Miller BOBCAT 225D PLUS User manual

Miller BOBCAT 225D PLUS User manual
 April 1996
Form: OM-404
Effective With Serial No. KG076022
7) Miller
OWNERS
MANUAL
Bobcat™ 225D pi
CCI/CV AC/DC Welding Generator For SMAW, FCAW, GMAW, GTAW Welding
Weldin Weld Rated oa Auxiliary Power
Mo de Output Welding Circuit Ratin Fuel Capacity Engine
Range Output 9
Voltage
225 À, 25 V,
CC/AC 50 — 225 A 100% Duty 80
Cycle
210 À, 25 V, Single-Phase, Deutz/Ruggerini MD-151
CC/DC 50—210A | 100% Duty 72 8 kVA/kW, 70/35 A, | 85gal(32L) Tank | Air-Cooled, Two-Cylinder,
Cycle 120/240 V AC, 60 Hz Diesel Engine
200 À, 20 V,
CV/DC 17-28V 100% Duty 33
Cycle
covar_om 4/65 — ST-801 331-B © +996 MILLER Electric Mig. Co. PRINTED IN USA
_
Ш
Se
MILLER'S TRUE BLUEG LIMITED WARRANTY
Effective February 7, 1996
(Equipment with a serial number preface cf “KD” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY — Subject tothe tarms and conditions below, MILLER Electric
Mig. Co,, Appleton, Wisconsin, waranis to its original retail purchaser that new
MILLER equipment sold afterthe effective date of this limited warranty is free of de-
facts in material and workmanship at the tima it is shipped by MILLER. THIS WAHR-
RANTY |S EXPAESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-.
NESS.
Within tha warranty periods listed below, MILLER will repair or replace any war-
ranted paris or components that fail due to such defects in matarial or workmanship.
MILLER must be notified in writing within thiny (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty clairs procedures to bo
followed.
MILLER shall honor warranty claims on warranted equipment listed balow in the
event of such a failure within the warranty time periods. AH warranty time parnicds
start on the date that the equipment was delivered to the original retail purchaser, or
one yaar after the equipment is sant to a North Amarican distributor or sighteen
months after the equipment is sant to an International distributor,
1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
" TranstomarRactifier Power Sourcas
“ Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
" Inverter Power Supplies
" Intalltig
* Robots (1 year labor)
3.. 2 Years -— Parts and Labor
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
. Air Compressors
4. 1 Year — Parts and Labor
* Motor Divan Guns
* Process Controlars
" IHPS Power Sources
, Water Coclant Systems
" HF Units
* Grids
* Spot Waldars
* Load Banks
" 50X Transformers
" Millar Cyclomatic Equipment
* Running Gaar/Trailers
" Plasma Cutting Torchas (except APT, ZIPCUT & PLAZCUT Models)
, Tecumseh Engines
* Deutz Engines (outside North America}
+ Field Options
(NOTE: Field options are covered under True Biue® for the remaining
warranty period of the product they are installed in, or for a minimum of
ona yaar — whichever is greater.)
5. 6 Months — Battenes
6. 90 Days ~ Parts and Labor
* MIG Guns/TIG Torches
* APT, ZIPCUT & PLAZCUT Made! Plasma Cutting Torches
Remote Contrals
* Accessory Kits
* Haptacement Parts
MILLER'S Trua Blue® Limited Warranty shall not apply to:
1. liars furnished by MILLER, but manufactured by others, such as engines or
trade accessorias, These items are covarad by the manufacturer's warranty, if
any.
2. Consumable components; such as contact tips, cutting nozzles, contactors
and relays or pars that fail dus to normal wear.
3. Equipment that has bean modified by any party other than MILLER, or equip-
ment that has been improperly installed, impropery operated of misused
based upon industry standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has been usedfor operation
outside of the specifications for the equipmant.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-
CIALANDLISTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusiva remadias
shall ba, at MILLER'S option: (1) repair, or (2) replacement; or, where auihorizad in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace»
ment at an authorized MILLER sarvice stalion; or (4) payment of or credit forthe pur-
chasa price {less reasonabla depreciation based upon actual use) upon retum of the
goods at customers risk and expanse. MILLER'S option of repair or replacement
will be FO.B., Factory at Applaton, Wisconsin, or FO,B, ate MILLER avihorizad ser-
vice facility as determined by MILLER. Therefore no compensation or reimburse-
ment for transportation costs of any kind wit ba allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES, IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-
TRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEQRY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER 16 EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an impliad warranty
lasts, or tha exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe-
cific legal rights, and other rights may be availadla, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties
or romadies other than as stated harein, and to the extant that they may not be
waivad, the {imitations and exclusions set out above may nct apply. This Limited
Warranty provides specific legal rights, and othar rights may be avaitable, but may
aN" from province to province.
т
. WHO DO | CONTACT?
For help,
For additional information, such as
contact your distributor shipment,
Technical Manuals (Service And Parts)
Engine Manuals
Circuit And Wiring Diagrams Department
Process Handbooks
User's Guides
Distributor Directories
contact your distributor
To file a claim for loss or damage during
m contact the delivering carrier
For assistance in filing or settling claims,
Eu contact your distributor and/or equipment
manufacturer's Transportation
Miller Electric Mfg. Co.
m FAX:
800-637-2348 (in USA), or
414-735-4136 {outside USA)
WRITE:
Miller Electric Mfg. Co.
P.O. Box 1079
Appleton, Wi 54912 USA
Always provide Model Name and Serial or Style Number
miler_warl 3/06
ERRATA SHEET August 12, 1996 FORM: OM-404
Use above FORM number when ordering extra manuals.
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data
appearing later in this manual.
CHANGES TO SECTION 6 — MAINTENANCE AND TROUBLESHOOTING
NOTE 15 Under normal conditions, engine oil and filter should be changed every 200 hours.
See maintenance label on this Errata Sheet to select correct engine oil.
Replace Section 6-2. Maintenance Label (see Page 2 on this Errata Sheet)
CHANGES TO SECTION 7 —- ELECTRICAL DIAGRAM
Replace Figure 7-1. Circuit Diagram For Welding Generator (see Page 3 on this Errata Sheet)
CHANGES TO SECTION 9 — PARTS LIST
Change Parts List as follows:
Dia. Part Replaced
> Mkgs. No. With Description Quantity
SAN ‚ +169 441 ............ Added ...COVER, top SS... ie 1
L273. ‚ +169 442 ,........... Added ... PANEL, side SS ,.........eeresecoreoreoaciaa, 2
. 27-32 ...TS1 ...,. 149618.......... 179 385... SOLENOID, 12VDC 464 pullhold ............... 1
‚ 28-62 ......,..... 159 911 .......... 180628 ... PANEL, frontlower .........—.—.e_.—__eocerrecevcao 1
. 28-63 ............ 165 817 ...,...... 134 792 ... LABEL, warning general precautionary ........... 1
C28 000000 182 612 ............ Added ... KIT, label... ieee 1
**First digit represents page no — digits following dash represent item no.
+ Part of Optional Stainless Steel Dress-Up Kit 043 051.
+When ordering a component originally displaying a precautionary label, the label shouid also.be ordered.
*Recommended Spare Parts.
