Miller | LB057826 | Owner Manual | Miller MILLER AIR PAK User manual

Miller MILLER AIR PAK User manual
OM-478
120 240AA
April 2002
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Equipment:
Battery Charging
Description
Engine Driven Welding Generator
Miller Air Pak
Visit our website at
www.MillerWelds.com

From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.
The following terms are
used interchangeably
throughout this manual:
Stick = SMAW
TIG = GTAW
MIG = GMAW
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
4
4
SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
7
8
8
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Air Compressor Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. AC Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Optional AC Power Plant Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Optional Battery Charging Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
10
11
11
12
12
13
14
15
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Precleaners, Exhaust Pipe, And Rain Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Installing Ether Cylinder (Optional Ether Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Remote 14 Receptacle RC3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Terminal Strip 3T Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Air Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
16
17
17
18
19
20
20
21
21
SECTION 5 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Front Panel Controls (See Section 5-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Description Of Standard Controls (See Section 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Example Of Remote Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
22
23
24
SECTION 6 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. 120 Volt GFCI Duplex Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Optional 230 Volt South African Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Optional 5 kVA/kW Power Plant Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Connecting Auxiliary Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
25
25
26
27
SECTION 7 − OPERATING OPTIONAL BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Jump Start/Battery Charge Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Jump Start/Battery Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Determining Battery Charging Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Battery Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Jump Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
29
29
30
31
(Continued)
TABLE OF CONTENTS
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Adjusting Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Checking And Replacing Engine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
32
34
35
36
36
37
38
39
39
40
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
50
51
52
SECTION 11 − AIR COMPRESSOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters . . . . . . . . . . . . . . . . . . . . . . .
11-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic
Equipment At 70-90 P.S.I.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
53
SECTION 12 − AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
SECTION 13 − SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . .
13-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding . . . . . . . . . . . . . . . .
13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . .
62
62
63
63
SECTION 14 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
64
64
65
SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
OPTIONS AND ACCESSORIES
WARRANTY
54
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_11/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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 only
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.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
ARC RAYS can burn eyes and skin.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-478 Page 1
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
HOT PARTS can cause severe burns.
Allow cooling period before maintaining.
Wear protective gloves and clothing when
working on a hot engine.
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
CYLINDERS can explode if damaged.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
Do not overfill tank − allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
OM-478 Page 2
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
MOVING PARTS can cause injury.
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
BATTERY ACID can BURN SKIN and
EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
ENGINE EXHAUST GASES can kill.
Use equipment outside in open, well-ventilated
areas.
If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
ENGINE HEAT can cause fire.
BATTERY EXPLOSION can BLIND.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas − see applicable codes.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
FLYING SPARKS can cause injury.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
READ INSTRUCTIONS.
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
OM-478 Page 3
H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-5. Principal Safety Standards
Safety 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 29 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, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
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
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-478 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom _nd_fre 11/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-5. Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des composants.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact avec
le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la
terre présentent un danger.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec
la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens isolants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que
le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre
du sectionneur ou que la fiche du cordon est raccordée à une prise
correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endommagé ou dénudé − remplacer le cordon immédiatement s’il est
endommagé − un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (laine ou cuir) et une protection des pieds.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant
dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des
blessures ou des accidents mortels. S’assurer que l’air de respiration ne
présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
OM-478 Page 5
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Prévoir une période de refroidissement avant d’effectuer des travaux d’entretien.
Porter des gants et des vêtements de protection pour
travailler sur un moteur chaud.
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec
précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords convenables pour cette application spécifique; les maintenir ainsi
que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
OM-478 Page 6
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Toujours vérifier le niveau de liquide de refroidissement dans le vase
d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme
suivant :
Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas approcher les mains des ventilateurs, courroies et autres pièces en mouvement.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux
d’entretien et de dépannage.
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes mobiles.
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes à la fin des travaux d’entretien et avant de faire démarrer le
moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention
sur le générateur.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
LES GAZ D’ÈCHAPPEMENT DU
MOTEUR peuvent provoquer des
accidents mortels.
Utiliser l’équipement à l’extérieur dans des zones ouvertes et bien ventilées.
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappement du moteur vers l’extérieur à distance des entrées d’air dans les bâtiments.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé −
voir codes en vigueur.
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Porter un écran facial pour protéger le visage et les
yeux.
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
Les étincelles risquent de causer un incendie − éloigner toute substance
inflammable.
LE SURCHAUFFEMENT peut endommager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES
CHARGES
ÉLECTROSTATIQUES
peuvent
endommager les circuits imprimés.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
Utiliser seulement les pièces de rechange d’origine.
Effecteur la maintenance et la mise en service
d’après le manuel et celui du moteur.
OM-478 Page 7
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio−navigation et de communication, les
services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
1-5. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-478 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci−dessus.
SECTION 2 − DEFINITIONS
2-1. Symbols And Definitions
Stop Engine
Fast (Run, Weld/
Power)
Slow (Idle)
Start Engine
Check engine belt
Check Air Cleaner
Ether Starting Aid
Engine
Battery (Engine)
Jump start/Battery
Charge
Battery Charge
Jump Start
Do Not Switch
Under Load
Read Operator’s
Manual
Certified/Trained
Mechanic
Engine Oil
Check Injectors/
Pump
Check Valve
Clearance
Fuel
Engine Coolant
Temperature
Hourmeter (HM)
Air Pressure
Temperature
Circulating
Compressor
Positive
Negative
Wire Feed
Welding Arc
Volts
Panel/Local
On
Direct Current
(DC)
Alternating
Current (AC)
Output
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
Constant Voltage
(CV)
Single Phase
Air Carbon Arc
Cutting (CAC-A)
Protective Earth
(Ground)
DC Electrode Positive
DC Electrode
Negative
Work Connection
Electrode
Connection
Circuit Breaker
Time
OPT
A
3
V
Amperes
Three Phase
1
h
Hours
14
s
Remote
Seconds
OM-478 Page 9
SECTION 3 − SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Welding
Mode
Weld
Output
Range
Rated
Welding
Output
Maximum
Open-Circuit
Voltage
(Nominal)
CC/DC
50 − 500 A
400 A,
36 Volts DC,
100% Duty
Cycle
95 (88)
45 − 350 A
300 A,
32 Volts AC,
100% Duty
Cycle
80 (65)
14 − 38 V
400 A,
36 Volts DC,
100% Duty
Cycle
55 (52)
CC/AC
CV/DC
Generator
Power
Rating
Single-Phase,
3 kVA/kW,
25 A,
120 V AC,
60 Hz
5 kVA/kW
AC Power
Plant
(Optional)
15 kVA/kW
AC Power
Plant
Single Phase,
10 kVA/kW ,
42 A,
120/240
/
V AC,
C
60 Hz;
Three-Phase,
5 kVA/kW,
12 A,
240 V AC,
60 Hz
Three-Phase,
15 kVA/kW,
36 A,
240 V AC,
60 Hz
Engine
Fuel
Tank
Capacity
Deutz
F4L-912
Air-Cooled,
Four-Cylinder
40 HP Diesel
Engine
15 gal
(57 L)
3-2. Air Compressor Specifications
Effective Working
Pressure
Air Tank
Capacity
Tank Pressure
Rating
Safety Relief Valve Rating
Air Control Governor Setting
40 SCFM (1.1 SCMM),
90 psig (620 kPa),
100% Duty Cycle
21 gal (79L)
150 psig (1034 kPa)
140 psig (965 kPa)
Cut-in pressure: 105 psig (724 kPa);
Cut-out pressure: 125 psig (862 kPa)
3-3. Dimensions, Weights, And Operating Angles
Dimensions
Height
58 (1473 mm)
Width
32 (813 mm)
Depth
68 in (1727 mm)
A
1-1/16 in (27 mm)
B
29-7/8 in (759 mm)
C
6-1/8 in (156 mm)
D
9-3/4 in (248 mm)
E
13-3/4 in (349 mm)
F
28-3/16 in (716 mm)
G
36 in (914 mm)
H
46-1/2 in (1181 mm)
J
50-1/2 in (1283 mm)
K
62-3/8 in (1584 mm)
L
21/32 in (17 mm) Dia.
16 Holes
Engine End
C
F
A
B
D
Do nott exceed
d tilt angles
l or engine
i
could be damaged or unit could tip.
E D
Do not move or operate unit where it
could tip.
G
H
J
K
17 5°
17.5
20°
20°
L
Weight
2250 lb (1021 kg)
OM-478 Page 10
ST-153 650
15°
3-4. Fuel Consumption
U.S. GAL/HR.
IMP. GAL/HR.
LITERS/HR.
The curve shows typical fuel use
under weld or generator power
loads.
7.57
1.67
2.00
6.81
1.50
1.80
6.06
1.33
1.60
5.30
1.17
1.40
4.54
1.00
1.20
3.79
0.83
1.00
3.03
0.67
0.80
2.27
0.50
0.60
1.51
0.33
0.40
0.76
0.17
0.20
0.00
0.00
0.00
28 CFM @ 90 PSI
AIR DELIVERY
W/O AIR
DELIVERY
1800 R.P.M.
(NO LOAD)
IDLE
1150 R.P.M.
0
50
100
150
200
250
300
350
400
450
500
DC WELD AMPERES AT 100% DUTY CYCLE
ST-188 312
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
100% Duty Cycle At 400 Amperes
Exceeding duty cycle can
damage unit and void
warranty.
WELD AMPERES
Continuous Welding
800
700
600
500
W/O AIR DELIVERY
400
W/28 CFM @ 90 PSI
CONSTANT AIR DELIVERY
300
250
200
10
15
20
25 30
40 50 60
% DUTY CYCLE
80
100
ST-188 311
OM-478 Page 11
3-6. Air Compressor Output Curve
The air output curve shows the volume and pressure of air available
from the air compressor.
110
100
90
80
S.C.F.M.
70
60
50
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
110
120
130
P.S.I.G.
SB-121 490-A
3-7. AC Generator Power
AC VOLTS
The ac power curve shows the generator power in amperes available
at the 120 and 240 volt receptacles.
150
300
125
250
100
200
75
150
50
100
25
50
0
0
3 KW
0
5
10
15
20
25
40
50
AC AMPERES IN 240V MODE
0
10
20
30
AC AMPERES IN 120V MODE
ST-109 365-C
OM-478 Page 12
3-8. Volt-Ampere Curves
A. For AC Mode
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
B. For Constant Current (CC) DC Mode
C. For Constant Voltage (CV) DC Mode
ST-188 211 / ST-188 212 / ST-188 220
OM-478 Page 13
3-9. AC Power Plant Curves
The ac power curves show the generator power in amperes available
at the single-phase 120/240 volt or
three-phase 240 volt terminals.
A. 10 KVA/KW Single-Phase AC Power Plant (No Weld Load)
260
250
240
AC VOLTS
230
220
210
200
190
180
0
10
20
30
40
50
60
70
80
90
100
AC AMPERES
B. 15 KVA/KW Three-Phase AC Power Plant (No Weld Load)
260
250
240
AC VOLTS
230
220
210
200
190
180
0
10
20
30
40
50
60
70
80
90
100
AC AMPERES
ST-188 214 / ST-188 213
OM-478 Page 14
3-10. Optional Battery Charging Output Curve
The battery charging curves show
the charging amperage and voltage
output of the welding generator.
