine
has revolved several times, release both switches.
5, Place the AUTOMATIC [IDLE CONTROL switch in
the OFF position.
6. Push the Run-Stop control fully in and lock.
IMPORTANT
Always ensure that the starter pinion and flywheel
have stopped rotating before reengaging the starter
| motor, otherwise the ring or pinion may be damaged. I
NOTE
Н the engine does not start after the START push-
button has been held for 15 seconds, release the
START pushbutton, hold the THERMOSTART
HEATER switch in the start position for 10 seconds,
and reengage the starter.
7. Hold the THERMOSTART HEATER switch in the
HEAT position for 15-20 seconds; then, while still
holding the switch, depress the START pushbutton. As
soon as the engine starts, release both switches and
place the AUTOMATIC [IDLE CONTROL switch in
the ON position. The OIL & TEMP and AMPS indi-
cator lamps should extinguish.
IMPORTANT
If the OIL & TEMP or AMPS indicator iamps remain
on after the engine has been started or illuminate
while the engine is running, shut the engine down
immediately. Find and correct the problem before
restarting the engine. J
8. Allow the engine to warm up for approximately three
minutes at idle rom.
9. Place the AUTOMATIC IDLE CONTROL switch in
the desired position. Refer to SECTION 6 — FUNC-
TION OF ENGINE CONTROLS for complete instruc-
tions on operation of the automatic idle device.
. ENGINE SHUTDOWN
1. Remove ail weld and power loads from the unit.
2. For models without an AUTOMATIC IDLE CON-
TROL switch: Push the Throttle contro! fully in and
lock.
For Models with an AUTOMATIC IDLE CONTROL
switch: Place the AUTOMATIC [DLE CONTROL
switch in the ON position.
3. Allow the engine to idle for a few minutes to permit the
internal engine temperature to equalize. Increase the
idling time if the engine has been operating for an
extended period or at full load.
4. Unlock and pull the Run-Stop control all the way out;
hold it in this position until the engine ceases to rotate.
5. Place the Engine Control switch in the OFF position.
—— ————— SECTION 8 - GENERATOR MAINTENANCE
8-1.
If any work is to be done on the rotor of the gen-
erator, loosen the injectors. This will prevent engine
compression from turning the rotor and catching the
repairperson’s hand between the rotor fan casting and
the stationary adapter casting. Also disconnect the
negative (-) battery cable from the battery.
GENERAL
The efficiency of the welding generator depends a great deal
on the care and attention given it. By following a definite
schedule of inspection and service, failure caused by neglect
can be avoided.
Occasional biowing out of the unit with clean, dry com-
pressed air is recommended. This should be performed
periodically, depending upon the location of the unit and the
amount of dust and dirt in the atmosphere,
This welding generator is equipped with hinged side panels to
permit easy access when performing inspection and mainten-
ance functions on the generator and engine.
. COLLECTOR RING BRUSHES
The brushes should be inspected periodically. Brush life is
very good under normal conditions. If the generator has been
operating in an extremely dusty or dirty place, a ciose check
of the brushes for freedom of movement and cleanliness
should be made weekly. Under normal use the slip rings will
discolor to a dark brown. If it should become necessary to
clean the slip rings, use a 3/0 or finer sandpaper followed by
a crocus cloth. Never use emery cloth as part of the emery
will embed itself into the rings and in turn destroy the carbon
brushes,
8-3. WELDING CABLES
Check connections periodically for tightness. The cables
should be inspected frequently and all breaks in the insula-
tion should be repaired with electrical insulating tape or the
cables replaced.
SECTION 9 - ENGINE MAINTENANCE em].
Refer to the engine handbook for detailed information
concerning maintenance on this engine. While the
handbook is a general coverage type publication, it
does contain vital maintenance instructions for this
engine.
9-1. LUBRICATION
IMPORTANT
This engine may use oi! during the break-in period
(first 50-75 hours of operation). Check the oil level
several times a day during this period. Do not idle
the engine longer than necessary for start-up and
shutdown procedures during the break-in period.
Piston rings, etc., will seat faster if the engine is
run at weld rpm (1850) and the welding generator
g 15 kept loaded as much as possible.
After about 50 to 75 hours of running time on the break-in
oil, drain the oil and change the filter. Premium heavy duty
oil, manufactured by any one of the major oil companies,
should be used as a replacement oil. Table 9-1 gives a list of
recommended grades and types of oil to use. The capacity of
the engine without a filter change is approximately 6 U.S.
quarts, with a filter change, approximately 7 U.S. quarts.
Check the dipstick to make sure oil level is up to the reguired
operating level.
IMPORTANT
Do not mix different brands of oils. Generally, motor
oils fall into two categories: phosphate base, and
sulphonate base. The phosphate base oils are acidic:
the sulphonates are alkaline. Although both bases
produce good oils, mixing the two bases produces a
chemical reaction which greatly reduces the lubri-
cating properties of either cil, The mixing of oils could
3 Cause extensive damage to the engine.
If the engine is operated under extremely heavy loads
for long periods of time or in an abnormally dusty or
dirty atmosphere, the oil and oi! filter should be
a changed more frequently.
in normal operation, the ol! and oi! filter should be changed
after about 150 hours, When operating below 15°F, change
every 50-80 hours. The oil shouid be drained after the engine
has been warmed up to normal operating temperature, thus
promoting foreign particle suspension in the oil and removal
when the oil is drained. Foreign particles tend to settle at the
bottom of the crankcase when the oil is allowed to cool,
avoiding removal and contaminating the new oil.