Section 6-2. Maintenance Label
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OM-404 Page 2
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SC-172137-D
Figure 7-1. Circuit Diagram For Welding Generator Prior To Serial No. KG198345
OM-404 Page 3
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Figure 7-1, Circuit Diagram For Welding Generator Effective With Serial No. KG198345
OM-404 Page 4
5
TABLE OF CONTENTS
SECTION 1 —- SAFETY PRECAUTIONS FORARCWELDING .................... coon, 1
1-1. Symbol Usage .........ee._eeesoeseveneorrorarenrear e encarnan sa a een a Ds 1
1-2. Arc Welding Hazards...........oeeeeeesevcirerevero,eseesore iii ener tar. 1
1-3. Engine Hazards ...........eserecssorservererrerseror enraotac TD eee 2
1-4. Additional Installation, Operation, And Maintenance Hazards ......................... 3
1-5. Principal Safety Standards ..............—ereeooorrenereorerera cen ta doren acen RREE 3
1-6. EMF Information ................. cont, a a eee ee a ee Se ea ee eau ed ee eee Ua 000 3
SECTION 2 — DEFINITIONS .............e.ee.0srevrariererereracoereroetrevararor eererene». 4
2-1. £Symbol Definitions ............—._._eeeeseareraarererere tac erereiore ren rerarenerez e 4
SECTION 3 — INSTALLATION .........meoercorenverarooooereae enracaacgnnatr art nrenanne rene 5
3-1. Installing Welding Generator ,...........eo_e.-ereervecorererenaenr an endaaoor rara» 5
3-2. Dimensions, Weights, And Operating Angles .........._.eee.engsnvarerosenrmererie.. 5
3-3. Fuel Consumption ...........__eeeo.eeenreorervarearvonererenarercannaorena nene your 6
3-4. Engine Prestart Checks ..............erecaraasmenmeadr river tara ere rereareacmonee, 6
3-5. Connecting The Batiery .............ceeerorroereercertrvenmersnec e reco renrne nee 7
3-6. Weld Output Terminais And Selecting Cable Sizes ............e_eeeeeeonesacdrorii. 7
SECTION 4 - OPERATING WELDING GENERATOR .......... HERE 8
4-1. Front Panel Controls ............eeoereerenzesr0a:rrereó ir arereri ai rara naa 8
4-2. Duty Cycle ..........__.eerrresrrerraneorerrraa re enar ter irranreenner rare nenmena em 9
SECTION 5 -— OPERATING AUXILIARY EQUIPMENT ............. cc ii iii iene 10
5-1. $5Standard Receptacles.............. e ii ere eae aaa 10
5-2. Optional Auxiliary Power Receptacles .......... co iii icine 11
5-3. Wiring Optional 240 Volt Plug ...........e_m--eeesvccsrererere rene re ene ee 12
SECTION 6 - MAINTENANCE AND TROUBLESHOOTING ................s000000rereci a 0 13
6-1. Maintenance .........._.rreeceervvorrrerreeeatrererer ene renarr no rnrenerer re 13
6-2. Maintenance Label .............ececearoerooneo:renrarorerearonoamoeraer rene verevaa 14
6-3. Inspecting And Cleaning Optional Spark Arrestor . ......... cc iii, 15
6-4. Changing Engine Oil, Oil Filter, And Fuel Filter .................... eee ea 16
6-5. Adjusting Engine Speed .............eemeeresreeesrrereren ere enero e enrie 17
6-6. €6Overload Protection .......... _eceeeeeéresverervenreace me reneecara acen rare re ne enn 17
6-7, Troubleshooting ........................ Aa a 4 4e 4 de NA AAA a A4 A4 ea a ea V4 aa 40000 19
SECTION 7 — ELECTRICAL DIAGRAM EEE 00 21
SECTION 8 — RUN-IN PROCEDURE .........201420100 24e s aa a a ea sas a aa aa aa aa aa Sa aa aan a 0 22
8-1. Wetstacking 102000000004 aa ea eee aa ea de a a eee a ae a ee Na da sa 0 sean 0 22
8-2. Run-in Procedure Using Load Bank .....10200240 0040 ea ae a na a ae es a a a a aa da a aan au 0 23
8-3. Run-In Procedure Using Resistance Grid ............. ii iii, 24
SECTION 9 — PARTS LIST i tit eee ee i et teeta eins 26
OM-404 - 4/96
SECTION 1 — SAFETY PRECAUTIONS FOR ARC WELDING
заботу rom 4/96
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this A Marks a special safety message.
procedure! The possible hazards are shown in the adjoining symbols. IF Means NOTE; not safety related.
—
This group of symbols means Wamingl Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards,
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and identify possible hazards.
When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety
information given below is oniy a summary of the more complete safety information found in the Safety
Standards listed in Section 1-5, Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit,
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill. terminal in disconnect box or that cord plug is connected to a
Touching live electrical parts can cause fatal properly grounded receptacle outlet.
—H shocks or severe burns. The electrode and work 7. When making input connections, attach proper grounding
The input power circuit and machine internal | o
circuits are also live when power is on. In 8. Frequently inspect input power cord for damage or bare wiring =-
semiautomatic or automatic wire welding, the wire, replace cord immediately if damaged — bare wiring can kill,
wire reel, drive roll housing, and all metal parts ;
touching the welding wire are electrically live. 9. Turn off ail equipment when not in use.
Incorrectly installed or improperly grounded 10. Do not use wom, damaged, undersized, or poorly spliced
equipment is a hazard. cables.
1. Bo not touch live electrical parts. 11. Do not drape cables over your body.
2. Wear dry, hale-free insulating gloves and body protection, 12, if earth grounding of the workplece is required, ground it directly
3. Insulate yourself from work and ground using dry insulating with a separate cable - do not use work clamp or work cable.
mats OF covers big enough to prevent any physical contact with 13. Do not touch electrode if you are in contact with the work,
the work or ground, ground, or another electrode from a different machine.
4. Disconnect input power or stop engine before installing or 14. Use only well-maintained equipment. Repair or replace
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
damaged parts at once. Maintain unit according to manual.
15. Wear a safety hamess if working above fioor level.
Owner's Manual and national, state, and local codes. 16. Keep ail panels and covers securely in place,
6. Always verify the supply ground — check and be sure that input 17. Clamp work cable with good metal-to-metal contact to
power cord ground wire is properly connected to ground workpiece or worktable as near the weld as practical.
ARC RAYS can burn eyes and skin; ARC RAYS
NOISE can damage hearing; FLYING
7 SLAG OR SPARKS can injure eyes. 2. Wear a welding helmet fitted with a proper shade of filter to
Arcravs from the welding process produce intense protect yourface and eyes when welding or watching {see ANSI
7 visible and invisible (ultraviolet and infrared) rays 249.1 and Z87.1 listed in Safety Standards).
— that can bum eyes and skin. Noise from some 3. Wear approved safety glasses with side shields.
processes can damage hearing. Chipping,
grinding, and welds cooling throw off pieces of 4. Use protective screens or barriers to protect others from flash
metal or slag. and glare; wam others not to watch the arc.
NOISE ;
5. Wear protective clothing made from durable, flame-resistant
1. Use approved ear plugs or ear muffs if noise level is high. material {wool and leather) and foot protection.
FUMES AND GASES can be hazardous 5. Work in a confined space only if it is well ventilated, or while
to your health. wearing an air-supplied respirator. Always have a trained
Welding produces fumes and gases. Breathing watchperson nearby. Weiding fumes and gases can displace air
these fumes and gases can be hazardous to your and lower the oxygen level causing injury or death. Be sure the
health. breathing air is safe.
6. Do notweld in locations near degreasing, cleaning, ofr spraying
1. Keep your head out of the fumes. Do not breathe the fumes. operations. The heatand rays of the arc can react with vapors to
2. If inside, ventilate the area and/or use exhaust at the arc to form highly toxic and irritating gases.
remove welding fumes and gases. 7. Do not weld on coated metals, such as galvanized, lead, or
3. [If ventilation is poor, use an approved air-supplied respirator. cadmium plated steel, unless the coating is removed from the
4, Read the Material Safety Data Sheets (MSDSs) and the weld area, the area 15 well ventilated, and if necessary, while
manufacturer's instruction for metals, consumables, coatings, wearing an air-supplied respirator, The coatings and any metals
cleaners, and degreasers. containing these etements can give off toxic fumes if welded.
OM-404 Page 1
CYLINDERS can explode if damaged. 4, Never drape a welding torch over a gas cylinder.