As battery voltage nears the charging voltage, charging current decreases.
50
40
DC VOLTS
30
MAX
20
MIN
10
0
0
100
200
300
400
500
600
700
DC AMPERES
ST-188 221
OM-478 Page 15
SECTION 4 − INSTALLATION
4-1. Installing Welding Generator
Movement
Airflow Clearance
Location
18 in
(460 mm)
Do Not Lift Unit From End
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Always securely fasten
welding generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes.
Grounding
3
1
4
GND/PE
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
OR
2
1
2
3
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
2
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
If unit does not have GFCI receptacles,
use
GFCIprotected extension cord.
install1 10/00 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
4-2. Connecting The Battery
Connect Negative (−)
Cable Last.
+
−
Tools Needed:
1/2 in
ST-153 654-B / Ref. ST-184 780-C / Ref. S-0756-B
OM-478 Page 16
4-3. Installing Precleaners, Exhaust Pipe, And Rain Cap
Stop engine and let cool.
2
3
Do not blow exhaust toward
air cleaner or air intake.
5
Remove rear, left side panel.
1
1
Air Cleaner
2
Precleaner
Remove tape from air cleaner
openings. Install precleaners on air
cleaners.
3
Exhaust Pipe
4
Muffler Extension
Remove tape from extension. Install exhaust pipe over extension.
Secure exhaust pipe to top cover
using supplied hardware.
4
5
Tools Needed:
1/2 in
Rain Cap
Install cap so it opens toward front
of unit.
ST-153 652
4-4. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface.
Follow run-in procedure in engine
manual. If unburned fuel and oil collect
in exhaust pipe during run-in, see
Section 10.
Fuel
Add fresh fuel before starting engine
the first time (see maintenance label
for specifications). Fill fuel tank up to
1/2 in. (13 mm) from top to allow room
for expansion. Check fuel level on a
cold engine before use each day.
Do not run out of fuel or air enters fuel
system and causes starting problems.
See engine manual to bleed air from
fuel system.
Oil
After fueling, check oil with unit on level
surface. If oil is not up to full mark on
dipstick, add oil (see maintenance label). Unit stops if oil pressure is too low
or oil temperature is too high.
Full
1/2 in
(13 mm)
Full
This unit has a low oil pressure
shutdown switch. However, some
conditions may cause engine
damage before the engine shuts
down. Check oil level often and do
not use the oil pressure shutdown
system to monitor oil level.
To improve cold weather starting:
Keep battery in good condition.
Store battery in warm area off concrete surface.
Diesel
Tools Needed:
3/8 in
Use fuel formulated for cold
weather (diesel fuel can gel in cold
weather). Contact local fuel supplier for fuel information.
Use correct grade oil for cold
weather (see engine manual).
Ref. ST-153 653-A
OM-478 Page 17
4-5. Connecting To Weld Output Terminals
Tools Needed:
3/8, 3/4 in
Location of Terminals
1
Access Door
2
Work Weld Output Terminal
3
Electrode Weld Output Terminal
4
Torch Cable Adapter
Adapter connects power and water to
torch and cooling system or drain.
2
1
3
Use only a proper torch cable
adapter positioned so it does
not hit frame, hardware, or
door during operation.
Connect cables as shown.
Close and secure access door.
SMAW Connections
GTAW Connections
3
3
2
4
Gas Or
Water Hose
OR
2
Work
Work
Ref. ST-121 578-D / Ref. ST-184 781-A / ST-800 578-F
OM-478 Page 18
4-6. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Weld Output
Terminals
Stop engine before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
2 ea. 4/0
(2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 3/0
(3x95)
600
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
3 ea. 4/0
(3x120)
3 ea. 4/0
(3x120)
Do not use worn, damaged, undersized, or
poorly spliced cables.
10 − 100% Duty Cycle
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
S-0007-E−
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
Notes
OM-478 Page 19
4-7. Installing Ether Cylinder (Optional Ether Starting Aid)
Stop engine.
Improper handling or exposure to ether can harm your
health. Follow manufacturer’s safety instructions on
cylinder.
1
Do not use Ether Starting Aid
while engine is running.
Open side door(s).
2
1
Ether Cylinder
2
Nozzle
Remove cover and clean cylinder
nozzle.
3
4
3
Clamp
4
Fitting
5
Cap
6
Valve
Remove cap and clean fitting.
Install cylinder on fitting. Tighten
clamp.
5
After installing cylinder, wait at
6
least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
Put cap on fitting when cylinder is
removed.
ether1 7/96 − ST-153 382-A / ST-180 933
4-8. Remote 14 Receptacle RC3 Information
Socket*
A
B
K
J
I
H
C L N
D M
G
E F
Socket Information
A
24 volts ac. Protected by circuit
breaker CB4.
B
Contact closure to A completes 24
volts ac contactor control circuit.
I
115 volts ac. Protected by circuit
breaker CB3.
J
Contact closure to I completes 115
volts ac contactor control circuit.
G
Circuit common for 24 and 115
volts ac circuits.
C
0 to +10 volts dc output to remote
control from min to max of Amperage/Voltage control R1.
D
Remote control circuit common.
E
0 to +10 volts dc input command
signal from remote control.
K
Chassis common.
OR
A/V
Ref. ST-800 729-A
*The remaining sockets are not used.
OM-478 Page 20
4-9. Terminal Strip 3T Connections
Stop engine.
If remote control plug does not fit in
receptacle RC3, wire cord directly
to terminal strip 3T.
Do not connect to Remote 14
receptacle RC3 and terminal
strip 3T at the same time. Use
only one remote control
method.
1
Open lower front door.
1
Terminal Strip 3T
Connect leads to 3T using terminal
information shown in Section 4-8.
Reinstall cover. Close door.
Tools Needed:
Ref. ST-121 578-F / Ref. S-184 781-A
4-10. Air Compressor Connections
Air compressor operates whenever
engine is running.
1
Open Position
1/2 in NPT Air Compressor
Fitting
Connect quick-disconnect air hose
to fitting (hose not supplied).
2
1
2
Air Shutoff Valve
Be sure valve is in open position
when using air compressor.
Closed Position
ST-800 727 / Ref. ST-121 578-F
OM-478 Page 21
SECTION 5 − OPERATING THE WELDING GENERATOR
5-1. Front Panel Controls (See Section 5-2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
23
22
21
20
19
18
17
24
ST-184 780-C / Ref. ST-121 578-F
OM-478 Page 22
5-2. Description Of Standard Controls (See Section 5-1)
This unit has a max OCV control circuit
that resets the Amperage/Voltage Control to maximum when the arc breaks.
When an arc is struck, weld output control returns to the front panel or remote
control setting. The Amperage/voltage
Control adjusts amperage only when
welding and does not adjust open-circuit
voltage (see item 24, Max OCV On/Off
switch).
1 Voltmeter
2 Ammeter
3 Ampere Range Switch
Do not switch under load.
Use switch to select one of five ampere
ranges. Use the lower four ranges for CC
welding and the highest range for CV/DC
welding. In each CC range, the upper number
is for CC/DC and the lower number is for CC/
AC. For most welding applications, use the
lowest amperage range possible to help prevent arc outages.
4 Amperage/Voltage Control
Control adjusts amperage within range selected by Ampere Range switch. Weld output
would be 235 A DC with controls set as shown
(50% of 140 to 330 A).
5 Ether Starting Aid Switch
(Optional)
Do not use Ether if engine is running.
Push switch up and release while cranking
engine to release ether.
6 Check Battery Light (Optional)
Stop engine and check battery if light goes on
while charging.
7 Battery Charge/Jump Start Selector
Switch (Optional)
Use switch to select battery jump start or
charging output (see Section 7).
8 Battery Charge Voltage Selector Switch
(Optional)
Place switch in position matching voltage of
battery being charged or jump started (see
Section 7).
9 Amperage/Voltage Control Switch
Use switch to select front panel or remote amperage control (see Section 5-3).
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position and connect remote control
to Remote 14 receptacle or terminal strip 3T
(see Sections 4-8 and 4-9).
10 CC/CV Selector Switch
Use switch to select type of weld output. Use
CC for Stick (SMAW) welding and Air Carbon
Arc Cutting. Use CV for wire feed processes
(MIG, FCAW). If using CV, place Ampere
Range switch in maximum position. To ensure wire feeder reliability and improve
arc starting, unit does not run at idle speed
when operated in CV mode.
Place CC/CV switch in CC position when
using generator power plant.
11 Output (Contactor) Switch
Use switch to control remote contactor connected to receptacle RC3 or terminal strip 3T
(see Sections 4-8 and 4-9).
12 Service Engine Air Cleaner Light
Service engine air cleaner if light goes on (see
Section 8-2).
13 Engine Control Switch
Use switch to start engine, select engine
speed, and stop engine.
In Run position, engine runs at weld/power
speed. In Run/Idle position, engine runs at
idle speed at no load and weld speed with load
applied. Turn to run position if using ac power
plant. Unit does not run at idle speed when operated in CV mode.
To Start: turn Engine Control switch to Start
position. Release switch when engine starts.
If the engine does not start, let engine
come to a complete stop before attempting restart.
To Stop: turn Engine Control switch to Off
position.
14 Check Engine Belt Light
Light goes on and engine stops if engine alternator is not working. Check engine belt (see
Section 8-8).
15 Service Compressor Air Cleaner Light
Service compressor air cleaner if light goes
on (see Section 8-2).
16 Fuel Gauge
17 Air Tank Moisture Drain Control
Before starting engine each day, pull control
out to drain moisture from air tank.
Push control in to close valve before
operating unit.
18 Battery Ampere Gauge
Use gauge to check amperage output to the
battery. The gauge reads near 0 (zero) when
the engine is running. If gauge is at a negative
number, the battery is discharging. Stop engine, and do not run until problem is fixed.
19 Air Pressure Gauge
Use gauge to check pressure in air storage
tank.
20 Oil Pressure Gauge/Switch
Use gauge/switch to check oil pressure. Normal operating pressure is about 50 psi (345
kPa). Engine stops if oil pressure is below 22
psi (152 kPa).
21 Engine Hour Meter
22 Oil Temperature Gauge/Switch
Use gauge/switch to check oil temperature.
Normal operating temperature is about 225°F
(107° C). Engine stops if oil temperature exceeds 265° F (129° C).
23 Output Selector Switch
Do not switch under load.
Use switch to select polarity of weld output.
For Direct Current Electrode Negative
(DCEN), use Electrode Negative position.
For Direct Current Electrode Positive
(DCEP), use Electrode Positive position. For
alternating current (AC), use AC position.
Use Jump Start/Battery Charge position to
turn on output at Jump Start/Battery Charge
receptacle (see Section 7).
24 Max OCV On/Off Switch
Use switch to disable max OCV control circuit. Place switch in On position for most
welding processes (see max OCV note at beginning of this section).