IMPORTANT
КИ ня E y TH В Co EEE й
Extreme caution is advised if a synthetic lubricant is
used in place of conventional motor oil, especially in
subfreezing or arctic conditions where condensation is
prevalent. Moisture may not stay in suspension in
these lubricants causing water to settle in low-lying
areas of the lubricating system. If accumulated water
should freeze, the engine may be damaged. The use of
conventional oil meeting API service designation CD
x ‘or CC is recommended.
9-2. COOLANT SYSTEM
IMPORTANT
The engine fan and alternator belts are subject to nor-
mat wear and should be checked for proper tension
periodically. Check and readjust tension after the first
50 hours of operation, and whenever belts are
replaced.
If the engine is to be operated in a temperature below OOF,
ensure that a good grade of anti-freeze is added to the cool-
ant system. Change the coolant solution as often as neces-
sary. The coolant system capacity is 7 quarts (U.S. Measure}.
During the break-in period of a new engine, one of the great-
est dangers is overheating. There are several possible causes of
overheating, but the basic causes are lack of engine lubri-
cation and coolant circulation.
At the first sign of overheating, shut the engine down and
make a thorough check to determine the cause,
Temperature of the engine coclant is regulated by a thermo-
static valve located in the outlet at the front of the cylinder
head. This unit retards the flow of coolant untii a predeter-
mined temperature is reached, usually varying between 17569
and 1850F, When this temperature range is achieved the valve
opens and free circulation of the coolant through the system
begins.
OM-460 Page 15
IMPORTANT
When it becomes necessary to service the air cleaner in
the field, follow the steps in Figure 8-1. It is recom-
mended that a spare element always be kept on hand
for replacement. New elements are available from your
distributor.
If the thermostat should fail, replace it im-
mediately. Ensure that the replacement has an
equal temperature rating. Do not run the engine
without a thermostat. If the thermostat remains
closed, the engine will overheat. If the thermostat
remains open, or the engine is run without a ther-
mostat, the engine will run cold. As a result, excess
carbon will accumulate, wetstacking will occur, and
the oil will become contaminated with sludge. I
9-3. ELECTRICAL SYSTEM
Check interconnecting wiring, etc., for tightness and flaws.
Check battery electrolyte level frequently. Add clean mineral
free or distilled water if possible. Keep battery terminals free
of corrosion.
IMPORTANT
Do not operate engine without the air cleaner element
in place. It is recommended that the element be re-
placed after six washings or 1 year, whichever comes
i first. E
9-5. FUEL FILTER SERVICE
The fuel filter shoutd be changed every 400 hours of opera-
tion or 12 months (whichever occurs first). Refer to the
engine handbook for further instructions.
| IMPORTANT
Do not attempt to operate the engine without the
battery connected. Do not attempt to remove the bat-
tery while the engine is running.
9-6. SPARK ARRESTOR (Optional)
IMPORTANT
9-4, AIR CLEANER SERVICE (Figure 9-1)
The engine exhaust system on this welding generator
The air cleaner is one of the most important parts of the
engine from the standpoint of engine life, An engine con-
sumes several thousand cubic feet of air per hour when oper-
ating. If dirty air gets into the engine, it can wear out a set of
piston rings within a few operating hours,
A dirty air cleaner element is usually accompanied by a loss
of power and black smoke in the engine exhaust, Servicing of
the element is accomplished in the following manner:
Remove the filter element lock assembly and seal. Inspect the
gasket on the end of the element for damage. Clean the ele-
ment as indicated in Figure 2-1. Wipe out the Inside of the air
cleaner housing before installing a new or cleaned element.
Do not use the element if the seal is damaged or missing.
has not been equipped with a spark arrestor unless it
was specifically ordered as an optional accessory. A
spark arrestor, maintained in effective working order,
is mandatory if this welding generator is to be
operated in a National Forest, or on California
grasstands, brush, or forest covered land {see Section
4442 of California Public Resources Code.) For other
I areas, check your state and local laws, i
Internal combustion engines operating in a highly combus-
tible environment are a common fire hazard. Glowing carbon
particles blown out with the exhaust can retain sufficient
heat to ignite materials. While no practical spark arresting
Table 9-1. Approved Lubricating Oils For Perkins Diesel Engine
Normal Working Temperature
S.A E. Designation
09°F. to 45°F.
(—18°C to 7°C)
10W
AOF. 800F.
(70C to 270€)
20/20W
{80°F or over
(279C, or over)
30
Esso Petroleum Co. Ltd.
Imperial Oil Ltd.
Essolube HDX 30W
Estor HDX 10W
Essofleet HDX 20
Essolube HDX 20
Estor HDX 20
Essofleet HDX 30
Essolube HDX 30°
Estor HDX 30
Shell Mex & B.P. Ltd.
Shelli Rotella T10W
B.P. Energol DS1-10W
Shell Rotella T 20/20W
B.P. Energol DS1-10W
Shell Rotella T30
B.P. Energol DS1-30
Alexander Duckham & Co. Ltd.
