OM-166 941C
Processes
July 1999
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
CBI 801D
(Per NSPR 10202)
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OM-166 941C − 7/99
TABLE OF CONTENTS
Section No.
Page No.
SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
1-2.
1-3.
1-4.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards Booklet Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
5
SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
2-2.
General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
SECTION 3 − SPECIFICATIONS
3-1.
3-2.
3-3.
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
SECTION 4 − INSTALLATION OR RELOCATION
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Grounding Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
9
10
10
10
11
12
14
14
4-10. Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − AUXILIARY POWER
5-1.
5-2.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120 Volt Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
SECTION 6 − OPERATOR CONTROLS
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
Ampere Ranges Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
16
17
17
17
17
17
18
18
18
18
18
18
18
18
Amperage & Voltage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Amperage & Voltage Control Switch . . . . . . . . . . . . . . . . . . . .
Output(Contactor) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Engine Air Cleaner Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Magnetic Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Oil Temperature Gauge/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Oil Pressure Gauge/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Battery Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Broken Cooling Belt Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 7 − SEQUENCE OF OPERATION
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
Shielded Metal Arc Welding (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
20
20
20
20
21
Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) . . . .
Air Carbon Arc Cutting And Gouging (CAC-A) . . . . . . . . . . . . . . . . . . .
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
25
26
26
26
27
27
27
28
28
28
29
30
31
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel/Water Separator And Sludge Drain Plug . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance-Free Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brushes And Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Run-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-1. Load Bank Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-2. Resistance Grid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − TROUBLESHOOTING
9-1.
9-2.
9-3.
9-4.
9-5.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster Battery Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
32
32
33
SECTION 10 − ELECTRICAL DIAGRAMS
Diagram 10-1. Circuit Diagram For Welding Generator . . . . . . . . . . . . . . . . . .
36
SECTION 11 − PARTS LIST
Figure 11-1A. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-1B. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-3. Panel, Lower Front w/Components . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-4. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-5. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
42
44
46
48
49
LIST OF TABLES AND CHARTS
Table 3-1. Welding Generator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-2. Air Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 4-1. Fuel Consumption Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-1. Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 5-1. AC Power Curve For 120 Volt Terminals . . . . . . . . . . . . . . . . . . . . .
7
8
8
10
11
15
Table 7-1. Suggested Electrode Diameter For Amperage Range (CAC-A Only) 20
Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
21
Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate
Various Pneumatic Equipment At Pressure Range 70-90 P.S.I.G. . . . . . . . .
22
23
25
33
34
34
34
Table 8-1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-2. Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-1. Weld/Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-2. Auxiliary Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-3. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9-4. Air Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
INTRODUCTION
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
We learn by experience. Learning safety through per-
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of
others teach you.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re-
search, development, and field experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The rea-
son for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im-
mediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan-
dard Z49.1 listed in Standards Index. NEVER ventilate
with oxygen.
Failure to observe these safe practices may cause seri-
ous injury or death. When safety becomes a habit, the
equipment can be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut-
ting; and 2-Arc Welding (and Cutting) (only).
Lead -, cadmium -, zinc -, mercury -, and beryllium-bear-
ing and similar materials, when welded (or cut) may pro-
duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each person
in the area as well as the operator must wear an air-sup-
plied respirator. For beryllium, both must be used.
Reference standards: Published Standards on safety
are also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most complete.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is re-
moved from the work surface, the area is well ventilated
and, if necessary, while wearing an air-supplied respira-
tor.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira-
tor.
1-2.
GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in
this manual, be sure to consult flux and electrode
manufacturers Material Safety Data Sheets
(MSDSs) for specific technical data and precaution-
ary measures concerning their material.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be sure that the space is safe before
re-entering it.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod-
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
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atmosphere or where the radiant energy can penetrate
to atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.
ment as recommended in A6.0. Waterfilling just below
working level may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense
of smell or sight to determine if it is safe to weld or cut.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate-
rial; misuse of compressed gases and cylinders; and
short circuits.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN-
DERS, listed 11 in Standards Index.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one or more relief devices.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ven-
tilators. If the work cannot be moved, move comb-
ustibles at least 35 feet away out of reach of sparks and
heat; or protect against ignition with suitable and snug-
fitting, fire-resistant covers or shields.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symp-
toms indicate a faulty regulator:
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after pres-
sure release.
Fire watcher must be standing by with suitable fire extin-
guishing equipment during and for some time after weld-
ing or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
Repair. Do NOT attempt to repair. Send faulty regula-
tors for repair to manufacturer’s designated repair cen-
ter, where special techniques and tools are used by
trained personnel.
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
2. Cylinders
c. openings (concealed or visible) in floors or walls
within 35 feet may expose combustibles to
sparks
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious ac-
cident. (See 1-3C.)
d. combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor’s approval that adequate precau-
tions have been taken.
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly han-
dled.
After work is done, check that area is free of sparks,
glowing embers, and flames.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or alter name, number, or other markings on a cylinder. It
is illegal and hazardous.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.0,
listed 7 in Standards Index.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the combusti-
ble’s solubility) followed by purging and inerting with ni-
trogen or carbon dioxide, and using protective equip-
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
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Locate or secure cylinders so they cannot be knocked
over.
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al-
low contents to exceed 130°F. Cool with water spray
where such exposure exists.
Adapters. Use a CGA adapter (available from your sup-
plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify
your supplier.
5. Pressurizing Steps:
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Drain regulator of residual gas through suitable vent be-
fore opening cylinder (or manifold valve) by turning ad-
justing screw in (clockwise). Draining prevents exces-
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Cylinder fittings should never be modified or ex-
changed.
3. Hose
Stand to side of regulator while opening cylinder valve.
Prohibited use. Never use hose other than that de-
signed for the specified gas. A general hose identifica-
tion rule is: red for fuel gas, green for oxygen, and black
for inert gases.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol-
lowing position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use ferrules or clamps designed for the hose (not ordi-
nary wire or other substitute) as a binding to connect
hoses to fittings.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
No copper tubing splices. Use only standard brass fit-
tings to splice hose.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of Ivory
Liquid* or equivalent per gallon of water). Bubbles indi-
cate leak. Clean off soapy water after test; dried soap is
combustible.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate leaks.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Repair leaky or worn hose by cutting area out and splic-
ing (1-2D3). Do NOT tape.
4. Proper Connections
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
*Trademark of Proctor & Gamble.
OM-166 941 Page 3
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1-3.
ARC WELDING
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in-
frared energy radiates, weldments are hot, and com-
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan-
dards referenced in index.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the out-
side air. Carbon monoxide can kill.
A. Burn Protection
C. Fire and Explosion Prevention
Comply with precautions in 1-2.
Comply with precautions in 1-2C.
The welding arc is intense and visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gas-
shielded arcs are more severe and painful. DON’T GET
BURNED; COMPLY WITH PRECAUTIONS.
Equipment’s rated capacity. Do not overload arc weld-
ing equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure ves-
sel. It creates a brittle area that can cause a violent rup-
ture or lead to such a rupture under rough handling.
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As nec-
essary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-re-
sistant leggings. Avoid outer garments of untreated cot-
ton.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the weld-
ing circuit, or in ungrounded, electrically-HOT equip-
ment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
protection.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock-
ets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
To protect against shock:
Wear dry insulating gloves and body protection. Keep
body and clothing dry. Never work in damp area without
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
can not be avoided. Sweat, sea water, or moisture be-
tween body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en-
able dangerous and possibly lethal currents to flow
through the body.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when broken,
pitted, or spattered.
A voltage will exist between the electrode and any con-
ducting object in the work circuit. Examples of conduct-
ing objects include, but are not limited to, buildings, elec-
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shielded arc) can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
1. Grounding the Equipment
Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 “Safety In Welding
And Cutting.”
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a sepa-
rate room or enclosed bay is best. In open areas, sur-
round the operation with low-reflective, non-combusti-
ble screens or panels. Allow for free air circulation, par-
ticularly at floor level.
When installing, connect the frames of each unit such as
welding power source, control, work table, and water cir-
culator to the building ground. Conductors must be ade-
OM-166 941 Page 4
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quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly
fatally. Do NOT GROUND to electrical conduit, or to a
pipe carrying ANY gas or flammable liquid such as oil or
fuel.
ject in contact with the electrode circuit unless
the welding power source is off.
b. Equipment without output on/off control (no
contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar proc-
esses may not be equipped with welding power
output on-off control devices. With such equip-
ment the electrode is electrically HOT when the
power switch is turned ON. Never touch the
electrode unless the welding power source is
off.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip-
ment ground lead to the third (live) wire, or the equip-
ment will become electrically HOT-a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-prong
plug is added for connection to a grounded mating re-
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a three-
prong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground prong.
Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or
red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld-
ing. If, in an emergency, it must be disconnected, guard
against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
Power disconnect switch must be available near the
welding power source.
3. Connectors
F. Protection For Wearers of Electronic Life Sup-
port Devices (Pacemakers)
Fully insulated lock-type connectors should be used to
join welding cable lengths.
Magnetic fields from high currents can affect pacemak-
er operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
4. Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
1-4.
STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
1. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before opera-
tion.
2. NIOSH, SAFETY AND HEALTH IN ARC WELD-
ING AND GAS WELDING AND CUTTING ob-
tainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington,
D.C. 20402.
6. Electrode
a. Equipment with output on/off control (contac-
tor)
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superinten-
dent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor-
mally are equipped with devices that permit on-
off control of the welding power output. When
so equipped the electrode wire becomes elec-
trically HOT when the power source switch is
ON and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob-
4. ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Ameri-
can National Standards Institute, 1430 Broad-
way, New York, NY 10018.
OM-166 941 Page 5
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5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
11. CGA Pamphlet P-1, SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS obtain-
able from the Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Ar-
lington, VA 22202.
6. ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROC-
ESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, On-
tario, Canada M9W 1R3.
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
13. NWSA booklet, WELDING SAFETY BIBLIOG-
RAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadel-
phia, PA 19103.
8. NFPA Standard 51, OXYGEN-FUEL GAS SYS-
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR
THE PREPARATION FOR WELDING AND
CUTTING OF CONTAINERS AND PIPING
THAT HAVE HELD HAZARDOUS SUB-
STANCES, obtainable from the American Weld-
ing Society, 550 N.W. LeJeune Rd, Miami, FL
33126.
9. NFPA Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
15. ANSI Standard Z88.2, PRACTICE FOR RESPI-
RATORY PROTECTION, obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
GENERAL INFORMATION AND SAFETY
2-2.
SAFETY ALERT SYMBOL AND SIGNAL
WORDS
A. General
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions.
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per-
sons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 − Safety Rules For Operation Of Arc Weld-
ing Power Source.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
OM-166 941 Page 6
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SECTION 3 − SPECIFICATIONS
Table 3-1. Welding Generator Specifications
Maximum
Rated Output
At 100%
Duty Cycle
Maximum
Engine Speed
(No Load)
Single-Phase
Auxiliary Power
While Welding
Weight
Open-Circuit
Voltage
Welding
Range
Net
Ship
(OCV)
95 Volts DC
800 Amperes
100 to 800
3 kVA/kW 60 Hz
2150 lbs.
2280 lbs.
(1034 kg)
1860 RPM
At 36 Volts DC Amps DC
80 Volts DC
Nominal
26 Amperes At 120 Volts (975 kg)
Conforms with NEMA EW1 (ANSI C87.1), “ELECTRIC ARC WELDING POWER SOURCES,” Class I (100).
47 in.
(1194 mm)
72 in.
(1829 mm)
32 in.
(813 mm)
21/32 in. (16.7 mm)
Dia. All Holes
Inches
62-3/8
50-1/2
46-1/2
36
Millimeters
1584
1283
1181
914
A
B
C
D
E
F
A
B
28-3/16
13-3/4
9-3/4
716
C
349
E
D
G
H
J
248
6-1/8
156
F
G
29-7/8
1-1/16
759
K
27
H
K
J
ST-147 323-B
Figure 3-1. Overall Dimensions And Mounting Hole Locations
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3-1.
DUTY CYCLE
and Air Carbon Arc Cutting And Gouging (CAC-A) pro-
cesses.
The duty cycle of a welding generator is the percentage
of a ten minute period that a welding generator can be
operated at a given output without causing overheating
and damage to the unit. This welding generator is rated
at 100 percent duty cycle when operated at 800 am-
peres. This means that the welding generator can be op-
erated at 800 amperes continuously without causing
damage to the unit.
The unit is equipped with a four-cylinder, air-cooled,
Deutz diesel engine (F4L-912). The air compressor in
this unit is mounted on the front of the engine, and it op-
erates whenever the engine is running. The compressor
delivers 12 cfm of air at a pressure of 100 psi (see Chart
3-2).
In addition to welding and air compressor operation, this
unit can provide up to 3 kVA/kW of 120 volts (26 am-
peres) ac electrical power for operating 50/60 Hz or 60
Hz auxiliary equipment while welding.
3-2.
VOLT-AMPERE CURVES (Chart 3-1)
The volt-ampere curves show the voltage and amper-
age output capabilities of the welding generator at mini-
mum and maximum of each coarse range. Curves of
other settings fall between the curves shown.
This unit is specially prepared for operation in harsh and
corrosive environments.
An optional Ether Starting Aid can be provided on the
welding generator and is covered within this Owner’s
Manual.
Chart 3-1. Volt-Ampere Curves
Chart 3-2. Air Output Curve
SB-168 387
3-3.
DESCRIPTION
This unit is a constant current (CC) dc arc welding gen-
erator designed for use with the Shielded Metal Arc
Welding (SMAW), Flux Cored Arc Welding (FCAW),
SB-143 883
SECTION 4 − INSTALLATION OR RELOCATION
IMPORTANT: Unless otherwise specified, all direc-
tions, such as left or right, are with respect to the opera-
tor facing the welding generator front panel.