If max OCV switch is in Off position, turn
Amperage/Voltage control to max for full
output from optional ac power plant.
OM-478 Page 23
5-3. Example Of Remote Amperage Control
In Example:
Min = 90 A DC/CC
Percentage of Range = 50 %
Max = 140 A DC/CC
(50% of 90 to 190)
Set Switches
Set Polarity
Set Range
Set Percentage
Min (90 A DC/CC)
2
Max (140 A DC/CC)
Adjust Remote Control
Ref. ST-184 780-C
OM-478 Page 24
SECTION 6 − OPERATING AUXILIARY EQUIPMENT
6-1. 120 Volt GFCI Duplex Receptacles
1
1
120 V 20 A AC GFCI
Receptacle GFCI1
2
120 V 20 A AC GFCI
Receptacle GFCI2
Receptacles supply 60 Hz singlephase power at weld/power speed.
2
3
Circuit Breaker CB1
4
Circuit Breaker CB2
CB1 protects GFCI1 and CB2 protects GFCI2 from overload. If CB1
or CB2 opens, the receptacle does
not work.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
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 to reset receptacle and resume
operation.
At least once a month, run en-
gine at weld/power speed and
press Test button to verify
GFCI is working properly.
5
3
Total Generator Power Output
Maximum output from each duplex
receptacle is 1.8 kVA/kW, and 3
kVA/kW from all receptacles. Generator power is not affected by weld
output.
4
EXAMPLE: If 15 A is drawn from
GFCI1, only 10 A is available at
GFCI2:
(120 V x 15 A) + (120 V x 10 A) = 3.0
kVA/kW
Ref. ST-184 781-A
6-2. Optional 230 Volt South African Receptacle
1
240V 13A
60 Hz
1
230 V 16 A AC Receptacle
RC1
RC1 supplies 60 Hz single-phase
power at weld/power speed. Maximum output from receptacle is 3
kVA/kW. Generator power is not affected by weld output.
2
Circuit Breaker CB1
CB1 protects RC1 from overload. If
the circuit breaker opens, the receptacle does not work. Press button to reset breaker.
If circuit breaker continues to
2
open, contact Factory Authorized Service Agent.
Ref. ST-182 096-A
OM-478 Page 25
6-3. Optional 5 kVA/kW Power Plant Receptacles
Single-Phase Power Receptacles
1
2
120V
1
240 V 13 A AC Duplex
Receptacle RC1
2
120 V 20 A AC GFCI
Receptacle GFCI2
RC1 and GFCI2 supply 60 Hz single-phase power at weld/power
speed.
AC
3
Circuit Breaker CB1 And CB2
15A
CB1 and CB2 protect RC1 from
overload. CB2 also protects GFCI2
from overload. If CB1 or CB2 open,
the respective receptacle(s) does
not work. Press button to reset
breaker.
If a circuit breaker continues to
open, contact Factory Authorized Service Agent.
4
15A
Total Generator Power Output
Combined output of RC1 and
GFCI2 is limited to 3 kVA/kW output
of the generator.
EXAMPLE: If 10 A is drawn from
GFCI2, only 7.5 A is available at
RC1:
4
(120 V x 10 A) + (240 V x 7.5 A) =
3.0 kVA/kW
5
3
240 Volts AC Three-Phase
Power Receptacle RC4
RC4 supplies 240 V, 12 A, 60 Hz
three-phase power at weld/power
speed. Maximum output from RC4
is 5 kVA/kW.
Three-Phase Power Receptacle
6
6
Circuit Breaker CB5
CB5 protects RC4 from overload. If
CB5 opens, the receptacle does
not work. Press button to reset
breaker.
5
240 VOLTS AC
THREE PHASE POWER
031 826
Tools Needed:
3/8 in
Ref. ST-150 972 / Ref. ST-174 757
OM-478 Page 26
6-4. Connecting AC Power Plant
Stop engine.
Power and weld outputs are
live at the same time. Disconnect or insulate unused
cables.
Have qualified person install
according to circuit diagram and
Section 12 − Generator Power
Guidelines.
Place
CC/CV switch in CC
position when using ac power
plant.
Remove junction box cover.
11
10
1
2
F3
240V
3
240V
240V
120V
1
120V
3
Lead 93
2
Lead 92
3
Lead 91
4
Lead 90 (Neutral)
5
Lead 42 (Circuit Grounding
Lead)
Lead 42 connects to front panel
Ground stud.
F2
F1
1
240V
6
Isolated Neutral Terminal
7
Jumper Lead 42
8
Grounding Terminal
Jumper 42 is connected to lead 90
at factory. Jumper 42 may be disconnected from neutral to meet
applicable electrical codes.
9
4
User-Supplied Leads
10 Load Terminals
8
5
Connect leads to terminals.
7
6
11 Fuses F1, F2, And F3
9
F1, F2, and F3 protect each load line
from overload.
Set
Engine Control switch to
Run when using generator
power.
If max OCV switch is in Off posi-
tion (see Section 5-1), turn Amperage/Voltage control to max
for full output from optional ac
power plant.
Volts
Single
Phase
1
120/240
Three
Phase
3
240
Amps
42
36
KVA/KW
10
15
AC
Output
Frequency
Engine Speed
60 Hz
1850 RPM
Max. Fuse Size
45 Amperes
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
93
91
90
92
Generator Windings
(See Section 9 For
Complete Circuit)
Tools Needed:
Ref. S-160 620C
OM-478 Page 27
SECTION 7 − OPERATING OPTIONAL BATTERY CHARGER
NOTE
Follow jump starting procedure to quickly start equipment having a weak or dead
battery. Follow charging procedure to trickle-charge a battery.
7-1. Jump Start/Battery Charge Cable Connections
Stop engine.
Do not charge or jump start a
battery which has loose terminals or one showing damage such as a cracked case
or cover.
Have only qualified persons
do battery charging work.
Keep cables away from
moving parts.
Do not use damaged cables.
Read supplied BCI Battery
Service
Manual
before
charging or jump starting.
6
5
1
2
1
Jump Start/Battery Charge
Plug
2
Red (+) Cable
3
Black (−) Cable
Obtain
cable
connectors.
4
with
proper
Remote Momentary-On
Switch And Plug
Remote switch is used only for
jump starting a battery. Press
switch to turn jump starting output
on. Release switch to turn output
off.
3
Open lower access door. Route
cable as shown. Insert plug into
Remote 14 receptacle, and tighten
threaded collar. Close door.
4
Tools Needed:
3/8 in
OM-478 Page 28
5
Cover
6
Jump Start/Battery Charge
Receptacle
Remove cover, and insert plug in
receptacle. Connect remaining end
of cable to equipment being jumpstarted or charged. Use correct
polarity (+ and −) when making connections.
ST-153 653-A
7-2. Jump Start/Battery Charge Controls
1
Output Selector Switch
Do not switch under load.
1
2
Use switch to select weld or battery
charge/jump start output. Output
automatically stops when terminal
voltage is 15 to 25 percent above
required battery voltage. Move
switch to weld position when done
charging/jump starting.
2
4
3
Battery Voltage Selector
Switch
Place switch in position matching
voltage of battery being jump
started or charged.
3
Battery Charge/Jump Start
Selector Switch
Use switch to select battery jump
start or charging output.
4
Battery Light
If light comes on while charging or
jump starting, stop the engine and
check the following:
a.
Polarity of connections (+
and −)
b.
Battery Voltage switch
position
c.
Output Selector switch
position
d.
Battery voltage.
Ref. ST-184 780-C
7-3. Determining Battery Charging Current
1
1
Battery Charging Chart Chart
Find battery cold crank amp (CCA)
rating on battery. Use CCA rating
on chart to find charge current setting for battery.
EXAMPLE: If battery CCA rating is
500, charging current from chart is
100 amperes.
Do not exceed charging current
found on chart. For longer battery
life, use lowest charge rate
possible.
S-115 587-A
OM-478 Page 29
7-4. Battery Charging Procedure
In Example:
Battery Voltage = 12 Volts
Battery CCA Rating = 500
Charge Current = 100 A (See Section 7-3)
Ampere Range Setting = 90 to 190 A
A/V Control Setting = 10
Stop Engine.
Set Battery Voltage Switch.
Set Charge/Jump Start
Switch To Charge.
Set Amperage/Voltage
Switch To Panel And Output (Contactor) Switch To
Remote. Turn Off
Remote Devices.
Determine Charge Current From
Battery CCA Rating And Chart
(See Section 7-3).
Set Output Selector Switch To Charge.
Do not switch under load.
Set Amperage.
Do not switch Ampere Ranges
while under load.
−
+
Connect Cables
(Observe Correct
Polarity).
Set Output (Contactor)
Switch To On Or Turn On
Remote Device.
Start Engine.
If Battery Light Goes On,
Stop Engine And Check
Battery Condition.
If Battery Light Goes On,
Stop Engine And Check
Connections.
Charge 10 minutes. Check Battery Voltage. Continue charging
if necessary.
Ref. ST-184 780-C / S-115 587-B
OM-478 Page 30
7-5. Jump Starting Procedure
Charge battery for 10 minutes
before jump starting battery
(see Section 7-4).
Charge Battery For 10
MInutes (See Section 7-4).
Set Output (Contactor)
Switch to Remote. Turn
Off Remote Device.
Set Charge/Jump Start
Switch To Jump Start.
Press switch only
while cranking engine of equipment
being started.
Set A/V control to max (100) and Ampere
Range switch to CV position.
Do not switch Ampere Ranges
while under load.
Press Remote Momentary On Switch
While Cranking Engine Of Equipment Being Jump Started. Release Switch When
Equipment Starts. Stop Welding Generator
And Disconnect Cables.
Ref. ST-184 780-C
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
NOTE
The air compressor normally requires service every 1200 hours of operation if
used regularly and operated in a clean, dry environment. The compressor will
require service more often if used infrequently or operated in dirty, humid
conditions.
To help minimize air compressor maintenance, use sufficient quantities of air to
allow compressor to cycle for a minimum of one hour per week.
Follow the storage procedure in the engine owner’s manual if the unit will not be
used for an extended period.
OM-478 Page 31
8-1. Routine Maintenance
Stop engine before maintaining.
See also Engine Manual and MainteRecycle
engine
fluids.
nance Label. Service engine more often
if used in severe conditions.
*
To be done by Factory Authorized
Service Agent.
8h
Wipe
Up
Spills.
FUEL
WATER
Check Fluid
Levels. See
Section 4-4.
OIL
Full
Drain Water
From Air
Tank. See
Section 5-1
Drain Water
From Fuel
System.
50 h
Clean And
Tighten
Weld
Terminals.
Clean Air Filters.
See Section 8-2.
100 h
Change Oil. See
Section 8-4.
Change Oil
Filter. See
Section 8-4.
Check
air
cleaner hoses
for cracks and
loose clamps.
Clean And
Tighten
Battery
Connections.
200 h
Replace
Unreadable
Labels.
250 h
Check And
Clean Spark
Arrestor. See
Section 8-9.
500 h
Repair Or
Replace
Cracked
Cables.
OM-478 Page 32
1000 h
FUEL
SLUDGE
Change Fuel
Filters. See
Section 8-4.