Fleetol HDX 10W
Fieetol HDX 20
Fieetol HDX 30
Regent Gil Company Lid.
Caltex/Texaco
Super RPM DELO Special 10
Ursa Oil S-1 SAE 10W
Super RPM DELO Special 20
Ursa Oil 5-1 SAE 20-20W
Super RPM DELO Special 30
Ursa Oil 5-1 SAE 30
Mobil Oil Company Limited
Delvac 1110
Delvac 1120
Delvac 1130
Amoco (U.K.) Ltd.
formerly (Vigzo! Oil Co. Ltd.)
Avena 1/10W Diesel Engine Cil
Avena 1/20 Diesel Engine Oil
Avena 1/30 Diesel Engine Oil
Castrol Ltd.
Castrol CR10
Deuso! CAI 10
Castrol CR20
Deuso! CRI 20
Castrol CR30
Deusol CRI 30
Germ Lubricants itd.
Germot D10/81
Germol D20/51B
Germo! D30/S1B
Guif Oil Group of Companies &
British American Oil Company
Guiflube Motor Oil HD 10W
B-A Peerless Heavy Duty Motor
ОН ОУ!
B-A Dieselube Super Duty Motor
Oil 10W
Gulflube Motor Oil HD20/20W
B-A Peerless Heavy Duty Motor
01 20-20W
B-A Dieselube Super Duty Motor
Oil 20-20W
Gulflube Motor Oil HD30
B-A Peerless Heavy Duty Motor
Oil 30 |
B-A Dieselube Super Duty Motor
Oil 30
And other reputable detergent oils to approved specification mcluding: Any lubricating oils which have
passed approval tests for the U.S. Ordnance Specification MIL-L2104A, with 1 percent sulphur fuel endorse-
ment, in their S.A.E. 10 and 30 grades, with a viscosity index of 80 minimum shall be deemed equally
acceptable.
Special Note: All grades listed above are detergent, Supplement 1, Heavy Duty Oils.
Where conditions of service warrant (e.g. continuous heavy load operation) the grades shown in the right
hand column may be used in lieu of those shown in the first and center columns,
Page 16
device will stop ail sparks, the device will minimize fire Replace the spark arrestor if inspection reveals any signs of
hazards by removing and trapping most solid particles failure.
provided that it is properly maintained.
B. Servicing The Carbon Trap
The carbon trap should be serviced weekly or every 50
operating hours, whichever occurs first. The entire spark
arrestor should be inspected every 1000 operating hours or
three times per season.
… CAUTION |
M Service the device in an area where there is no danger B
: from flying sparks or hot carbon particles. }
1. Visually examine the outside of the device for holes, 1. Stop the engine and allow the exhaust system to cool.
cracks, or metal corrosion. o
A. Inspection
2. Remove the cleanout plug from the bottom of the spark
. With the engine stopped, look inside the spark arrestor
outlet tube with a flashlight or other light source. Visually
examine the vanes and the outlet tube for metal or weld
failure. The vanes must be firmly attached to the inlet
tube and the outlet tube must be completely intact {this
is an important factor in maintaining spark arresting
arrestor with a wrench. If a crust has formed over the
hole, break it loose with a screwdriver or similar tool.
3. Start the engine and run it at idle rpm to blow collected
particles out the cleanout hole. If particles are slow to
discharge, momentarily cover the end of the exhaust
efficiency).
3. Check the mounting clamp to ensure that the spark
arrestor 15 securely mounted.
stack.
4. Stop the engine. Replace and secure the cleanout plug.
For a temporary expedient
in the field, the element
can be cleaned by tapping
the side or the end care-
fully against the palm of
the hand.
CAUTION: Do not tap ele-
ment against a hard surface.
The element may be damaged
by doing so.
Compressed air, not to ex-
ceed 100 tbs. of pressure
can clean the element. In-
sert nozzle inside the ele-
ment and blow out dust.
Clean dust from the out-
side of the element by
hoiding the nozzle at least
6 inches from the ele-
If compressed air is not
available, or if soot, oily
vapor, or any dirt is pres-
ent which cannot be re-
moved by compressed air,
then the element is to be
washed. Agitate element
in warm water containing
a non-sudsing detergent.
Reverse flush with clean
water to thoroughly rinse
all loosened foreign ma-
terial from the filter.
ment. : CAUTION: Do not use water
` hotter than the hand can
stand; solvents or of; fuel oil
or gasoline.
3.
Shake out excess water from the
element and allow to air dry.
CAUTION: Do not attempt tc remove
excess water by using compressed air.
An even fine pattern of light
through the element, when a
light is held inside the element,
indicates that the element is
clean. Any large spot of light in-
dicates that the element is dam-
aged and, therefore, is unfit for
further use. Replace the element.
Figure 9-1. Air Cleaner Service
To minimize down time, created
by waiting for the element to dry,
it 15 suggested that the newly
cleaned filter be replaced by a
similar standby unit.
TA-900 716-7
OM-460 Page 17
— SECTION 10- TROUBLESHOOTING
CAUTION
Hazardous voltages are present on the internal cir-
cuitry of the welding generator while the engine is -
running. Shut down the engine before attempting any
inspection or work on the inside of the unit.