CAUTION: RESTRICTED AIRFLOW causes
overheating and possible damage to inter-
nal parts.
• Maintain at least 18 inches (457 mm) of unre-
stricted space on all sides of unit, and keep
underside free of obstructions.
4-1.
LOCATION (Figure 3-1)
A proper installation site should be selected for the weld-
ing generator if the unit is to provide dependable service
and remain relatively maintenance free.
• Do not place any filtering device over the
intake air passages of this welding generator.
Warranty is void if any type of filtering device is
used.
WARNING: ENGINE EXHAUST GASES can
kill.
• Operate in open, well-ventilated areas or if
operated indoors, vent engine exhaust out-
side the building.
The service life and operating efficiency of this
unit are reduced when the unit is subjected to
extreme levels of dust, dirt, moisture, corrosive
vapors, and extreme heat.
• Keep engine exhaust vent outlet away from
building air intakes.
OM-166 941 Page 8
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A. Lifting Of Equipment
WARNING: INCORRECT LIFTING will dam-
The mounting location should allow sufficient room to
remove the top cover and side panels for maintenance
and repair functions.
age internal parts; FALLING EQUIPMENT
can cause serious personal injury and
equipment damage.
• Use lifting eye to lift unit only, NOT gas cylin-
ders, trailer, or any other heavy options, ac-
cessories, or devices.
Use a properly fitting cover (optional) over the welding
generator when not in operation to protect the unit from
the environment. Be sure unit is cool before installing
any cover.
C. Spark Arrestor Considerations
• Use equipment of adequate capacity to lift the
WARNING: ENGINE EXHAUST SPARKS can
cause fire.
• Exhaust spark arrestor must be installed in
accordance with local, state, and federal
regulations.
unit.
• Use lift forks at least 42 in. (1067 mm) long.
• Lift only from engine-end (end opposite front
panel).
The engine exhaust system on this welding generator is
not equipped with a spark arrestor. A spark arrestor,
maintained in effective working order, is mandatory if
this welding generator is to be operated in a National
Forest or on California Grasslands, brush, or forest cov-
ered land (see Section 4442 of California Public Re-
sources Code). For other areas, check your state and
local laws. If a spark arrestor (optional) is desired, con-
tact your dealer/distributor.
B. Trailer Mounting
CAUTION: UNCONTROLLED TILTING OF
TRAILER can result in personal injury or
equipment damage.
• Distribute weight so that trailer tongue weight
is approximately 10% of gross trailer weight.
• Follow trailer manufacturer’s instructions
when mounting welding generator onto
trailer.
4-2.
EXHAUST EXTENSION INSTALLATION
OPERATION ON UNLEVEL SURFACE can
cause improper lubrication and result in
severe engine damage.
WARNING: HOT ENGINE PARTS can cause
severe burns.
• Operate unit in an approximately level posi-
• If applicable, shut down engine and allow ex-
haust system to cool before installing exhaust
extension.
tion.
• See Figure 4-1 for maximum allowable tilt for
proper operation.
1. Install exhaust extension through top cover
opening, over muffler extension elbow. (Be sure
to face end of extension away from air cleaner;
see Figure 3-1).
• Check crankcase oil level with unit on a level
surface.
Exceeding these limits can cause severe engine
damage and improper operation.
2. Secure exhaust extension to top cover of unit us-
ing supplied hardware.
Front
Panel
4-3.
CONNECTING THE BATTERY
WARNING: BATTERY ACID can burn eyes
and skin and destroy clothing and other ma-
terial.
17.5
• Wear a face shield and proper protective
15
clothing when working with batteries.
Side View Of Unit
ABNORMAL VOLTAGE can cause damage
to engine electrical components.
• Do not operate engine without the battery
Front
Panel
connected.
• Do not disconnect the battery while the en-
37.5
45
gine is running.
IMPORTANT: Be sure the Engine Control switch is in
the OFF position before connecting battery.
End View Of Unit
Ref. S-0024
Figure 4-1. Allowable Tilt Angles For Welding
Generator Engine
This unit is equipped with a maintenance-free battery.
To place the unit in service, remove the left, rear side
panel, connect the negative (−) battery cable to the neg-
ative battery terminal, and reinstall the side panel. No
other preparation should be required. If the battery does
not supply enough power to crank the engine, charge
the battery according to Section 8-6.
Holes are provided in the base for securing the unit in a
permanent location or to a trailer or transport vehicle.
Figure 3-1 gives overall dimensions and base mounting
hole layout.
OM-166 941 Page 9
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4-4.
FUEL
lower front panel of this unit (see Figure 4-2). If oil level is
below the lower pointer when engine is running, add oil
according to the recommendations in the Engine Man-
ufacturer’s Manual (F4L-912 engine). The oil cap is lo-
cated under the access door on the top cover.
WARNING: REMOVE FUEL CAP SLOWLY;
FUEL SPRAY may cause injury; FUEL may
be under pressure.
• Rotate fuel cap slowly and wait until hissing
stops before removing cap.
IMPORTANT: This engine is equipped with an Oil Pres-
sure Shutdown gauge/switch and an Oil Temperature
Shutdown gauge/switch. If oil pressure becomes too
low or oil temperature rises to a level that may cause en-
gine damage, the respective gauge/switch shuts down
the engine. The shutdown oil pressure has been factory
set at 30 psi (207 kPa), and the shutdown oil tempera-
ture has been set at 265°F (130°C).
ENGINE FUEL can cause fire or explosion.
• Stop engine before checking or adding fuel.
• Do not spill fuel; if spilled, wipe up.
• Do not refuel if engine is hot or running.
• Do not refuel near sparks or open flame.
• Do not smoke while refueling.
• Do not fill fuel tank to top; allow 1/2 in. (13
B. Wetstacking Considerations
mm) from fuel to tank top for expansion.
Wetstacking is an accumulation of unburned fuel and oil
in the exhaust pipe. The engine may use oil and wet-
stacking may occur during the run-in period if the piston
rings are not seated properly. If oil consumption and
wetstacking occur during run-in period, see Section
8-12.
• Do not weld on fuel tank.
IMPORTANT: Fill fuel tank up to 1/2 in. (13 mm) from
top with fresh fuel before starting engine the first time.
Rust and corrosion preventative was added to inside of
fuel tank and engine at the factory and could cause
rough engine running if not properly diluted with a full
tank of fresh fuel.
4-6.
EQUIPMENT GROUNDING TERMINAL
The capacity of the fuel tank is 30 gallons U.S. Measure
(114 liters). See the Engine Manufacturer’s Manual for
fuel recommendations. Chart 4-1 illustrates typical fuel
consumption under specific load conditions. Fuel con-
sumption varies from one engine to another. Different
brands of fuel, operating conditions, condition of the en-
gine, etc., also affect the fuel consumption level.
GROUND
This unit is equipped with a grounding terminal for
grounding the generator case. The grounding terminal
is located on the lower front panel (see Figure 4-2).
Since the generator neutral is connected to the frame,
the equipment grounding terminal must be connected to
a proper earth ground. Additionally, comply with all na-
tional, regional, and local codes concerning portable
generators for the specific application.
Keep the fuel tank filled to ensure that the injector sys-
tem receives an adequate supply of fuel. The fuel cap is
located on the lower front panel, behind the right access
door (see Figure 4-2). If the fuel tank is allowed to empty,
air will enter the system, causing starting problems. The
Engine Manufacturer’s Manual outlines procedures for
air bleeding the fuel system.
For detailed grounding instructions consult your na-
tional, regional, and local codes. If additional informa-
tion regarding your operating circumstances and/or
grounding requirements is needed, consult a qualified
electrician or your dealer. After determining the extent to
which any grounding requirements apply to your par-
ticular situation, follow them explicitly.
4-5.
LUBRICATION (Figure 4-2)
A. Oil And Oil Level Indicator
The engine is shipped with its crankcase filled with SAE
20 break-in oil. An oil level indicator is provided on the
Chart 4-1. Fuel Consumption Curve
SB-168 472
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4-7.
WELD OUTPUT CONNECTIONS (Table 4-1
And Figure 4-2)
B. Weld Cable Preparation
1. Install electrode holder to cable following man-
ufacturer’s instructions. Always use an insulated
electrode holder to ensure operator safety.
RATED WELD OUTPUT
2. Install correct size lugs onto ends of both cables
for connecting to work clamp, electrode holder or
wire feeder, and weld output terminals.
To obtain full rated output from this unit, it is necessary to
select, prepare, and install proper weld cables. Failure
to comply in any of these areas may result in
unsatisfactory welding performance.
3. Install work clamp onto cable.
C. Weld Output Connections
A. Weld Cable Selection
Use the following guidelines to select weld cables:
POSITIVE
NEGATIVE
1. Use the shortest possible cables, and place
cables close together. Excessive cable lengths
may reduce output or cause unit overload due to
added resistance.
−
+
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
2. Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-cir-
cuit voltage (ocv) of the welding generator (see
Table 3-1 for unit maximum ocv rating).
• Stop engine, and disconnect negative (−) bat-
tery cable before making any weld output
connections.
MOVING PARTS can cause serious injury.
3. Select weld cable size according to maximum
weld output and total length of connecting cables
in weld circuit. For example, if a 25 foot (7.5 m)
wire feeder or electrode holder cable is used with
a 25 foot (7.5 m) work cable, select the cable size
recommended in Table 4-1 for 50 feet (15 m).
• Keep away from moving parts such as fans,
belts, and rotors.
1. Open and secure the lower front panel access
door, and route weld cables through bracket on
front upright to the weld output terminals (see
Figure 4-2).
4. Do not use damaged or frayed cables.
Table 4-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
100 ft (30 m) Or Less
10 To 60% 60 Thru 100%
Welding
Amperes
10 Thru 100% Duty Cycle
Duty Cycle
Duty Cycle
100
150
200
250
300
350
400
500
600
700
800
900
4
3
4
3
4
3
2
1
1/0
1/0
2
1
1/0
2/0
3/0
3/0
3
2
1
1/0
2/0
3/0
4/0
4/0
2
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
4-4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
1
1/0
2/0
2/0
3/0
4/0
2-2/0
2-2/0
2-3/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
1/0
1/0
2/0
3/0
4/0
4/0
2-2/0
3/0
4/0
2-2/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
3/0
4/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
3-3/0
2-2/0
2-3/0
2-3/0
2-4/0
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
S-0007-D
OM-166 941 Page 11
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2. For Shielded Metal Arc Welding (SMAW) and Air
Carbon Arc Cutting and Gouging (CAC-A) (Elec-
trode Positive/Reverse Polarity), connect weld
cables as follows:
4-8.
REMOTE CONTROL CONNECTIONS
Receptacle Information And
A. Remote
9
Connections (Figures 4-2 And 4-3)
REMOTE 9
FEEDER
a. Connect one end of work cable to NEGATIVE
(−) weld output terminal.
b. Connect end of electrode holder cable to POSI-
TIVE (+) weld output terminal.
A/V AMPERAGE/
VOLTAGE
IMPORTANT: For Electrode Negative/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
OUTPUT
(CONTACTOR)
REMOTE 9 receptacle RC3, located under the lower
front panel access door (see Figure 4-2), is provided to
connect any of the following equipment to the welding
generator circuitry:
3. For Wire Feeding Processes (GMAW, FCAW,
SAW) (Electrode Positive/Reverse Polarity),
connect weld cables as follows:
a. Remote Contactor
a. Connect one end of work cable to NEGATIVE
(−) weld output terminal.
b. Remote Amperage or Voltage control
b. Connect end of electrode holder cable to POSI-
TIVE (+) weld output terminal and remaining
end to terminal on the wire feeder drive housing
(see wire feeder Owner’s Manual for location).
c. Wire feeder which provides contactor control to
the welding generator.
d. Combination of the above.
To Make connections, align keyway, insert plug, and ro-
tate threaded collar fully clockwise.
4. Close and secure front panel access door.
Circuit Breaker CB3
Terminal
Strip 3T
Circuit Breaker CB1
(see Section 9-3)
Remote 9
Receptacle
Equipment
Grounding
Terminal
Oil Level
Indicator
Strain Relief
Fuel Cap
POSITIVE (+)
Weld Output
Terminals
NEGATIVE (−)
Weld Output
Terminals
Ref. ST-147 322-E
Figure 4-2. Lower Front Panel Components And Connections
OM-166 941 Page 12
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If supplied remote control cord is not suitable for con-
necting to the REMOTE 9 receptacle RC3, proceed with
one of the following alternatives;
F
I
G
E
C
D
H
1. Wire a plug or cord to interface with REMOTE 9
receptacle RC3 using socket information in Sec-
tion C.
A
B
Ref. S-0706
2. Wire remote control cord directly to terminal strip
within unit according to Section B.
Figure 4-3. Front View Of Remote 9 Receptacle
With Socket Locations
B. REMOTE Terminal Strip 3T Information And
Connections (Figures 4-2 And 4-4)
Socket A/Terminal A:
Contact closure to Socket B/Terminal B
completes the 115 volts ac contactor con-
trol circuit; protected by circuit breaker
CB3.
WARNING: ELECTRIC SHOCK can kill; UN-
EXPECTED OUTPUT can cause serious in-
jury.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−)
battery cable from battery before making any
internal inspection or connections.
Socket B/Terminal B:
Contactor closure to Socket A/Terminal A
completes the 115 volts ac contactor con-
trol circuit.
• Do not connect to REMOTE 9 receptacle and
terminal strip at the same time.
Socket H/Terminal J:
Since the OUTPUT (CONTACTOR) can be en-
ergized from either the receptacle or terminal
strip, it is vital to use only one remote control
method.
Command reference; +10 volts dc.