OR
1/2 in.
(13 mm)
Blow Out Or
Vacuum Inside.
During Heavy
Service,
Clean Monthly.
Drain Sludge
From Fuel
Tank. See
Section 8-4.
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
Check
Valve
Clearance.*
Check Belt
Tension. See
Section 8-8.
1200 h
Service Air
Compressor.*
3000 h
Clean/Set
Injectors.*
OM-478 Page 33
8-2. Servicing Air Cleaner
Stop engine.
1
2
3
Do not run engine without air
cleaner or with dirty element. Engine damage caused by using a
damaged element is not covered
by the warranty.
4
The air cleaner primary element can
be cleaned but the dirt holding capacity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while cleaning and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary
element.
Optional
5
If you decide to clean the primary element, we strongly recommend installing an optional safety element to provide additional engine protection.
Never clean a safety element. Replace the safety element after servicing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
2
Housing
3
Safety Element (Optional)
4
Primary Element
5
Dust Cap
6
Dust Ejector
To clean air filter:
Blow
Inspect
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary element if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-478 Page 34
Air Filter Service . . . . . . . 50 hours or less − see Owner’s Manual
Air Filter Element . . . . . . MILLER 020 319, Donaldson P181052, Fram CAK 253
See Engine Manual for complete engine care.
Give Engine Specification and Serial Number when ordering parts.
Diesel
−20
40
20W/20
−10
+
Cranking Performance at 0°F
(-18°C) . . . . . . . . 815 Amps
Valve Clearance −Cold
Intake . . . . . . . 0.006 in (0.15 mm)
Exhaust . . . . . 0.006 in (0.15 mm)
Engine Cooling
Engine RPM − No Load
Weld/Power . . . . 1850
10W
0
15W/40
10
15W/30
30
20
10W/40
77
68
59
50
41
32
23
14
5
−4
−13
−22
−31
−40
Battery . . . . . . . . BCI Group 31
30 °C
10W/30
Recommended Oil . . . . API Service Classification
CD/CE (or better)
Oil And Filter Change . .
dirty conditions . . . . . 100 hours or less
normal conditions . . . 125 to 150 hours
Oil Filter . . . . . . . . . . . . . Deutz 117-4418,
Fleetguard LF4056,
Fram PH2842,
Hastings P352 or FP352,
MILLER 064 677
Oil Capacity . . . . . . . . . . 11.5 qt (11 L) or 12 qt
(11.4 L) with filter change
°F 86
5W/30 (Synthetic)
Check
daily.
Avoid recirculation of air from hot air
exit to blower intake.
Blower Belt . . Deutz 223-5256,
Gates 7580
−30
−40
*
*Only with engine
oil preheating
Fuel Capacity . . . . . . . . . 19 gal (72.8 L)
Fuel Grade . . . . . . . . . . . 1-D or 2-D Cetane No. 45 min.
Primary Fuel Filter/
Water Separator . . . . . . . MILLER 062 342, Fram P1107
Secondary Fuel Filter . . . MILLER 064 686, Deutz 117-4423, Fram P4102
Fill filter with clean fuel before installing − read instructions on filter.
*
Have only trained technician maintain injection pump and injectors. AIR, WATER, or
GASOLINE will harm the injection system. If engine has run out of fuel or fuel filter is
changed, bleeding of air may be required. Check engine manual for proper
procedure.
Injectors should be checked annually.
Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours −
see Owner’s Manual
S-120 629-G
8-3. Maintenance Label
DEUTZ F4L912 DIESEL ENGINE
OM-478 Page 35
8-4. Servicing Engine Fuel And Lubrication Systems
Stop engine.
1
Fuel Filter
See engine manual for fuel filter replacement procedure.
2
Oil Filter
3
Oil Drain
See engine manual for oil change
procedure.
4
Fuel/Water Separator
5
Petcock
To drain water from fuel system, put
metal container under petcock and
open petcock. Close petcock when
fuel appears.
1
2
6
4
Sludge Drain Plug
To drain sludge, put metal container
under drain, and remove plug. Reinstall plug when done.
Close side door.
5
3
Tools Needed:
6
7/16 in
Ref. ST-153 653-A / Ref. ST-184 780-C
8-5. Adjusting Air Pressure
Governor cut-in pressure is 105 psi
(724 kPa) and cut-out pressure is
125 psi (862 kPa).
Cut-in
and cut-out pressure
values are ± 5 psi (34 kPa).
Check pressure using air pressure
gauge on front panel. If necessary,
adjust cut-out pressure as follows:
2
4
3
1
1
Governor
2
Rubber Boot
3
Jam Nut
4
Screw
Remove boot and loosen nut. Turn
screw clockwise (increase pressure) or counterclockwise (decrease) until cut-out pressure is
125 psi (862 kPa).
Tighten nut and replace boot.
Tools Needed:
Ref. ST-153 653-A / Ref. ST-801 325-A / Ref. ST-184 780-C
OM-478 Page 36
8-6. Adjusting Engine Speed
Stop engine.
Engine speeds have been factory
set and should not require adjustment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load
speeds. If necessary, adjust
speeds as follows:
Engine Speed
(No Load)
1850 rpm
(61.6 Hz)
Idle Speed Adjustment
1250 rpm
(41.6 Hz)
1
Throttle Solenoid
2
Adjustment Rod
3
Throttle Rod
Disconnect throttle
adjustment rod.
4
rod
from
Locknut
Loosen locknuts.
Start engine, and place Engine
Control switch in Run/Idle position.
5
Throttle Lever
Push lever forward until engine
runs at idle speed. While holding lever in the idle position, reconnect
throttle rod to adjustment rod. Tighten locknuts.
Weld/Power Speed Adjustment
Place Engine Control switch in Run
position.
6
Protective Cap
7
Locknut
Remove cap and loosen locknut.
8
Injection Pump Adjustment
Rod
Turn rod until engine runs at weld/
power speed. Tighten locknut.
Stop engine.
4
8
7
Reinstall protective cap.
Close side door.
1
2
3
5
6
Tools Needed:
3/8, 7/16 in
Ref. ST-121 577-B / Ref. ST-153 653-A / Ref. ST-184 780-C
OM-478 Page 37
8-7. Overload Protection
Stop engine.
If
a circuit breaker or fuse
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
1
1
Circuit Breaker CB3
CB3 protects the 115 volts ac output to Remote 14 receptacle RC3 or
terminal strip 3T. If CB3 opens, the
115 volts ac output stops.
2
Circuit Breaker CB4
CB4 protects the 24 volts ac output
to Remote 14 receptacle RC3 or
terminal strip 3T. If CB4 opens, the
24 volts ac stops.
2
Press button to reset breaker.
3
Fuse F11 (See Parts List)
4
Throttle Solenoid
Fuse F11 protects throttle solenoid
from overload. If F11 opens, the engine does not run at idle rpm.
3
4
Check F11 and replace if open.
Check movement of solenoid and
adjustment of weld speed throttle
link (see Section 8-6). If F11
continues to open, replace throttle
solenoid.
5
Magnetic Shutdown Switch
MS1
6
Fuse F (See Parts List)
7
Fuse F6 (See Parts List)
Remove screw to open upper front
panel access door.
5
Fuse F protects the magnetic shutdown switch MS1 from damage due
to overload. If F opens, the engine
stops. Do not run engine until
problem is corrected.
Check fuse, and replace if open.
7
Fuse F6 protects the excitation circuit from damage due to overload.
If F6 opens, there will be low/no
weld and generator power output.
6
Check fuse, and replace if open.
Tools Needed:
Ref. ST-184 780-F / Ref. ST-184 781-A / Ref. ST-153 653-A / ST-153 702-A
OM-478 Page 38
8-8. Checking And Replacing Engine Belt
Stop engine.
A V-belt drives the engine cooling
fan and alternator. To check
tightness of belt, proceed as
follows:
Remove rear panel and guard from
engine pulley.
1
1
2
3
Fan Pulley
Alternator Pulley
Engine Belt
Position straight edge along top of
pulleys. Pull down belt as far as it
will go, and measure distance from
belt to straight edge.
1/2 in (13 mm)
Maximum
2
If less than 1/2 in (13 mm), belt is
okay. If not okay, adjust belt as
follows:
4
Alternator Bracket
Loosen hex nut on bracket.
5
4
5
3
Alternator Pivot Hex Nut
Loosen hex nut. Pivot alternator
clockwise until belt is tight. Tighten
hex nuts.
Recheck tightness of belt. Readjust
if necessary.
Replace belt if damaged or
cracked. Replace belt as follows:
Loosen hex nuts, pivot alternator
counterclockwise, and remove
belt. Install new belt, pivot alternator
clockwise, adjust tightness, and
tighten hex nuts. Recheck tightness of belt after operating engine
15 minutes.
Reinstall guard and rear panel.
Tools Needed:
1/2 in, 13 mm, 17mm
Ref. ST-121 577-B / Ref. ST-184 781-A
8-9. Servicing Optional Spark Arrestor
Stop engine and let cool.
1
Spark Arrestor
2
Cleanout Plug
Remove plug and remove any dirt
covering cleanout hole.
3
3
2
1
Exhaust Pipe
Start engine, and run at idle speed
to blow dirt out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe.
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
ST-157 313-A / Ref. ST-184 781-A
OM-478 Page 39
8-10. Troubleshooting
A. Welding
Trouble
No weld output.
Remedy
Check position of Ampere Range and Output Selector switches.
Place Output/Contactor Control switch in On position, or place switch in Remote position and connect
remote contactor to optional Remote 14 receptacle RC3 or terminal strip 3T (see Sections 4-8 and 4-9).
Disconnect equipment from generator power receptacles during start-up.
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-8 and 4-9).
Reset circuit breaker CB3 and/or CB4 (see Section 8-7).
Check fuse F6, and replace if necessary (see Section 8-7).
Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1 and
PC2.
Erratic weld output.
Check and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Tighten lead connections to Ampere Range switch.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
High or low weld output.
Check engine speed, and adjust if necessary (see Section 8-6).
Check CC/CV switch position.
If low weld output, check fuse F6, and replace if necessary (see Section 8-7).
Low open-circuit voltage.
Check engine speed, and adjust if necessary (see Section 8-6).
Check CC/CV switch position.
Have Factory Authorized Service Agent check circuit boards PC1 and PC2.
Maximum weld output only in each Have Factory Authorized Service Agent check Amperage/Voltage control R1, capacitor C8, diode D8,
ampere range.
integrated rectifier SR5, control relay CR8, and CV regulator board PC2.
Wire feeder does not work.
Reset circuit breaker CB3 and/or CB4 (see Section 8-7).
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-8 and 4-9).
Repair or replace wire feeder.
No amperage control.
Place Amperage/Voltage Control switch in correct position.
Check connections to Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-8 and 4-9).
Repair or replace remote control device.
Have Factory Authorized Service Agent check controls.
No CV weld output.
Check and secure connections to optional Remote 14 receptacle RC3 or terminal strip 2T (see Section
4-8 or 4-9).
Repair or replace remote control device.