Troubleshooting of internal circuitry should be per-
| formed by qualified personnel only, a
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in this
It 1s assumed that proper installation has been made,
according to Section 3 of this manual, and that the welding
generator has been functioning properly until this trouble
developed.
Use this chart in conjunction with the circuit diagram while
performing troubleshooting procedures. If the trouble is not
remedied after performing these procedures, the nearest
Factory Authorized Service Station should be contacted. In
all cases of equipment malfunction, the manufacturer's
recommendations should be strictly followed.
welding generator.
TROUBLE
PROBABLE CAUSE
REMEDY
No 120 VOLTS AC output. Weld
output is normal.
Circuit Breaker CB1 open.
Reset Circuit Breaker CB1.
Low 120 VOLTS AC output,
FINE ADJUSTMENT controi R1
set to position other than 100.
Rotate FINE ADJUSTMENT contro! R1 to 100.
Low weid and 120 VOLTS AC
output.
Throttie control is not pulled
fully out (models without AUTO-
MATIC IDLE CONTROL switch).
Pull the Throttle control fully out and lock.
AUTOMATIC IDLE CONTROL | Place AUTOMATIC IDLE CONTROL switch 54 in the
switch 54 (optional) is in ON | OFF position.
position.
Belt between exciting alternator | Tighten belt.
and generator slipping.
Erratic weld output.
Damp, defective, or wrong type
electrodes.
Try different electrodes.
Improper connections to
electrode or workpiece,
Check and tighten loose connections.
Erratic weld and power output.
Dirty
brushes.
stip rings and/or worn
Clean slip rings and/or replace worn brushes {refer ta Section
5).
Battery discharges between uses.
Engine Control switch S1 left in
ON position.
Ensure the Engine Control switch $1 is left in the OFF
position when the unit is shutdown.
Build up of acid on ‘top of
battery. {White-grayish
substance).
Ciean battery with soda solution; rinse with clear water.
Infrequent use.
Periodicaliy recharge battery.
Defective battery.
Replace battery.
Automatic idle device (optional)
inoperative,
Fuse F2 open.
*Replace fuse F2.
“if it becomes necessary to replace any fuse in the welding generator, ensure that a fuse of the proper size is used.
Page 18
tiny 1111
A A BOE Dr E E E .
PC BOARD TERMINAL REFERENCE =
РС; =
I
m
m
2
| |
EQUIPMENT | в | |
GROUND REAR VIEW
| es 240V, pct]
r DN | Dz 47 D3
= CB | PT
| OPTIONAL KIT
cut | INCLUDING 240VOLT | 3
RECEPTACLE pi
NOTE, GROUND STRAP MUST BE == == =— — == —— Ds
INSTALLED BETWEEN ENGINE ; CAUTION
FRAME AND WELTER FRAME REFER TO OWNERS
MANUAL BEFORE
if 42 h ATTEMPTING VOLTAGE |
| CHANGE-ÔVER 4 WELD METERS—"
(OPTIONAL?
= == = == = — = = = = = === == == == === === == — —— _
AUTO. IDLE CONTROL &
ENGINE CONTROL TOTAL TIME METER
1
|
SWITCH | (OPTIONAL
SE - — NEGATIVE POSITIVE
[os
12 VOLT
BAT
НЧ ИИ
Circuit Diagram No. B-079 701
Figure 10-1. Circuit Diagram
OM-480 Page 19
March 1979 FORM: OM-460B
Effective With Serial No. HJ149358
MODEL
Big D2
69 68
7p
Fig C
Figure A — Main Assembly
OM-460 Page 1
35
36
TD-053 145-8
"NE
7
7
Ik
<
A Я
PTE
[EEE EL EE rs
IAE
M TO
i y EIA IE 1 ES
y PTI FE
ZIFFERN. PERF,
yr
i
36
includes
Items 41-43
7
\/
Pa 2%
ons
#
o
~~
40
44
Fig B
ОМ-460 Раде 2
Page 3
item Dia. Factory
No. Mkgs. Part No, Description Quantity
Figure A Main Assembly
1 017430 STRAP, mounting - fuel tank ..........ocoecenoraaanerarco 2
2 010434 STRIP, rubber 1/2x 2x 4-1/2 111110404244 ee a aa a a ane 0 2
3 030 194 TANK, fuel {consistingof}) ..................... ee. 1
4 018 858 ‚CAP, tank - fuel eee 1
010869 FITTING, pipe - brass bushing 1/4 x 1/8 NPT .............. 2
605 288 FITTING, pipe - galvanized plug sg hd 1/8 NPT ........... й 2
5 020 185 FITTING, pipe - brass elbow street 1/8 NPT ............... 1
6 604 313 FITTING, brass - barbed male 1/4 TBG x 1/8 NPT .......... 1
7 604 314 HOSE, neoprene No. T x 1/4 ID (20 inches req'd - order by ft.) 2 ft.