Shielding gas cytinders contain gas under high 5. Never allow a welding electrode to touch any cylinder.
pressure. It damaged, a cylinder can explode. 6. Never weld on a pressurized cylinder — explosion will result.
Ince gas cylinders are normally par of ie welding 7. Use only correct shielding gas cylinders, regulators, hoses, and
process, be sure to reat tham carefully. fittings designed for the specific application; maintain them and
associated parts in good condition,
1. Protect compressed gas cylinders from excessive heat, 8. Tum face away from valve outlet when opening cylinder valve.
mechanical shocks, slag, open flames, sparks, and arcs. 0. Keep protective cap in place over valve except when cylinder is
2. Install cylinders in an upright position by securing to a stationary in use or connected for use.
support or cylinder rack to prevent falling or tipping. 10. Read and follow instructions on compressed gas cylinders,
3. Keep cylinders away from any welding or other electrical associated equipment, and CGA publication P-1 listed in Safety
circuits. Standards.
WELDING can cause fire or explosion. 6. Be aware that welding on a ceiling, fioor, bulkhead, or partition
= = Welding on closed containers, such as tanks, can cause fire on the hidden side.
(| drums, or pipes, can cause them to blow up. Sparks 7. Do not weld on closed containers such as tanks, drums, or
can fly off from the welding arc. The fiying sparks, pipes, unless they are properly prepared according to AWS F4.1
hot workplece, and hot equipment can cause fires (ses Safety Standards)
and bums. Accidental contact of electrode to metal |
objects can cause sparks, explosion, overheating, 8. Connact work cable to the work as close to the welding area as
or fire. Chack and be sure the area is safe before practical to prevent welding current from traveling long, possibly
doing any welding. unknown paths and causing electric shock and fire hazards.
1. Protect yourself and others from flying sparks and hot metal, 9. Do not use welder 10 thaw frozen pipes.
2. Do not weld where flying sparks can strike flammable material. 10. Remove slick electrode from holder or cut off welding wire at
3. Remove all Hammables within 35 (10.7 m) of the welding arc. If contact tip when not in use.
this is not possible, tightly cover them with approved covers. 11. Wear oil-free protective garments such as leather gloves, heavy
4, Be alertthat welding sparks and hot materials from welding can shirt, cuffless trousers, high shoes, and a cap.
easily go through small cracks and openings to adjacent areas. 12. Remove any combustibles, such as a butane lighter or matches,
5. Watch for fire, and keep a fire extinguisher nearby. from your person before doing any welding.
1-3. Engine Hazards
ENGINE EXHAUST GASES can kill. 1. Use equipmant outside in open, well-ventilated areas.
Engines produce harmful exhaust gases. 2, If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or 2. Do not add fuel while smoking or if unit is near any sparks or
explosion. open flames. |
Engine fuel is highly flammable. 3. Do not overtill tank — allow room for fuel to expand.
4. Do not spill fuel. If fuel is spilled, clean up before starting
1. Stop engine and let it cool off before checking or adding fuel. angine.
и MOVING PARTS can cause injury. 3. Have only qualified people remove guards or covers for
Moving parts, such as fans, rotors, and belts can maintenance and troubleshooting as necessary,
cut fingers and hands and catch loose clothing. 4, To prevent accidental starting during servicing, disconnect
> negative (=) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
1. Keep all doors, panels, covers, and guards closed and parts.
securely in place. 6. Reinstall panels or guards and close doors when servicing is
2, Stop engine before installing or connecting unit. finished and before starting engine.
SPARKS can cause BATTERY GASES +. Always wear a face shield when working on a battery.
TO EXPLODE; BATTERY ACID can 2, Stop engine before disconnecting or connecting battery
burn eyes and skin. cables.
3. Do not allow tools to cause sparks when working on a battery.
Batteries contain acid and generate explosive 4. Do not use welder to charge battenes or jump start vehicles.
gases. 5, Observe correct polarity (+ and —) on batteries.
STEAM AND PRESSURIZED HOT 1. Ifthe engine is warm and checking is needed, follow steps 2
COOLANT can burn face, eyes, and and 3.
skin. 2. Wear safety glasses and gloves and put a rag over cap.
It is best to check coolant level when engine is 3. Turn cap slightly and let pressure escape slowly before
cold to avoid scalding.
completely removing cap.
OM-404 Page 2
A WARNING
MOVING PARTS can cause injury.
1. Before working of generator, remove spark plugs
or injectors to keep engine from kicking back or
starting.
2. Block flywheel so that it will not tum while working
on generator components,
1-4. Additional Installation, Operation, And Maintenance Hazards
READ INSTRUCTIONS.
1. Use only genuine MILLER replacement parts.
2. Reinstall injectors and bleed air from fuel system
according to engine manual.
FLYING PIECES OF METAL or DIRT can
injure eyes.
1. Wear safely glasses with side shields or face
shield.
DO NOT LET ENGINE EXHAUST SPARKS
CAUSE FIRE.
1. Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
STATIC ELECTRICITY can damage parts
on circuit boards.
1. Put on grounded wrist strap BEFORE handling
boards or parts.
2. Use proper static-proof bags and boxes to store,
move, or ship PC boards.
LOW VOLTAGE AND FREQUENCY CAN
DAMAGE electrical equipment such as
MOTORS.
1. Tum off or unplug equipment before starting or
stopping engine.
A
MAGNETIC FIELDS FROM HIGH
CURRENTS can affect pacemaker
operation.
1. Pacemaker wearers keep away.
2. Wearers should consult their doctor before going
near arc welding, gouging, or spot welding
EQUIPMENT.
1. Allow cooling period.
2. Reduce current or reduce duty cycle before
starting to weld again.
3. Follow rated duty cycle.
| OVERUSE can cause OVERHEATED
operations.
HOT PARTS can cause severe burns.
1, .Allow cooling period before maintaining.
on à hot engine.
2. Wear protective gloves and clothing when working
TILTING OF TRAILER can cause injury.
1. Use tongue jack or blocks to support weight.
2. Properly install welding generator onto trailer
according to instructions supplied with trailer.
personal injury and equipment damage.
gas cylinders, or any other accessories.
2, Use equipment of adequate capacity to lift unit.
FALLING EQUIPMENT can cause serious
1. Use lifting eye to lift unit only, NOT running gear,
BATTERY ACID can BURN SKIN AND
EYES.
1. Do not tip.
2. Replace damagsd battery.
3. Flush eyes and skin immediately with water.
1-5. Principal Safety Standards
Safely in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 28 CFR 1910, from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL. 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANS! Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10016.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The following is a quotation from the Genaral Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields — Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
Office, May 1989): “. ., there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to
interpret the evidence in a single coherent framework, Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are also recommended for pacemaker
wearers. Consult your doctor for complete information.
OM-404 Page 3
SECTION 2 — DEFINITIONS
2-1. Symbol Definitions
Fast Fast/Slow
8) Stop Engine € (Run, Weld/Power) € / ~~ (Run/ldle) <? Slow (Idie)
[|
г) Start Engine Glow Plug Temperature E Fuel
TA Engine Oil Check actors! Совок valve Battery (Engine)
; Read Operators A \/
Engine EN Manual Amperes Volts
Gas Metal Arc mT Shielded Metal Arc JF Gas Tungsten Arc | ——— A
" й Welding (GMAW) e. Welding (SMAW) e 7 Welding (TIG) o © Circuit Breaker
Alternating Current
(AC) Output
Positive — Negative
Time (Ground)
5 |+||
a Protective Earth
=)
Welding Arc
(Electrode)
Do not switch
while welding
Work Connection
Hours < Seconds
|
„^^
©
OM-404 Page 4
SECTION 3 - INSTALLATION
3-1. Installing Welding Generator
i, YJ
Mn Shi
Movement Airflow Clearance Location
A Do Not Lift Unit From End
Grounding 1 Generator Base
1 3 2 Metal Vehicle Frame
4
3 Equipment Grounding
Terminal
y 4 Grounding Cable
OR Use #10 AWG or larger insulated
copper wire.