Socket F/Terminal G:
MOVING PARTS can cause serious injury.
Control circuit common.
Socket G/Terminal H:
• Keep away from moving parts such as fans,
belts, and rotors.
Input command signal from wiper of re-
mote control potentiometer; 0 volts equals
machine minimum; +10 volts equals ma-
chine maximum.
Terminal strip 3T, mounted on the lower front panel (see
Figure 4-2), is included in case the plug supplied on the
remote control cord is not suitable for connections to the
REMOTE 9 receptacle RC3.
Socket C/Terminal C:
115 volts ac circuit common; also con-
nected to welding power source chassis.
To make connections, proceed as follows:
1. Remove existing plug from remote control cord.
2. Open and secure lower front door.
Socket D/Terminal D:
Up to 10 amperes of 115 volts ac, 60 Hz,
with respect to terminal
common).
C
(circuit
3. Locate strain reliefs provided on lower front panel
(see Figure 4-2).
Terminals L and M of 3T:
4. Insert leads from cord through strain relief.
Terminals supply 30 amperes of 115 volts
ac, 60 Hz, auxiliary power. Terminal L is
circuit common.
5. For Remote Electrical Cutoff Switch, remove
jumper link between terminals N and P.
Terminals E/Terminal E or F:
Weld Voltage
6. Connect leads to terminal strip 3T using terminal
information provided in Section C.
Feedback.
Polarity
determined by connection at terminal E (+)
or F (−).
7. Secure the cord in the strain relief.
8. Close and secure door.
Terminal N and P of 3T:
Closed circuit between terminals N and P
is normal condition. Open circuit between
terminals N and P is Remote Emergency
Electrical Cutoff condition.
C. Socket/Terminal Information (Figure 4-4)
The following lists the functions of the sockets of RE-
MOTE 9 receptacle RC3 (see Figure 4-3), and the termi-
nals of strip 3T (see Figure 4-4). The following socket/
terminal information is provided in case it is necessary to
wire the auxiliary equipment cord.
Terminal I/Terminal K:
Machine chassis (Equipment Ground).
OM-166 941 Page 13
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4-9.
AIR COMPRESSOR CONNECTIONS
IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
cylinder is inserted. If dirt is present in either of these ar-
eas, the system may not work.
This unit delivers 12 cfm of air at a pressure of 100 psi
whenever the engine is running. A 1/2 in. NPT fitting for
air compressor connections is provided on the top cover
of the unit.
1. Open and secure right rear side door.
To make connections to the air compressor, obtain and
install a quick-connect connector onto the air compres-
sor fitting.
2. If applicable, remove protective cap from ether
valve, or remove old ether cylinder from unit.
3. Loosen cylinder clamp, install ether cylinder, and
tighten clamp.
4-10. ETHER STARTING AID (Optional)
IMPORTANT: After installing or replacing ether cylin-
der, do not use or test ether start system for at least 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
This unit is shipped without the ether cylinder. Before
this device is operational, an ether cylinder must be ob-
tained and installed. To install the ether cylinder, pro-
ceed as follows:
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm
your health.
• Follow the manufacturer’s safety instructions
on the cylinder when handling ether compo-
nents.
4. Using a liquid soap and water solution, check all
ether start system connections for leaks. If a leak
exists, escaping gas will produce bubbles in the
solution.
5. Close and secure side door.
Ref. ST-164 613-A
Figure 4-4. Terminal Strip 3T Information
OM-166 941 Page 14
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SECTION 5 − AUXILIARY POWER
A brief period (less than 5 seconds) of large current draw
is required for starting motor-driven equipment. This
generator can supply 25% of rated current output at the
terminal strip for motor starting. Disconnect motor from
generator before starting engine. Use adequate size
cords so that voltage drop at the motor is not excessive.
Voltage drops significantly when starting motor-driven
equipment.
POWER OUTPUT
WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
Ground fault circuit interrupters (GFCI) may be re-
quired. Check local and state codes, and the latest issue
of the National Electrical Code.
• Do not touch live electrical parts.
• Stop the engine and disconnect negative (−)
battery cable from battery before making in-
ternal inspection or reconnection.
5-2.
120 VOLT TERMINALS (Chart 5-1, And
Figure 4-2)
• Ground generator as required by any applica-
WARNING: ELECTRIC SHOCK can kill.
ble national, state, and local electrical codes.
• Do not touch live electrical parts.
The generator neutral is connected to the frame;
therefore, the equipment grounding terminal
must be connected to a proper earth ground.
• Stop engine, and disconnect negative (−)
battery cable from battery before beginning
this installation.
• Do not connect to any electrical distribution
system normally supplied by utility power un-
less a proper transfer switch and grounding
procedure are employed.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT SURFACES can cause severe burns.
• Keep away from moving parts such as fans,
• Wear protective gloves and clothing when
belts, and rotors.
working near a hot engine.
• Keep all covers and panels in place while op-
• Allow components to cool completely be-
erating.
fore touching.
Warranty is void if unit is operated with any por-
tion of the outer enclosure removed.
IMPORTANT: All directions, such as left or right, are
with respect to the operator facing the welding generator
front panel. Retain all hardware removed during this
procedure for reinstallation unless specifically told
otherwise.
ELECTRIC SPARKS can cause fire.
• Disconnect weld cables when using auxiliary
power.
The weld output terminals are electrically ener-
gized when the engine is running and the con-
tactor (if applicable) is energized.
Chart 5-1. AC Power Curve For 120 Volt Terminals
• Watch for fire.
• Have a fire extinguisher nearby, and know
how to use it.
LOW VOLTAGE AND FREQUENCY can dam-
age electrical equipment.
• Turn off or unplug all electrical equipment
connected to auxiliary power before starting
or stopping the engine.
When starting or stopping, the engine has low
speed which causes low voltage and frequency.
5-1.
GENERAL
Calculate load requirements before connecting equip-
ment to the auxiliary power terminals on terminal strip
3T. For best performance (voltage and frequency regu-
lation), limit connected load to approximately 90% of
generator capability.
SB-109 365-B
OM-166 941 Page 15
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A. Auxiliary Equipment Connections To Terminal
Strip 3T (Figure 4-2)
3. Locate three strain reliefs on lower front panel.
4. Insert leads from cord(s) through a strain relief.
WARNING: Read and follow safety infor-
mation at beginning of entire Section 5-2
before proceeding.
5. Connect leads to terminal strip 3T using terminal
information provided in Figure 4-4.
6. Secure the cord(s) in the strain relief(s).
7. Close and secure door.
B. Protection
Terminal strip 3T is provided to directly wire the auxiliary
power cord(s) into the unit. To make connections, pro-
ceed as follows:
1. Remove plug from auxiliary equipment cord(s), if
applicable.
Circuit breaker CB1 protects the 120 volts ac auxiliary
power terminals from overload. See Section 9-3 for CB1
location and resetting procedure.
2. Open and secure lower front door.
SECTION 6 − OPERATOR CONTROLS
Amperage &
Voltage Adjustment
Control
Service Engine Remote Amperage &
Output
(Contactor)
Switch
Air Cleaner
Light
Voltage Switch
Check Alternator
Light
Engine Control
Switch
Voltmeter
Ammeter
Fuel Gauge
Battery Ampere
Gauge
Ampere
Ranges
Switch
Engine Hours
Meter
Oil Temperature
Gauge/Switch
Oil Pressure
Gauge/Switch
Ref. ST-147 322-E
Figure 8-1. Operator Controls
6-1.
AMPERE RANGES SWITCH (Figure 6-1)
The AMPERAGE & VOLTAGE ADJUSTMENT control
adjusts welding amperage within range selected by Am-
pere Ranges switch.The scale surrounding the control
is calibrated in percent and does not indicate an actual
amperage or voltage value.
The Ampere Ranges switch provides two coarse am-
perage ranges. When in LOW OUTPUT, amperage
range is 100-350 amperes. When in HIGH OUTPUT,
amperage range is 300-800 amperes.
IMPORTANT: The AMPERAGE & VOLTAGE AD-
JUSTMENT control may be adjusted while welding.
CAUTION: ARCING can damage switch
contacts.
• Do not change the position of the Ampere
6-3.
ENGINE CONTROL SWITCH (Figure 6-1)
Ranges switch while welding or under load.
Arcing causes the contacts to become pitted
and eventually inoperative.
6-2.
AMPERAGE & VOLTAGE ADJUSTMENT
CONTROL (Figure 6-1)
A/V
The Engine Control switch has three positions: START,
RUN, and OFF.
AMPERAGE AND VOLTAGE
ADJUSTMENT
OM-166 941 Page 16
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A. START Position
If remote amperage or voltage is not desired, place the
AMPERAGE & VOLTAGE switch in the PANEL posi-
tion. Only the AMPERAGE & VOLTAGE ADJUST-
MENT control will adjust output.
6-5.
OUTPUT(CONTACTOR) SWITCH (Figure
6-1)
Rotating the switch to the START position starts the en-
gine. Release the switch as soon as the engine starts,
and the switch automatically returns to the RUN posi-
tion.
ON
B. RUN Position
REMOTE
RUN
OUTPUT
(CONTACTOR)
When the Engine Control switch is in the RUN position,
engine speed remains at governed weld/power speed
(1860 rpm).
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
C. OFF Position
• Do not touch the output terminals when the
contactor is energized.
• Do not touch welding wire or electrode and
work clamp at same time.
When the OUTPUT/CONTACTOR switch is in
the ON position, open-circuit voltage is present
at the weld output terminals for as long as the
engine is running.
Rotating the Engine Control switch to the OFF position
disconnects battery voltage, thereby shutting down the
engine.
If the OUTPUT(CONTACTOR) switch is in the ON posi-
tion, open-circuit voltage will be present at the output
terminals whenever the engine is running.
6-4.
REMOTE AMPERAGE & VOLTAGE CON-
TROL SWITCH (Figure 6-1)
If remote contactor control by means of a wire feeder or
remote device is desired, make connections to the RE-
MOTE 9 receptacle or terminal strip 3T according to
Section 4-8, and place the OUTPUT(CONTACTOR)
switch in the REMOTE position. Open-circuit voltage is
present at the weld output terminals whenever the gun
switch or remote device is closed.
PANEL
REMOTE
A/V
6-6.
SERVICE ENGINE AIR CLEANER LIGHT
(Figure 6-1)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not touch the output terminals when the
This unit is equipped with an engine air cleaner. When
the SERVICE ENGINE AIR CLEANER light PL1 comes
on, the air cleaner requires servicing (see Section 8-2).
contactor is energized
• Do not touch welding wire or electrode and
work clamp at same time.
6-7.
CHECK ALTERNATOR (Figure 6-1)
If remote amperage or voltage control is desired, make
connections to the REMOTE 9 receptacle terminal strip
according to Section 4-8, and place the AMPERAGE &
VOLTAGE switch in the REMOTE position. When a Re-
mote Amperage or Voltage Control is being used, the re-
mote control functions as a fine amperage or voltage ad-
justment for the AMPERAGE & VOLTAGE ADJUST-
MENT control on the welding generator. For example, if
the AMPERAGE & VOLTAGE ADJUSTMENT control
on the welding generator is set at midrange, the Remote
Amperage or Voltage Control will provide (from mini-
mum to maximum adjustment) fine amperage or voltage
adjustment of one half of the welding generator output
for the range selected. For complete remote control of
the output, rotate the AMPERAGE & VOLTAGE AD-
JUSTMENT control to the maximum position.
The CHECK ALTERNATOR light PL3 comes on if the al-
ternator requires servicing. If the light comes on, check
for loose or broken engine belt.
6-8.
HOUR METER (Figure 6-1)
This unit is equipped with an hour meter. The meter, la-
beled ENGINE HOURS, registers the total hours of en-
gine operation. This information is useful for routine
maintenance on the engine.
OM-166 941 Page 17
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6-9.
FUEL GAUGE (Figure 6-1)
6-13. BATTERY GAUGE (Figure 6-1)
+
BATTERY
FUEL
The FUEL Gauge indicates the level of fuel remaining in
the fuel tank. The unit is equipped with a 30 gallon (114
L) fuel tank.
The BATTERY voltmeter registers the alternator-
supplied output voltage to the battery. The meter should
always register 12-15 volts dc while the engine is run-
ning. If the voltage is outside this range, stop the engine,
and determine the cause. Do not operate the engine un-
til the trouble has been corrected.
6-10. MAGNETIC SHUTDOWN SWITCH
An internal switch automatically shuts down the engine
if oil pressure drops to an unsafe level or oil temperature
becomes too high.
6-14. METERS (Figure 6-1)
The switch assembly is located directly behind the up-
per front panel access door, in the upper left corner. The
switch is protected by a fuse located on the bottom of the
switch assembly. Should this fuse open, the engine
would not start. See Section 9-3 for fuse replacement
procedure.
The meters are provided to monitor the welding opera-
tion; however, they are not intended for exact amperage
or voltage measurements. These meters are internally
connected to the output circuit.
The voltmeter indicates the voltage at the weld termi-
nals, but not necessarily the actual voltage at the weld-
ing arc (due to cable resistance, poor connections, etc.).
The ammeter indicates the amperage output of the unit.
6-11. OIL TEMPERATURE GAUGE/SWITCH (Fig-
ure 6-1)
6-15. BROKEN COOLING BELT SHUTDOWN
SWITCH
An internal switch automatically shuts down the engine
if the cooling belt breaks. The cooling belt is located on
the rear of the engine. If the engine shuts down, check
for broken cooling belt.
The OIL TEMPERATURE gauge/switch registers the
temperature of the oil in the lubricating system. If the oil
temperature rises to a level that may cause engine dam-
age (factory set at 265°F, 130°C), switch closes and
magnetic shutdown switch stops the engine (see Sec-
tion 6-10).