3 017479 SEAL, weather - Hfteye ............e a.m. .nararodnracmoa 1
9 007 608 BRACKET, mounting - air cieaner .......20440420 1144434 40 1
10 018 765 AIR CLEANER, intake - carburetor dry type (consisting of) 1
11 018859 .CAP, air cleaner .. 112001004444 114 Le LA LA Aa ea aa ae i
12 008 698 BAFFLE, dust -Cap .... oii 4 414 0 a 1 a aa 0 à i
13 021 117 .WING NUT ASSEMBLY ........ ieee 1
14 *017 309 .ELEMENT, air cleaner .................. ee... 1
15 000272 .CLAMP, air cleaner ............ —..0-m.0ne0nrravoneno 1
16 010 863 CLAMP, hose 2-1/16-3clampdia ............. .. e... 2
17 007 447 HOSE, air cleaner - molded tii. 1
010333 BUSHING, 2 OD x 1-5/8 10 х 5/8 ......... iin. 1
18 031865 CLAMP, mounting-aircleaner ........... 0. uuu... 1
19 032452 CABLE, battery - positive .................. eva LL. i
010021 CLAMP, steel - cushion 9/16 dia x 11/32 hole ............. 1
20 030 344 DOOR, access - battery ............... 0. .rerarerev. 1
21 010015 BOLT, J5/16-18...... ee ee eee 4
22 005 612 DOOR, side ..... co ea, 2
23 007 3/0 COVER, top ............ eee ee ses 1
24 035 968 WASHER, neoprene 5-7/8 OD x 3-5/8 1D x 1/16 ........... 1
25 004 719 CAP, weather - exhaust No. 2 1-1/2 dia pipe .............. 1
26 028 089 DOOR, access - radiator CaP vv vt mi tet ter ee eee eee 1
27 027 529 PIN, cotter 1/4 x 3-1/2 ... ee sina 6
28 017421 CATCH, door ............. 2. ..eererxerecizensreoa 2
29 053 724 GUARD, fan ........ o... maeneonovarvanrverxerco0aoo 2
30 007 448 kHOSE, radiator - flex 1-1/2 1D x 18 ga wall X 2 ............. 1
31 010862 CLAMP, hose 1-13/16 - 3 clamp dia ..................... 2
32 007 352 RADIATOR, (consisting of) ......... un. | 1
33 605 982 CAP, radiator ......2 2111 112 2 14 4 a 4 a 4 4 a 4 4 4e 4 4 a a ea a 0 1
34 007 368 ENCLOSURE, radiator ............... 2... aa aa ane 1
35 032 453 CABLE, battery -negative . . ..... iri eee ea 1
36 010860 CLAMP, hose 13/16-1-3/4clampdia.................... 2
37 007 446 HOSE, radiator -lowermolded ..................... .... 1
38 006 015 FITTING, pipe - brass drain cock 1/4 NPT ................ 1
39 007 365 MOUNT, engine - front .........e.eecraereriverreenverer 1
40 008 159 ENGINE, diesel - electric start (consisting of) .............. 1
Alt, Reg . ALTERNATOR (included with engine - see engine parts list) . 1
010516 -SsWIiVEL, wire - inner ........_—.—eémerararverde aran ddd<arna 1
035388 .BRACKET, mounting -cablethrottle ................... 1
006015 . FITTING, pipe -brassdraincock 1/4 NPT ............... 1
015 732 |. FITTING, pipe - brass elbow street 45 1/8 NPT ........... 1
015 787 . FITTING, brass - barbed flared inverted female 1/4 TBG .... 1
604 309 . FITTING, brass - barbed flared male RS 1/4 TBG x 1/4N ... 1
41 55 025 473 SWITCH, shut - down low oil ............ 0.0... 1
42 56 025 474 SWITCH, shut - down high temperature ................. 1
43 . BLADE, fan {included with engine - see engine parts list) ... 1
| 026 837 .iNSULATOR, terminal - nylon ...........e.e soe, 1
44 Figure B GENERATOR ASSEMBLY (See Page 6) ................. 1
45 007 686 PIPE, exhaust - engine ......... cium ..s0creneo. i
46 004 535 FITTING, pipe - black coupling 1-1/4 NPT ................ 1
item Dia. Factory
No. Mkgs. Part No. | Description Quantity
Figure A Main Assembly {Cont'd.}
005 544 COMPOUND, adhesive - sealant .......2222 020210 ea 114 10 14 ea a 1e a a 0040 1
47 004 720 MUFFLER, exhaust - engine iii a 0 0 0 a a 0 tien 1
48 017 477 ROD, holddown - battery ......w._w..éreoreorzarerernererareovoreaveda 2
49 Ван 032230 BATTERY, 12 volts 99 amp .............es22senvararer.reresó rene. 1
50 030 342 TRAY, slide - battery .............o_—e—_.ec.0rmoerere0areda:rarereaoo. 1
51 006 977 MOUNT, top .....2221100 104414 4 4 4 da a 4 ee 4 в вк 8 4 8 ee 4e a 4 8 eu de 0 ea о 1
52 007 298 TUBING, steel 5/8 OD x 12 ga wall x 2 LA LA A pe a 4 a eee ee ee 1
53 006 978 MOUNT, bottom ..........e_.eeeeaaorraao0nororaorererearorereno, 1
54 004 444 UPRIGHT, base - Center RR eines 1
55 010144 CLAMP, nylon 7/16 dia ..............0es-00sraarerere dr arerarenen 1
56 603 107 HOSE, neoprene - slit 5/32 ID x 11/32 OD torder by foot) ..............e. 1 ft.