Have Factory Authorized Service Agent check CV regulator board PC2 and connector board PC30 and
connections, and replace if necessary.
Low CV weld output.
OM-478 Page 40
Set Ampere Range switch to highest range.
Min or max CV weld output only.
Check position of Amperage/voltage control and Amperage/Voltage Control switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV regulator board PC2.
Tungsten electrode oxidizing and not
remaining bright at end of weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Wandering arc − poor control of direction of arc.
Reduce gas flow rate.
Select proper size tungsten.
Properly prepare tungsten.
B. Generator Power Trouble
Trouble
No output at ac receptacles.
Remedy
Reset circuit breakers (see Section 6-1, 6-2, or 6-3).
Press GFCI reset button on GFCI receptacles (see Section 6-1).
Check fuse F6, and replace if necessary (see Section 8-7).
Have Factory Authorized Service Agent check brushes and slip rings.
High generator power output voltage.
Check engine speed, and adjust if necessary (see Section 8-6).
Low generator power output voltage.
Check fuse F6, and replace if necessary (see Section 8-7).
No or low output at single or threephase ac power plant.
Place Output(Contactor) or Amperage/Voltage switch in Panel position, or connect remote contactor
to Remote 14 receptacle or terminal strip 3T (see Sections 4-8 and 4-9).
Place CV/CC switch in CC position.
Place Output Selector switch in Electrode Positive, Electrode Negative, or AC position.
Check and replace fuse F1, F2, and/or F3 if necessary (see Section 6-4).
Check engine speed, and adjust if necessary (see Section 8-6).
Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1 and
PC2.
Check position of max OCV On/Off switch. If switch is in Off position, turn Amperage/Voltage control
to max for full output from ac power plant.
C. Engine
Trouble
Engine does not start.
Remedy
Check fuel level (see Section 4-4).
Check battery, and replace if necessary.
Check magnetic shutdown switch fuse F, and replace if necessary (see Section 8-7).
Check engine battery charging system according to engine service manual.
Engine suddenly stops.
If Check Cooling System/Alternator light is on, check engine belt.
Check engine oil level (see Section 4-4). Engine stops if oil pressure is too low or oil temperature is
too high.
Check magnetic shutdown switch fuse F, and replace if necessary (see Section 8-7).
Engine remains at idle rpm when Engine Have Factory Authorized Service Agent check continuity and connections of current transformer CT1
Control switch is in the Run or Run/ Idle and idle module.
position and a load is applied.
OM-478 Page 41
Engine remains at weld rpm when En- Check fuse F11, and replace if open (see Section 8-7).
gine Control switch is in the Run/Idle position and load is removed.
Move CC/CV switch to CC position. Unit does not run at idle speed in CV mode.
Have Factory Authorized Service Agent check continuity and connections of current transformer CT1
and idle module.
Engine does not stop when Engine
Control switch is placed in Off position.
Have Factory Authorized Service Agent check diode D9
Air compressor does not build up pressure or builds pressure slowly.
Have Factory Authorized Service Agent check air compressor.
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine.
D. Optional Battery Charging System
Trouble
Battery discharges between uses.
Remedy
Be sure Engine Control switch is in Off position when unit is not being used.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
No battery charge output; Battery light
is On.
Place Output Selector switch in Jump Start/Battery Charge position.
Check and tighten battery connections if necessary.
Battery being charged is bad. Properly dispose of battery.
No battery charge output; Battery light
is Off.
Place Output Selector switch in Jump Start/Battery Charge position.
Place Output (Contactor) switch in Remote position, and connect remote push button to Remote 14
receptacle.
E. Air Compressor
Trouble
Remedy
Air compressor fails to build pressure or Have Factory Authorized Service Agent check air compressor components.
builds pressure slowly.
Low air pressure.
Check for leaks in air lines and hoses.
Disconnect air line at air control valve, and start engine to run air compressor. If air blows out of disconnected line, check air control valve. If air does not blow out of line, have Factory Authorized Service Agent
check air compressor.
Have Factory Authorized Service Agent check compressor for rated output.
Pneumatic tools freeze up because of Install optional Turbo 2000 air dryer/filter kit (Miller part no. 043 249).
moisture in compressed air.
Induce an antifreeze solution into the air supply.
Oil in air lines.
OM-478 Page 42
Install optional Turbo 2000 air dryer/filter kit (Miller part no. 043 249).
Notes
OM-478 Page 43
SECTION 9 − ELECTRICAL DIAGRAMS
Figure 9-1. Circuit Diagram For Welding Generator
OM-478 Page 44
203 734
OM-478 Page 45
Figure 9-2. Circuit Diagram For Welding Generator With Optional Battery Charger
OM-478 Page 46
204 736
OM-478 Page 47
Figure 9-3. Circuit Diagram For Welding Generator With Optional 5 kVA/kW Auxiliary Power Plant
OM-478 Page 48
203 735
OM-478 Page 49
SECTION 10 − RUN-IN PROCEDURE
run_in1 8/01
10-1. Wetstacking
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1
2
Welding Generator
Run diesel engines near rated voltage and current during run-in period
to properly seat piston rings and
prevent wetstacking. See nameplate, rating label, or specifications
section in this manual to find rated
voltage and current.
Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generator is kept loaded during
run-in.
2
Engine Exhaust Pipe
1
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for additional engine run-in information.
OM-478 Page 50
10-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
4
2
1
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
1 Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or generator auxiliary power receptacle.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
correct
polarity.
3
Start engine and run for several
minutes.
Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generator is loaded properly.
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
4 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-478 Page 51
10-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equipment damage may occur.
2
1 Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2 Welding Generator
Place A/V range switch in maximum position, A/V control in minimum position, and Output Selector
switch (if present) in either DC
position.
3 Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connectors (polarity is not important).
4
3
5
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 voltage and current of
the generator (see nameplate, rating label, or the specifications section in this manual).
4
+
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
Check oil level frequently during run-in; add oil if needed.
After one hour (minimum), place
A/V control in minimum position,
then shut down grid to remove load.
Run engine several minutes at no
load.
Stop engine and let cool.
6 Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-478 Page 52
SECTION 11 − AIR COMPRESSOR TABLES
11-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
Gauge Pressure In
Receiver (lb)
Orifice Diameter (in) And Free Air Flow (CFM)
1/64
1/32
3/64
1/16
3/32
1/8
3/16
1/4
1
0.027
0.107
0.242
0.430
0.97
1.72
3.86
6.85
2
0.038
0.153
0.342
0.607
1.36
2.43
5.42
9.74
3
0.046
0.188
0.471
0.750
1.68
2.98
6.71
11.9
5
0.059
0.242
0.545
0.965
2.18
3.86
8.71
15.4
10
0.084
0.342
0.77
1.36
3.08
5.45
12.3
21.8
15
0.103
0.418
0.94
1.67
3.75
6.65
15.0
26.7
20
0.119
0.485
1.07
1.93
4.25
7.7
17.1
30.8
25
0.133
0.54
1.21
2.16
4.75
8.6
19.4
34.5
30
0.156
0.632
1.40
2.52
5.6
10.0
22.5
40.0
35
0.173
0.71
1.56
2.80
6.2
11.2
25.0
44.7
40
0.19
0.77
1.71
3.07
6.8
12.3
27.3
49.1
45
0.208
0.843
1.9
3.36
7.6
13.4
30.3
53.8
50
0.225
9.14
2.05
3.64
8.2
14.5
32.8
58.2
60
0.26
1.05
2.35
4.2
9.4
16.8
37.5
67.0
70
0.295
1.19
2.68
4.76
10.7
19.0
43.0
76.0
80
0.33
1.33
2.97
5.32
11.9
21.2
47.5
85.0
90
0.364
1.47
3.28
5.87
13.1
23.5
52.5
94.0
100
0.40
1.61
3.66
6.45
14.5
25.8
58.3
103.0
110
0.43
1.76
3.95
7.00
15.7
28.0
63.0
112.0
120
0.47
1.90
4.27
7.58
17.0
30.2
68.0
121.0
130
0.50
2.04
4.57
8.13
18.2
32.4
73.0
130.0
140
0.54
2.17
4.87
8.68
19.5
34.5
78.0
138.0
150
0.57
2.33
5.2
9.20
20.7
36.7
83.0
147.0
175
0.66
2.65
5.94
10.6
23.8
42.1
95.0
169.0
200
0.76
3.07
6.90
12.2
27.5
48.7
110.0
195.0
OM-478 Page 53
11-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At
70-90 P.S.I.G.
MISCELLANEOUS
PORTABLE
TOOLS
Percent Use Factor And
Compressed Air Consumption (CF)
Percent Use Factor And
Compressed Air Consumption (CF)
1 min
MISCELLANEOUS
PORTABLE
TOOLS
8.75
25
Burring Tool, Large
3.6
6.0
8.4
24
8.75
12.25
35
Rammers, Small
3.9
3.25
9.1
13
1.8
3.0
4.2
12
Rammers, Medium
5.1
8.5
11.9
34
Screwdriver,
#6 to 5/16” Screw
3.6
6.0
8.4
24
Rammers, Large
6.0
10.0
14.0
40
Tapper, to 3/8”
3.0
5.0
7.0
20
Backfill Tamper
3.75
6.25
8.75
25
Nutsetters, to 3/8”
3.6
6.0
8.4
24
Compression Riveter
Nutsetters, to 3/4”
4.5
7.5
10.5
30
Air Motor,
1 Horsepower
3.75
6.3
8.75
25
Impact Wrench, 1/4”
2.25
3.75
5.3
15
Air Motor,
2 Horsepower
7.5
12.5
17.5
50
Impact Wrench, 3/8”
3.0
5.0
7.0
20
Impact Wrench, 5/8”
4.5
7.5
10.5
30
Air Motor,
3 Horsepower
11.25
18.75
26.3
75
Impact Wrench, 3/4”
5.25
8.75
12.25
35
Impact Wrench, 1”
6.75
11.25
15.75
45
Impact Wrench, 1-1/4”
8.25
13.75
19.2
55
Die Grinder, Small
2.25
3.75
5.3
15
Paint Spray Gun
(Production)
Die Grinder, Medium
3.6
6.0
8.4
24
HAMMERS
Horizontal Grinder, 2”
3.0
5.0
7.0
20
Horizontal Grinder, 4”
9.0
15.0
21.0
Horizontal Grinder, 6”
9.0
15.0
Horizontal Grinder, 8”
12.0
Vertical Grinders and
Sanders, 5” Pad
9 sec
15 sec
21 sec
Drill, 1/18” to 3/8”
3.75
6.25
Drill, 3/8” to 5/16”
5.25
Screwdriver,
#2 to #6 Screw
9 sec
15 sec
21 sec
1 min
0.2 cu. ft. per cycle
Air Motor Hoist
1000#
1 cu. ft. per foot of lift
Air Motor Hoist,
2000#
1 cu. ft. per foot of lift
3.0
5.00
7.00
20
Scaling Hammer
1.3
3.0
4.2
12
60
Chipping Hammer
4.5
7.5
10.5
30
21.0
60
Riveting Hammer,
Light
2.25
3.75
5.25
15
20.0
28.0
80
Riveting Hammer,
Heavy
4.5
7.5
10.5
30
5.25
8.75
12.25
35
SAWS
Vertical Grinders and
Sanders, 7” Pad
9.0
15.0
21.0
60
Circular, 8”
6.75
11.25
15.75
45
Vertical Grinders and
Sanders, 9” Pad
Circular, 12”
9.75
16.25
23.8
65
10.5
17.5
24.5
70
Chain, Lightweight
4.20
7.0
9.8
28
Burring Toll, Small
2.25
3.75
5.3
15
Chain, Heavy Duty
13.1
21.8
30.5
87
Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)
OM-478 Page 54
SECTION 12 − GENERATOR POWER GUIDELINES
12-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
aux_pwr 3/02 − Ref. ST-159 730 / ST-800 577
12-2. Grounding Generator To Truck Or Trailer Frame
1
2
3
4
Generator Base
Metal Vehicle Frame
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
1
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
4
GND/PE
OR
2
2
Electrically bond generator
frame to vehicle frame by
metal-to-metal contact.