—— A If unit does not have GFCI
receptacles, use GFCI-
protecied extension cord.
Electrically bond generator frame fo VEL
vehicle frame by melal-to-metal
2 contact. 2
install 3/96 — Ref. ST-800 652 / Rel. ST-B00 477-A 7 ST-158 936-A / 5-0854
3-2. Dimensions, Weights, And Operating Angles
A Dimensions HE 2
= В
o Height 31 in (787 mm) A
| +
—+— |+ 4 Width 18-3/4 in (476 mm) A Do not exceed operating angles while
D N running or engine damage will occur.
G Depth 46 in (1164 mm) A Do not move or operate unit where itcouid
4 Holes В.
А 18 In (457 mm)
ЕЁ B 16-1/2 in (419 mm)
С 3/4 in (19 mm)
25°
D 3-1/8 in {79 mm) 259
| + + |
E 32-3/4 in (832 mm) angles! 3/06
| F 45-1/2 in (1156 mm) Weight
Engine End G 13/32 in (10 mm) Dia. 614 Ib (279 kg)
ST-800 426
OM-404 Page 5
3-3. Fuel Consumption
1.25 The fuel consumption curve
shows typical fuel use
under weld or power foads.
4.73 1.04
> FOC WELD 3700 RPH
3.78 0.84 1.00 1 7
pd em
re
2.04 0.63 0.70 A
0,95 0,41 0.25
o 25 50 76 100 120 180 175 200 250 27
AC/DC WELD AMPERES AT I00X DUTY CYCLE
U.B. GAL./7HR.
IMP.GAL. MR.
1 1 1 1 1 | 1 1 Г Г 1
0 | «0 2.0 3.0 4.0 5.0 5.0 7.0 8,0 2.0 10.0 HO
POWER KVA AT 100% DUTY CYCLE
SB-145 981
3-4. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface. Unit
is shipped with 10W30 engine oil.
[7 Follow run-in procedure in
engine manual.
if unburned fue! and oil collect
in exhaust pipe during run-in,
see Section 8.
Ref. ST-161 983 / Ref. ST-801 331-B
OM-404 Page 6
3-5. Connecting The Battery
Tools Needed:
QE 3/6, 12 In
A Connect (-) cable last,
Raf. ST-800 394-B / Ref. ST-172 786-B / Ref. 5-0756-D
3-6. Weld Output Terminals And Selecting Cable Sizes
A ARC WELDING can cause Electromagnetic Interference.
То reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the
Hioor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this weiding machine is
installed and grounded according to this manual. If interference still occurs, the user must take extra measures such
as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150% | 200 | 250 | 3004 | 3504 | 400 #
100 ft (30 m) Or Less | 45m) | (60m) | (om) | (g0m) | (105 m) | (120 m)
10-60% | 60 - 100%
Weld Output Welding | Duty Duty 10 — 100% Duty Cycle
Р Cycle Cycle
100 4 4 4 3 2 1 1/0 1/0
159 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
—
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 410 2-210 2-30 2-3/0
A a
Work Electrode
ST.801 458 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mits per ampere. 5-0007-0
OM-404 Page 7
SECTION 4 — OPERATING WELDING GENERATOR
4-1.
Front Panel Controls
AB
W =k
e
De
DO NOT SWITCH
UNDER LOAD
ELE RT]
À £
t
ë
Os 70°F (21°C)
108 32°F (0°C)
208 —4°F (—20°C)
1 Engine Control Switch
Use switch to start engine, select speed,
and stop engine. In Run/ldie position, en-
gine runs at idle rpm at no load, and weld/
power rpm under load. In Run position, en-
gine runs at weld/power rpm.
17 Place switch in Run position to operate
most GMAW equipment.
2 Glow Plug Switch (Optional)
If necessary, push switch up before start-up
{see table),
3 ldle Lock Switch
In Start position and engine control switch in
Run or Runfidle, engine is locked in idle
rom.
In Run/ldie position and Engine Control
switch in Run/ldle, engine runs at idle rom
at no load and weld/power rem under load.
A
10 E A
FINE ADJUST
ENGINE
Total All Loads 8600 Waits
Cf i
O)
O
Right Side
+ STICK/ TG 240V7\, E 120,
= pt 2m me ream
“|
MN sa
& a О | | | 0
e | I 0 D
NO 0 00
Da A rar | 0 D
DO NOT SWITCH a re
UNDER LOAD prope
Ul br: AC POWER
и N, | Че
Glow Plug Time
а
2
In Runidie position and Engine Control
switch in Run, engine runs at weld/power
rpm.
To start: move idle lock switch and engine
control switch to Start. Release engine con-
trol switch when engine starts. Do not crank
engine if engine is still turning.
Move idle lock switch to Runvidls after en-
gine wamns.
To stop: move engine control switch to Off.
4 Weld Process Selector Switch
Use switch to select type of weld output.
Use a positive (+) position for Direct Current
Electrode Positive (DCEP) and a negative
{—} position for Direct Current Electrode
Negative. Use AC position tor altemating
current.
5 Coarse Adjust Switch
Ly
7
Ref. ST-172 786-B / Ref. ST-801 434
Use switch to select weld amperage range
when Weld Process Selector switch is in
Stick/Tig position, or voltage range when
switch is in Wire position.
17 For best arc starts, use lowest amper-
age range possible.
6 Fine Adjust Control
Use control to select weld amperage (Stick/
Tig) or voltage (Wire) within the range se-
lected by the Coarse Adjust switch. Control
may be adjusted white welding. Weld output
would be 110 amps DC with control settings
as shown (50% of 70 to 150). Scale is for ref-
erence only,
7 Engine Hour Meter
8 Manual Shutoff Lever
Turn lever counterclockwise to stop engine
if engine control switch does not work,
OM-404 Page 8
4-2. Duty Cycle
Duty cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
A Exceeding duty cycle can
225 AC/CC damage unit and void
warranty.
00/00
$
0 15 20 25 30 40 50 60 70 80 SO MO
x DUTY CYCLE
100% Duty Cycle at 225 Amperes AC, 210 Amperes CC/DC, 200 Amperes CV/DC
Continuous Welding
58-119 454-А
OM-404 Page 9
SECTION 5 — OPERATING AUXILIARY EQUIPMENT
Standard Receptacles
aE
1 207,
О
ОГ
0
120\ ^\,
ПГ
0
| AC POWER
SIMULTANEOUS WELDING AND POWER
WITH FINE ADJUST SET AT 10
pao | ano” | cepto | reco
Amperes Amperes
210 1000 8 4
140 4300 36 18
90 6000 50 25
Ref. 8-166 360-A
A If unit does not have GFC!
receptacles, use GFCI-
protected extension cord.
7 Auxiliary power decreases as
weld current increases.
Set Fine Adjust contro! R1 at
10 for full auxiliary power.
1 120V 15 A AC Duplex Re-
ceptacle RC3
2 120V 15 A AC Duplex Re-
ceptacie RC2
RC3 and RC2 supply 60 Hz single-
phase power at wald/power speed.
Maximum output from RC3 or RC2
is 2.4 KVA/KW (CSA: 1.8 KVA/KW).
3 240V 50 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/hower speed. Maxi-
mum output is 8 KVA/KW.
4 Circuit Breaker CB3
5 Circuit Breaker CB4
6 Circuit Breakers CB1 And
CB2
CB3 protects RC2 and CB4 pro-
tects RC3 fromoverioad. If a circuit
breaker opens, the receptacle
does not work. Press button to re-
set breaker.
CB1 and CB2 protect RC1 from
overload. If CB1 or CB? opens,
RC1 and one of the 120 volt recep-
tacles does not work, 120 volis
may still be present at RC1.