57 TEl 038 621 BLOCK, terminal! 30 amp 4 pole ................ RK 1
58 053 967 INSULATION, rectifier «oot ire te ee ete eet tee ei eta es 1
59 038 620 LINK, jumper - terminal Block . «o.oo oot tt 2.2000. 0000000. 2
60 062 372 BRACKET, mounting - strip terminal ........e.eeeerevdererededar erre, 1
61 035860 RECTIFIER ASSEMBLY (consisting of). .............—.. . eQnxrxer.. 1
62 SR1;2 035704 .RECTIFIER, integrated 6 amp 600 volts ................ eee... 2
63 031926 .HEATSINK, rectifier. . .......... RR sei 1
64 005780 PANEL, side - right hand .............eessrordrarrerereevec ce cenena. 1
65 010 266 SPRING, extension 3/8 OD x 2- 1/2 Ce a ee 2
66 017420 IN 4 a (To arado rane»anionea 2
67 010679 MOUNT, dualstud 2x 3 inches ..... iit iii ie ee ieee ae aaa en SE 2
68 007 611 BASE Lee a ae a 00e i
69 005 793 UPRIGHT, base - front ...... he eh hee eee eee ata. . 1
70 Figure C BRACKET, mounting - power output (See Page 7) ..........ee.emeaaraao 1
71 005 601 PANEL, front - lower «oo ott ee ee ee ee ee eee 1
72 Figure D PANEL, front - with components (See Page 8)... ...................... 1
73 R3 030630 RESISTOR, WW fixed 11 watt 100 chm ....... i iii. 1
74 R2 030 764 RESISTOR, WW adj 50 watt 10 0hm.............ee 0 m..0aídarase e 1
75 21 005 727 REACTOR (consisting of) ...........eeeo-esarecradorerecarareocern 1
**005 658 .COIL, left hand .................. eeneareeconnoaroereareróme 1
**005 659 .COIL, center ............. . .rearerecrrecvioorarcóone reco, 1
*005 660 .COIL,righthand ........22200 1010 04 LL LA LL da LA a aa aa a La L Lee 1
75 72 005 726 STABILIZER ........ a. 0vexrrere nia va drarenorerarcarerv0 ara 0 1
77 005 709 FRAME, mounting - reactor & stabilizer ............. _eemerereorerEe.. 1
78 604 308 FITTING, brass - barbed male 1/4 TBG x 1/4 NPT ........... e... | 1
79 010 314 VALVE, shut - off fuel 1/4 TBG x 1/44 N . oi ee eee ieee à 1
80 603 125 STRIP, cotton 1/8 x 1 (order by ft}... RR ane 4 ft.
Parts For Optional Equipment
A 025 663 METER, amp de 50 MY 0-400 scale .......... rire. - 1
CRT 005 857 RELAY, reed .....1122 220044 144 4 4e 4 A 4 44 a 4 A LL A A4 a 2 a 4 a a a a aa 1140 1
F2 “012663 FUSE, miniature - glass slo-blo 3 amp 120000442040 L a aa aa ea a ae 4 1
012617 HOLDER, fuse -miniature 1/4 xX 1-1/4 112120411244 ie 1 4 4 4 a aa ae 0 1
54 011801 SWITCH, toggle SPST 10 amp 125 volts ........._eeexresrorerveosrrdea 1
Shunt 030 060 SHUNT, meter 400 amp 50MY ......... ee eee eee 1
TS1 032 933 SOLENOID, 12 volts 20 amp puli/Rold type ........10244 0110014 вк, 1
008 038 BRACKET, mounting - solenoid idle automatic ............._.e.éececenrveea 1
025 722 TACHOMETER, mechanical ........o titi eee eee eee. 1
024 820 SHAFT, flex - tachometer ........e.e... 0 000aaaa AA 1
027 735 HANDLE . «ee 4 A4 4 A0 A a a 4 a 4 ee a 40 2
008 241 COVER, top-tachometer 122001002000 LL 4 rer 1
TT 032936 METER, hour 4-40 volts o.oo eee eee eee ee 1
\ 025 638 METER, volts de 0-100 scale ............ 2.2... RR 2 Le 1
PC1 039396 CIRCUIT CARD ASSEMBLY, weid/idle electronic (consisting of) .......... 1
C50,54 035522 .CAPACITOR, mylar 0.047 uf 100 volts ............ 2... ..renaoo, 2
C51,52 031651 CAPACITOR, tantalum 68 uf20voltsde ........ ct rin... 2
OM-460 Page 4
Item Dia, Factory
No. Mkgs. Part No. Description Quantity
Figure À Main Assembly {Cont'd.)