S-0854
OM-478 Page 55
12-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
2
Use ground device as stated
in electrical codes.
3
ST-800 576-B
12-4. How Much Power Does Equipment Require?
1
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running (see Section 12-8).
3
3
Rating Data
Rating shows volts and amperes,
or watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-478 Page 56
12-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
12-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-478 Page 57
12-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
OM-478 Page 58
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
12-8. Power Required To Start Motor
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230
HP = 1/4
Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A Starting the motor requires 12.2 amperes.
230
S-0624
12-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
1
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-478 Page 59
12-10. Typical Connections To Supply Standby Power
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
1
2
Customer-supplied equipment is required if
3
generator is to supply standby power during
emergencies or power outages.
1
Obtain and install correct switch.
Switch rating must be same as or
greater than the branch overcurrent
protection.
240 V
120/240 Volt
60 Hz
Three-Wire
Service
4
120 V
5
Neutral
2
Circuit Breakers or Fused
Disconnect Switch
Obtain and install correct circuit
breakers or switch.
120 V
3
Extension Cord
Select as shown in Section 12-11.
6
Generator Connections
Connect terminals or plug of adequate amperage capacity to cord.
Follow all applicable codes and
safety practices.
240 V
120 V
Load
Power Company Service
Meter
Main and Branch Overcurrent
Protection
Double-Pole, Double-Throw
Transfer Switch
120 V
4
7
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
7
Load Connections
CB
or
Item 4 is not necessary if circuit
protection is already present in
generator power circuit.
F1
5
6
240 V
120/240 Volt
Single-Phase
Three-Wire
Generator Output
Connection
120 V
120 V
Ground
S-0405-A
OM-478 Page 60
12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-478 Page 61
SECTION 13 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
NOTE
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.
13-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode
Negative/Straight Polarity
DC − Argon − Electrode
Positive/Reverse Polarity
AC − Argon − Using
High Frequency
AC − Argon − Balanced
Wave Using High Freq.
.010”
Up to 15
*
Up to 15
Up to 10
.020”
5-20
*
5-20
10-20
Pure Tungsten
(Green Band)
.040”
15-80
*
10-60
20-30
1/16”
70-150
10-20
50-100
30-80
3/32”
125-225
15-30
100-160
60-130
1/8”
225-360
25-40
150-210
100-180
5/32”
360-450
40-55
200-275
160-240
3/16”
450-720
55-80
250-350
190-300
1/4”
720-950
80-125
325-450
250-400
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
1/8”
250-400
25-40
225-360
160-250
5/32”
400-500
40-55
300-450
200-320
2% Thorium Alloyed
Tungsten (Red Band)
3/16”
500-750
55-80
400-500
290-390
1/4”
750-1000
80-125
600-800
340-525
.010”
*
*
Up to 20
Up to 15
.020”
*
*
15-35
5-20
.040”
*
*
20-80
20-60
1/16”
*
*
50-150
60-120
3/32”
*
*
130-250
100-180
Zirconium Alloyed Tungsten (Brown Band)
1/8”
*
*
225-360
160-250
5/32”
*
*
300-450
200-320
3/16”
*
*
400-550
290-390
1/4”
*
*
600-800
340-525
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
OM-478 Page 62
13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
1
2
Tungsten Electrode
Balled End
Understand and
follow
safety symbols at start of
Section 14-1 before preparing tungsten.
1
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recommended for a given electrode diameter (see Section 13-1), or a dc
electrode positive amperage.
1-1/2 Times
Electrode Diameter
2
Ref. S-0161
13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
1
1
2
2
Tungsten Electrode
Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
3
1
2
Stable Arc
Flat
Diameter of this flat determines
amperage capacity.
3
4
Grinding Wheel
Straight Ground
1
2
3
4
Arc Wander
Point
Grinding Wheel
Radial Ground
4
Ideal Tungsten Preparation − Stable Arc
1
2
3
4
Wrong Tungsten Preparation − Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-478 Page 63
SECTION 14 − GUIDELINES FOR TIG WELDING (GTAW)
14-1. Positioning The Torch
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
3
1
Workpiece
Make sure workpiece is clean
before welding.
2
2
Work Clamp
Place as close to the weld as
possible.
4
3
4
5
90°
Torch
Filler Rod (If Applicable)
Tungsten Electrode
Select and prepare tungsten
according to Sections 13-1, and
13-2 or 13-3.
1
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
Arc length is the distance from the
tungsten to the workpiece.
10−15°
As a general guide, start with an
extension and arc length equal to
diameter of tungsten.
4
5
10−25°
ST-161 892
14-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
Tilt torch
Remove rod
OM-478 Page 64
15°
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
14-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
10°
20°
40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
ST-162 003 / S-0792
OM-478 Page 65
OM-478 Page 66
Hardware is common and
98
Figure 15-1. Main Assembly (Part 1 Of 2)
82
83
84−Fig15-3
not available unless listed.
99
104
81
96
97
103
102
105
106
95
86
108
79
30
93
85−Fig15-4
94
107
2
92
78
87
91
76
77
88
90
1
75
3
4
74
72
73
89
5
70
7
69
8
61
31
62
63
64
71−Fig15-5
6
56
25
67
55
9
32 31
68
10
59
60
65
66
58
35 36
34
11
57
37
12
56
39
31
32
55
38
54
53
13
25
52
45
46
30
14
20
51
42
43
44
41
40
14
24
48
28
50
21
49
31
32
47
29
19
22
23
17
16
18
27
26
18
ST-121 286-H (Part 1 of 2)
32
31
21
14 15
SECTION 15 − PARTS LIST
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly (Part 1 Of 2)
. . . 1 . . . . Z1 . . . . 186 907 . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 049 525 . . NUT, speed push-on-type .312-18 U type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 2 . . . . R3 . . . . 128 862 . . RESISTOR, WW adj 375W 50 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . 118 642 . . FRAME, mtg air tank/reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . 135 290 . . BRACKET, support valve drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . 145 023 . . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . TE4 . . . 038 621 . . BLOCK, term 30A 4P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . 145 035 . . INSULATOR, strip terminal voltage changeover . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . 118 643 . . UPRIGHT, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . 017 479 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦041 480 . . STARTING AID, diesel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . ES1 . . . 046 410 . . . . ATOMIZER, .125 L elbow orf 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 113 342 . . . . ADAPTER, atomizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 020 185 . . . . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Fig 15-3 for additional parts
. . . 10 . . . . . . . . . . . . 083 859 . . . . BRACKET, mtg fuel filter/quick start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . 034 074 . . . . STARTING AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . 118 068 . . TANK, air (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 195 832 . . . . TANK, air 21 gal 2.8 cubic ft 225PSI max . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 173 438 . . . . FITTING, pipe plug recessed sq 1.500NPT . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . 118 132 . . . . FITTING, pipe stl nipple hex 3/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . 010 830 . . . . FITTING, pipe brs nipple hex 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 15 . . . . . . . . . . . . 135 448 . . . . FILTER, air inline 1/4FNPT inlet 1/4MNPT outlet . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . 602 936 . . . . FITTING, pipe galv tee .250NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . 088 683 . . . . VALVE, relief 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . 106 394 . . . . FITTING, brs flrd conn M hd 1/4tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . 134 959 . . . . VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . 010 678 . . . . FITTING, pipe brs elbow st 1/4NPT LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . 145 282 . . . . FITTING, hose brs barbed elbow 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . 195 831 . . . . VALVE, check air 450PSI 3/4FNPT inlet 3/4MNPT outlet . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . 118 136 . . . . FITTING, pipe stl adapter swivel M 3/4NPSM x 3/4NPT . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . 076 357 . . . . FITTING, pipe brs elbow 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . 118 706 . . AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . 175 456 . . HOSE, air SAE .250 ID x .500 OD x 41 in (See Fig 15-2 Item 68 ) . . . . . . 1
. . . 27 . . . . . . . . . . . . 120 303 . . HOSE, pressure air gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . 138 098 . . HOSE, sst 20.750 lg 3/4NPT M ftg & 3/4NPT M inv . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . 024 799 . . BALL JOINT, .250-28thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . 135 195 . . STUD, stl .250-20 x 22 .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . 134 835 . . HOSE, SAE .312 ID x .560 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . 12ft
. . . 32 . . . . . . . . . . . . 172 071 . . CLAMP, hose .520-.605clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 33 . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . CR2,9 . . 090 104 . . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . 032 453 . . CABLE, bat neg w/clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . 118 644 . . HOLD DOWN, bat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . 182 276 . . CABLE, battery pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . 116 707 . . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . 601 945 . . SCREW, cap stl hexhd .625-18 x 4.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 41 . . . . . . . . . . . . 071 731 . . WASHER, flat stl .656 ID x2.250 OD x .187thk pld . . . . . . . . . . . . . . . . . . . . 4
. . . 42 . . . . . . . . . . . . 071 890 . . RETAINER, mount engine/generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 43 . . . . . . . . . . . . 071 730 . . TUBING, stl .875 ID x 12ga wall x 2.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 44 . . . . . . . . . . . . 083 476 . . TUBING, nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 45 . . . . . . . . . . . . 601 851 . . NUT, stl slflkg hex reg .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 46 . . . . . . . . . . . . 118 452 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-478 Page 67
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly (Part 1 Of 2) (Continued)
. . . 47 . . . . . . . . . . . . 159 012
. . . 48 . . . . . . . . . . . . 159 013
. . . 49 . . . . . . . . . . . . 089 351
. . . 50 . . . . . . . . . . . . 117 227
. . . 51 . . . . . . . . . . . . 062 342
. . . 52 . . . . . . . . . . . . 083 553
. . . 53 . . . . . . . . . . . . 135 205
. . . 54 . . . . . . . . . . . . 092 434
. . . 55 . . . . . . . . . . . . 039 599
. . . 56 . . . . . . . . . . . . 119 486
. . . 57 . . . . . . . . . . . . 146 358
. . . 58 . . . . . . . . . . . . 601 965
. . . 59 . . . . . . . . . . . +159 014
. . . 60 . . . . . . . . . . . . 602 887
. . . 61 . . . . . . . . . . . . 121 823
. . . 62 . . . . . . . . . . . . 167 298
. . . 63 . . . . . . . . . . . . 010 876
. . . . . . . . . . . . . . . . . . 059 875
. . . 64 . . . . . . . . . . . . 088 684
. . . 65 . . . . . . . . . . . . 010 460
. . . 66 . . . BAT . . . 012 724
. . . 67 . . . SR4 ♦♦118 757
. . . . . . . . . . . . . . . . . . 121 430
. . . . . . . . . . . . . . . . . . 117 572
. . . . . . . . . . . . . . . . . . 028 516
. . . 68 . . . . . . . . . . . . 118 754
. . . . . . . . . . . . . . . . . . 118 755
. . . 69 . . . . . . . . . . . . 116 981
. . . 70 . . . SR3 . . . 142 507
. . . 71 . . . . . . . . . . . . Fig 15-5
. . . 72 . . . . . . . . . . . . 601 872
. . . 73 . . . . . . . . . . . . 602 213
. . . 74 . . . . . . . . . . . . 118 640
. . . 75 . . . . . . . . . . . . 122 354
. . . 76 . . . . . . . . . . . . 107 343
. . . 77 . . . . . . . . . . . . 024 035
. . . 78 . . . . . . . . . . . . 118 790
. . . 79 . . . . . . . . . . . . 019 603
. . . 80 . . . . . . . . . . . . Deleted
. . . 81 . . . . . . . . . . . . 134 792
. . . 82 . . . . . . . . . ♦♦115 588
. . . 83 . . . . . . . . . . . +127 304
. . . 83 . . . . . . . . +♦♦127 305
. . . 84 . . . . . . . . . . . . Fig 15-3
. . . 85 . . . . . . . . . . . . Fig 15-4