Combined output of all receptacles
limited to 8 kVA/KW rating of the
generator,
EXAMPLE: If 15 A is drawn from
each 120 V duplex receptacle, only
18 A is available at the 240V
receptacle:
2х (120 М х 15 А) + (240V X18 A)
= 7.9 KVA/KW
7 Auxiliary Power While
Welding Chart (For
Reference Only)
Ref. ST-172 786-B
OM-404 Page 10
5-2. Optional Auxiliary Power Receptacles
Pa
9,0 © ©
VU
О nn: a
1,0) OOF
=
=
=
AC POWER
2
AC POWER
3
AC POWER
À If unit does not have GFCI
receptacles, use GFCI-
protected extension cord.
I Auxiliary power decreases as
weld current increases.
Sat Fine Adjust control R1 at
10 for full awxdliary power.
Combined output of all receptacles
limited to 8 KVA/KW rating of the
generator,
GFCI Receptacle Option
1 120V 15 A AC GFC! Recep-
tacles GFCI2 And GFCI3
GFCI2 and GFCI3 supply 60 Hz
single-phase power at weld/power
speed. Maximum output from
GFCI2 or GFCI3 is 2.4 kVA/KW.
Circuit breaker protection is the
same as standard receptacles.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for
damaged tools, cords, plugs, etc.
connected to the receptacle. Press
button fo reset receptacle and
resume operation.
I= At least once a month, run
engine at weldpower speed
and press Test button to verify
GFCI is working property.
South African And Australian
Receptacie Options
2 240 V 16 À AC South African
Receptactes RC1, RC2, And
АСЗ
3 240V 15 A AC Australian
Recaptacles RCT, RC2, And
RC3
Receptacles supply 60 Hz single-
phase power at weld/power speed.
Maximum output from each recep-
tacle is 3.6 KVA/KW.
4 Circuit Breakers CB1, CB2,
CB3
CB1, CB2, and CB3 protect RCA,
RCZ, and RCS from ovenicad. 1f a
circuit breaker opens, the recep-
tacie does not work, Press button
to reset breaker.
5 Circuit Breaker CB4
CB4 protects all the receptacles
from overload. if CB4 opens, none
of the receptacles work,
Ref. ST-172 786-B / Ref, ST-171 204 / Raf. ST-172 113
OM-404 Page 11
5-3. Wiring Optional 240 Volt Plug
The plug can be wired for a 240 Y,
ET 2-wire load or a 120/240V, 3-wire
load. See circuit diagram.
Вр 7 1 Plug Wired For 120/240 V,
С Available In A a 3-Wire Load
urrent Available In Amperes When wired for 120 Y [oads, each
240 V Each 120 V Duplex duplex receptacle shares a load
Receptacie" Receptacie with one half of 240 V receptacle.
35 0 2 Plug Wired For 240 Y, 2-Wire
Load
o. o 3 Neutral (Silver) Terminal
20 15 4 Load 1 (Brass) Terminal
15 20 5 Load? (Brass) Terminal
V x A = Walts 6 Ground (Green) Terminal
*One 240 Y load or two 120 V loads. 7 Amperes Available Using
120/240 V Plug
Tools Needed:
ST-120 813-D
OM-404 Page 12
SECTION 6 — MAINTENANCE AND TROUBLESHOOTING
6-1. Maintenance
e —
A Stop engine before maintaining,
[7 See also Engine Manual and maintenance
R |
всусе апоте label. Maintain more often during severe
conditions.
O an
| Check Fluid №» Service
Spills See Section 3-4 Filter
© son
Clean And
ий! ©
' 2 Terminals Element
O) 100h
Change OU. Sees .
Section 6-4 And Change О!
Maintenance Mer. 4
Label Section
Clean Cooling Clean And
so ponen
es Engine attery
Manual Connections
Replace Repi
Check Fuel Filter. Damaged Or
Valve See Section Unreadable
Clearance 6-4. Labels
O) 250h O) sooh
nan park Repair Or Replace Clean/Set
Arrestor. ZT Cracked Cables Injectors
See Section And Cords \
6-3. NN
© 1000h
Blow Out Or
Vacuum Inside.
OM-404 Page 13
6-2. Maintenance Label
TROLLS Lele RERO Ro ati eee ES NEO RSA TORRENT
LT | | 61-S41-2z 21n9g 'E69 990 HITA - 7 91d [18nd Aiepuoosg
— sin0uy Bunesado 0sz a9/lA95 puy uoloadsu| J0)sauy clef INT RE =p uly ES CU ENTES
(JULIO) PLA LAT 10 В, A "UI OY “ON SUBlS a! IE ¡an
PEC QATAR SRE: pie le RCE
Motos
oBueuo 1914 QUM (1 6:1)10 Z
pci le 43 Во EUA HO ENE
*Hiy 'si10j9alul pue diund uonoefu; urejuieíu ивющшцое: решел Аио влен {TAM Tale
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SINOY 00} SANS He ET Te BEE
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Buyoon suibuz SD» DEO7 ON — INdH 8UBug
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Puy ysnd
(PRIN R-F Io} VT ToT Ne JERR =>7 = I8 4,0 18 aouBwLONag Bunueip
By НЕ : |
A AR CE SI sued SuLsplo usym JIBQUINY [BUas pue uojjesyadg aulbug aan
‘aie0 auibus lado 10) ¡2ntejy SUISUS 835
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OM-404 Page 14
6-3. Inspecting And Cleaning Optional Spark Arrestor
2 Cleanout Plug
Remove plug and remove dirt cov-
ering cleanout hole.
3 Exhaust Pipe
Start engine and run at idle speed
to blow out cleanout hole. if nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
A Stop engine and let cool.
> 1 park Arrestor
OFF «5
Stop engine and allow to cool.
Reinstall cleanout plug.
Tools Needed:
ess
Z—Z———— 56 in
Hof. ST-801 331-B / ST-800 497 -A / Ref. ST-172 786-B
OM-404 Page 15
6-4. Changing Engine Oil, Oil Filter, And Fuel Filter
O, A Stop engine and let cool.
wei Tools Needed: 1 Ol Drain Valve
2
3
4
1/2 ID x 12 In Hose
Oil Filter
ON Fill Cap
5 Ol Dipstick
Change engine oil and filter ac-
cording to engine Owner's Manual.
6 Fuel Line
7 Primary Fuel Filter
Replace lina if cracked or wom.
Install new filter. Wipe up any
spilled fuel.
8 Secondary Fuel Filter
Remove filter and install new filter
element according to engine Own-
er's Manual. Replace fuel line if
cracked or wom. Wipe up spilled
fuel.
9 Hand Primer
Push lever 10 to 12 times to prime
injector system.
Start engine and check for fuel
leaks.
Stop engine, tighten connections
as necessary, and wipe up spitled
fuel.
Ref. ST-172 785-B / Aaf. ST-801 331-B / ST-891 434 / 5-0842
OM-404 Page 16
6-5. Adjusting Engine Speed
a Po |
| 8 Engine speeds have been factory
: a set and should not require adjust-
ment. Alter tuning engine, check
— engine speeds with a tachometer.
See table for proper no load engine
speeds. If necessary, adjust
speeds as follows:
Idle Speed Adjustment:
«> 2000 rpm 1 Throttle Cable
E 3750 rpm 2 Throttle Cable Stop Screw
Start engine and run at idle speed.
Loosen screw and adjust cable un-
ti engine runs at correct idle
speed. Do not allow slack in cable.
Tighten screw.
Weld/Power Speed Adjustment:
Run engine at weld/power speed.
3 Weld/Power Speed Screw
4 wWeld/Power Speed Jam Nut
Loosen jam nut. Turn screw clock-
wise to decrease speed and coun-
terclockwise to increase speed.
Tighten jam nut.
Stop engine.