6-16. ETHER STARTING AID (Optional)
The cold weather starting components provide a means
of applying a premeasured portion of ether into the man-
ifold. The amount of ether supplied should be sufficient
to permit easy engine starting under cold weather condi-
tions.
6-12. OIL PRESSURE GAUGE/SWITCH (Figure
6-1)
Depressing ETHER STARTING AID switch for one sec-
ond while cranking the engine will provide the proper
amount of ether to the manifold. This control will function
only while cranking the engine.
CAUTION: ETHER INJECTION WHILE EN-
GINE IS RUNNING can cause engine dam-
age.
The OIL PRESSURE gauge/switch registers the lubri-
cating system pressure in pounds per square inch (psi).
The pressure registered by the gauge should remain
constant for a given engine speed. Should the pressure
fluctuate or drop, stop the engine, and do not operate
until the trouble has been corrected. If the oil pressure
drops to a level that may cause engine damage, switch
closes and magnetic shutdown switch stops the engine
(see Section 6-10). The shutdown oil pressure is factory
set at 30 psi (207 kPa). Normal operating pressure is ap-
proximately 50 psi (345 kPa).
• Do not actuate ETHER STARTING AID while
engine is running.
IMPORTANT: Ether is sprayed into the engine when
this switch is released. Depressing the switch does not
spray the ether into the engine but rather fills the valve
chamber.
OM-166 941 Page 18
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SECTION 7 − SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can kill;
7-1.
SHIELDED METAL ARC WELDING (SMAW)
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
• Do not touch live electrical parts.
• Stop the engine and disconnect negative (−)
battery cable from battery before inspecting
or servicing.
1. Install and connect unit according to Section 4.
2. Wear dry insulating gloves and clothing.
3. Connect work clamp to clean, bare metal at
workpiece.
• Keep away from moving parts such as fans,
belts, and rotors.
• Keep all covers and panels in place while op-
4. Select proper electrode.
erating.
5. Set Ampere Ranges switch and rotate AMPER-
AGE & VOLTAGE ADJUSTMENT control to the
desired position (see Sections 6-1 and 6-2).
Warranty is void if the welding generator is oper-
ated with any portion of the outer enclosure re-
moved.
6. If remote amperage control is not used, place
AMPERAGE & VOLTAGE switch in the PANEL
position. If remote amperage control is to be
used, place AMPERAGE & VOLTAGE switch in
the REMOTE position.
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
7. If remote contactor control is not used, place
OUTPUT(CONTACTOR) switch in the ON posi-
tion. If remote contactor control is to be used,
place OUTPUT(CONTACTOR) switch in the RE-
MOTE position.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
• Use in open, well ventilated areas or vent ex-
8. Start engine as instructed in Section 7-6.
haust out of doors.
9. Connect desired auxiliary equipment to the 120
volts ac terminals according to Section 5.
HOT METAL, SPATTER, SLAG, and EX-
HAUST can cause fire and burns.
10. Place Engine Control switch in the RUN position.
11. Energize auxiliary equipment, if applicable.
• Watch for fire.
• Have a fire extinguisher nearby, and know
how to use it.
12. Wear welding helmet with proper filter lens ac-
cording to ANSI Z49.1.
• Allow work and equipment to cool before han-
dling.
13. Insert electrode into electrode holder.
14. Begin welding.
ENGINE FUEL can cause fire or explosion.
• Stop engine before checking or adding fuel.
• Do not spill fuel; if spilled, wipe up.
• Do not refuel if engine is hot or running.
• Do not refuel near sparks or open flame.
• Do not smoke while refueling.
7-2.
GAS METAL ARC (GMAW) AND FLUX
CORED ARC WELDING (FCAW)
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
• Do not fill tank to top; allow room for expan-
sion.
1. Install and connect unit according to Section 4.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
2. Install and connect wire feeder to the terminal
strip according to wire feeder Owner’s Manual
and Section 4-8.
• Wearers should consult with their doctor be-
fore going near arc welding, gouging, or spot
welding operations.
3. Wear dry insulating gloves and clothing.
4. Connect work clamp to clean, bare metal at
workpiece.
See Section 1-Safety Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.
5. Set Ampere Ranges switch and rotate AMPER-
AGE & VOLTAGE ADJUSTMENT control to the
desired position (see Section 6-1 and 6-2).
OM-166 941 Page 19
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6. If remote amperage or voltage control is not
used, place AMPERAGE & VOLTAGE switch in
the PANEL position. If remote amperage or volt-
age control is to be used, place AMPERAGE &
VOLTAGE switch in the REMOTE position.
Table 7-1. Suggested Electrode Diameter For
Amperage Range (CAC-A Only)
Electrode Diameter
Amperage Range
Inches
Millimeters Minimum Maximum
7. If remote contactor control is not used, place
OUTPUT(CONTACTOR) switch in the ON posi-
tion. If remote contactor control is to be used,
place OUTPUT(CONTACTOR) switch in the RE-
MOTE position.
1/8
5/32
3/16
1/4
5/16
3/8
1/2
5/8
3/4
1
3.2
4.0
30
90
60
150
4.8
200
300
350
450
800
1000
1250
1600
250
6.4
400
8. Turn on shielding gas supply, if applicable.
9. Start engine as instructed in Section 7-6.
7.9
450
9.5
600
12.7
15.9
19.0
25.4
1000
1250
1600
2200
10. Connect desired auxiliary equipment to the 120
volts ac terminals according to Section 5.
11. Place Engine Control switch in the RUN position.
12. Energize auxiliary equipment, if applicable.
13. Wear welding helmet with proper filter lens ac-
cording to ANSI Z49.1.
7-4.
AUXILIARY POWER OPERATION
14. Begin welding.
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
7-3.
AIR CARBON ARC CUTTING AND GOUGING
(CAC-A) (Table 7-1)
1. Install and connect unit according to Section 4.
2. Install and connect auxiliary power equipment
cord(s) to 120 volts auxiliary power terminals ac-
cording to Section 5-2.
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
3. Start engine as instructed in Section 7-6.
4. Place Engine Control switch in the RUN position.
1. Install and connect unit according to Section 4.
2. Wear dry insulating gloves and clothing.
5. Energize auxiliary equipment, if applicable. Auxil-
iary power may be obtained whenever engine is
running.
3. Connect work clamp to clean, bare metal at work-
piece.
7-5.
AIR COMPRESSOR OPERATION (Tables 7-2
And 7-3)
4. Place AMPERAGE & VOLTAGE switch in the
PANEL position.
1. Install and connect unit according to Section 4.
2. Install a quick-connect connector onto the air
compressor fitting in top cover of unit.
5. Place OUTPUT(CONTACTOR) switch in the ON
position.
3. Start engine as instructed in Section 7-6.
4. Begin operation.
6. Set Ampere Ranges switch and rotate AMPER-
AGE & VOLTAGE ADJUSTMENT control to the
desired position (see Sections 6-1 and 6-2).
7-6.
STARTING THE ENGINE
7. Start engine as instructed in Section 7-6.
IMPORTANT: Read entire engine Owner’s Manual
(Deutz F4L-912 engine) before operating engine.
8. Connect desired auxiliary equipment to the 120
volts ac terminals according to Section 5.
1. Engine Prestart Checks
a. Oil Level
9. Place Engine Control switch in the RUN position.
10. Energize auxiliary equipment, if applicable.
Check engine oil level. If oil level is low, fill to top
mark on dipstick (see engine Owner’s Manual
for oil selection specifications and Section 4-5).
11. Wear welding helmet with proper filter lens ac-
cording to ANSI Z49.1.
If oil consumption and wetstacking occur during
run-in period, see Section 8-12.
12. Begin welding.
OM-166 941 Page 20
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b. Fuel Level
release ETHER STARTING AID switch after one
second.
WARNING: REMOVE FUEL CAP SLOWLY;
FUEL SPRAY may cause injury; FUEL may
be under pressure.
CAUTION: REENGAGING STARTER MO-
TOR while flywheel is rotating or EXCEED-
ING RATED CRANKING TIME can damage
starting components.
• Rotate fuel cap slowly and wait until hissing
stops before removing cap.
• Do not reengage starter motor until starter
pinion and flywheel have stopped rotating.
Check fuel level. If necessary, fill tank with
fresh, clean fuel (see engine Owner’s Manual
for fuel specifications).
• Do not exceed maximum cranking time of 20
seconds.
Allow two minutes cooling time before attempt-
ing to restart engine.
c. Cooling System
Check the air cooling system by inspecting the
air intake and exhaust openings for blockage
and blower impeller for obstruction and free
movement. Check the blower/alternator belt for
proper tension (see the engine Owner’s Man-
ual), and ensure that all sheet metal cowlings,
shrouds, and panels are properly in place and
secure.
3. As soon as engine starts, release Engine Control
switch, and allow the engine to warm up for ap-
proximately three minutes with no weld or power
load applied.
7-7.
STOPPING THE ENGINE
1. Stop all operations, and turn off or disconnect any
auxiliary equipment.
d. Air Cleaner
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
Check air cleaner service indicator daily (see
Section 6-6).
• Shut off gas supply when not in use.
2. Rotate Engine Control switch to the OFF posi-
tion.
2. Rotate Engine Control switch to the START posi-
tion, and if applicable, depress ETHER START-
ING AID switch, if applicable, at the same time —
Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
Gauge Pressure In
Receiver (lbs.)
Orifice Diameter And Free Air Flow (CFM)
1/64”
1/32”
3/64”
1/16”
3/32”
1/8”
3/16”
1/4”
1
2
3
5
10
0.027
0.038
0.046
0.059
0.084
0.107
0.153
0.188
0.242
0.342
0.242
0.342
0.471
0.545
0.77
0.430
0.607
0.750
0.965
1.36
0.97
1.36
1.68
2.18
3.08
1.72
2.43
2.98
3.86
5.45
3.86
5.42
6.71
8.71
12.3
6.85
9.74
11.9
15.4
21.8
15
20
25
30
35
0.103
0.119
0.133
0.156
0.173
0.418
0.485
0.54
0.632
0.71
0.94
1.07
1.21
1.40
1.56
1.67
1.93
2.16
2.52
2.80
3.75
4.25
4.75
5.6
6.65
7.7
8.6
10.0
11.2
15.0
17.1
19.4
22.5
25.0
26.7
30.8
34.5
40.0
44.7
6.2
40
45
50
60
70
0.19
0.208
0.225
0.26
0.77
0.843
9.14
1.05
1.19
1.71
1.9
2.05
2.35
2.68
3.07
3.36
3.64
4.2
6.8
7.6
8.2
9.4
10.7
12.3
13.4
14.5
16.8
19.0
27.3
30.3
32.8
37.5
43.0
49.1
53.8
58.2
67.0
76.0
0.295
4.76
80
90
100
110
120
0.33
0.364
0.40
0.43
0.47
1.33
1.47
1.61
1.76
1.90
2.97
3.28
3.66
3.95
4.27
5.32
5.87
6.45
7.00
7.58
11.9
13.1
14.5
15.7
17.0
21.2
23.5
25.8
28.0
30.2
47.5
52.5
58.3
63.0
68.0
85.0
94.0
103.0
112.0
121.0
130
140
150
175
200
0.50
0.54
0.57
0.66
0.76
2.04
2.17
2.33
2.65
3.07
4.57
4.87
5.2
5.94
6.90
8.13
8.68
9.20
10.6
12.2
18.2
19.5
20.7
23.8
27.5
32.4
34.5
36.7
42.1
48.7
73.0
78.0
83.0
95.0
110.0
130.0
138.0
147.0
169.0
195.0
OM-166 941 Page 21
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Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate Various Pneumatic
Equipment At Pressure Range 70-90 P.S.I.G.
Percent Use Factor And
Percent Use Factor And
MISCELLANEOUS
PORTABLE
TOOLS
MISCELLANEOUS
PORTABLE
TOOLS
Compressed Air Consumption (CF)
Compressed Air Consumption (CF)
9 sec
15 sec
21 sec
1 min
9 sec
15 sec
21 sec
1 min
Drill, 1/18” to 3/8”
Drill, 3/8” to 5/16”
3.75
6.25
8.75
25
Burring Tool, Large
Rammers, Small
3.6
6.0
8.4
24
5.25
8.75
12.25
35
3.9
3.25
9.1
13
Screwdriver,
#2 to #6 Screw
1.8
3.0
4.2
12
Rammers, Medium
5.1
8.5
11.9
34
Screwdriver,
#6 to 5/16” Screw
3.6
3.0
3.6
4.5
6.0
5.0
6.0
7.5
8.4
7.0
24
20
24
30
Rammers, Large
Backfill Tamper
6.0
10.0
6.25
14.0
8.75
40
25
Tapper, to 3/8”
3.75
Nutsetters, to 3/8”
Nutsetters, to 3/4”
8.4
Compression Riveter
0.2 cu. ft. per cycle
10.5
Air Motor,
1 Horsepower
3.75
7.5
6.3
8.75
25
50
75
Impact Wrench, 1/4”
2.25
3.75
5.3
15
Air Motor,
2 Horsepower
12.5
18.75
17.5
26.3
Impact Wrench, 3/8”
Impact Wrench, 5/8”
Impact Wrench, 3/4”
Impact Wrench, 1”
3.0
4.5
5.0
7.5
7.0
10.5
12.25
15.75
19.2
5.3
20
30
35
45
55
15
24
20
60
60
Air Motor,
3 Horsepower
11.25
Air Motor Hoist
1000#
5.25
6.75
8.25
2.25
3.6
8.75
11.25
13.75
3.75
6.0
1 cu. ft. per foot of lift
1 cu. ft. per foot of lift
Air Motor Hoist,
2000#
Impact Wrench, 1-1/4”
Die Grinder, Small
Paint Spray Gun
(Production)
3.0
5.00
7.00
20
Die Grinder, Medium
Horizontal Grinder, 2”
Horizontal Grinder, 4”
Horizontal Grinder, 6”
8.4
HAMMERS
3.0
5.0
7.0
Scaling Hammer
Chipping Hammer
1.3
4.5
3.0
7.5
4.2
12
30
9.0
15.0
15.0
21.0
21.0
10.5
9.0
Riveting Hammer,
Light
2.25
4.5
3.75
7.5
5.25
10.5
15
30
Horizontal Grinder, 8”
12.0
5.25
9.0
20.0
8.75
15.0
28.0
12.25
21.0
80
35
60
Riveting Hammer,
Heavy
Vertical Grinders and
Sanders, 5” Pad
SAWS
Vertical Grinders and
Sanders, 7” Pad
Circular, 8”
6.75
9.75
4.20
13.1
11.25
16.25
7.0
15.75
23.8
9.8
45
65
28
87
Circular, 12”
Vertical Grinders and
Sanders, 9” Pad
10.5
2.25
17.5
3.75
24.5
5.3
70
15
Chain, Lightweight
Chain, Heavy Duty
Burring Toll, Small
21.8
30.5
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-166 941 Page 22
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SECTION 8 − MAINTENANCE
8-1.