Ch3 076 992 . CAPACITOR, electrolytic 10 uf 2B volts Lo. se ea 1
D50-52 026 202 .DiODE, rectifier 1 amp 400 volts straight polarity ......._—..em_erereroo. 3
F50 *007 823. FUSE, subminiature - picofuse 3 amp 125 volts ........e_eee.erecergóae. 1
Q50 000088 TRANSISTOR, 800 MA 40 volts NEN ..........oe_re-e00aarerereev en 1
051 039355 . TRANSISTOR, 0.15 amp 400 volts PNP LL ...2 100400 a 4 44 a 44 4 0 8 ea a 0 0 1
R50,53,61 030 033. RESISTOR, carbon 0.5 watt 470 0h . 1112200012 44 24 4 0 4 a 4 0 0 6 a ana 00 3
R51,56,60 605 919 . RESISTOR, carbon 0.25 watt 47 0hm .. 11101022 RG 3
Н52 605916 . RESISTOR, carbon 0.25 watt TKohm .......... coi... 1
R54 605 918 . RESISTOR, carbon 0.25 watt 100 ohm. ....... cin ini a race» 1
R55 007 293 |. RESISTOR, carbon 0.5 watt 680K ohm... iio i ies. 1
R57 035 884 . RESISTOR, carbon film 0.25 watt 100K ohm .................... ee. 1
R58 039 332 . RESISTOR, carbon film 0.26 watt 16K ohm .......................... 1
R59 035886 . RESISTOR, carbon film 0.2bwatt 22Kohm ......... cin... 1
SCR50,51 007 973 .THYRISTOR, SCR 8 amp 200 volts .. cuit iit ee eee 2
026 750 . MOUNTING PAD, semiconductor . . .. orto eee ee ie eae 1
007 824 SPRING, extension ..........e..ecsmemana ca iaa, ea RE 1
006 094 TOOL KIT, diesel engine ........22004 004404 ee ea ea a ae ea a ee a 110 1000 1
*Recommended Spare Parts.
** Replace At Factory Or Factory Authorized Service Station.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
82
81
Page 5
Figure B — Generator Assembly
TD-007 287
item Dia. Factory
No. Mkgs. Part No. Description Quantity
Figure B Generator Assembly (See Fig. A Page 3 Item 44)
81 006 047 PULLEY, V 11122144 0 4 0 4 4e 14 4 4 4 4 4 4 1 4 4 44 0 a 0 8 0 4 4 8 4 6 a 4 0 0 1
82 005 572 BELT, V-notehed .....1221 21204 40 44 4 a 0 ea 01 14e 1 ee 11 0120 6 1
83 005 755 ENDBELL ...............em2es0dcaneaavvorecsrvesmuraon. 1
84 5SR3 006 062 DIODE ASSEMBLY, reverse polarity (consisting of) ............ 1
85 025 305 INSULATOR .........eexsucororociaareve anne enanmada 2
86 037 306 .DIODE, 150 amp 300 volts reverse polarity ...........e.c ee... 3
87 025 306 INSULATOR .......... .emereresarerorvkraararanme eoerra 0 5
88 V3vSI 025 932 SUPPRESSOR, 75 uf 10ohmw/leads ....................... 1
89 005 876 HOSE, neoprene -slit 5/32 1Dx11/320Dx 7-1/8 ............. 1
90 **079 927 STATOR, QENEratOr «oir tte tt it tee ste eee eee 1
91 008 799 BAFFLE, air - generator .............e_0r-eneoreorevasin e 1
92 006 086 ROTOR, generator (consisting of) ..........re.ereaervararmen. i
93 ' 024 617 . RING, retaining - external .......222 1221212 1e eu a a ea nan ee 1
94 053 390 BEARING, ball... voit ee ee eee eee ees 1
95 005 797 . FAN, rotor .........eeceeoemeaeaoranrndadnraroonroore ndo on i
035775 .KEY,steel 3/8 x 3/8 X 1-1/2 iii iii ein 7
96 D1 006 712 SUPPRESSOR, surge excitation 3 amp 600 volts ............... 1
97 Alt 005928 ALTERNATOR, 37 amp 12 volts ov vee eee ieee ven 1
98 005 765 BRACKET, mounting -alternator . ....... RER 1
99 605 430 PULLEY,single belt ........ LA ea 8 4 8 8 2 8 68 4e 8 80 a 0 114 Aa 110 6 1
100 061 441 STRAP Lt ee ee tee ee eee 1
101 005 799 BARREL, rectifier ...... iii tei ieee 1
102 004 994 BRACKET, mounting-brush holder. ................ cc... 1
103 003 923 CAP, hoider - brush . oii i ei eee eee iene aaa 2
104 004 993 BAR, retaining - brush holder ..........reeeemevererareomero 1.
105 “003921 BRUSH, w/spring..........e_eeereerorvarveoeeaeeao rec. 2
106 005 614 HOLDER, brush - w/tabs ..........reesvaareorereóe roer. 2
107 005 745 BRACKET, mounting-brush holder... ...................... 1
108 SR3 006 063 DIODE ASSEMBLY, straight polarity {consistingof) ............ 1
109 024 305 .INSULATOR LL... 122211124144 4 4 4 ee a 4e ae ae a a a ae aa ane 2
110 037 305 . DIODE, 150 amp 300 volts straight polarity ................. 3
* Recommended Spare Parts.