Г 5
O у
у
= C
A |
o
e
Tools Needed:
>=
Right Side I———€ 1/4 in, mmm
Ref. 37-801 434
6-6. Overload Protection
A. Circuit Breaker CB7 And Fusible Link (Optional With Glow Plug)
—
Wl
Internal circuit breaker CB7 and the fusibie link protect the optional glow plug system from overheating. If giow plugs
overheat, CB7 automatically stops the heating process. Wait one minute for CB7 to automatically reset before using
glow plugs. if the engine is hard to start in cold weather, check the fusible link and replace if open. If circuit breaker or
fusible link continues to open, contact Factory Authorized Service Agent.
OM-404 Page 17
B. Circuit Breaker CB8
y 1 Circuit Breaker CB8
E CB8 protects the idle solenoid. If
CB8 opens, engine drops to idle
speed.
Check throttle solenoid and cable
for obstructions and throttle link-
age for proper adjustment. Press
button to reset circuit breaker,
IF If circuit breaker continues to
open, contact Factory Autho-
tized Service Agent.
—
G
3 0
o
=D
o
=r =>
©:
cé
==
©
©
ST-E01 458 / Ref. ST-172 766-B
C. Fuse F1
A Stop engine and disconnect
battery negative (-) cable.
Remove top cover.
1 Fuse F1 (See Paris List For
Rating)
Fi protects the exciter stator from
overload.
Replace F1 if open. Reinstall top
cover before operating unit.
[7 If fuse continues to open,
contact Factory Authorized
Service Agent.
ъ
Ls Tools Needed:
о 0) <= п
ла
С 3/8, 1/2 п
Ref. ST-801 477
OM-404 Page 18
6-7. Troubleshooting
A. Welding
NN
& UNS er
Trouble
Remedy
No weld output.
Check control settings (see Section 4-1).
Check weld connections.
Check fuse F1 and replace if open (see Section 6-6).
Be sure ail equipment is disconnected from receptacies when starting unit.
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.
Low weld output.
Check fuse F1 and replace If open {see Section 6-6).
Check control settings (see Section 4-1),
Check and adjust engine speed (see Section 6-5).
Service air cleaner according to engine manual,
Have Factory Authorized Service Agent check brushes and slip rings.
High weld output.
Check control settings (see Section 4-1).
Check and adjust engine speed (see Section 6-5).
Erratic weld output.
Check control settings (see Section 4-1).
Tighten and clean connections to electrode and workpiece.
Use dry, properly-stored electrodes for SMAW and GTAW.
Tighten and clean connections both inside and outside welding generator.
Check and adjust engine speed (see Section 6-5).
Have Factory Authorized Service Agent check brushes and slip rings.
B. Auxiliary Power
À
ED
Trouble
Remedy
No output at auxiliary power
receptacles.
Reset circuit breakers (see Sections 5-1 and 5-2).
Press optional GFCI receptacle Reset button (see Section 5-2).
Check fuse F1 and replace if open {see Section 6-6).
Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2.
High power output.
Check and adjust engine speed (see Section 6-5).
Low power output.
Check fuse F1 and replace if open (see Section 6-6).
Increase Fine Adjust control R1 setting.
Erratic power output.
Check fuel level (see Section 3-4).
Check and adjust engine speed (see Section 6-5).
Check receptacle wiring and connections,
Have Factory Authorized Service Agent check brushes and slip rings.
OM-404 Page 19
C. Engine
À
ú ¿We
Trouble
Remedy
Engine will not start.
Check fuel level {see Section 3-4).
Check battery and engine charging system.
Check oil level. Check tow oil pressure shutdown switch (see Section 3-4).
Have Factory Authorized Service Agent check optional glow plug system fusible link, and replace if
open (see Section 6-6).
Have Factory Authorized Service Agent check Engine Control switch, and replace if necessary.
See engine manual.
Engine starts, but stops when Engine
Control switch returns to Run position.
Check oil level, Check low cil pressure shutdown switch (see Section 3-4).
Have Factory Authorized Service Agent check Engine Control switch, and replace it necessary.
Battery discharges between uses.
Clean battery terminals and posts with baking soda solution; rinse with clear water.
Periodically recharge battery (approximately every three months).
Have Factory Authorized Service Agent check voltage regulator.
Replace battery,
Unstable or sluggish engine speeds.
Readjust throttie linkage if necessary (see Section 6-5).
Tune engine according to engine manual.
Engine stops during normal operation.
Check fuel level (see Section 3-4).
Check oil level, Check low oil pressure shutdown switch (see Section 3-4).
Have Factory Authorized Service Agent check Engine Control switch, and replace if necessary.
Engine idles but does not reach weld
speed.
Check and reset circuit breaker CB8 (see Section 6-6). Check solenoid linkage for obstructions.
Have Factory Authorized Service Agent check Engine Control switch, and replace if necessary.
Have Factory Authorized Service Agent check Control Relay CR1, Current Transformer CT1, and
Auto Idle Module PC1.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine (see Section 8 and engine manual).
Engine will not stop.
Stop engine using manual shut off lever. Have Factory Authorized Service Agent check unit.
OM-404 Page 20
SECTION 7 — ELECTRICAL DIAGRAM
|
=
Le,
— JL
LL
— —— —— — AS EPS SE ds ass E — — — — — | =
— EEN: “VE EEE EE EE SEE SE —_— —]]]][—]—[— ———————— DDD — ——
О
SC-172 137-C
NE
Figure 7-1. Circuit Diagram For Weiding Generator
OM-404 Page 21
SECTION 8 — RUN-IN PROCEDURE
run_ini 4/96
8-1. Wetstacking
1 Welding Generator
Run diesel engines near rated
output during run-in period to prop-
erly seat piston rings and prevent
wétstacking. See nameplate or
rating label to find rated output.
7 Donotidie engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded dur-
ing run-in.
2 Engine Exhaust Pipe
Wetstacking is unbumed fuel and
oil In the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a
wet, black, tar-like substance, dry
the engine using one of the follow-
ing run-in procedures.
See the engine manual for addi-
tional engine run-in information.
OM-404 Page 22
8-2. Run-In Procedure Using Load Bank
Á Do not touch hot exhaust
pipe, engine parts, or load
bank/grid,
A Keepexhaust and pipe away
from flammables.
Stop engine.
1 Load Bank
Tum all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2 Welding Generator
Place AV range switch In maxi-
mum position, AV control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe correct
+ polarity.
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator AN control so
load equals rated generator output
(see nameplate).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
(7 Check oil level frequently dur-
ing run-in; add oil if needed.
After one hour {minimum) place
A/V control in minimum position,
then tum off load bank to remove
load. Run engine several minutes
at no load,
4 Engine Exhaust Pipe
Stop engine and allow it to cool.
Repeat procedure if wetstacking is
present.
5-0683
OM-404 Page 23
8-3. Run-In Procedure Using Resistance Grid
A Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
A Keopexhaust and pipe away
from flammables.
Stop engine.
1 Resistance Grid
Use grid sized for generator rated
output.
Turn Off grid.
2 Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
cutput terminals using proper size
weld cables with correct connec-
tors {polarity is not important).
4 Voltmeter
5 Clamp-On Ammeter
Connect voltmeter and ammeter
as shown, if not provided on
generator.
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated generator output (see
nameplate).
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
EZ Check oil level frequently dur-
ing run-in; add oil if needed.
After one hour (minimum), place
AV control in minimum position,
then shut down grid to remove
load. Run engine several minutes
at no load.
6 Engine Exhaust Pipe
Stop engine and allow it to cool.