ROUTINE MAINTENANCE (Table 8-1)
C. Oil, Filter, And Drain
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List for part numbers of
precautionary labels.
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
The engine is equipped with a full-flow oil filter. Change
the oil and filter according to instructions on unit mainte-
nance label and in engine Owner’s Manual (Deutz
F4L-912 engine). Use correct type and grade of oil as
listed in instructions for expected temperature range be-
fore next oil and filter change.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−)
battery cable from battery before inspecting,
maintaining, or servicing.
This unit is equipped with an oil drain hose secured in a
clamp behind the rear panel. A valve is provided in the
hose inside the right side base rail. To drain oil from en-
gine, remove drain hose from clamp and open valve.
Close valve and reinstall hose into clamp before adding
new oil.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
IMPORTANT: This engine is equipped with an Oil Pres-
sure Shutdown gauge/switch and an Oil Temperature
Shutdown gauge/switch. If oil pressure becomes too
low or oil temperature rises to a level that may cause en-
gine damage, the respective gauge/switch shuts down
the unit. The shutdown oil pressure has been factory set
at 30 psi (207 kPa), and the shutdown oil temperature
has been set at 265° F (130° C).
• Wear protective gloves and clothing when
working on a hot engine.
BATTERY ACID can burn eyes, skin, destroy
clothing, and damage other material.
• Wear correct eye and body protection.
Maintenance to be performed only by qualified
persons.
A. Cables And Wiring
D. Cleaning And Inspecting
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
Check interconnecting wiring and connections for
tightness and flaws. Be sure that the weld output cable
connections are clean and tight. Check the insulation for
breaks or other signs of damage. Repair or replace
cables or wiring as necessary.
When performing routine oil changes at intervals
specified on the unit maintenance label, clean and
inspect the unit as follows:
1. Keep the inside of the welding generator clean by
blowing out the unit with clean, dry compressed
air.
B. Battery
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
2. Wipe oil and fuel spills from engine immediately
to avoid accumulation of dust.
3. Check for fluid leaks indicating loose oil or fuel
connections. Tighten loose connections, and
clean oil or fuel spills off engine.
Inspect the battery for loose connections, damaged
cables, corrosion, cracked case or cover, loose
holddowns, and loose or deformed terminal posts.
IMPORTANT: See the engine Owner’s Manual (Deutz
F4L-912 engine) for complete engine care.
Clean and tighten connections, replace cables, or
replace battery if necessary.
Table 8-1. Maintenance Schedule
Frequency*
Every day.
Maintenance
Check fuel and oil levels (see Sections 4-4, 4-5, and 8-1C, and engine Owner’s Manual,
Deutz F4L-912 engine).
Every 100 to 150 hours. Change oil and filter (see engine Owner’s Manual, Deutz F4L-912 engine).
Check cables, wiring (see Section 8-1A), and battery (see Section 8-1B).
Units in heavy service environments: Check labels; clean and inspect unit (see Section 8-1).
Change fuel/water separator (see Section 8-3).
Every 250 hours.
Every 1000 hours.
Replace fuel filter (see Section 8-4).Check brushes and slip rings (see Section 8-9).
Check all labels (see IMPORTANT block, Section 8-1). Clean and inspect unit (see Section 8-1D).
*Frequency of service is based on unit operated 40 hours per week. Increase frequency of maintenance if usage exceeds 40 hours per week.
OM-166 941 Page 23
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3 0
- 2 0 2 0 W
1 0 W
Figure 8-1. Engine Maintenance Label
OM-166 941 Page 24
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8-2.
AIR CLEANER SERVICE (Table 8-2)
The air cleaner on this unit is equipped with precleaners.
Remove the precleaner cover and empty the dust re-
ceptacle when dirt accumulates up to the indicator
marks on the side of the precleaner.
CAUTION: DIRTY AIR can damage engine.
• Do not operate engine with dirty air cleaner
element in place.
• Do not operate engine without air cleaner ele-
IMPORTANT: A dirty air cleaner element is usually ac-
companied by a loss of power and excessive smoke in
the engine exhaust.
ment in place.
The air cleaner is one of the most important parts of the
engine from the standpoint of engine life. If dirty air gets
into the engine, it can cause major engine damage
within a few operating hours. The air cleaner must be
serviced when the SERVICE ENGINE AIR CLEANER
Indicator light PL1 comes on. If PL1 comes on, empty
dust cap, and inspect air cleaner and element.
When it becomes necessary to service the air cleaner in
the field, follow the steps in Table 8-2. Keep a spare ele-
ment on hand for replacement. New elements are avail-
able from your welding equipment distributor.
Table 8-2. Air Cleaner Service
1. Stop engine.
5. Wipe out element chamber
with clean, damp cloth.
7. Reinstall element.
8. Replace cover.
Follow
These
Easy
2. Wipe off cover before
opening air cleaner.
6. Inspect new element and all
gaskets for shipping damage before use.
3. Remove cover.
Steps:
4. Remove element.
1. Don’t attempt to service air
cleaner with engine running.
3. Don’t leave open air cleaner exposed
to blowing dust while you clean element.
Replace cover.
5. For Donaclone air cleaners ,
don’t blow out Donaclone tube
section without element, cover
and inner cover (if any)
correctly installed or you will
blow dust into the engine.
Important
2. Don’t blow out the inside of
the air cleaner with compressed
air.
4. If air cleaner is horizontally mounted,
be sure that dust cup is positioned so
arrows point up.
Clean element by one of the
following methods:
re-use. However, washing does
(When cleaning Cyclopac
elements, do not remove
plastic fin assembly − back-
flowing with compressed air or
washing will remove dust from
beneath the fin assembly).
How To
Clean
a better job and must be used when
exhaust soot has lodged in fine pores
of the filter media. Use Donaldson D-1400
detergent which contains a special
additive for removing soot and carbon.
Compressed Air or Washing.
Elements
For
Compressed air is recommended
when element will be re-used
immediately because a washed
element must be dried before
Re-Use
Replace element after 6 cleanings or
annually, whichever occurs first.
Compressed Air
Washing
Inspection
Direct air through element in
the direction opposite to normal
air flow through the element.
Move nozzle up and down while
rotating element. Keep nozzle
at least one inch from pleated
paper. Maximum air pressure −
100 P.S.I.
1. Soak element 15 minutes or more
in Donaldson D-1400 and water solution.
See carton for full instructions.
Place bright light inside
element and rotate element
slowly. If any rupture, holes
or damaged gaskets are
discovered − replace.
2. Rinse until water is clear (Maximum
water pressure 40 P.S.I.)
3. Air-dry or use warm flowing air, max.
160 F. Do not use compressed air or
light bulbs.
S-0091/4-89
OM-166 941 Page 25
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Oil Fill Cap
8-3.
FUEL/WATER SEPARATOR AND SLUDGE
DRAIN PLUG
WARNING: ENGINE FUEL can cause fire or
explosion.
Fuel Filter
• Do not drain fuel tank while engine is running.
• Do not smoke while handling fuel.
Engine Speed
Adjustment
Screw
• Do not allow fuel to drain onto the engine or
other components.
• Do not spill fuel; if spilled, wipe up.
• Have a fire extinguisher nearby, and know
how to use it.
A. Fuel/Water Separator
The fuel/water separator, located on the right base rail
near the engine, is provided to drain off water from the
fuel system. Before starting the engine for the first time
each day, open the fuel drain plug on the bottom of the
separator, and drain the water into a metal container.
Close the drain plug at the first signs of fuel. The fuel/
water separator should be changed every 125 hours of
operation or every four months, whichever occurs first.
Ref. ST-147 321-A
Figure 8-2. Right Side And Rear View Of Engine
8-5.
BATTERY REPLACEMENT PROCEDURE
B. Sludge Drain Plug
WARNING: SPARKS OR FLAMES can cause
BATTERY GASES to explode; BATTERY
ACID can burn eyes and skin.
A sludge drain plug, located on the lower right front cor-
ner of the unit, is provided to drain off sediment from the
fuel tank. Once a week, drain the sludge into a metal
container. If the fuel is extremely dirty, drain the sludge
daily.
• Stop engine before disconnecting or
connecting battery cables.
• Keep sparks, flames, cigarettes, and other
ignition sources away from batteries.
• Do not allow tools to cause sparks when
working on a battery.
8-4.
FUEL FILTER (Figure 8-2)
• Always wear a face shield and proper
protective gloves and clothing when working
on a battery.
WARNING: ENGINE FUEL can cause fire or
explosion.
Use the following procedure to prevent sparks when
removing or installing a battery:
• Stop engine before working on fuel system.
• Do not spill fuel; if spilled wipe up.
1. Be sure engine is fully stopped, and Engine
Control switch is in the OFF position.
• Do not service fuel filter if engine is hot or run-
ning.
2. Locate battery in unit.
• Do not service fuel filter near sparks or open
flame.
3. Open door or remove panels as necessary.
• Do not smoke while servicing fuel filter.
4. Disconnect negative (−) battery cable first and
positive (+) cable last.
• Have a fire extinguisher nearby, and know
how to use it.
5. Remove holddown device.
6. Remove battery.
This welding generator is equipped with a cartridge-type
fuel filter located above the oil filter on the right side of
the unit. The fuel filter should be replaced after 1000
hours of operation, or more often depending on the qual-
ity of fuel used and how dusty and dirty the location is in
which the engine is being used. To replace the fuel filter,
refer to the Engine Manufacturer’s Manual.
7. Install new (or charged) battery.
8. Reinstall and secure holddown device.
9. Connect positive (+) cable first and negative (−)
cable last.
10. Securely reinstall or close doors or panels.
OM-166 941 Page 26
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8-6.
MAINTENANCE-FREE BATTERY CHARG-
ING
3. If the battery does not have removable vent caps,
check the condition of the battery as follows:
a. Check the stabilized open−circuit voltage of the
battery. For a 12 volt battery, any reading below
12.4 volts indicates the battery needs charging.
Disconnect both battery cables from the bat-
tery, and allow battery voltage to stabilize for
several hours.
WARNING: CHARGING A FROZEN BAT-
TERY can cause the battery to explode and
result in serious personal injury or damage
to equipment.
• Allow battery to warm up to 60° F (16°C) be-
fore charging if battery is frozen.
b. If the stabilized open−circuit voltage is below
12.4 volts, charge the battery following the bat-
tery charger manufacturer’s instructions.
BATTERY ACID can burn eyes and skin and
destroy clothing and other materials; BAT-
TERY GASES can explode and shatter bat-
tery.
4. Remove damp cloth from battery.
5. Reinstall battery in unit.
• Wear a face shield, proper protective cloth-
ing, and remove all metal jewelry.
• Do not spill or splash battery fluid.
6. Replace battery holddown, and tighten securely.
Do not overtighten.
• Do not apply pressure to walls of filled bat-
tery—use battery carrier or place hands on
opposite corners when lifting battery.
7. Connect positive (+) battery cable to positive (+)
battery terminal.
• Keep sparks, flames, cigarettes, and other ig-
8. Connect negative (−) battery cable to negative
(−) battery terminal.
nition sources away from batteries.
• Use enough ventilation to keep battery gases
from building up during and for several hours
after battery charging.
8-7.
GOVERNOR
The governor has been set at the factory and should not
require further adjustment.
• Do not touch or move connections on battery
while battery charger is on.
• Turn battery charger off before making con-
8-8.
ENGINE SPEED ADJUSTMENTS (Figure 8-2)
nections to battery.
WARNING: ELECTRIC SHOCK can kill.
• Do not lean over battery when charging.
• Do not touch live electrical parts.
• Be sure battery charger connections to bat-
• Stop engine, and disconnect negative (−)
battery cable from battery before inspecting,
maintaining, or servicing.
tery are clean and tight.
• Keep vent caps in place and cover top of bat-
tery with damp cloth.
MOVING PARTS can cause serious injury.
• Be sure battery charger output matches bat-
• Keep away from moving parts such as fans,
tery voltage.
belts, and rotors.
• Turn the battery charger off before discon-
HOT ENGINE PARTS can cause severe
burns.
necting the charger from the battery.
• Wear protective gloves and clothing when
1. Remove battery from unit, and place on a level
worktable or other suitable surface.
working on a hot engine.
Maintenance to be performed only by qualified
persons.