**Replace At Factory Or Factory Authorized Service Station.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
— OM-460 Page 6
Figure C — Bracket, Mounting - Power Output
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 7
item Factory
No. Part No. Description Quantity
Figure C Bracket, Mounting - Power Output (See Fig. A Page 4 Item 70)
121 005 742 BRACKET, mounting - terminal power output .......... nena . 1
122 039 046 TERMINAL, power output - black {consistingof} .................. 1
123 601 976 .SCREW, cap - steel hex hd 1/2-13x 1-1/2 ee as 1
124 053 032 CLIP, spring - bus bar .......... eo r_e.eereorneaeaa ea nene . 1
125 032045 TERMINAL BOARD, black .......... o... .0s0neddoravoaoaraaa 1
126 601 880 .NUT, steel - hex jam 1/2-13 .......... iin. ae 1
127 039044 BUS BAR Loot KR HERR KR 0 1
128 601 879 NUT, steel -hex full 1/2-13 112114042044 0 6 a sa ne 5 Ce eee 1
129 039 047 TERMINAL, power gutput - red (consisting of) ........._erese0svernoo 1
130 053 032 CLIP, spring - bus bar .......... ee. seneereoeaanenaeo ra rmrercro 1
131 601 976 .SCREW, cap - steel hex hd 1/2-13x 1-1/2 ......... inn, 1
132 039 049 . TERMINAL BOARD, red....... oe s0araaconvoar ene dera ana, 1
133 601 880 . NUT, steel - hex ¡am 1/2-13 LL 1111101114 4 6 440 a a a a 4 4 ea ua a a 0 0 1
134 039044 BUS BAR Le A a a a RR KR RR RR AK 1
135 601 879 .NUT, steel - hex full 1/2-13 i ie eins 1
NG
ro
135
134
133
129 4
132
131
130
=
TB-053 391
Item Dia. Factory
No. Mkgs. Part No. | Description Quantity
Figure D Panel, Front - With Components (See Fig. A Page 4 Item 72)
141 019754 HANDLE, switch - range ......... oreevecerrverererroenorerercrrecaro cara 1
142 010 836 PIN, spring - compression 3/16 x 1-1/4 i eee 1
143 NAMEPLATE (order by model and serial numbers) ....................... 1
144 079813 PANEL, front - upper ot iii i in it i eet settee cae a aaa i
145 53 005 015 SWITCH, range (See Fig. D1 Page 9) .............eececveorocarerecare a. 1
146 R1 *005 355 RHEOSTAT, WW BO watt Qohm .... Lt tie tea aie ans 1
147 005 890 STRIP, friction -rheostat .............. PS 1
148 026 837 INSULATOR, terminal - nylon ... 11.204202 4404444 44 4 ee 4e 4 4 ee 4 ee 0 0 00 0 0 2
149 CB1 079560 CIRCUIT BREAKER, thermo - manual reset 25 amp ... 1.142044 1 44 10001 10 0000 1
150 $1 053 359 SWITCH, toggle SPST 20 amp 125 voltsac.....1022224 0404 44404 40 ea 1 a eee 00 1
151 RC] 604 176 RECEPTACLE, straight - duplex grounded 2P3W . .. .............. vn... 1
152 PB1 011767 SWITCH, push - button starter ......1222 2244 4 44 6 0 4 0 4 4 4 4 a a a 1 a a a 4 RR 1
153 52 021 384 SWITCH, toggle SPDT .....0214 22214 224 4e 4e 0 4 0 ee a a a ea 0 a ea ea ee ss a ae 0 0 1
154 005 789 HANDLE, theostat .....120222 00 21 12 04 4 4 a eet eter tei terete aman 01 04 0 1
602 178 SCREW, set - steel 10-24 x 1/4 1.112442 4 4 4 40 a 4 4 4 4 4 0 4e 8 0 ue 0 0 a ea eu 0 1
195 021 385 BOOT, toggle - switch lever... 121020210012 20 4 8 8 4 114 0 8 4 8e 1 se 1 04 a 2 000 1
156 PL12 004943 LIGHT, indicator 9-14 volts de red lens double .............. ener eae 1
157 019516 CONTROL, push - pull ............_resre0arerecrverCaor tamacvoeadrrerenmenme 1
158 007 163 CONTROL, push - pull locking .............. ree aa ee 1
158
157 TC-053 1448
156
154
Figure D — Panel, Front - With Components
"Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-460 Page 8
[tem Factory |
No. Part No. Description Quantity
Figure DT 005015 Switch, Range (See Fig. D Page 8 Item 145)
171 005 001 BRACKET, mounting -switch ........... ei 1
172 010671 SPRING, extension ..........e-eraroraraarvenoooerenenecoea 1
173 017428 LOCATOR, quadrant ...........e... e. e000rere0ea ao AA 1
174 004 998 CONTACT BOARD ASSEMBLY, switch - range (consisting of} ........ 1
175 100 623 .GUIDE,contactboard-movable ............. cin 3
176 100 622 .SHIM, guide - contact board .............. ee eeodeeoreaco een. 3
177 011980 .CONTACT BOARD, movable switch ..........._.eeonmeccurecacoo 2
178 004 999 CONTACT BOARD, stationary .................. J 2
179 011645 .CONTACT ASSEMBLY, movable {consistingof) .................. 3
180 011075 ., SPRING, pressure RER RR RR RK a a a a a 0 à 1
181 011953 ..CONTACT .............. ee ee eee 0 2
182 ‚ 011074 ..SPRING, pressure 121002000000 ee ee aa aa aa ea a see 1
183 011644 CONTACT, Stationary ....... vette ee eee ein 15
179 183 °
includes 181 182
item 180
174 4
180
T2011 273 TB-O11 100
Figure D1 — Switch, Range
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 9
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