Repeat procedure if wetstacking is
present. 5.0684
OM-404 Page 24
NOTES
OM-404 Page 25
SECTION 9 — PARTS LIST
ST-801 516
OM-404 Page 26
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 9-1. Main Assembly
A +159 907 .. COVER, top .......eeeeeeroneonroivesavareerenredreer2m rasa 1
00 D ecran eee ana nn a 000 108 487 .. LABEL, warning falling equipment can cause serious injury ....... 1
0 ieee 169329 .. PANEL, side ...........e_.eeeeesevosvecocorererearsrresecn rece. 2
a 159914 .. UPRIGHT, base ..........e_eeeewreesnvecorerereresrivecreceno, 1
eB вкл ко о... 160 975 .. SEAL, weather lift eye ...........—.——e_.ezeecerecesnedererereene2, 1
E - .................. 168 640 .. SEAL, tank fuel filler Neck ...........c_——eeoececorerecamedacaco, 1
2. Uonenvavrorarereron 164 928 .. SEAL, barrel 11.78 ID x .378thk ............ cc vivian... 1
E: 172 663 .. PANEL, rear lOWer .........e.._er_eeeseccrcarorcococonrarvrerereaa 1
E: 147 601 .. CAP, tank screw-on w/vent ..........——ee _ ec eee.eéseenercererer: 1
RP | à PAS 172 657 .. TANK, fuel 8.5gal (consistingof) ................. iat. 1
Ee nnenanecorenonaa 172681 .... FITTING, hose stl ........... cite iain 1
DH A 178 632 .... FITTING, stand pipe hose .250 x 7.325 1g .........e.rerveseno. 1
AS 124 253 .... BUSHING, tank fuel nn |
a E PS 172 742 .. CLAMP, hose .240-.300cip dia sIfting ............._eee-e.renena. 1
e I nnearanonocarenra nrecaon en. FUEL, return line (see engine parts list) ........................ 1
LAB eee ea eee 107 816 .. HOSE, SAE .250 ID x .500 OD (order by ft) ..................... 1ft
e 1Bunircccrerecereree. 066 113 .. FILTER, fuel in-line 250 ..0.0000000000 A 1
17 es eee neue ne 084 173 .. CLAMP, hose .460-545clpdiasifttng.................... coh. 3
AB 165437 .. CLIP, snap-in 472bundle .........e o o.ee..reesezeorrecsresrmane 2
19 141 975 .. WASHER, flat copper .......2224440 44004 aa eee ea a aa aa sense ne 1
e ZO e ss aus aucunes 177 123 .. SWITCH, pressure 0it4PSIl ......................... PAPERS 1
MVL LL Lea a a ea aan ue 142 118 .. FITTING, pipe brs adapter 1/8BNPT x8m-1-6G .................. 1
E TD +172 635 .. ENGINE, diesel elec start ...........c—.—._—eeccooceocarércare 1
Вос LL 1112 aa a ana ne 142 322 .. BRACKET, mtgfuelfilter............... ci iii. 1
га. 24 nnioniaranooarenern reno 0 BASE, fuel filter (see engine parts list) .............eee.0=eerre.. 1
LL 2h aan a cena uen 6 066 893 .. ELEMENT, fuel filter .............ee.e.eevsroveaoaaar een 1
‚. 26 .................. 165 271 .. VALVE, oil drain 3/8-18NPTF ......... cc iii es da es au 00 1
7 A ккк.. 172 634 .. FITTING, adapter oil drairn .............oe.ees0s0ririerer ren. 1
e 2B ee 149610 .. STOP, cable throttle ............_._.— ——.—eeerdcsasosirasiereaane 1
PD nannanaaaaonaaa 150 203 .. SPRING, ¢cprsn .372 0D x 051 wirex 1.8600 .................... 1
BO a aa anne 176 897 .. ARM, throttle ..........— eo oene.ereddcdaeneeeeeenadanvveraa nena 1
2 BL... eee ae es ae ane 172 668 .. CONTROL, push/pull .......... es rece... 1
160320000000 TS1 ...... 149618 .. SOLENOID, 12VDC 44A pul/holdw/ospring .................... 1
LE 1 ee 174803 .. BRACKET, mtgsolenoid .................... PARA 1
12 BL. LL Lea a eee 066 702 .. OIL FILTER .....012012 202000 aa a ea sa es ee ee ea ee ee a ee ee seen san» 1
2 FDL 112 eee ea ea en aan Fig 9-3 .. GENERATOR ..............00srearrecacecereeoasorer er rene. 1
Brennen 087 318 .. CLAMP, sil cush 1.000dia x .203mtghole ....................... 2
CBT 0 176 890 .. HOLD DOWN, battery ......... iii ii ieee 1
LBB. La Lacs Lee ee 168 385 .. LABEL, warning battery explosioncanblind ..................... 1
9er +159 917 .. DOOR, access battery .......220000 00404444 ea aa a aa a ee aa 1000 1
AO .................. 173921 .. CABLE, bat pos (included w/engine) ..........._._._eesrxearereo. 1
LA 2 ea sean nan 0 108081 .. TERMINAL PROTECTOR, batterypostmtg ..................... 2
Ur: Lea eee aan ae 167 677 .. BATTERY, stor 12V 430crk 7578V ..........-.—eseenrrrrenere vea. 1
PC: PEO 082 319 .. CABLE, bat neg ........ñee_eeerreerecorerorarcorecaranectiaane. 1
RP AS 172669 .. CABLE, bat neg ...........eonereeererevarireerenreroareamere, 1
AA Le aan annee 165 630 .. BOLT, J st| .250-20 x 6,500 ........ citi iii, 2
AB a Lace sens ae see 172 720 .. BRACKET, mtg engine upper ........._e.ee__eeenescecreererea_a 1
AB snuoaroaarare 166 094 .. MOUNT, engine vibration .........—...— —eevrrerrsrrecsrererr 002. 3
AT вне вкенкккеккку, 172719 .. BRACKET, mtg engine lower ..........._eeeeeesrrevecrocrerrea_s 1
BB. LL a Lee are 159906 .. PAN, base ......12222 00001 a 44 ue 14e 4 a a ea ea 0 a aa aa ea 4 ra 00 01008 1
AB AAA AS 173094 .. LABEL, engine maintenance .........._.e_eecsere rien rene 6 1
Bee 160 844 .. COVER, base .........eoeeecrrirorerareo-ercorersna re ereccara 4
51.2... DC-Z ..... 1666578 .. STABILIZER ..... i i ire aerea. 1
1 BOL. eee een eee 164 920 .. BRACKET, mta stab/reactor..... 10.244004 0 iii iia, 2
LL. B3 AC-Z...... 176301 .. REACTOR .........e.eseredcicerrere rene rara revenen ere có, 1
e BA iirrorconedareno 172 715 .. ВНАСКЕТ, пи! депегаюг........... 5..5... nay 1
2255101 0s eee eu a nn 0 172 714 .. BRACKET, mtg engine .......2204 400044 aa ea a eee a a ae ua aa» 1
‚ 56 .................. 127 854 ,. CLAMP, stlcush 1.312diax .343mighole ................. ae 1
OM-404 Page 27
No. Mkgs. No. Description Quantity
Figure 9-1. Main Assembly (Continued)
RE 7 ARS 172 707 .. SEAL, fuel hose fitting ..........2002200000 00e sea ea ea ane ee sante» 1
BB... eee 172 625 .. BRACKET, mtg rectifier/components ................. coins. 1
...59....... IT eee... 172661 .. BLOCK, stud connection 6 position ............ee.eevreveverrava 1
‚., 60 ee 100000 173734 .. LINK, jumper .........—.ee_e-eeeeesesvesorseravenrenran e tenecenrcs 2
E -) SAT ...... 142 503 .. RECTIFIER, si 1 ph 300A 400PIV 21.222200 ea ea ee sac ae au 06 1
7 2..5... к.кв као о +159 911 ,. PANEL, frontlower .........202 0004540 as seu 0 ea nana nan ana 1 00 1
Darren 165817 .. LABEL, warning general precautionary .............. coins 1
A -" eee Fig 9-2 .. PANEL, frontw/components ..............c.. iii, 1