2. If battery has removable vent caps, check the
condition of the electrolyte as follows:
The engine speeds have been factory adjusted and
should not require frequent readjustment. After tuning
the engine, check the speeds with a tachometer. With
no load applied, the weld/power speed should be 1860
rpm. If necessary, adjust the speeds as follows:
a. Check electrolyte temperature in one of the
center cells with a battery thermometer. For
each 10°F (6°C) increment above 80°F (27°C),
a correction factor of 0.004 specific gravity
must be added to the specific gravity reading
taken in Step 2b. For each 10°F (6°C) incre-
ment below 80°F (27°C), 0.004 must be sub-
tracted from the reading taken in Step 2b.
1. Open and secure right rear side door.
2. Loosen nut on end of engine speed adjusting
screw (see Figure 8-2).
3. Start the engine as instructed in Section 7-6.
4. Adjust the weld/power speed as follows:
b. Check the specific gravity of each cell with a hy-
drometer. (Draw in and expel the electrolyte two
or three times from the first cell to be tested to
adjust the temperature of the hydrometer to
that of the electrolyte.)
IMPORTANT: All directions, such as clockwise and
counterclockwise, are with respect to the operator fac-
ing the rear panel of the unit.
a. To increase weld/power speed, rotate the en-
gine speed adjustment screw clockwise.
c. If a corrected specific gravity reading of 1.225 at
80°F (27°C) is not obtained, replace the vent
caps and recharge the battery following the bat-
tery charger manufacturer’s instructions.
b. To decrease weld/power speed, rotate the en-
gine adjustment screw counterclockwise.
OM-166 941 Page 27
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5. When the weld/power speed reaches 1860 rpm,
prevent the adjustment screw from turning, and
tighten the securing nut.
No indicator is provided to show the amount of ether left
in the cylinder; therefore, it is recommended that a spare
cylinder be kept on hand. Generally, the ether cylinder is
empty if the engine fails to start in cold weather while uti-
lizing the cold weather starting system.
6. Stop engine.
7. Close and secure side door.
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm
your health.
8-9.
BRUSHES AND SLIP RINGS (Figure 8-3)
• Follow the manufacturer’s safety instructions
on the cylinder when handling ether compo-
nents.
WARNING: ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−) bat-
tery cable from battery before inspecting,
maintaining, or servicing.
The cylinder can be weighed to determine the amount
of ether inside. The cylinder weighs 33 ounces (936 gr)
when full, and it weighs 15 ounces (425 gr) when empty.
To replace the ether cylinder, see Section 4-10.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
cylinder is inserted. If dirt is present in either of these ar-
eas, the system may not work.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
Brush life is very good under most operating conditions.
The brushes and slip rings should be inspected every
six months or whenever excitation voltage is lost. Be
sure that slip rings are clean and brushes are free to
move. If the welding generator has been operating un-
der extremely dusty or dirty conditions, increase the fre-
quency of inspection.
IMPORTANT: After installing or replacing ether cylin-
der, do not use or test ether start system for at least 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
8-11. SPARK ARRESTOR
Under normal use, the slip rings will discolor to a dark
brown. If a buildup of brush material is noted, it may be
necessary to clean the slip rings. Clean rings with a
number 220 or finer sandpaper, and polish rings with
crocus cloth. Never use emery cloth because part of the
emery will embed itself into the rings and, in turn, de-
stroy the carbon brushes.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine and disconnect negative (−)
battery cable from battery before beginning
this installation.
MOVING PARTS can cause severe injury.
Replace the brushes if they become chipped or broken
or if less than 1/2 in. (12.7 mm) of brush material is left.
• Keep away from moving parts such as fans,
belts, and rotors.
ENGINE EXHAUST SPARKS can cause fire.
• Exhaust spark arrestor must be installed in
accordance with local, state, and federal
regulations.
1/2 in. (12.7 mm)
Minimum
• Stop engine before cleaning spark arrestor.
• Clean spark arrestor in a noncombustible
environment.
S-0234
HOT PARTS can cause severe burns.
Figure 8-3. Brush Replacement
• The exhaust system must be cold when
servicing the spark arrestor.
8-10. ETHER STARTING AID (Optional)
Internal combustion engines operating in a highly com-
bustible environment are a common fire hazard. Glow-
ing carbon particles blown out with the exhaust can re-
tain sufficient heat to ignite materials. While no practical
spark arresting device will stop all sparks, this device will
minimize fire hazards by removing and trapping most
solid particles provided that is is properly maintained.
CAUTION:
ETHER INJECTION WHILE
ENGINE IS RUNNING can cause engine
damage.
• Do not actuate ETHER STARTING AID while
engine is running.
The ether used in the cold weather starting aid system is
contained in a replaceable cylinder located behind the
right rear side door on the center portion of the frame.
Inspect and service spark arrestor every 250 operation
hours.
OM-166 941 Page 28
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Removal of the device from the exhaust system is not
necessary for servicing. Proceed as follows to service
spark arrestor:
occur during the run-in period if the engine is left at idle
rpm too long, or the welding generator is not heavily
loaded.
1. Stop the engine, and allow the exhaust system to
cool.
If wetstacking occurs, complete one of the following pro-
cedures to dry the engine (see engine Owner’s Manual,
F4L-912 diesel engine). A resistance load is required to
fully load the generator during the run-in procedure. A
load bank or resistance grid may provide a constant load
for run-in, however, a load bank is preferred. If a load
bank is available, proceed with the run-in procedure pro-
vided in Subsection A. If a resistance grid is being used,
proceed to Subsection B.
2. Remove the cleanout plug from the bottom of the
spark arrestor. If a crust has formed over the
hole, break it loose with a screwdriver or similar
tool.
3. Start the engine, and run it at idle rpm to blow col-
lected particles out the cleanout hole. If particles
are slow to discharge, momentarily cover the end
of the exhaust stack.
A. Run-In Procedure Using Load Bank (Diagram
8-1)
4. Stop the engine, and allow the exhaust system to
cool.
WARNING: Read and follow safety infor-
mation at beginning of entire Section 8-12
before proceeding.
5. Replace and secure the cleanout plug.
1. Stop engine.
8-12. RUN-IN PROCEDURE
IMPORTANT: Weld cables supplied with load bank may
be inadequate for run-in procedure. Use weld cables of
proper size with appropriate connectors to connect load
bank to generator (see load bank Owner’s Manual).
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine before inspecting, connecting,
or servicing.
2. Connect cables from load bank to generator weld
output terminals observing correct polarity (see
Diagram 8-1).
• Do not leave live unit unattended when
engine is running.
• Keep all panels, covers, and guards
3. Place all load switches in the OFF position.
securely in place while engine is running.
IMPORTANT: If load bank requires 115 volts ac, it may
be connected to the welding generator auxiliary power
terminal strip, if applicable.
MOVING PARTS can cause severe injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
4. Place welding generator AMPERAGE & VOLT-
AGE ADJUSTMENT control in the minimum po-
sition.
• Wear protective gloves and clothing when
working on hot engine parts or components.
5. Start engine as instructed in Section 7-6, and al-
low engine to warm up for approximately three
minutes.
CAUTION: LOW OIL LEVEL can damage
engine; ENGINE MAY USE OIL AND WETS-
TACKING may occur during run-in period.
6. Adjust load bank switches and generator controls
to provide a load equal to rated generator output.
• Check oil level several times a day during
run-in period, and add oil if required.
• See engine Owner’s Manual (Deutz
F4L-912 diesel engine) for run-in informa-
tion.
For example, if rated generator output is 350 am-
peres, 40 volts at 100% duty cycle, adjust
switches until values indicated by load meters
equal rated generator output.
• Do not idle engine longer than necessary
during run-in period.
7. Allow engine to run under load for at least one
hour. Check engine and load bank meters after
the first five minutes and every 15 minutes there-
after to be sure equipment is operating properly.
• Piston rings seat faster if engine runs at
weld/power rpm, and the welding generator
is kept loaded during the run-in period.
The run-in procedure for diesel engines is different than
those associated with gasoline engines. Diesel engines
must be run at near-rated load during the run-in period to
ensure proper seating of piston rings and to prevent
wetstacking. Wetstacking is an accumulation of un-
burned fuel and oil in the exhaust pipe. Wetstacking can
8. After running engine under load for at least one
hour, remove load by shutting down load bank.
9. Allow engine to idle for approximately three min-
utes to permit internal engine temperatures to
equalize.
OM-166 941 Page 29
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Welding
Generator
Load Bank
Positive (+)
Weld Output
Terminal
Negative (−)
Weld Output
Terminal
+
−
Voltmeter
−
+
And
Ammeter
Weld
Cables
S-0456
Diagram 8-1. Load Bank Connections
10. Stop engine, and disconnect load bank cables.
11. Allow exhaust system to cool.
are not provided, connect voltmeter and clamp-
on dc ammeter as shown in Diagram 8-2.
9. Connect remaining ends of weld cables to gener-
ator weld output terminals (polarity is not impor-
tant).
12. Inspect inside of exhaust pipe. If pipe is dry, the
run-in procedure is complete. If pipe is coated
with a wet, black, tar-like substance, repeat run-
in procedure.
10. Start engine as instructed in Section 7-6, and al-
low engine to warm up for approximately three
minutes.
B. Run-In Procedure Using Resistance Grid (Dia-
gram 8-2)
CAUTION: ARCING can damage switch
contacts.
WARNING: Read and follow safety infor-
mation at beginning of entire Section 8-12
before proceeding.
• Do not change the position of the grid
switches while engine is running.
1. Stop engine.
Arcing causes the contacts to become pitted
and eventually inoperative.
2. Obtain resistance grid adequately sized for rated
output of welding generator.
11. Check meters. Adjust load with generator con-
trols or, if necessary, by changing positions of grid
switches until values indicated by meters equal
rated generator output.
3. Obtain two weld cables of proper size to connect
resistance grid to generator (see Section 4-7).
4. If a voltmeter and ammeter are not provided on
the welding generator, obtain a voltmeter and
clamp-on dc ammeter.
12. Allow engine to run under load for at least one
hour. Check engine and meters after the first five
minutes and every 15 minutes thereafter to be
sure equipment is operating properly
5. Place welding generator AMPERAGE & VOLT-
AGE ADJUSTMENT control in the minimum po-
sition.
13. After running engine under load for at least one
hour, remove load by shutting down resistance
grid.
6. Adjust grid switches and generator controls to
provide a load approximately equal to rated gen-
erator output.
14. Allow engine to idle for approximately three min-
utes to permit internal engine temperatures to
equalize.
For example, if rated generator output is 350 am-
peres, 40 volts at 100% duty cycle, adjust
switches until values indicated by meters equals
rated generator output.
15. Stop engine, and disconnect weld cables.
16. Allow exhaust system to cool.
7. Connect one weld cable to grid input receptacle
and remaining weld cable to grid output recep-
tacle (see Diagram 8-2).
17. Inspect inside of exhaust pipe. If pipe is dry, the
run-in procedure is complete. If pipe is coated
with a wet, black, tar-like substance, repeat run-
in procedure.
8. If a voltmeter and ammeter are provided on the
welding generator, proceed to Step 9. If meters
OM-166 941 Page 30
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Welding
Generator
Voltmeter And
Ammeter
(If so equipped)
Resistance Grid
Input And Output
Receptacles
Weld Output
Terminals
(Polarity Not
Important)
Weld
Cables
♦ Clamp-On
V
DC Ammeter
♦ Voltmeter
A
♦ Required if welding generator is not equipped with meters.
S-0457
Diagram 8-2. Resistance Grid Connections
SECTION 9 − TROUBLESHOOTING
9-1.
GENERAL
• Wear correct eye and body protection, and
remove all metal jewelry.
It is assumed that proper installation has been made,
according to Section 4 of this manual, the operator is fa-
miliar with the function of controls, the welding generator
was functioning properly, and the trouble is not related to
the welding process.
• Keep jumper cables clear of moving parts.
• Ensure that both batteries are of the same
voltage.
• Do not jump start a trailer mounted welding
generator with the towing vehicle battery un-
less the trailer is completely disconnected
from the towing vehicle.
9-2.
BOOSTER BATTERY JUMP STARTING
If it is necessary to jump start this unit, use the following
safety precautions and the step-by-step procedures in
order of appearance.
• Do not jump start a vehicle mounted welding
generator from the vehicle battery.
• If booster battery is installed in vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
WARNING: BATTERY GASES OR A DAM-
AGED BATTERY can explode thereby shat-
tering the battery; BATTERY ACID can burn
eyes, skin, destroy clothing, and damage
other material; MOVING PARTS AND IM-
PROPER CONNECTIONS can cause serious
personal injury and damage equipment.
• Do not jump start by applying power to weld
output receptacles or terminals.
• Do not allow jumper cables to contact any
other metal while attaching or removing ca-
bles.
• Keep sparks, flames, cigarettes, and other ig-
1. Use properly insulated jumper cables of ade-
quate size.
nition sources away from battery.
• Ensure that all personnel are a safe distance
from batteries and clear of moving parts while
starting.
2. Connect ends of one cable to positive (+) termi-
nals of each battery.
3. Connect one end of other cable to negative (−)
terminal of booster battery.
• Do not jump start a frozen or completely dis-
charged battery.
4. Connect remaining end of cable to welding gen-
erator engine block at least 18 inches (457 mm)
from battery (do not connect to welding generator
case, frame, or equipment grounding terminal as
damage to equipment can result).
• Do not jump start a battery which has loose
terminals or one having evidence of damage
such as a cracked case or cover.
• Be sure that vent caps are tight and level on
both batteries and cover both batteries with a
damp cloth.
5. Wait at least one minute after connecting cables
before starting engine.
OM-166 941 Page 31
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6. Start engine following procedures outlined in
Section 7 (Sequence of Operation) of this man-
ual. If the unit does not start after cranking for
twenty seconds, stop the jump starting proce-
dure. More than twenty seconds seldom starts
the engine unless some mechanical adjustment
is made.