. . . 86 . . . . . . . . . . . . 087 341
. . . 87 . . . . . . . . . . . . 121 699
. . . 88 . . . CT1 . . . 105 370
. . . 89 . . R4,VR1 . . 046 819
. . . 90 . . . . . . . . . . . . 010 083
. . . 91 . . . CT2 . . . 110 924
. . . 92 . . . . . . . . . . . . 604 102
. . . 93 . . . . . . . . . . . . 057 360
. . . 94 . . . . . . . . . . . . 134 903
. . . 95 . . . . . . . . . . . . 026 947
OM-478 Page 68
. . HOSE, oil drain 11.000 3/4 swivel fem 1/2MNPT . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, pipe stl elbow M 1/2tbg x .500NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BASE, filter fuel w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . NUT, .625-11 stl elastic stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . SCREW, .625-11 x 1.250hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . FITTING, brs barbed M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . TUBE, pick up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . SENDER, fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . BASE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, pipe brs plug hexhd 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning do not lift frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . VENT, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HANGER, minerallic No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . TUBING, stl .375 OD x .256 ID x .437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . VALVE, ball bronze 1/2 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOLT, L stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BATTERY, 12V 95A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER, SCR main (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . THYRISTOR, SCR 865A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CLAMP, thyristor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . PIN, spring .125 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . STAND-OFF, insul .312-16 x 2.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BRACKET, rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECTIFIER, si 3ph 450A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . NUT, stl hex jam .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GUARD, splash fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GROMMET, rbr neck filter fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAP, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ANGLE, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . KNOB, ball 1.250 OD w/.250-20thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.....................................................................
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning battery charging precautionary . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PANEL, front lower w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUMPER, door 1.000 in OD x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . SPACER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HANGER, minerallic No. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, current 500/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BLANK, snap-in nyl 1.375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, insul .250-20 x 1.000 lg x.312thd . . . . . . . . . . . . . . . . . . . . . . . 1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-1. Main Assembly (Part 1 Of 2) (Continued)
. . . 96 . . . . . . . . . . . . 149 541 . . HOLDER, fuse crtg 60A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . F1-3 . . *012 625 . . FUSE, crtg 45A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 98 . . . . . . . . . . . +132 116 . . COVER, junction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . 160 620 . . LABEL, warning 3ph auxiliary pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 101 . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 102 . . . C8 . . . . 170 674 . . CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . SR5 . . . 035 704 . . RECTIFIER, integrated 40 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . CR98 . . . 113 247 . . RELAY, 12 VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . R8 . . . . 030 844 . . RESISTOR, WW fixed 25 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 605 741 . . CLIP, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 106 . . CR8 . . . 044 588 . . RELAY, encl 12 VDC 3PDT 10 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 107 . . . . . . . . . . . 186 679 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC10 . . . 168 071 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG10 . . 168 071 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . D8 . . . . 192 307 . . KIT, diode w/washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 030 170 . . BUSHING, snap-in nylon .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦♦Part of 042 182 Optional Jump Start/Battery Charging *Recommended Spare Parts
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-2. Main Assembly (Part 2 Of 2)
. . . 1 . . . . . . . . . . . . 118 073
. . . 2 . . . . . . . . . . . . 117 486
. . . 3 . . . . . . . . . . . +123 475
. . . . . . . . . . . . . . . . . . 186 678
. . . . . . . . . . . . . . . . . . 015 714
. . . 4 . . . . . . . . . . . . 108 487
. . . 5 . . . . . . . . . . . . 089 178
. . . 6 . . . . . . . . . . . . 046 544
. . . 7 . . . . . . . . . . . . 121 418
. . . 8 . . . . . . . . . . . . Deleted
. . . 9 . . . . . . . . . . . . 010 863
. . . 10 . . . . . . . . . . . . 045 657
. . . 11 . . . . . . . . . . . . 021 114
. . . 12 . . . . . . . . . . . *020 319
. . . 13 . . . . . . . . . . . . 021 117
. . . 14 . . . . . . . . . . . . 004 115
. . . 15 . . . . . . . . . . . . 021 116
. . . 16 . . . . . . . . . . . . 021 115
. . . 17 . . . . . . . . . . . . 089 343
. . . 18 . . . . . . . . . . . . 004 130
. . . 19 . . . . . . . . . . . +119 987
. . . . . . . . . . . . . . . . . . 087 341
. . . 20 . . . . . . . . . . . . 120 629
. . . 21 . . . . . . . . . . . . 158 610
. . . 22 . . . . . . . . . . . . 119 797
. . CAP, rain 3 in ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, air line support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GROMMET, rbr 1.5 id X 1.625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning falling equipment etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . GROMMET, rbr 3.000 ID x 3.500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PRECLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . HOSE, elb air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
.....................................................................
. . CLAMP, hose 2.062-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . CLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . NUT, wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BAFFLE, dust cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CAP, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BAND, mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . RIVET, nyl .250dia x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . BRACKET, door support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . DOOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning electric shock and moving parts . . . . . . . . . . . . . . . . . . . . . . 2
. . BAFFLE, air manifold exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-478 Page 69
1
61
2
OM-478 Page 70
not available unless listed.
3
4
Hardware is common and
Figure 15-2. Main Assembly (Part 2 of 2)
5
60
6
59
7
9
58
21
19
18
17
20
57
22
41
56
16
55
11 12 13 14
10
9
62
28
31
30
29
27
54−Fig 15-6
15 Includes
Item 16
25
24
51 50
53 52
26
32
33
9
49
37
38
39
29
35
36
30
63
62
45
46
47
48
47
43
44
31
7
66
65
42
64
40
ST-121 286-J (Part 2 0f 2)
Includes
Item 41
34
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-2. Main Assembly (Part 2 Of 2) (Continued)
. . . 24 . . . . . . . . . . . . 138 098 . . HOSE, sst 20.750 lg 3/4NPT M ftg & 3/4NPT M inv . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . 089 973 . . BOLT, U stl .250-20 x 1.125 wide x 2.250 deep . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . 118 075 . . GASKET, flanged air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . 118 349 . . AIR LINE, compressor to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . 121 417 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . S10,11 . . 118 067 . . SWITCH, vacuum air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . 073 655 . . FITTING, pipe brs nipple hex 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . 089 129 . . PIPE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . +117 457 . . PANEL, engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . +117 257 . . PANEL, engine end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . 121 416 . . HOSE, elb air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . 117 228 . . BRACKET, mtg air line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . 023 313 . . CLAMP, hose 3.250-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . 048 213 . . BAFFLE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . 095 970 . . STRIP, nprn wsl eng firewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . 117 017 . . ENGINE, diesel electric (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . Fig 15-5 . . . . COMPRESSOR, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . . . 065 554 . . . . MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR, (included w/engine see engine parts list) . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 065 556 . . . . PIPE CLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 064 744 . . . . GASKET, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 064 432 . . . . STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 065 557 . . . . BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 066 145 . . . . WASHER/DISC/PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 064 520 . . . . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 065 559 . . . . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 065 129 . . . . NUT, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . . . 141 346 . . SHUT DOWN KIT, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . . . . . . . . . . . . 137 180 . . CLAMP, stl cush .875dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 172 071 . . CLAMP, hose .520-.605clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . . . 119 956 . . BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . . 191 718 . . ROD, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . F11 . . *085 874 . . FUSE, mintr gl slo blo 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . . . 117 225 . . BRACKET, mtg solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . . . 107 333 . . LINK, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 51 . . . . TS1 . . . 183 030 . . SOLENOID, 12VDC 44A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . . . 159 184 . . TUBING, stl .875 OD x .563 ID x .312 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 53 . . . . . . . . . . . . 119 836 . . TUBING, stl .875 OD x .563 ID x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 54 . . . . . . . . . . . . Fig 15-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55 . . . . . . . . . . . . 166 805 . . BAFFLE, air manifold exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 56 . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 57 . . . . . . . . . . . . 119 664 . . PIPE, muffler extension elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 58 . . . . . . . . . . . . 119 861 . . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 59 . . . . . . . . . . . . 193 050 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 60 . . . . . . . . . . . . 170 549 . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 61 . . . . . . . . . . . . 170 550 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 120 304 . . BLANK, snap-in nyl .250mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 62 . . . . . . . . . . . . 186 177 . . HOSE, air 43 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 63 . . . . . . . . . . . . 110 743 . . FITTING, flrd brs conn m hd 1/4 tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 64 . . . . . . . . . . . . 174 582 . . GOVERNOR, air control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 65 . . . . . . . . . . . . 010 289 . . FITTING, flrd brs invt conn m 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 66 . . . . . . . . . . . . 175 456 . . HOSE, air SAE .250ID x .500 OD x 41 in (See Fig 15-1 Item 18) . . . . . . . .
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
2
1
2
2
1
1
1
1
1
1
1
1
3
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-478 Page 71
Hardware is common and
not available unless listed.