…..65....... CT1 ...... 179494 .. TRANSFORMER, current sensing .......e_ce.eerenresrrecioaurs 1
BBL ee 177 136 .. CLAMP, capacitor 2.500dia clip ..........eeeeesvararareri sere. 1
67... . C1....... 176 719 .. CAPACITOR, eictit 1000uf 75VDC .....020 00001 aa na nana a ea a 0006 1
2 GB... Les eee sue 172731 .. HOLDER, fuse mintr .......22200200 400000 a ea an ane nana sean un 0 1
‚.. 69....... F1...... *169 296 .. FUSE, mintr gl 25A 125V ........eesneeserrorese re reene ere... 1
,… 70...... SR23 ..... 035 704 .. RECTIFIER, integ 40A 800V .........ecweomrerrerooreoneaarria.. 2
uan R2....... 165 599 .. RESISTOR, WW adj 225W 0-6 ohm ...........e.—eeeeoeovrecoo 1
Cees RC4 ...... 116045 .. CONNECTOR & PINS ............—eererererosonrervrentecrenceecaa 1
Ce ieee PLGS ..... 136810 .. CONNECTOR & PINS rer |
etes an une PLG4 ..... 135556 .. CONNECTOR & SOCKETS 22.208500 es eee sense convenu 1
RAA RC6 ...... 168844 .. CONNECTOR, rect 4 pin/skt rept ............02000000 000 eu aan 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
“Recommended Spare Parts. |
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
item Dia. Part
No. Mkas. No. Description Quantity
Figure 9-2. Panel, Front w/Components (Fig 9-1 Item 64)
eae. St1....... 162 671 .. SWITCH, polarity S position ............... co ana ea ne ae uen» 1
раз @ RKKKKR KR nan» NAMEPLATE, (order by model and serial number) ............... 1
Le D Las as ea ee ace 000 165 602 .. PANEL, front ........00200 40002 a ea eee a aa a ee ea ee a a aaa 1
Ld US S3....... 165 487 .. SWITCH, selector 4 position 224200000000 eee a aan ee aa 0 1
oD UU y 117243 .. RHEOSTAT, WW 100W 10 ohm ...........ereeesxerervororene 1
e Borra. PC1 ...... 142 725 .. MODULE, weld/power 7 pin ........22000 00000 sa sa ea na aa na 00 1
SA СВ ...... 173069 .. RELAY, enct 12VDC SPDT 158A 125VDC ............ ivan, 1
eB A S2....... 176 606 .. SWITCH, ignition 4 positionw/outhandle ....................... 1
‚ 9...... RC2,3 ..... 167 657 .. RECEPTACLE, strdx grd 2P3W 156A 125V ..................... 2
...10,...... CB1.2 ..... 117501 .. CIRCUIT BREAKER, man reset 1P 40A 250VAC ................ 2
SAL CB3,4 ..... 093 996 .. CIRCUIT BREAKER, man reset 1P 20A250VAC ................ 2
12... S5....... 011 609 .. SWITCH, tgl SPDT 158A 125VDG 1000000000000 usa au eue 1
WERKE RER 021 385 .. BOOT, tgl switch jever .....0000000rR- KK]
….13....... CBs ...... 083432 .. CIRCUIT BREAKER, man reset 1P 104 250VDC ................ 1
14.122200. HM ...... 145247 .. METER, hour 12-24VDC ....... cc ieee, 1
Lo 1B 119014 .. LEVER, switch .........e_eeaavesrexvere re rereccir enano. 1
e 18... R3,VR1 .... 046819 .. SUPPRESSOR ..........esesesevesverrererencendnecerr ever re, 1
..17.... Work, Elect ... 099255 .. TERMINAL, pwr output neutral (consistingof) ................... 2
NS [- PE 601 976 .... SCREW, .500-13 x 1.500hexhd stl ............... cots, 1
2.5. 19 a aa 0e a eu a 039 040 .... TERMINAL BOARD, neutral 122220000000 0 aa aa sea a ea an a 0 1
1e BOL es 601 880 .... МОТ, .500-13 х .31 high stl .......e.e.eeraradsrarei erre. 1
ee D LL ae aa ee rene ee 039 044 .... BUS BAR, termbd .....2221102 000 aa aa a ae a a ea ae se nan aan» 1
A 501 879 .... NUT, .500-13 x 44 highstl .............. cc. viii, 1
OM-404 Page 28
No. Mkgs. No. Description Quantity
Figure 9-2. Panel, Front w/Components (Fig 8-1 item 64)
(Continued)
LL. 23... RC1 ...... 164 704 .. RECEPTACLE, str3P4W S50A 125/250V .............. cits. 1
e QA ea 083 030 .. STUD, brs .250-20 x 1.750 .........-esereversmerarecarerecem.. 1
2. DLL Lee ee na a aa nan 010915 .. WASHER, flat .250 ID brs ........eeo ._ernooaaaaaa ran ze er een e 0 3
EP BO ane aa aa ae» 601 836 .. NUT, .250-20 brs .......ee.eresvnonvredcarecoaaoarececioraaaen. 3
a QT ea 159 921 .. BEZEL .......ecsndearaaacaroareavorecarercarace dareredcene. 1
e QB nnucirerraverean a 147 195 .. NUT, .375-27 Myl ..........eerervcacoraerarearecnacrer ramon 0 5
га. 29 narerreriaraaa. 148 956 .. HANDLE, switch ...........e_ereesennveranereaaveeamareeiencan. 2
BO urenrrerareria 097 924 .. KNOB, pointer ..........e.e e eeeenerevirsesvenederervenereo 1
7
17
ST-B01 517
Figure 9-2. Panel, Front w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-404 Page 29
No, No. Description Quantity
Figure 9-3. Generator (Fig 9-1 Item 35)
на, Тео. 013 367 ... LABEL, warning moving parts can cause serious injury .........c_ecenxereca: 1
e Banano 165 818 .. . LABEL, warning engine fuel can cause fire .......222000 00140000 ae ana ee seen 1
1 D 14000 +172 652 ... STATOR, generator ........e..—ee_eocreereoroerecesrorereveconmerereoro va 1
Aaa 179 885... ROTOR, generator (consisting of) .............ecos.ereeeerriianverereon eme 1
2 5 O 053 390 .... BEARING, bali rdi sgl row 1.370 x 2.830 Xx .6 ..........——o—rereescacnrenee e. 1
12 B 2.20. 160566 .... FAN, rotor .........2220202 004 ea ea ee an ee ea ea ea 0 ee ea ea sd aa a aa aa es nn. 1
2.0 Tenues 172 665 ... ADAPTER, engine 000020000044 a ea ea ae ae a ee ee ee ee de ae de eee san 00 1
08 142 156 .., SCREW, .375-16 Xx 1.750hexhd ...........oeeeeeercoroervririorssreco sere. 4
029.000. 160573... STUD, stl .375-16 X 17.125 .........ece.eexerenrrerovenrereenwarererennte. 4
e. 10...... 125 548 .. . HOLDER, brush elect .............ec_eeeceaarreresnoneaariencenreneveaor. e.
| E 005614 ... HOLDER, brush .........._.eseeecscoascacarerrvrenacaraeresnanrenen ener Te
E *126 984... BRUSH w/SPRING ...........eo-evresrisocacarenerenonmecarrececoeoarerera,
e Bonne, 161 306 ...CAP, brushholder ............e_eecreceresrerereneamecnvenarereecerrn e.
e A enana 047 879... BAR, retaining brushholder ..........._....eceresrrescorervirecererenn en en
...15...... 010910... WASHER, fiat .d06 ID sil ............_ereerosreerrerene care vera reno cenerar
.. 16...... 010 909 ...NUT, .375-16Stl............eeemecararioreazorarenaaraorarenenvtórererbedao
y A 160 943 ... ENDBELL, (consisting of) ..........c_.....0ces0r0er0airiraceear eran.
e Bee... 143220 .... O-RING, 2.859 ID x ,139CS
16 ST-800 798
Figure 9-3, Generator
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts,
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-404 Page 30
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