If CB3 opens, 115 volts ac output to socket/terminal D of
REMOTE 9 receptacle RC3 and terminal strip 3T stops,
and the remote amperage/voltage control will not
function.
C. Replacement Of Low Oil Pressure/High Oil
Temperature Shutdown System Fuse F
7. Remove jumper cable from engine block.
WARNING: Read and follow safety informa-
tion at beginning of Section 9-3 before pro-
ceeding.
8. Remove other end of same cable from booster
battery negative (−) terminal.
9. Remove other jumper cable from booster battery
positive (+) terminal.
1. Remove securing screws, and open upper front
access door.
10. Remove remaining end of cable from welding
generator battery positive (+) terminal.
2. Locate shutdown switch MS1 on left, rear side of
front access door.
11. Discard damp cloths.
3. Locate fuse F on bottom of shutdown switch
MS1.
9-3.
OVERLOAD PROTECTION (Figure 4-2)
WARNING: ELECTRIC SHOCK can kill.
4. Remove and check fuse, and replace if neces-
sary.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−) bat-
tery cable from battery before inspecting,
maintaining, or servicing.
5. Close and secure front access door.
9-4.
CIRCUIT BOARD HANDLING PRECAU-
TIONS
MOVING PARTS can cause serious personal
injury.
• Keep away from moving parts such as fans,
WARNING: ELECTRIC SHOCK can kill
belts, and rotors.
• Do not touch live electrical parts.
HOT ENGINE PARTS can cause severe
burns.
• Stop engine, and disconnect negative (−) bat-
tery cable from battery before inspecting,
maintaining, or servicing.
• Wear protective gloves and clothing when
working on a hot engine.
HOT ENGINE PARTS can cause severe
burns.
INCORRECT FUSE can damage unit.
• Be sure replacement fuse is same size, type,
• Wear protective gloves and clothing when
and rating.
working on a hot engine.
A. Circuit Breaker CB1 (Figure 4-2)
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit board compo-
nents.
WARNING: Read and follow safety informa-
tion at beginning of Section 9-3 before pro-
ceeding.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport all static−sensitive components in
Circuit breaker CB1 protects the 120 volts ac auxiliary
power terminals on terminal strip 3T from overload. CB1
is located behind the lower front door. When CB1 opens,
the ON/OFF switch goes to the OFF position, and 3T will
not operate. If CB1 opens, locate and correct the prob-
lem, and place the circuit breaker switch in the ON posi-
tion.
proper static-shielding carriers or packages.
• Perform work only at a static−safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned before closing access door.
EXCESSIVE PRESSURE can break circuit
board.
B. Circuit Breaker CB3 (Figure 4-2)
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
WARNING: Read and follow safety informa-
tion at beginning of Section 9-3 before pro-
ceeding.
If any circuit board is not working, follow the precautions
above, and contact the nearest Factory Authorized Ser-
vice Station/Service Distributor.
Circuit breaker CB3 protects the unit wiring from over-
load and damage. CB3 is located behind the lower front
door.
OM-166 941 Page 32
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9-5.
TROUBLESHOOTING (Tables 9-1 Thru 9-4)
The following tables are designed to diagnose and pro-
vide remedies for some of the troubles that may develop
in this welding generator.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect the negative (−)
battery cable before inspecting, maintaining,
or servicing.
Use these tables in conjunction with the circuit diagram
while performing troubleshooting procedure. If the
trouble is not remedied after performing these proce-
dures, contact the nearest Factory Authorized Service
Station/Service Distributor. In all cases of equipment
malfunction, strictly follow the manufacturer’s proce-
dures and instructions.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
Troubleshooting to be performed only by quali-
fied persons.
Table 9-1. Weld/Power Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
No weld output.
Amperage Ranges switch S9 Place S9 in LOW OUTPUT or HIGH OUTPUT
between positions. position (see Section 6-1).
OUTPUT (CONTACTOR) Place S5 in ON position, or install Remote Con-
switch S5 in REMOTE position tactor Control device.
and Remote Contactor device
not connected.
Incorrect or poor connection to Check and secure connections (see Section
REMOTE 9 receptacle or termi- 4-8).
nal strip 3T.
Circuit breaker CB3 open Reset CB3 (see Section 9-3).
(GMAW only).
Poor contact between slip rings Clean slip rings (see Section 8-9).
and brushes.
Replace brushes according to Section 8-9.
Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1.
Authorized Service Station/Service Distributor.
Erratic weld output.
Loose or dirty connections.
Check connections both inside and outside the
unit.
Connection at work.
Damp electrode.
Check connection. Be sure connection is clean
and tight.
Use dry, properly stored electrode.
Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1.
Authorized Service Station/Service Distributor.
Electrode polarity.
High engine speed.
See Section 4-7C.
High welding output voltage.
Wire feeder inoperative.
Check and adjust engine speed according to
Section 8-8.
Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1.
Authorized Service Station/Service Distributor.
Circuit breaker CB3.
Reset CB3 according to Section 9-3.
OM-166 941 Page 33
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Table 9-2. Auxiliary Power Troubleshooting
PROBABLE CAUSE
AUXILIARY POWER
TROUBLE
REMEDY
No 120 volt output at 3T termi- Circuit breaker CB1 open.
nals L and M.
Reset CB1 (see Section 9-3).
Poor contact between slip
rings and brushes.
Clean slip rings (see Section 8-9).
Replace brushes according to Section 8-9.
High auxiliary power output
voltage.
High engine speed.
Check and adjust engine speed according to
Section 8-8. (Maximum voltages should not
exceed 132 volts for single-phase power.)
Table 9-3. Engine Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
Engine does not start.
Out of fuel.
Fill fuel tank, and air vent fuel system (see En-
gine Manufacturer’s Manual.)
Battery problem.
Check engine battery charging system accord-
ing to engine service manual (not supplied with
engine).
Inspect electrical system (see Section 8-1). If
trouble is isolated to battery, replace it.
Jump start the engine using approved safety
practices and booster battery (see Section
9-2).
Engine Control switch S1.
Check S1, and replace if necessary.
Oil Pressure gauge/switch or
See Sections 6-10 thru 6-11; see Engine Man-
Oil Temperature gauge/switch ufacturer’s Manual (F4L-912 engine).
activated, or other engine
trouble.
MS1 fuse F.
Check and replace F, if necessary (see Sec-
tion 9-3).
Engine suddenly shuts down. Broken cooling belt.
High oil temperature.
Check and replace belt (see Section 6-15).
Check engine oil level and add oil if necessary;
check for cooling air flow obstructions.
Low oil pressure.
MS1 fuse F.
Check engine oil level, and add oil if necessary
(see Section 4-5).
Check and replace F if necessary (see Section
9-3).
Table 9-4. Air Compressor Troubleshooting
AIR COMPRESSOR
TROUBLE
CAUSE
REMEDY
Air compressor fails to build
pressure or builds pressure
slowly.
Engine air compressor.
Service air compressor. Contact nearest Au-
thorized Service Station/Service Distributor.
Pneumatic tools freeze up.
Moisture in compressed air.
Induce an antifreeze solution into the air sup-
ply. Contact nearest Authorized Service Sta-
tion/Service Distributor.
OM-166 941 Page 34
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NOTES
OM-166 941 Page 35
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SECTION 10 − ELECTRICAL DIAGRAMS
Diagram 10-1. Circuit Diagram For Welding Generator
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SC-168 908-B
OM-166 941 Page 37
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SECTION 11 − PARTS LIST
Figure 11-1A. Main Assembly
ST-800 491-B (1 of 2)
OM-166 941 Page 38
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 11-1A. Main Assembly
Quantity
. . . 1 . . . . . . . . . . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . 4ft
. . . 2 . . . . . . . . . . . . . . . . . . . 131 123 . . SHIELD, heat upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . 146 240 . . BRACKET, heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . 1063920009309 . . HOSE, air 43.000 3/4 swivel both ends . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . 0302390009309 . . FITTING, stl flrd conn fem 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . 1261610009309 . . FITTING, pipe brs adapter 1/2NPT x M22 x 1.5 . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . 1448660009309 . . SEAL, ring copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . 1448670009309 . . VALVE, control air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . 1448320009309 . . FITTING, pipe brs adapter 1/2fem NPT x M22 x 1.5 . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . . 602 904 . . FITTING, pipe stl elb st .500NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . . . . 010 917 . . HANGER, minerallic No. 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 12 . . . . . . . . . . . . 1224390009309 . . AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . . . . 138 098 . . HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV
(same as Item 5 Fig 11-1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . Shunt . . . . . . . . . 072 426 . . SHUNT, meter 50MV 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . . . . . . . . 14172390009309 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . PLG7,12 . . . . . . . . 047 636 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 079 535 . . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . . 14
. . . 18 . . . . . . . . . . . . . . . . . . . 143 922 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3 . . . . . . . . 2
. . . 19 . . . . T2 . . . . 1479850009309 . . TRANSFORMER, control (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC8 . . . . . . . . . . 167 640 . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 113 633 . . . . . . CONNECTOR, rect pin 20-14ga Amp 350218-1 . . . . . . . . . . . . 4
. . . . . . . . . PLG8 . . . . . . . . . 136 810 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . 4
. . . 20 . . . . Z1 . . . . 1290740009880 . . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . 1107430009309 . . FITTING, stl flrd conn M 1/2tbg x .750-16 . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . 1551670009309 . . UPRIGHT, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 601 965 . . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . . . . . . 017 479 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . 1551680009309 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . . . . . . . . 134 456 . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . 1186440009309 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . . . 032 452 . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . BAT . . . . . . . . . . 012 724 . . BATTERY, stor 12V 550crk 165RSV . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1448270009309 . . INSULATOR ASSEMBLY, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . 010 460 . . STUD, stl .312-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . CR2,4 . . . . . . . . . 090 104 . . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG9,10 . . . . . . . . 148 850 . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . . . . . . . 601 851 . . NUT, stl slf lkg hex reg .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . . . . . . . . 1169780009309 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . . 083 553 . . BASE, filter fuel w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . . 145 281 . . FITTING, hose brs barb elb M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . . . . . . . 099 542 . . CLAMP, hose .645-.828clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 37 . . . . . . . . . . . . . . . . . . . 134 836 . . HOSE, SAE .375 ID x .620 OD (order by ft) . . . . . . . . . . . . . . . . . . . 7ft
. . . . . . . . . . . . . . . . . . . . . . . . . 023 562 . . CLAMP, hose .312-.875clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . . . . . . . 117 227 . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . *062 342 . . SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . . 089 120 . . CLAMP, hose .375-.450clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . . 073 433 . . FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . 2
. . . 42 . . . . . . . . . . . . 1194860009309 . . TUBE, pick-up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 43 . . . . 2T . . . . . . . . . . . 163 656 . . BLOCK, term 65A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . 0570560009309 . . BRACKET, mtg term strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . . . . . 081 646 . . FITTING, brs barbed M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . . . . . 146 357 . . SENDER, fuel gauge 11.000 deep . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . . . . . . . 121 823 . . LABEL, warning do not lift from this end . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . . . . . 010 678 . . FITTING, pipe brs elb st 1/4NPT LH . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-166 941 Page 39
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1A. Main Assembly (Continued)
. . . 49 . . . . . . . . . . . . . . . . . . . 073 433 . . FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . 0456660009309 . . LATCH, door snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 51 . . . . . . . . . . . . 1187900009309 . . ANGLE, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . . . . . . 010 914 . . HANGER, minerallic No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . . . . . 087 341 . . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 54 . . . . . . . . . . . . 1551660009309 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 121 699 . . SPACER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . 601 965 . . SCREW, .375-16 x 1.000hexhd (used on fuel filter bracket also) . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 602 213 . . WASHER, lock stl split .375 (used on fuel filter bracket also) . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 601 871 . . NUT, stl hex jam .375-16 (used on fuel filter bracket also) . . . . . . . 4
. . . 55 . . . . . . . . . . . . 1311880009309 . . FRAME, mtg reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 007 025 . . SCREW, cap stl hexhd .625-11 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 602 218 . . WASHER, lock stl split .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 085 980 . . NUT, stl hex full fnsh .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 56 . . . . . . . . . . . . 1311270009309 . . BRACKET, rect RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . SR3 . . . . . . . . . . 142 507 . . RECTIFIER, si 3ph 450A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . 1448180009309 . . BUS BAR, rectifier AC to AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 58 . . . . . . . . . . . . . . . . . . . 030 170 . . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . 1
. . . 59 . . . RC12 . . . . . . . . . 047 637 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . 14
. . . 60 . . . . . . . . . . . . 1215410009309 . . BRACKET, rect LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . . . . . 026 947 . . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 62 . . . . . . . . . . . . 1376100009309 . . BUS BAR, neg term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 . . . . . . . . 2
. . . 64 . . . PLG6 . . . . . . . . . 048 598 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . 16
. . . 65 . . . . . . . . . . . . . . . . . . . Fig 11-4 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . . Fig 11-3 . . PANEL, lower front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . . . . . 122 354 . . GUARD, splash fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . . . . . . 107 343 . . GROMMET, rbr neck filter fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . 0240350009309 . . CAP, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . 1448230010202 . . DOOR, front lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . . . . . . 147 911 . . PLATE, ident diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . 1448210009309 . . WINDOW, door lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1448220009309 . . FRAME, support window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . +1292260010202 . . DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . . . . . . . . Fig 11-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . . . . . . . 131 125 . . SHIELD, heat lower LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . . . . . . . 131 124 . . SHIELD, heat lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . 1312430009309 . . BUS BAR, pos term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . 1317500009309 . . BUS BAR, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 120 188 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 136 615 . . LABEL, caution refer to Owner’s Manual . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 164 617 . . CLIP, wiring straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 164 616 . . CLIP, wiring offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 135 784 . . CLIP, conduit convoluted 3/4 in 6.35mm mtg hole . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . 149 616 . . CLAMP, stl cush .187dia x .344mtg hole . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 010 021 . . CLAMP, stl cush .562dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 034 116 . . CLAMP, stl cush .625dia x .468mtg hole . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 010 014 . . CLAMP, stl cush .750dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . 020 279 . . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 127 854 . . CLAMP, stl cush 1.312dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 089 256 . . CLAMP, stl cush 1.750dia x .531mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 010 143 . . CLAMP, nyl .375 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 40
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Item
Dia.