4
2
3
1
1
32
6
7
5
8
9
8
29
16 15
14
10
26
30
31
31
11
31
28
27
23
24
25
12
22
21
16 15 14
24
23
20
17
19
13
18
ST-121 288-D
Figure 15-3. Panel, Front w/Components
OM-478 Page 72
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-3. Panel, Front w/Components (Fig 15-1 Item 84)
. . . 1 . . . . . . . . . . . . . 086 706 . . SPACER, range switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . S3 . . . . . . 119 850 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . 118 340 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . S2 . . . . . . 113 483 . . SWITCH, selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . R1 . . . . . 072 623 . . POTENTIOMETER, C 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . S7 . . . . ♦011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . S12 . . . ♦011 622 . . SWITCH, tgl 3PDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . S4,5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . S6 . . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . S8 . . ♦♦021 467 . . SWITCH, tgl SPST MC 3A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . S1 . . . . . 176 606 . . SWITCH, ignition 4 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG11 . . . 177 859 . . CONNECTOR, body 5 terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 088 731 . . BUSHING, snap-in nyl .375 ID x .500mtg hole . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . 119 014 . . LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . 082 788 . . HOLDER, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . ♦082 788 . . HOLDER, light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . PL1-3 . . . *048 155 . . BULB, indicator 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . PL4 . . . ♦048 155 . . BULB, indicator 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 082 789 . . LENS, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . ♦082 789 . . LENS, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . FG . . . . . 118 066 . . GAUGE, fuel elec 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . A1 . . . . . . 118 060 . . METER, A DC 60-0-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 129 870 . . GAUGE, pressure oil 25-30PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 128 829 . . KIT, oil line 44.000 in c 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . 129 837 . . GAUGE/SWITCH, temp oil mech 250deg . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . 118 069 . . GAUGE, air pressure mech 0-150PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . HM . . . . . 118 058 . . METER, hour 8-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . 090 231 . . HANDLE, range switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . .
. . . 27 . . . . A2 . . . . . 164 873 . . METER, amp AC/DC 0-500 0-600 DC scale . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . V . . . . . 164 874 . . METER, volt AC/DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID x .437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . ♦♦021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . ♦021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ♦♦♦042 188 . . COVER, locking nameplate (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 123 205 . . . . HINGE, cover front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 123 207 . . . . COVER, panel front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 136 474 . . . . STRIP, reinforcing panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 087 341 . . . . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 122 613 . . . . BOLT, U stl .38-18 1.500 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
1
1
1
2
1
1
1
1
1
1
3
1
3
1
3
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
3
1
2
1
1
1
1
2
1
3
♦Part of 042 182 Optional Jump Start/Battery Charging
♦♦Part of 041 480 Optional Ether Starting Aid
*Recommended Spare Parts
♦♦♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-478 Page 73
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-4. Panel, Front Lower w/Components (Fig 15-1 Item 85)
... 1 ............
... 2 ............
... 3 ............
... 4 ............
... 5 ............
... 6 ............
..................
. . . 7 . . GFCI1,2 .
..................
. . . 8 . . . CB1,2 . .
. . . 9 . . . CB3,4 . .
. . . 10 . . . . RC3 . . .
..................
..................
..................
. . . 11 . . . . PC5 . . .
. . . 12 . . . . . . . . . . . .
039 047
601 880
039 044
039 049
601 976
150 267
603 107
151 981
073 690
139 266
083 432
143 976
134 734
134 731
079 739
152 966
097 132
. . TERMINAL, pwr output (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, cap hexhd .500-13 x 1.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, nprn slit bk .156 ID x .343 OD (order by ft) . . . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE, GFCI str dx grd 2P3W 15/20A 125V . . . . . . . . . . . . . . . . . .
. . PLUG, str grd armd 2P3W 15A 125V P&S 5266DF
. . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, circ 14 pin plug Amp 213571-2
. . CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
. . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
. . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and
5
1
not available unless listed.
4
3
2
2
1
1
7
26
6
2
2
2
1
1
1
1
2ft
2
7
8
2
9
10
25
9
24
14
11
15
12
23
13
16
20
21
22
12
19
17
12
1
18
ST-140 458-D
Figure 15-4. Panel, Front Lower w/Components
OM-478 Page 74
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-4. Panel, Front Lower w/Components (Fig 15-1 Item 85)
(Continued)
. . . 13 . . . PC30 . . 150 415 . . CIRCUIT CARD, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6-8 . 165 668 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 14 . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . 15 . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 16 . . . . . . . . . . . . 083 030 . . STUD, brs .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC6 . . . 148 608 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident lower panel (order by model and serial number) . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . 170 391 . . CONNECTOR, circ protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 020 279 . . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . 3T . . . . 038 601 . . BLOCK, term 30A 9P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID x .437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . 150 270 . . COVER, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . ♦092 681 . . CONNECTOR, plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦118 341 . . BRACKET, mtg receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . RC4 . . ♦119 863 . . CONNECTOR, receptacle battery boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . S9 . . . . 011 609 . . SWITCH, toggle SPDT 15A 125 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . ♦136 102 . . REMOTE CONTROL, starter (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 046 433 . . . . SWITCH, PB MC No 36VDC w/black cap . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 010 291 . . . . WASHER, flat .625 ID x 1.250 OD x .125thk nylafil . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 603 588 . . . . WASHER, fbr .468 ID x 1.000 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 008 014 . . . . HANDLE, grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 600 340 . . . . CABLE, port No. 16 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ft
. . . . . . . . . . . . . . . . . . 141 162 . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . ♦♦♦042 242 . . 5 KVA/KW THREE PHASE AC POWER, (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT3 . . . 123 529 . . . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . SR4 . . . 131 828 . . . . RECTIFIER, integ 100A 1200V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . T1 . . . . 123 572 . . . . TRANSFORMER, 1/2 kVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 1T . . . . 038 602 . . . . BLOCK, term 30A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 153 496 . . . . BRACKET, mtg transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 123 581 . . . . BRACKET, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . GFCI2 . . 147 939 . . . . RECEPTACLE, gfci str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . 604 103 . . . . RECEPTACLE, str dx grd 2P3W 15A 250V . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 007 469 . . . . RECEPTACLE, twlk grd 2P4W 30A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB5 . . . 123 879 . . . . CIRCUIT BREAKER, man reset 3P 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 042 240 . . SOUTH AFRICAN RECEPTACLE KIT (consisting of) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . 131 274 . . . . RECEPTACLE, str grd 2P3W 16A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB1 . . . 139 266 . . . . CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Part of 042 182 Optional Jump Start/Battery Charging
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-478 Page 75
Hardware is common and
not available unless listed.
1
2
16
18
17
3
9
15
14
13
12
9
11
10
4
6
8
7
5
ST-140 459-A
Figure 15-5. Control Box
OM-478 Page 76
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-5. Control Box (Fig 15-1 Item 71)
. . . 1 . . . . . . 2T . . . . . . . . 129 939 . . . BLOCK, term 10A 19P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 122 216 . . . CONNECTOR, blk 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . 187 013 . . . ENCLOSURE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . CR6 . . . . . . . 052 603 . . . RELAY, encl 110VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . CR1 . . . . . . . 173 069 . . . RELAY, encl 12 VDC SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . MS1 . . . . . . . 118 072 . . . SWITCH, magnetic shutdown (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . F . . . . . . . . *073 426 . . . . FUSE, mintr gl 5A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . 1T . . . . . . . . 098 828 . . . BLOCK, term 10A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . SR1 . . . . . . . 035 704 . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . D1, D9 . . . . . . 189 701 . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . . . . . 134 201 . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . PC2 . . . . . . . 185 747 . . . CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG2 . . . . . . . 115 092 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . PC3 . . . . . ♦166 685 . . . CIRCUIT CARD, battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG4 . . . . . ♦148 439 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG3 . . . . . ♦158 720 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . IM . . . . . . . . 195 706 . . . MODULE, pull to idle 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . . . . 172 731 . . . HOLDER, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . F6 . . . . . . . *073 426 . . . FUSE, mintr gl slo-blo 5A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . R5 . . . . . . ♦121 137 . . . RESISTOR, WW fxd 5W 33 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . PC1 . . . . . . . 185 746 . . . CIRCUIT CARD, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PLG1 . . . . . . . 135 275 . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . SR2 . . . . . . . 097 353 . . . DIODE/SCR, bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1
1
1
1
1
1
1
2
12
1
1
1
1
2
1
1
1
1
1
1
1
♦Part of 042 182 Optional Jump Start/Battery Charging
*Recommended Spare Parts
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-478 Page 77
14
12
11
37
13
15
16
10
36
17
9
35
8
34
18
7
6
19
5
4
20
3
21
33
22
2
32
23
1
24
31
30
29
25
26
28
27
Hardware is common and
not available unless listed.
Ref. ST-143 803-B
Figure 15-6. Compressor, Air
OM-478 Page 78
Item
No.
Part
No.
Description
Quantity
Figure 15-6. Compressor, Air
. . . 1 . . . . . . 066 133 . . HOUSING INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . 066 134 . . GRIPPING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . 066 135 . . CIRCLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . 066 136 . . GUIDE RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . 066 137 . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . 066 138 . . PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . 066 139 . . SEAL/SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . 066 140 . . WASHER/DISC/PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . 066 142 . . SEALING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . 066 143 . . NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . 139 406 . . COVER, compressor air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . 066 681 . . CLAMPING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . 066 141 . . HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . 066 145 . . WASHER/DISC/PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 14 . . . . . . 066 131 . . LOCKING NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . 066 130 . . INSERT PIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . 066 132 . . O-SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . 066 129 . . COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . 066 128 . . SPRING WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . 066 127 . . VALVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . 066 126 . . VALVE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . 066 123 . . NOTCHED PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . 066 125 . . VALVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . 066 124 . . SPRING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . 066 122 . . SPACER RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . 066 121 . . VALVE SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . 066 153 . . WAISTED BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 26 . . . . . . 066 154 . . WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . 066 119 . . GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . 066 152 . . SEALING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 29 . . . . . . 066 115 . . NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . 066 120 . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . 066 144 . . STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . 066 116 . . SHIM, 1.0mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 32 . . . . . . 066 159 . . SHIM, .5mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . 066 117 . . CYLINDER LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . 066 149 . . CIRCLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . 066 148 . . PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . 066 118 . . PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . 066 510 . . SET OF RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-478 Page 79
Item
No.
Part
No.
Description
Quantity
Figure 15-7. Generator (Fig 15-2 Item 54)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
13
14
15
. . . . . . 173 066
. . . . . . 018 614
. . . . . . *151 299
. . . . . . 600 270
. . . . . . 152 044
. . . . . . 013 367
. . . . . +170 496
. . . . . . 039 207
. . . . . . 083 751
. . . . . . 024 617
. . . . . . 053 390
. . . . . . 083 748
. . . . . . 180 684
. . . . . ♦123 687
. . . . . . 173 068
. . . . . . 143 220
. . BRACKET, mtg brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRUSH SET, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, holder brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, excitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, excitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and
not available unless listed.
9
10
1
3
1
1
1
2
1
1
1
1
1
1
1
1
1
1
12
11
7
8
6
2
4
5
3
1
13
15
14
ST-134 503-E
Figure 15-7. Generator
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-478 Page 80
Effective January 1, 2001
(Equipment with a serial number preface of “LB” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Your distributor also gives
you ...
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts − 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 10/01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
File a claim for loss or damage during
shipment.
 2002 Miller Electric Mfg. Co.
1/02
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