Part
No.
No. Mkgs.
Description
Quantity
Figure 11-1B. Main Assembly
. . . 1 . . . . . . . . . . . . 1448720009309 . . BAFFLE, air upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . 006 086 . . BLANK, snap-in 1.500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See engine manual for replacement parts
. . . 4 . . . . . . . . . . . . 1448200009309 . . BRACKET, mtg air line to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . . . 138 098 . . HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV
(same as Item 13 Fig 11-1A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . . 192 197 . . BRACKET, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . 1187060009309 . . AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 023 313 . . CLAMP, hose 3.250-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . . 162 625 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . . . . 010 863 . . CLAMP, hose 2.062-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 11 . . . . . . . . . . . . 1626660009309 . . TUBING, air cleaner intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . . 073 655 . . FITTING, pipe brs nipple hex 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . S11 . . . . . . . . . . 118 067 . . SWITCH, vacuum air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . 1371640009309 . . HOSE, air input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . . 010 497 . . CLAMP, hose .750 − 1.750clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 16 . . . . . . . . . . . . 1183490009309 . . AIR LINE, compressor to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . 1448300009309 . . FITTING, pipe brs adapter M 3/4NPSM x 26mm x 1.5 . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . 1448310009309 . . SEAL, ring copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . 1371790009309 . . AIR COMPRESSOR, 300cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . 1261620009309 . . SHIELD, heat compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . . 151 734 . . ENGINE, Deutz dsl elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1065390009309 . . O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1065380009146 . . STARTER, engine 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 164 618 . . SHUTDOWN KIT, rsv type governor . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . 1528460009309 . . HOSE, air cleaner elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . 1532490009309 . . BAFFLE, upper air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . 1142710009309 . . COMPOUND, sealant material (order by ft) . . . . . . . . . . . . . . . . . . . 5ft
. . . 25 . . . . . . . . . . . +1528530010202 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . 1174860010202 . . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . . 122 382 . . CAP, rain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment can cause serious injury . . . . . . 2
. . . 29 . . . . . . . . . . . . . . . . . . . 163 226 . . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . 021 116 . . . . CAP, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . 004 115 . . . . BAFFLE, dust cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . . . . 021 117 . . . . NUT, wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . . . *020 319 . . . . ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . . . . . 021 114 . . . . CLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . . 021 115 . . . . BAND, mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . 1528450009309 . . HOSE, air cleaner elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . 0280890010202 . . DOOR, access radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . . 147 913 . . PLATE, ident engine lube oil only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 147 912 . . PLATE, ident oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . . 089 178 . . GROMMET, rbr 3.000 ID x 3.500mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . . . . . 049 170 . . GROMMET, rbr 2.500 ID x 2.750mtg hole . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . . 004 130 . . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . 1214130010202 . . PANEL, end baffle air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . +1453150010202 . . DOOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1311870010202 . . PANEL, engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 146 389 . . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . . 147 923 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . 2
. . . 45 . . . . . . . . . . . . . . . . . . . 119 861 . . LATCH, paddle series 300 w/lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . 1198510010202 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . 1172190010202 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 48 . . . . . . . . . . . . . . . . . . . 149 971 . . FITTING, pipe brs adapter bhd 1/2NPT x 1.500 lg . . . . . . . . . . . . . . 1
OM-166 941 Page 41
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Figure 11-1B. Main Assembly
ST-800 491-B (2 of 2)
OM-166 941 Page 42
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Item
Dia.
Part
No.
No. Mkgs.
Description
Quantity
Figure 11-1B. Main Assembly (Continued)
. . . 49 . . . . . . . . . . . . . . . . . . . 089 351 . . FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . 1532480009309 . . BAFFLE, lower air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . 1528480009309 . . BRACKET, oil neck w/cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . 1528520009309 . . PIPE, oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 54 . . . . . . . . . . . . 1529040009309 . . CLAMP, hose 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 55 . . . . . . . . . . . . 1528470009309 . . HOSE, oil filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . 4
. . . 57 . . . . . . . . . . . . . . . . . . . 602 246 . . WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 58 . . . . . . . . . . . . . . . . . . . 071 731 . . WASHER, flat stl .656 ID x 2.250 OD . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 59 . . . . . . . . . . . . . . . . . . . 601 945 . . SCREW, cap stl hexhd .625-18 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 60 . . . . . . . . . . . . . . . . . . . 116 707 . . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . . . . . 603 110 . . HOSE, nprn .500 ID x .687 OD (order by ft) . . . . . . . . . . . . . . . . . . . 2ft
. . . 62 . . . . . . . . . . . . . . . . . . . 010 858 . . CLAMP, hose .500-.906clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . 0395990009309 . . FITTING, brs barbed M 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . . . . . . 088 684 . . VALVE, ball bronze 1/2thd female . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . 1063940009309 . . FITTING, stl flrd conn M 1/2tbg x 1/2tbg . . . . . . . . . . . . . . . . . . . . . . 2
. . . 66 . . . . . . . . . . . . 1178270009309 . . FITTING, pipe stl tee F 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . 1107430009309 . . FITTING, brs flrd conn M hd 1/4tbg x 1/8NPT . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . 1355720009309 . . HOSE, oil 47.000 3/4 swivel both ends
(same as Item 29 Fig 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . . . . . . 118 452 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . . . . . . 131 208 . . STOP, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . 1448100009309 . . HOSE, cooling compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . . . . . . . Fig 11-5 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . 1448640009309 . . BAFFLE, air lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . . . . . . 132 712 . . PIPE, muffler extension elb 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 119 836 . . TUBING, stl .875 OD x .563 ID x .875 lg . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . ♦041 481 . . STARTING AID, diesel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . ES1 . . . . . . . . . ♦034 074 . . . . VALVE, ether (diesel starting aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦083 859 . . . . BRACKET, mtg fuel filter/quick start . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦195 754 . . . . ADAPTER, atomizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦046 410 . . . . ATOMIZER, .125 L elbow orf 12 o’clock from inlet . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦035 325 . . . . LABEL, ether starting aid caution etc . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . S8 . . . . . . . . . . ♦021 467 . . . . SWITCH, tgl SPST 3A 250V off-none-(on) spd term . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦021 385 . . . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . ♦020 185 . . . . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 43
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5
3*
6
24
23
25
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22
21
8
9
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9
19
11
12
18 17 16 15
14
ST-800 490-A
13
*Includes Item 4
Figure 11-2. Panel, Front w/Components
OM-166 941 Page 44
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Panel, Front w/Components (Fig 11-1A Item 75)
. . . 1 . . . . S9 . . . . 1346300009880 . . SWITCH, range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . 1183400010202 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . R1 . . . . . . . . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . S4 . . . . . . . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . S5 . . . . . . . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . S1 . . . . . . . . . . . 172 070 . . SWITCH, ignition 5posn w/out handle . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and NSPR number) . 1
. . . 10 . . . . . . . . . . . . . . . . . . . 125 707 . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . FG . . . . . . . . . . 118 066 . . GAUGE, fuel elec 12V neg grd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . V2 . . . . . . . . . . . 164 747 . . METER, volt batt chg 8-18 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . OG . . . . . . . . . . 129 870 . . GAUGE, pressure oil 25-30PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 128 829 . . KIT, oil line 44.000 in 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . 1298370009309 . . GAUGE/SWITCH, temp oil mech 300deg setting . . . . . . . . . . . . . . 1
. . . 15 . . . . HM . . . . . . . . . . 118 058 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . . 082 788 . . HOLDER, light ind only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . PL1,3 . . . . . . . . *048 155 . . BULB, incand flg base 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . . . . . . . . . . . . . . . . 082 789 . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . . . . 010 647 . . PIN, spring .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . . . . . 090 231 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . A2 . . . . . . . . . . . 164 875 . . METER, amp DC 50MV 0-1K scale . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . V1 . . . . . . . . . . . 164 872 . . METER, volt DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and NSPR number) . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 45
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9
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7
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11
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27 28 29
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26
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21
ST-147 320-F
25
24
Figure 11-3. Panel, Lower Front w/Components
OM-166 941 Page 46
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Panel, Lower Front w/Components
(Fig 11-1A Item 66)
. . . 1 . . . . . . . . . . . . 0386120009309 . . TERMINAL ASSEMBLY, pwr output (consisting of) . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . . . . . 601 840 . . . . NUT, brs hex .500-13 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . . . . . . . 601 839 . . . . NUT, brs hex .500-13 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . . . . . 038 847 . . . . BUS BAR, term pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . Neg/Pos . . . . . . . . 038 613 . . . . TERMINAL BOARD, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . . 038 900 . . . . STUD, brs .500-13 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . . . . 602 247 . . . . WASHER, flat stl SAE .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . . . . . 605 787 . . . . WASHER, lock stl intl tooth .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . C1,2 . . . . . . . . . . 085 321 . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 601 976 . . SCREW, cap stl hexhd .500-13 x 1.500 (bus bar to terminal) . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . 044 942 . . NUT, locking .500-13 (bus bar to terminal) . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . . . . . 097 132 . . STAND-OFF, 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 11 . . . . PC3 . . . . . . . . . . 150 415 . . CIRCUIT CARD, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG3-5 . . . . . . . . 165 668 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . 10
. . . 12 . . VR1/R4 . . . . . . . . 046 819 . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . RC3 . . . . . . . . . . 085 302 . . CONNECTOR, circ 9skt rcpt Amphenol MS-3102A-20-16S . . . . . . 1
. . . 14 . . . . CB3 . . . . . . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC4 . . . . . . . . . . 152 966 . . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CB1 . . . 1532470009309 . . CIRCUIT BREAKER, mag SPDT 30A 250VAC . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . 1502670009309 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . . . . 083 030 . . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 ID x .625 OD . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 20 . . . . . . . . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 21 . . . . . . . . . . . . 0918600009309 . . STRAIN RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . . . . . . . 010 916 . . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . 3T . . . . . . . . . . . 073 873 . . BLOCK, term 30A 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . 1482370009309 . . COVER, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . 1479080009309 . . GAUGE, oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . 1224460009309 . . FITTING, pipe galv nipple .500NPT x 1.500 lg . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . 0886900009309 . . FITTING, stl flrd elbow fem 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . 1355720009309 . . HOSE, oil 47.000 3/4 swivel both ends
(same as Item 70 Fig 11-1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . . . . 039 885 . . CONNECTOR, circ protective cap Amphenol 9760-20 . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating lower
(order by model and NSPR number) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1577780009309 . . STRAP, grounding (front panel to base) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . 1577920009309 . . STRAP, grounding (front panel to control box) . . . . . . . . . . . . . . . . . 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 47
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Control Box (Fig 11-1A Item 65)
. . . 1 . . . . . . . . . . . . 1186380009309 . . ENCLOSURE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . T1 . . . . 0700700009309 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . RC6 . . . . . . . . . . 090 246 . . CONNECTOR w/PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 079 535 . . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . . 16
. . . 4 . . . . RC7 . . . . . . . . . . 047 637 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . 14
. . . 5 . . . . D1 . . . . . . . . . . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . 1562370009309 . . BRACKET, holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . 1T . . . . . . . . . . . 098 828 . . BLOCK, term, 10A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 129 524 . . TERMINAL, frict .250 x .032 uninsul male . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . 8
. . . 10 . . . . PC2 . . . . . . . . . . 160 888 . . CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG2 . . . . . . . . . 168 071 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . 9
. . . 11 . . . . PC1 . . . 1337570009309 . . CIRCUIT CARD, field current regulator . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG1 . . . . . . . . . 135 275 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . 15
. . . 12 . . . . CR1 . . . . . . . . . . 044 588 . . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CR3 . . . . . . . . . . 059 268 . . RELAY, encl 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . SR2 . . . . . . . . . . 097 353 . . DIODE/SCR, bridge intg 2SCR 3 diodes . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . MS1 . . . . . . . . . . 118 072 . . SWITCH, magnetic shutdown 12VDC (consisting of) . . . . . . . . . . . 1
. . . 16 . . . . . F . . . . . . . . . . *048 317 . . . . FUSE, mintr gl 14A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . 045 852 . . CLIP, component .687dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . . 1
1
16
15
13
14
2
12
8
9
11
7
6
3
5
4
ST-800 489
10
*Recommended Spare Parts.
Figure 11-4. Control Box
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 48
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Item
No.
Part
No.
Description
Quantity
Figure 11-5. Generator (Fig 11-1B Item 72)
. . . 1 . . . . . . . . . . . . . . . 018 614 . . BRUSH SET, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 2 . . . . . . . . . . . . . . *151 299 . . . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 600 270 . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 152 044 . . . . CAP, brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 049 650 . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . +140 096 . . STATOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 039 207 . . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 083 751 . . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . 024 617 . . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 053 390 . . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . 083 748 . . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . 1450210009309 . . STATOR, exciter/endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 601 965 . . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 15 . . . . . . . . . . . . . . . 153 299 . . ENDBELL, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 004 203 . . STRIP, nyl .050 x 4.000 x 9.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
12
9
11
10
7
8
6
1
4
3
2
5
13
16
14
17
15
SD-134 503-C
Figure 11-5. Generator
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 49
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Notes
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